A power transformer core structure suitable for high current operating conditions

Abstract

The utility model relates to a kind of electric power transformer body structure suitable for large current operating condition, comprising: low voltage coil, high voltage coil and voltage regulating coil, three concentrically arranged in turn, low voltage coil is located outer layer, high voltage coil is located in the middle, voltage regulating coil is located in inner layer;Low voltage coil is connected to transformer outlet end by the electrically conductive component with hollow structure;Voltage regulating coil is laminated structure, with head outlet end and tail outlet end located on the same side;Insulating isolation component is arranged between coil, and is connected with transformer external circuit by insulating connecting component;Coil structure is installed on body support platform.The utility model solves the technical problems of traditional transformer under large current low voltage operating condition, such as outlet difficulty, potential difference interference and unreliable lead connection.

Description

Technical Field

[0001] This utility model relates to a power transformer body structure suitable for high current operating conditions. Background Technology

[0002] In existing transformer designs, especially under low-voltage, high-current conditions, the limitations of traditional coil structure layouts and lead connection methods have become increasingly apparent. For transformers employing a double-split core structure, when the low-voltage rated current reaches 6536A, continuing to use the traditional built-in low-voltage coil design and spiral arrangement of the voltage regulating coil will present numerous technical challenges.

[0003] Firstly, traditionally, the low-voltage coil is typically located in the innermost layer of the transformer core, a design that operates stably at conventional current levels. However, when the low-voltage current increases significantly, the required low-voltage conductor cross-section must also increase accordingly, resulting in thicker wire gauges and a corresponding increase in lead-out dimensions. In this situation, having the coil located in the inner layer of the core leads to difficulties in wire routing, complicates spatial wiring, inconveniences operation, and may even affect the overall assembly quality.

[0004] Secondly, existing voltage regulating coils mostly employ a helical winding structure and are led out in three sections: upper, middle, and lower. When the voltage regulating coil is still arranged internally in a double-split structure, its leads need to pass through the outer high-voltage and low-voltage coils. This crossing, under high current conditions, can easily induce a potential difference in the conductor path. This potential difference originates from complex electromagnetic field coupling and asymmetrical current distribution, which may not only interfere with the normal operation of the transformer but also pose potential electrical safety risks and even affect the transformer's lifespan and reliability.

[0005] Finally, existing double-split structures often use U-shaped busbars for bridging low-voltage leads. While this approach is simple, it has several drawbacks in practical applications. Due to the large number of studs required for connection and the limited length of the U-shaped busbars, resistance imbalance is easily caused, leading to inconsistent current distribution and potentially localized overheating. Furthermore, the inter-busbar contact stability under this structure is poor. In addition, the small distance between the low-voltage coil leads and the copper busbars / box walls complicates the lead soldering process, restricts operating space, and makes it difficult to meet high-quality, standardized manufacturing and assembly requirements.

[0006] In summary, traditional structures suffer from drawbacks such as difficulty in wiring, potential difference issues, and poor reliability of lead connections when dealing with high current and low voltage output requirements. Structural optimization and design innovation are urgently needed to improve the electrical performance and assembly reliability of the system. Utility Model Content

[0007] The purpose of this utility model is to overcome the shortcomings of the prior art and provide a power transformer body structure suitable for high current operating conditions.

[0008] A transformer body structure suitable for high-current operation conditions includes:

[0009] The low-voltage coil, high-voltage coil, and voltage regulating coil are arranged concentrically in sequence, with the low-voltage coil located on the outer layer, the high-voltage coil located in the middle, and the voltage regulating coil located on the inner layer.

[0010] The low-voltage coil is connected to the transformer output terminal via a conductive component with a hollow structure.

[0011] The voltage regulating coil has a stacked structure, with a head output end and a tail output end located on the same side;

[0012] Insulating isolation components are provided between the coils, and they are connected to the external circuit of the transformer through insulating connection components;

[0013] The coil structure is mounted on the device support platform.

[0014] Furthermore, the conductive component is a hollow copper tube.

[0015] Furthermore, the hollow copper tube is connected to the low-voltage coil by welding or mechanical fastening.

[0016] Furthermore, the voltage regulating coil has a multi-layer stacked structure with at least two winding layers to enhance its longitudinal insulation performance.

[0017] Furthermore, the insulating isolation component provided between the coils is an insulating plate or insulating pad based on a high-strength heat-resistant composite material.

[0018] Furthermore, the device support platform is a pressure-bearing bracket with an insulating and anti-slip structure, used to stabilize the overall structure of the coil and maintain its relative position.

[0019] Beneficial effects: Compared with the prior art, the present invention has the following advantages:

[0020] This structure simplifies the wiring connection by placing the low-voltage coil on the outermost layer of the transformer body, significantly reducing the complexity and manufacturing difficulty of the low-voltage, high-current leads. This allows for cost savings while meeting the requirements of ultra-high current operation. The high-voltage coil is positioned midway between the regulating coil and the low-voltage coil, effectively optimizing the overall magnetic field distribution, reducing leakage inductance, and decreasing the insulation distance between the high and low voltage coils, thereby reducing the amount of insulation material used and related costs.

[0021] The voltage regulating coil adopts an innovative layered winding structure, designed with a double-lead configuration where both the head and tail leads are located on the same side. This structure improves wiring convenience while effectively avoiding the insulation risks associated with winding leads passing through the transformer body, further reducing the probability of insulation damage, enhancing operational safety, and achieving a dual optimization of compactness and economy in structural layout.

[0022] To replace the traditional copper busbar structure, this invention uses a hollow copper tube as a low-voltage conductive connector. On one hand, the hollow structure significantly reduces the skin effect, improving conductivity under high current. On the other hand, this design effectively saves space occupied by the conductor in the cross-sectional direction, which is beneficial for improving assembly efficiency and the overall compactness of the transformer. Simultaneously, the use of hollow copper tubes reduces reliance on bolted connections, simplifies the installation process, and makes wiring operations more convenient and efficient.

[0023] Furthermore, the optimized layout of the overall structure effectively reduces the size of the transformer body, providing more compact space for on-site installation while meeting electrical performance requirements, further reducing installation and maintenance costs for users. The internal lead connection path is simple and clear, effectively avoiding insufficient insulation distance and insulation defects caused by complex wiring, fundamentally improving the safety and reliability of transformer operation. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of the vessel's structure;

[0025] Figure 2 This is a schematic diagram of the output terminals of the voltage regulating coil;

[0026] In the diagram, 1 is the low-voltage coil, 2 is the high-voltage coil, 3 is the voltage regulating coil, 4 is the head outlet, and 5 is the tail outlet. Detailed Implementation

[0027] To enhance understanding of this utility model, the present utility model will be further described in detail below with reference to the embodiments and accompanying drawings. These embodiments are only used to explain the present utility model and do not constitute a limitation on the scope of protection of the present utility model.

[0028] A power transformer body structure suitable for high-current operation includes a low-voltage coil 1, a high-voltage coil 2, and a voltage regulating coil 3, which are arranged concentrically in sequence. The low-voltage coil 1 is located in the outer layer, the high-voltage coil 2 is located in the middle, and the voltage regulating coil 3 is located in the inner layer. The low-voltage coil 1 is connected to the transformer output terminal through a conductive component with a hollow structure. The voltage regulating coil 3 has a stacked structure with a head output terminal 4 and a tail output terminal 5 located on the same side. Insulating isolation components are provided between the coils, and they are connected to the external circuit of the transformer through insulating connection components. The coil structure is installed on the transformer body support platform.

[0029] This structure, with its concentric arrangement of low-voltage coil 1 on the outermost layer, high-voltage coil 2 in the middle, and voltage regulating coil 3 on the innermost layer, effectively reduces leakage flux and improves electromagnetic coupling efficiency. The low-voltage coil 1 uses a hollow conductive component to connect the output terminals, enhancing conductivity and facilitating heat dissipation. The voltage regulating coil 3 is designed with a stacked structure, and its head and tail output terminals 5 are both located on the same side, facilitating integrated wiring and reducing voltage drop caused by winding length. The insulating isolation components ensure electrical insulation between the coils, preventing high-voltage breakdown, while the insulating connection components ensure reliable connection to external circuits.

[0030] This device structure is suitable for high-current operation scenarios. Concentric arrangement optimizes magnetic flux distribution, improving electrical performance. The hollow conductive components enhance conductivity and facilitate oil or air cooling, improving system safety and stability. The stacked design of the voltage regulating coil 3 increases longitudinal insulation strength, and the same-side arrangement of the output terminals simplifies wiring, effectively reducing installation time and space requirements. The introduction of insulation and connection components further enhances electrical safety and structural reliability, ensuring long-term stable system operation.

[0031] In one possible implementation, the conductive component is a hollow copper tube.

[0032] Hollow copper tubing is used as the conductive component due to its excellent conductivity and high mechanical strength, making it suitable for stable conduction under high current conditions. Because of copper's high conductivity, it can carry a larger current load per unit cross-sectional area. Simultaneously, the hollow structure facilitates the formation of oil or airflow channels, which is beneficial for heat exchange and heat dissipation, preventing conductor damage due to overheating. This structure also facilitates welding or mechanical fastening to the coil ends, simplifying the assembly process.

[0033] The application of hollow copper tubes not only improves overall conductivity but also facilitates heat dissipation, enhancing the reliability and safety of the system under high-current operating conditions. Furthermore, their excellent machinability and weldability facilitate integration with the transformer body, effectively improving production efficiency and assembly consistency.

[0034] In one possible implementation, the hollow copper tube is connected to the low-voltage coil 1 by welding or mechanical fastening.

[0035] When connected by welding, a metallurgical bond is formed between the hollow copper tube and the low-voltage coil conductor 1, ensuring the stability and durability of the electrical connection. If a mechanical fastening method, such as bolt clamping or crimping, is used, a reliable electrical connection is achieved through high-voltage contact, facilitating later maintenance or replacement. Both methods ensure good conductivity and vibration resistance during operation.

[0036] Welding provides a highly reliable permanent connection, suitable for long-term operating environments; mechanical fastening offers advantages such as convenient assembly and repeated disassembly / reassembly, facilitating later maintenance and replacement. Both methods enhance the overall stability and operational flexibility of the system.

[0037] In one possible implementation, the voltage regulating coil 3 has a multi-layer stacked structure with at least two winding layers to enhance its longitudinal insulation performance.

[0038] The voltage regulating coil 3 adopts a multi-layered winding configuration, with the windings arranged axially in layers, separated by an insulating medium. This effectively disperses the voltage gradient and enhances insulation performance. Under high-voltage conditions, this structure can suppress local electric field concentration, reduce the risk of breakdown, and improve the overall voltage resistance of the coil. Its distributed wiring structure also contributes to a uniform magnetic field distribution, reducing leakage inductance and electromagnetic interference.

[0039] The multi-layer lap winding structure enhances the longitudinal insulation capability of the voltage regulating coil 3, adapting to higher voltage and current requirements and improving system safety. This structure can significantly extend the service life of insulation materials and improve overall operational reliability, making it particularly suitable for operating environments with frequent voltage fluctuations or high insulation requirements.

[0040] In one possible implementation, the insulating isolation component disposed between the coils is an insulating plate or insulating pad based on a high-strength heat-resistant composite material.

[0041] Insulating isolation components are located between coils at different potentials and are made of high-strength composite insulating materials, maintaining mechanical and electrical stability under high temperatures and high electric field strengths. These materials are typically composed of an epoxy resin matrix and glass fiber reinforcement, possessing excellent thermal stability, compressive strength, and insulation properties. The installation of insulating plates or pads not only provides electrical isolation but also structural support, suppressing vibration and displacement between coils.

[0042] Isolation components made of high-strength, heat-resistant insulating materials can effectively prevent breakdown faults and extend the service life of transformers; at the same time, they have good mechanical strength, ensuring the stability and compactness of the transformer body structure, and improving the overall seismic performance and operational safety level.

[0043] In one possible implementation, the coil support platform is a pressure-bearing bracket with an insulating and anti-slip structure, used to stabilize the overall coil structure and maintain its relative position.

[0044] The pressure-bearing support forms the basic support platform for the transformer body. Its surface is equipped with anti-slip textures or raised structures to effectively prevent the coil from shifting due to mechanical vibration during transportation and operation. The platform is made of materials with good mechanical strength and insulation properties, which can withstand the static load of the coil and the stress generated by thermal expansion and contraction, while preventing the formation of potential short circuit paths and improving overall safety.

[0045] The insulated, anti-slip support platform enhances the overall stability and vibration resistance of the transformer body structure, ensuring accurate positioning of each coil and effectively reducing the mechanical failure rate. Simultaneously, the insulation structure reduces the risk of partial discharge and electrical accidents, improving the overall electrical safety level of the transformer.

[0046] Working Principle: The overall structure adopts a concentric arrangement of three layers of coils: an inner voltage regulating coil 3, a middle high-voltage coil 2, and an outer low-voltage coil 1. The voltage regulating coil 3 has a multi-layer stacked structure with high longitudinal insulation performance. Its head outlet 4 and tail outlet 5 are both located on the same side, facilitating external wiring and unified wiring management. The high-voltage coil 2 is located in the middle layer, serving as the power transmission channel, and together with the voltage regulating coil 3 and low-voltage coil 1, forms the main magnetic circuit system. The low-voltage coil 1 is located in the outermost layer and is directly connected to the transformer's outlet terminal through a hollow conductive component. The conductive component is preferably a hollow copper tube, which can be connected to the low-voltage coil 1 by welding or mechanical fastening to achieve a reliable electrical connection. Each coil is electrically isolated by an insulating isolation component made of high-strength heat-resistant composite material, and connected to the external circuit using an insulating connection component. The entire coil structure is mounted on a pressure-bearing support with an anti-slip insulating structure. The support serves as a platform for the transformer body, providing necessary structural support and electrical isolation.

[0047] The working principle of this structure is mainly reflected in the following aspects: First, the concentric arrangement of the three-layer coils optimizes the electromagnetic coupling path, reduces leakage flux, improves transformer efficiency, and suppresses electromagnetic interference. The voltage regulating coil 3 enhances longitudinal electrical insulation performance through multi-layer winding, effectively suppressing electric field concentration in high-potential-difference regions and reducing the risk of insulation breakdown. The magnetic flux path between the high-voltage coil 2 and the low-voltage coil 1 is short, resulting in high energy transfer efficiency. The low-voltage coil 1 conducts electricity directly through a hollow copper tube, which possesses excellent conductivity and structural strength. Its cavity can also serve as an oil or air passage for heat dissipation, ensuring thermal stability during high-current operation. The connection between the copper tube and the low-voltage coil 1 can be achieved through welding to achieve metallurgical contact, or through mechanical fastening to ensure maintainability and vibration resistance. The insulating isolation components placed between the coils not only provide efficient insulation but also withstand radial and axial forces, effectively limiting structural displacement caused by electromagnetic forces or thermal expansion during coil operation. The insulating pressure-bearing bracket at the bottom of the device body is equipped with an anti-slip structure, which effectively fixes the position of the overall coil. At the same time, its insulation characteristics avoid the risk of short circuit in the electrical path, enhancing the overall safety and reliability of the system.

[0048] The above description is only a preferred embodiment of the present utility model and is not intended to limit the present utility model. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.

Claims

1. A transformer body structure suitable for high-current operation, characterized in that, include: The low-voltage coil, high-voltage coil, and voltage regulating coil are arranged concentrically in sequence, with the low-voltage coil located on the outer layer, the high-voltage coil located in the middle, and the voltage regulating coil located on the inner layer. The low-voltage coil is connected to the transformer output terminal via a conductive component with a hollow structure. The voltage regulating coil has a stacked structure, with a head output end and a tail output end located on the same side; Insulating isolation components are provided between the coils, and they are connected to the external circuit of the transformer through insulating connection components; The coil is mounted on the support platform of the device body.

2. The power transformer body structure as described in claim 1, characterized in that, The conductive component is a hollow copper tube.

3. The power transformer body structure as described in claim 2, characterized in that, The hollow copper tube is connected to the low-voltage coil by welding or mechanical fastening.

4. The power transformer body structure as described in claim 1, characterized in that, The voltage regulating coil has a multi-layer stacked structure with at least two winding layers to enhance its longitudinal insulation performance.

5. The power transformer body structure as described in claim 1, characterized in that, The insulating isolation components provided between the coils are insulating boards or insulating pads based on high-strength heat-resistant composite materials.

6. The power transformer body structure as described in claim 1, characterized in that, The device body support platform is a pressure-bearing bracket with an insulating and anti-slip structure, used to stabilize the overall structure of the coil and maintain its relative position.

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