A box transformer for power generation that is easy to assemble

Abstract

The application relates to a box transformer for power generation which is convenient to assemble and belongs to the technical field of box transformers; the box transformer comprises a box body and a transformer assembly, the transformer assembly is arranged in the box body, and the transformer assembly comprises an iron core and a segmented coil; each phase coil of the segmented coil is divided into an upper segment sub-coil and a lower segment sub-coil; the upper segment sub-coil and the lower segment sub-coil are two-segment detachable series connection structures; the upper segment sub-coil and the lower segment sub-coil are integrally formed by adopting a modular insulation framework, the outer wall is integrated with axial heat dissipation fins, and the inner wall is attached with an insulation gasket; the outer wall of the upper segment sub-coil and the lower segment sub-coil is provided with a sliding block matched with horizontal guide rails of a box body mounting support, the sliding block can slide into a corresponding position of the iron core along the horizontal guide rails, and the upper segment sub-coil and the lower segment sub-coil are fixed by cooperating with vertical positioning clamps; the transformer coil structure is mainly improved, and the problems of great coil hoisting difficulty, complicated structure assembly and low wiring efficiency in box transformer assembly are solved.

Description

Technical Field

[0001] This invention relates to a conveniently assembled prefabricated transformer for power generation, belonging to the technical field of prefabricated transformers. Background Technology

[0002] In a prefabricated substation (referred to as "prefabricated substation"), the core equipment for voltage transformation and power distribution in a power generation system, the ease of its assembly directly affects the construction efficiency of a power generation project. Existing prefabricated substations have the following drawbacks:

[0003] Limited transformer coil assembly: The transformer coils in traditional box-type substations are mostly integrally wound structures, which require hoisting into the box as a whole during assembly. However, the space inside the box is narrow, making the hoisting operation difficult and time-consuming.

[0004] Low coil structure integration: The insulation and heat dissipation structures of the coils need to be assembled separately, which is a complicated process and further reduces the overall assembly efficiency of the transformer substation.

[0005] The wiring operation is complicated: the connection between the coil and the external circuit needs to be soldered / bolted on site one by one, which is complicated and prone to poor contact problems.

[0006] For example, Chinese Patent Publication No. CN108417349A discloses a box-type transformer, including a box body, an openable and closable door hinged to one side of the box body, and a cover covering the top of the box body. The box body has a chamber for accommodating electrical components. The cover is an arc-shaped surface that is higher in the middle and lower on both sides, and the horizontal projection of the cover overlaps the horizontal projection of the box body. Multiple elongated heat dissipation holes are provided on both side walls of the box body. An arc-shaped baffle extending downwards is connected to the upper edge of each heat dissipation hole, and a heat dissipation mechanism is connected to the lower edge of each heat dissipation hole. Four support mechanisms are provided at the bottom of the box body. This invention can control the degree of shading of the heat dissipation holes in real time according to the ambient humidity, allowing for stable installation in outdoor working environments. It is dustproof and moisture-proof, and has the advantages of low cost and easy installation, making it suitable for large-scale promotion.

[0007] However, the improvements only addressed the enclosure and did not involve modifications to the transformer and coils. A more conveniently assembled prefabricated transformer for power generation is still needed, with a focus on improving the transformer coil structure to address the challenges of coil hoisting, complex assembly, and low wiring efficiency during prefabricated transformer assembly. Summary of the Invention

[0008] The purpose of this invention is to provide a conveniently assembled prefabricated transformer for power generation, with a focus on improving the transformer coil structure to solve the problems of difficult coil hoisting, cumbersome structural assembly, and low wiring efficiency in the assembly of prefabricated transformers.

[0009] The present invention discloses a conveniently assembled power generation transformer box, comprising a box and a transformer assembly. The transformer assembly is housed within the box and includes an iron core and segmented coils. Each phase coil of the segmented coil is divided into an upper sub-coil and a lower sub-coil, which are two detachable series-connected structures. The upper and lower sub-coils are integrally formed using a modular insulating frame, with axial heat dissipation fins integrated on the outer wall and insulating pads attached to the inner wall. The outer walls of the upper and lower sub-coils are provided with sliders that match the horizontal guide rails of the box mounting bracket, allowing them to slide along the horizontal guide rails into the corresponding positions of the iron core and be fixed in place with vertical positioning clips.

[0010] The substation's basic structure is constructed using a "segmented + modular + precise assembly" approach. Each phase coil is divided into two detachable sections, reducing the weight of a single coil section by more than 50% compared to the overall coil. Combined with a sliding assembly system using a "slider-horizontal guide rail," no large hoisting equipment is needed. A single person can slide the coil along the guide rail into the corresponding position on the iron core and quickly fix it using vertical positioning clips. This shortens the assembly time for single-phase coils, making it particularly suitable for assembly scenarios with limited internal space in substations. The modular, one-piece molded insulating frame avoids the heat dissipation dead zones found in traditional spliced ​​frames. Axial heat dissipation fins integrated into the outer wall improve heat dissipation efficiency by 50%, while the insulating pads attached to the inner wall strengthen the insulation between the coil and the iron core. The detachable structure allows for coil maintenance without disassembling the entire substation; simply loosening the vertical positioning clips allows for the extraction of individual coil sections, reducing maintenance labor costs. The modular design also facilitates single-section replacement in case of faults, minimizing downtime. The cooperation between the guide rail and the slider reduces the coil positioning deviation, ensures the concentricity of the coil and the iron core, and avoids electromagnetic noise and local overheating problems caused by positioning deviation.

[0011] Preferably, the upper segment coil has a positioning female sleeve at its lower end; the lower segment coil has a positioning male sleeve at its upper end that is adapted to the positioning female sleeve; the upper segment coil and the lower segment coil are detachably connected in series through the positioning female sleeve and the positioning male sleeve; the positioning female sleeve is equipped with an elastic conductive clip, and the positioning male sleeve has a conductive contact end that contacts and engages with the elastic conductive clip.

[0012] By combining a positioning female sleeve, a male sleeve, and a flexible conductive clip, the pain points of traditional segmented coils—namely, unreliable connections and poor conductivity stability—are resolved. This achieves integrated mechanical positioning and electrical connection: the matching structure of the positioning female sleeve and male sleeve ensures accurate mechanical positioning when the two coil segments are connected, while the tight fit between the flexible conductive clip and the conductive contact end simultaneously completes the electrical connection, avoiding the cumbersome process of "positioning before wiring" in traditional segmented coils and reducing assembly steps. Breaking the prejudice that "segmentation inevitably reduces conductivity stability," the elastic pressure of the flexible conductive clip keeps the contact resistance stably controlled within 3.5mΩ, lower than the 8.7mΩ of traditional integral coils, overcoming the industry's limited understanding that "segmented coils are only suitable for low-voltage, small-capacity equipment." The plug-in structure of the female and male sleeves allows for tool-free connection and separation, and with the help of guide rail assembly, a rapid, end-to-end operation of "slide-in-connect-fix" is achieved.

[0013] Of course, the positions of the positioning female sleeve and the positioning male sleeve can also be interchanged, that is, the lower end of the upper segment coil is provided with a positioning male sleeve; the upper end of the lower segment coil is provided with a positioning female sleeve that matches the positioning male sleeve. Similarly, the positions of the elastic conductive clip and the conductive contact end can also be interchanged.

[0014] Preferably, the positioning female sleeve is frustum-shaped, and an elastic conductive clip is installed inside the frustum-shaped positioning female sleeve; the positioning male sleeve is a frustum-shaped positioning male sleeve that mates with the conical surface of the frustum-shaped positioning female sleeve, and the frustum-shaped positioning male sleeve is provided with a conductive contact end that contacts and mates with the elastic conductive clip.

[0015] The positioning female and male sleeves are optimized to have a frustum-shaped conical surface fit, further enhancing connection reliability and assembly convenience. The conical structure has a natural self-guiding function, eliminating the need for precise alignment when the two coil segments are mated. The male sleeve can automatically slide into the appropriate position along the conical surface of the female sleeve, improving assembly error tolerance and allowing even novice operators to quickly complete the mating process. The conical fit increases the contact area compared to a cylindrical surface, improving both mating guidance and fit, further reducing contact resistance. The "wedge effect" of the conical surface makes the coil less prone to loosening in vibrating environments (such as transformer substation transportation or wind power scenarios), significantly enhancing vibration resistance and stability. The conical fit converts axial assembly force into radial clamping force, requiring only a small pushing force from the operator to complete a tight mating, reducing assembly torque and improving operational comfort.

[0016] Preferably, the frustum-shaped positioning female sleeve includes a female sleeve guide section and a female sleeve mating section connected in sequence; the frustum-shaped positioning male sleeve includes a male sleeve guide section adapted to the female sleeve guide section and a male sleeve mating section adapted to the female sleeve mating section; the end of the male sleeve mating section of the frustum-shaped positioning male sleeve is provided with an annular positioning boss.

[0017] By employing a segmented design of "guide section + mating section" and adding a ring-shaped positioning boss, a three-tiered protection system of "precise guidance - reliable mating - limit protection" is achieved. The guide section of the female and male sleeves first completes the initial positioning, and then the mating section achieves precise fitting, forming an assembly logic of "coarse positioning - fine mating," avoiding damage to the conductive clips or contact ends due to over-assembly. The ring-shaped positioning boss directly limits the maximum insertion depth, structurally eliminating the risk of over-assembly. The segmented conical structure makes machining accuracy easier to control. The large taper of the guide section facilitates insertion, while the small taper of the mating section ensures a tight fit. During mass production, the deviation in the docking accuracy of each coil is reduced, improving product consistency. Mechanical wear caused by over-assembly is avoided, extending the service life of the elastic conductive clips and conductive contact ends, and reducing maintenance and replacement costs.

[0018] Preferably, the end of the mating section of the frustum-shaped positioning sleeve is provided with an annular groove, and an elastic locking ring is assembled in the annular groove. The elastic locking ring is an open-type beryllium bronze ring.

[0019] An open-type elastic locking ring is introduced, further optimizing the "anti-loosening" requirement for conical mating. Its beneficial effects focus on reliability and durability. The open-type elastic locking ring naturally opens after the male fitting is inserted, generating a clamping force on the annular positioning boss through elastic deformation. Combined with the conical wedge effect, it prevents joint loosening, solving the core hidden danger of "vibration loosening" in traditional segmented coils. The beryllium bronze material, after aging treatment, has high hardness, making it suitable for extreme power generation scenarios such as high-altitude and high-temperature environments. The open structure allows the locking ring to be reused; only a slight axial force is needed to retract the ring during disassembly, avoiding the disassembly losses of traditional rigid locking structures and reducing maintenance costs.

[0020] Preferably, the elastic conductive clip is a 3-lobed structure evenly distributed along the circumference, the elastic conductive clip is made of beryllium bronze, its surface is silver-plated and the contact area is processed with an arc-shaped groove; the conductive contact end is a cylindrical structure, made of copper and its surface is silver-plated.

[0021] The structural parameters of the elastic conductive clip and the conductive contact end are refined to enhance conductivity from the aspects of material, shape, and process. The three-lobed beryllium bronze conductive clip is evenly distributed circumferentially, forming a "face-to-face" multi-point contact with the cylindrical copper contact end, resulting in a large contact area. The high elasticity of beryllium bronze and the high conductivity of copper, combined with a silver plating layer (to reduce the risk of oxidation), result in low contact resistance. The arc-shaped groove in the contact area of ​​the conductive clip fits perfectly with the cylindrical contact end, ensuring the contact area even with minor assembly deviations.

[0022] The silver plating layer can effectively suppress the generation of electric arcs, and the high hardness of the copper contact end (after cold work hardening treatment) reduces wear and extends the service life of conductive components.

[0023] Preferably, the upper or lower segment coil is in a form that can be connected and disconnected, so that the number of turns of the coil can be adjusted.

[0024] The newly added "adjustable number of turns" function solves the adaptability limitations of traditional box-type transformers, and can meet the voltage fluctuation requirements of distributed photovoltaic, wind power and other scenarios without replacing the coils.

[0025] Preferably, multiple electrical taps are led out from the winding of the upper or lower segment coil at specific turns positions; multiple sets of mutually insulated elastic conductive clips are integrated inside the positioning female sleeve, each elastic conductive clip being connected to a tap of the coil via an internal wire; multiple sets of conductive contact terminals are correspondingly provided on the positioning male sleeve; a rotary or toggle selector switch is provided on the modular insulating frame of the upper or lower segment coil, the moving contact of the switch being connected to the "common terminal" of the coil, and the stationary contact being connected to the corresponding multiple elastic conductive clips respectively.

[0026] By combining multiple taps, multiple sets of conductive clips, and a selector switch, the selector switch switches the elastic conductive clips corresponding to different taps, enabling adjustment of the total number of turns in three or more levels (e.g., 400 turns, 350 turns, 300 turns), and providing a wide voltage range. Rotary or toggle switches are integrated into a modular frame, offering short switching response time and eliminating the need to disassemble the coil or rewiring.

[0027] Preferably, on the end face of the upper or lower segment coil, multiple sets of identical male and female connectors are arranged side by side along the circumference, and each set of male and female connectors is connected to different taps of the coil; when the upper and lower segment coils are connected, the male connector is connected to different sets of female connectors by rotating the coil angle, thereby changing the taps connected to the circuit.

[0028] The "mechanical rotation adjustment" scheme, with adjustable turns, adapts to different operating habits and scenarios. By rotating the coil angle, different sets of male and female connectors are connected, enabling tap switching. The entire process is mechanical, eliminating the need for electrical switches or control circuits, thus avoiding adjustment failures caused by electrical component malfunctions. This is particularly suitable for power generation scenarios with strong electromagnetic interference. Multiple sets of male and female connectors are arranged side-by-side along the circumference, eliminating the need for additional axial or radial dimensions of the coil, making it more suitable for small-capacity, small-volume transformer substations. Each set of male and female connectors can employ the aforementioned conical fit + elastic locking structure, automatically achieving positioning and locking after rotational connection. Different sets of connectors can be designed with anti-misconnection features (such as differences in the number of bosses) to prevent incorrect connection and short circuits, improving the adjustment fault tolerance rate.

[0029] The present invention provides a conveniently assembled prefabricated transformer for power generation, which has the following advantages:

[0030] This design establishes a progressive relationship of "basic structure - connection optimization - performance enhancement - functional expansion," breaking through the limitations of traditional prefabricated substations across all dimensions, including assembly, conductivity, heat dissipation, and adaptation. Furthermore, through an innovative combination of "segmented + adjustable" design, it adapts to the diverse needs of power generation scenarios. The key improvement lies in the transformer coil structure, addressing issues such as the difficulty of coil hoisting, cumbersome structural assembly, and low wiring efficiency in prefabricated substation assembly. Attached Figure Description

[0031] Figure 1 This is a schematic diagram of the structure of a conveniently assembled power generation box-type substation according to the present invention;

[0032] Figure 2 This is a schematic diagram of the structure of a segmented coil according to the present invention;

[0033] Figure 3 This is a schematic cross-sectional view of the upper segment coil according to the present invention;

[0034] Figure 4 This is a bottom view schematic diagram of the upper segment sub-coil structure according to the present invention;

[0035] Figure 5 This is a schematic diagram of the structure of a lower segment coil according to the present invention.

[0036] In the diagram: 1. Housing; 2. Transformer assembly; 3. Iron core; 4. Segmented coil; 5. Upper segment coil; 6. Lower segment coil; 7. Heat dissipation fins; 8. Mounting bracket; 9. Horizontal guide rail; 10. Vertical positioning clip; 11. Positioning female sleeve; 12. Positioning male sleeve; 13. Elastic conductive clamp; 14. Conductive contact end; 15. Female sleeve guide section; 16. Female sleeve mating section; 17. Male sleeve guide section; 18. Male sleeve mating section; 19. Annular positioning boss; 20. Annular groove; 21. Elastic locking ring; 22. Male connector; 23. Female connector. Detailed Implementation

[0037] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.

[0038] Example 1

[0039] like Figures 1-5 As shown, this embodiment discloses a conveniently assembled prefabricated transformer for power generation, comprising:

[0040] Box 1: The inner wall of box 1 is pre-installed with modular mounting brackets 8 (including horizontal guide rails 9 and vertical positioning clips 10).

[0041] Transformer assembly 2: Located inside housing 1, including iron core 3 and segmented coil 4;

[0042] Among them, the segmented coil 4 is the core improved structure:

[0043] Each phase coil is divided into two detachable series structures: upper sub-coil 5 and lower sub-coil 6.

[0044] The upper section coil 5 and the lower section coil 6 adopt a modular insulating frame: the frame is integrally formed from epoxy glass cloth board, the outer wall integrates axial heat dissipation fins 7, and the inner wall is attached with insulating pads;

[0045] Series structure: The lower end of the upper sub-coil 5 and the lower sub-coil 6 are connected in series in a detachable manner through a quick connector of a frustum-shaped positioning sleeve and an elastic conductive clip 13. The frustum-shaped positioning sleeve enables precise alignment of the sub-coils, and the elastic conductive clip 13 can automatically complete the electrical connection between the two sub-coils.

[0046] Assembly and adaptation structure: The lower end of the upper segment coil 5 and the outer wall of the lower segment coil 6 are provided with sliders that match the horizontal guide rail 9 of the mounting bracket 8 of the housing 1. They can slide along the guide rail into the corresponding position of the iron core 3 and be fixed with the vertical positioning card 10.

[0047] Each phase coil is divided into an upper sub-coil 5 and a lower sub-coil 6. The two sections are symmetrical in structure and only the connection ends are compatible. Taking a certain phase of a three-phase 10kV / 0.4kV power generation box-type substation as an example:

[0048] part Segment A (Upper segment coil 5) Segment B (Lower segment coil 6) Modular skeleton Epoxy glass cloth board (FR-4, 8mm thickness) is integrally molded with axial heat dissipation fins integrated on the outer wall. Same as section A winding Copper foil (0.5mm thick, 120mm wide) is wound with 200 turns. Same as section A (200 turns, total 400 turns when connected in series with section A) Connection end structure The lower end is equipped with a frustum-shaped positioning sleeve 11 and an elastic conductive clip 13. The upper end is equipped with a frustum-shaped positioning male sleeve and a conductive contact end. Installation adapter structure The outer wall is equipped with two nylon sliders (size: 40mm×20mm×10mm) that match the guide rails of the box. Same as section A

[0049] Table 1

[0050] 1. Frustum-shaped positioning and connection structure

[0051] Positioning sleeve taper: 1:1.2 (for quick alignment and to ensure coaxiality after connection);

[0052] Positioning sleeve dimensions: length 20mm, male sleeve outer diameter 30mm, female sleeve inner diameter 30.2mm (0.2mm assembly clearance reserved);

[0053] Positioning sleeve material: non-magnetic stainless steel (to avoid magnetic hysteresis loss and improve structural strength).

[0054] Elastic conductive clip 13:

[0055] Material: Beryllium bronze (good elasticity and high conductivity);

[0056] Structure: 3-lobed open clamp, initial clamp opening angle 15°, contact pressure ≥5N after assembly (to ensure the stability of electrical connection).

[0057] Surface treatment: Silver plating (to reduce contact resistance).

[0058] 2. Integrated insulation and heat dissipation structure

[0059] Insulating liner on the inner wall of the skeleton: polyimide film, bonded to the skeleton with epoxy adhesive;

[0060] External wall heat dissipation fins 7: integrally formed with the frame, fin height 15mm, spacing 10mm, the fin surface is coated with thermal grease (to improve the heat exchange efficiency with the heat dissipation channel of the box 1).

[0061] Assembly process:

[0062] Assembly of Box 1: Connect the horizontal guide rail 9 and vertical positioning clip 10 inside Box 1 to form a complete installation structure;

[0063] Assembly of the lower segment coil 6: Slide the lower segment coil 6 of each phase into the lower area of ​​the corresponding phase of the iron core 3 along the horizontal guide rail 9, and fix its position by the vertical positioning clip 10;

[0064] Core 3 installation: Place the transformer core 3 into the corresponding position inside the lower section coil 6 and fix it in the preset position using fasteners;

[0065] Assembly of upper segment coil 5: Place the upper segment coil 5 of each phase into the upper area of ​​the corresponding phase of the iron core 3, align it with the lower segment coil 6 through the frustum-shaped positioning sleeve, and the elastic conductive clip 13 automatically completes the electrical connection. Then, fix the upper segment coil 5 to the mounting bracket 8 through the fixing parts.

[0066] Subsequent assembly: Install the other electrical components of the transformer in sequence, and complete the splicing and sealing of unit 1 of the enclosure.

[0067] Test Project Traditional integral coil (control group) This scheme uses segmented coils (experimental group). Performance Comparison Test conditions On-resistance at room temperature (single-phase coil) 8.7mΩ 3.2mΩ Resistance decreased by 63.2% Temperature 25℃, humidity 45% 120℃ high temperature on-resistance 11.3mΩ 4.5mΩ Resistance decreased by 59.3%. Temperature rise of the simulated coil in the constant temperature chamber Resistance change rate after 100,000 vibration tests 4.2% 0.8% Stability improved by 81% Vibration frequency 10-50Hz, amplitude 2mm (suitable for transport / operation vibration of prefabricated substations) Continuity after lightning impulse (10kV) No abnormalities No abnormalities Performance is flat Impulse voltage waveform 1.2 / 50μs Contact pressure (elastic conductive clip) - 6.8N Meets electrical conductivity requirements Pressure sensor (accuracy ±0.1N)

[0068] Table 2

[0069] Breaking through the prejudice that "segmentation inevitably reduces conductivity stability", the elastic pressure of the elastic conductive clamp 13 keeps the contact resistance stably controlled within 3.5mΩ, which is lower than the 8.7mΩ of the traditional integral coil, thus solving the industry's cognitive limitation that "segmented coils are only suitable for low-voltage, small-capacity equipment".

[0070] Example 2

[0071] Based on Example 1, multiple independent conductive units and a mechanical switching mechanism enable the upper segment coil 5 and the lower segment coil 6 to form a "selectable on / off" connection, achieving graded adjustment of the coil turns. This satisfies the convenience of prefabricated substation assembly while solving the pain point of traditional coils having a fixed number of turns and being unable to adapt to different voltage / load requirements.

[0072] 1. Upper segment coil 5 (adjustable end) structure

[0073] Multiple sets of elastic conductive clips 13: Three sets of independent elastic conductive clips 13 (denoted as clip 1, clip 2, and clip 3) are evenly distributed in a ring around the bottom of the upper segment coil 5, each set corresponding to a different number of turns taps:

[0074] Clip 1: Corresponds to the total number of turns (200 turns) of the upper segment coil 5, located in the innermost annular area;

[0075] Clip 2: Corresponds to the 5150-turn tap of the upper segment coil, located in the middle ring area;

[0076] Clip 3: Corresponds to the 5100-turn tap of the upper segment coil, located in the outermost annular area;

[0077] Each set of conductive clamps has the same structure as the original design, but the sets are separated by an insulating partition (polyimide material, 2mm thick) to prevent short circuits.

[0078] Switching mechanism mounting slot: An annular groove 20 is provided on the outer side of the top of the upper section coil 5 for installing a rotatable switching ring. The switching ring is connected to the coil frame through a bearing and can rotate 360° while being axially fixed.

[0079] 2. Structure of lower segment coil 6 (fixed end)

[0080] Corresponding conductive contact terminals 14: The top of the lower segment coil 6 is provided with 3 sets of annularly distributed conductive contact terminals 14 (denoted as contact 1, contact 2, and contact 3), which correspond one-to-one with the 3 sets of elastic conductive clips 13 of the upper segment coil 5.

[0081] Contact 1: Connects to the lower segment coil 6 with all 200 turns; its inner diameter is compatible with clamp 1.

[0082] Contact 2: Connects to the lower segment coil 6 with all 200 turns (the lower segment coil 6 has no taps, the total number of turns is fixed, and the total number of turns is adjusted by the taps of the upper segment coil 5).

[0083] Contact 3: Connects to the lower segment coil 6 with all 200 turns;

[0084] The conductive contact 14 is a ring-shaped copper busbar (5mm thick) with silver plating on the surface.

[0085] 3. Mechanical switching mechanism (core on / off control component)

[0086] Switching ring: It adopts an epoxy glass cloth board + embedded conductive sheet structure. The outer ring of the switching ring is equipped with an operating lever (extending to the outside of the coil for easy manual adjustment), and the inner ring is equipped with a set of arc-shaped conductive sheets (the width of which matches the single set of conductive clips).

[0087] Conductive sheet material: phosphor bronze plated with silver, contact pressure with elastic conductive clip 13 ≥6N;

[0088] The switching ring has three positioning slots that work with the spring positioning beads of the upper segment coil 5 to ensure that each set of conductive clamps is accurately connected to the corresponding contact end after switching, without any offset.

[0089] Insulation design: Except for the conductive sheet area, the rest of the switching ring is made of insulating material.

[0090] 4. Turns adjustment logic

[0091] By rotating the operating lever of the switching ring, the 13 sets of flexible conductive clips are selected for operation, thereby achieving graded adjustment of the total number of turns:

[0092] Switch position Conductive combination Upper section coil 5 turns The lower segment coil has 6 turns. Total number of turns Suitable voltage scenarios Gear 1 Clip 1 ↔ Touch 1 200 turns 200 turns 400 turns 10kV rated voltage Gear 2 Clip 2 ↔ Touch 2 150 turns 200 turns 350 turns 8.75kV voltage regulation Gear 3 Clip 3 ↔ Touch 3 100 turns 200 turns 300 turns 7.5kV voltage regulation

[0093] Table 3

[0094] 5. Locking and anti-misoperation design

[0095] After the switching ring is positioned, the spring positioning ball is embedded in the slot to prevent vibration from causing gear shift.

[0096] The operating lever is equipped with a protective cover (which is snapped together with the coil frame). Adjustment can only be made after the cover is opened to avoid accidental activation.

[0097] Each gear position has a scale mark (1, 2, 3) on the corresponding lever position. Combined with the observation window of the transformer box, the current number of turns can be intuitively confirmed.

[0098] This technology combines "segmented rapid assembly" with "gradually adjustable turns" for the first time, resolving the contradictions of "complex assembly of adjustable coils" and "single-function coils" in traditional technologies. The integrated design of the switching mechanism, elastic conductive clamp 13, and positioning structure allows for switching without additional tools, making it far more convenient than traditional tap-adjustable coils (which require disassembly and wiring). Combining the advantages of the original segmented assembly, it reduces installation difficulty and improves the flexibility of transformer substation operation and maintenance, overcoming the limitations of traditional transformer substations.

[0099] Example 3

[0100] like Figure 2 As shown, unlike Embodiment 1, three identical sets of male connectors 22 and female connectors 23 are arranged side by side along the circumference on the end face of the lower segment coil 6. Each set of male connectors 22 and female connectors 23 is connected to the 200-turn, 150-turn, and 100-turn taps of the lower segment coil 6, respectively. When the upper segment coil 5 and the lower segment coil 6 are connected, the angle of the lower segment coil 6 is rotated so that the male connector 22 is connected to the different sets of female connectors 23 of the lower segment coil 6. After the male connector 22 is inserted into the female connector 23, the annular positioning boss 19 at the end of the male sleeve mating section 18 is embedded in the annular groove 20 of the female sleeve mating section 16. The elastic locking ring 21 automatically clamps the positioning boss 19 to complete the fixation, thereby changing the taps of the connected circuit to achieve the adjustment of the number of turns.

Claims

1. A conveniently assembled prefabricated transformer for power generation, characterized in that, The system includes a housing (1) and a transformer assembly (2). The transformer assembly (2) is located inside the housing (1) and includes an iron core (3) and segmented coils (4). Each phase of the segmented coil (4) is divided into an upper sub-coil (5) and a lower sub-coil (6). The upper sub-coil (5) and the lower sub-coil (6) are two detachable series structures. The upper sub-coil (5) and the lower sub-coil (6) are integrally formed with a modular insulating skeleton, with axial heat dissipation fins (7) integrated on the outer wall and insulating pads attached to the inner wall. The outer walls of the upper sub-coil (5) and the lower sub-coil (6) are provided with sliders that match the horizontal guide rails (9) of the mounting bracket (8) of the housing (1). The sliders can slide into the corresponding position of the iron core (3) along the horizontal guide rails (9) and be fixed with vertical positioning clips (10). The upper sub-coil (5) is provided with a positioning female sleeve (11) at its lower end; the lower sub-coil (6) is provided with a positioning male sleeve (12) that is adapted to the positioning female sleeve (11) at its upper end; the upper sub-coil (5) and the lower sub-coil (6) are detachably connected in series through the positioning female sleeve (11) and the positioning male sleeve (12); the positioning female sleeve (11) is equipped with an elastic conductive clip (13), and the positioning male sleeve (12) is provided with a conductive contact end (14) that contacts and cooperates with the elastic conductive clip (13); The positioning female sleeve (11) is frustum-shaped, and an elastic conductive clip (13) is installed inside the frustum-shaped positioning female sleeve (11); the positioning male sleeve (12) is a frustum-shaped positioning male sleeve (12) that fits with the conical surface of the frustum-shaped positioning female sleeve (11), and the frustum-shaped positioning male sleeve (12) is provided with a conductive contact end (14) that contacts and fits with the elastic conductive clip (13). Inside the winding of the upper sub-coil (5) or the lower sub-coil (6), multiple electrical taps are led out at specific turns positions; the positioning female sleeve (11) integrates multiple sets of mutually insulated elastic conductive clips (13), each elastic conductive clip (13) is connected to a tap of the coil through an internal wire, and the positioning male sleeve (12) is provided with multiple sets of conductive contact ends (14); the modular insulating frame of the upper sub-coil (5) or the lower sub-coil (6) is provided with a rotary or toggle selector switch, the moving contact of the selector switch is connected to the "common end" of the coil, and the stationary contact is connected to the corresponding multiple elastic conductive clips (13).

2. The easily assembled prefabricated transformer for power generation according to claim 1, characterized in that, The frustum-shaped positioning female sleeve (11) includes a female sleeve guide section (15) and a female sleeve mating section (16) connected in sequence; the frustum-shaped positioning male sleeve (12) includes a male sleeve guide section (17) adapted to the female sleeve guide section (15) and a male sleeve mating section (18) adapted to the female sleeve mating section (16); the end of the male sleeve mating section (18) of the frustum-shaped positioning male sleeve (12) is provided with an annular positioning boss (19).

3. The easily assembled prefabricated transformer for power generation according to claim 2, characterized in that, The end of the mating section (16) of the frustum-shaped positioning sleeve (11) is provided with an annular groove (20), and an elastic locking ring (21) is assembled in the annular groove (20). The elastic locking ring (21) is an open beryllium bronze ring.

4. The easily assembled prefabricated transformer for power generation according to claim 1, characterized in that, The elastic conductive clip (13) is a 3-lobed structure evenly distributed along the circumference. The elastic conductive clip (13) is made of beryllium bronze, its surface is silver-plated and the contact area is processed with an arc-shaped groove. The conductive contact end (14) is a cylindrical structure, made of copper and its surface is silver-plated.

5. A conveniently assembled prefabricated transformer for power generation according to claim 1, characterized in that, The upper segment coil (5) or the lower segment coil (6) is in a form that can be connected and disconnected so that the number of turns of the coil can be adjusted.

6. A conveniently assembled prefabricated transformer for power generation according to claim 5, characterized in that, On the end face of the upper sub-coil (5) or the lower sub-coil (6), multiple sets of identical male connectors (22) and female connectors (23) are arranged side by side along the circumference. Each set of male connectors (22) and female connectors (23) is connected to different taps of the coil. When the upper sub-coil (5) and the lower sub-coil (6) are connected, the male connector (22) is connected to different sets of female connectors (23) by rotating the angle of the coil, thereby changing the taps connected to the circuit.

Images