A capacity-increasing structure of a calcium carbide furnace transformer
By coordinating the electromagnetic module and the winding topology module, and combining the integrated winding of multi-strand windings and segmented windings, along with the signal acquisition of the load sensor and the dynamic control of the controller, the problem of insufficient capacity of the electric furnace transformer was solved, thereby increasing the transformer capacity and ensuring the stable operation of the calcium carbide furnace, thus improving production efficiency and product quality.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- WUHAI ZHONGLIAN CHEM CO LTD
- Filing Date
- 2025-07-28
- Publication Date
- 2026-07-24
AI Technical Summary
The limited capacity of electric furnace transformers makes it difficult to withstand the impact load of calcium carbide furnaces, leading to voltage fluctuations, affecting arc stability and calcium carbide product quality, and making it difficult to ensure continuous and stable production.
By employing the coordinated connection of electromagnetic modules, winding topology modules, electrical withstand modules, voltage regulation and stabilization modules, operating condition adaptation modules, and thermal management modules, combined with the integrated winding of multi-strand windings and segmented windings, signal acquisition from load sensors, and dynamic control by the controller, the transformer capacity can be increased and its operation stabilized.
This has resulted in increased transformer capacity, stable operation of the calcium carbide furnace, reduced operating losses, and improved efficiency and product quality in calcium carbide production.
Smart Images
Figure CN224554144U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of calcium carbide production equipment modification technology, and in particular to a capacity expansion structure for a calcium carbide furnace transformer. Background Technology
[0002] The electric furnace transformer converts the high-voltage, low-flow electricity from the power grid into low-voltage, high-current electricity suitable for calcium carbide furnace production. The low-voltage, high-current electricity from the secondary side of the transformer is transmitted to the calcium carbide furnace through a short grid and three-phase electrodes. The current flows through the furnace charge, generating arc heat and resistance heat. The furnace charge reacts at a high temperature of 1800–2200 degrees Celsius to produce calcium carbide.
[0003] Transformers have limited capacity and cannot withstand the impact load of calcium carbide furnaces. They are prone to limiting operating load and are easily overloaded when faced with load fluctuations, causing severe voltage fluctuations, damaging arc stability, affecting the quality of calcium carbide products, and making it difficult to ensure continuous and stable production. Utility Model Content
[0004] To overcome the above deficiencies, this utility model provides a capacity-enhancing structure for an electric furnace transformer, aiming to improve the problem of limited capacity of electric furnace transformers.
[0005] To achieve the above objectives, this utility model provides the following technical solution: a capacity-enhancing structure for a calcium carbide furnace transformer, comprising an electromagnetic module, a winding topology module, an electrical withstand module, a voltage regulating and stabilizing module, an operating condition adaptation module, and a thermal management module. The electromagnetic module is electrically connected to the winding topology module, the winding topology module is electrically connected to the electrical withstand module, the electrical withstand module is electrically connected to the voltage regulating and stabilizing module, the voltage regulating and stabilizing module is electrically connected to the operating condition adaptation module, and the operating condition adaptation module is electrically connected to the thermal management module.
[0006] Preferably, the thermal management module includes a cooling system and a temperature sensor, and the output of the temperature sensor is electrically connected to the input of the operating condition adaptation module.
[0007] Preferably, the cooling system is electrically connected to the electrical withstand module and the electromagnetic module, and the thermal management module is bidirectionally electrically connected to the electrical withstand module.
[0008] Preferably, the electromagnetic module and the electrical withstand module are bidirectionally electrically connected.
[0009] Preferably, the electromagnetic module includes a multi-strand winding and an iron core, the electrical withstand module includes a high-voltage insulation layer and a high-voltage bushing, the winding topology module includes segmented windings and winding supports, the operating condition adaptation module includes a load sensor and a controller, and the voltage regulation and stabilization module includes a voltage regulating switch and a voltage monitor.
[0010] Preferably, the segmented winding is integrated with the multi-strand winding.
[0011] Preferably, the controller is connected to the load sensor and the temperature sensor, and outputs control signals to the voltage regulator switch and the thermal management module.
[0012] Preferably, the input terminal of the load sensor is electrically connected to the output terminal of the external short network, and the load sensor collects the current signal of the external short network and transmits it to the controller.
[0013] This utility model has the following beneficial effects:
[0014] 1. In this utility model, the transformer capacity is increased by the coordinated connection of the electromagnetic module, winding topology module, electrical withstand module, voltage regulation and stabilization module and operating condition adaptation module, combined with the integrated winding of multi-strand winding and segmented winding, the acquisition of external signals by the load sensor and the dynamic control of the controller.
[0015] 2. In this utility model, the long-term stable operation of the transformer after capacity expansion is achieved through the cooperation of the cooling system of the thermal management module and the temperature sensor, the signal interaction between the temperature sensor and the operating condition adaptation module, and the connection between the cooling system and the electrical withstand module and the electromagnetic module. Attached Figure Description
[0016] Figure 1 A schematic block diagram of the modular structure of a capacity-enhancing structure for a calcium carbide furnace transformer proposed in this utility model;
[0017] Figure 2 This utility model presents a schematic block diagram of an electromagnetic module for a capacity-enhancing structure of a calcium carbide furnace transformer.
[0018] Figure 3 This is a schematic block diagram of the electrical withstand module of the capacity expansion structure of a calcium carbide furnace transformer proposed in this utility model;
[0019] Figure 4 This is a schematic block diagram of the winding topology module of a capacity-enhancing structure for a calcium carbide furnace transformer proposed in this utility model.
[0020] Figure 5 This is a schematic block diagram of the working condition adaptation module for the capacity expansion structure of a calcium carbide furnace transformer proposed in this utility model.
[0021] Figure 6 This is a schematic block diagram of a voltage regulation and stabilization module for a capacity expansion structure of a calcium carbide furnace transformer proposed in this utility model;
[0022] Figure 7 This is a schematic block diagram of the thermal management module of a capacity-enhancing structure for a calcium carbide furnace transformer proposed in this utility model. Detailed Implementation
[0023] The technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this utility model, and not all embodiments. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of this utility model.
[0024] Reference Figure 1 The present invention provides an embodiment of a capacity-enhancing structure for a calcium carbide furnace transformer, comprising an electromagnetic module, a winding topology module, an electrical withstand module, a voltage regulating and stabilizing module, an operating condition adaptation module, and a thermal management module. The electromagnetic module is electrically connected to the winding topology module, the winding topology module is electrically connected to the electrical withstand module, the electrical withstand module is electrically connected to the voltage regulating and stabilizing module, the voltage regulating and stabilizing module is electrically connected to the operating condition adaptation module, and the operating condition adaptation module is electrically connected to the thermal management module.
[0025] Specifically, the connection between the electromagnetic module and the winding topology module, through the integrated winding of multi-strand and segmented windings, optimizes the current distribution path, reduces winding losses, breaks through the capacity limitations of the transformer, and achieves higher power density power conversion. The cooperation between the winding topology module and the electrical withstand module, utilizing the synergy of the high-voltage insulation layer and the high-voltage bushing, ensures insulation reliability under high-voltage environments. The connection between the electrical withstand module and the voltage regulation and stabilization module enables the transformer to dynamically adjust the output voltage according to load changes, maintain arc stability, and improve calcium carbide production efficiency. The linkage between the voltage regulation and stabilization module and the operating condition adaptation module, through the real-time acquisition of external short-circuit current signals by the load sensor, allows the controller to precisely adjust the voltage regulation switch based on the signal, achieving accurate load adaptation and reducing reactive power loss. The synergy between the modules achieves capacity improvement and enhances production stability.
[0026] Reference Figure 7 The thermal management module includes a cooling system and a temperature sensor. The output of the temperature sensor is electrically connected to the input of the operating condition adaptation module.
[0027] Specifically, the cooling system of the thermal management module and the temperature sensor form a temperature control system. The temperature sensor captures the temperature status of key components of the electromagnetic module and electrical withstand module in real time and transmits the signal to the operating condition adaptation module. This allows the operating condition adaptation module to dynamically adjust the operating intensity of the cooling system based on temperature changes, preventing insulation aging or winding performance degradation caused by local overheating. This provides a stable temperature environment for the transformer to continuously withstand high power output after capacity expansion, ensuring long-term reliable operation of the equipment at higher capacities.
[0028] Reference Figure 2 , Figure 3 and Figure 7The cooling system is electrically connected to the electrical withstand module and the electromagnetic module, and the thermal management module is bidirectionally electrically connected to the electrical withstand module.
[0029] Specifically, when the electromagnetic module generates heat, the cooling system starts simultaneously to remove the heat from the windings and iron core, maintaining electromagnetic conversion efficiency. Meanwhile, the heat generated by the high-voltage insulation layer and high-voltage bushing of the electrical withstand module during current transmission is also monitored in real time by the cooling system, preventing the insulation material from degrading due to high temperatures. The bidirectional connection between the thermal management module and the electrical withstand module achieves a closed loop of temperature feedback and insulation performance optimization. The temperature sensor transmits monitoring data to the operating condition adaptation module. After analysis by the controller, the cooling system precisely adjusts the heat dissipation power. At the same time, the electrical withstand module can dynamically adjust insulation parameters according to the temperature status, maintaining stable heat dissipation while improving insulation reliability, ensuring the continuous and stable operation of the calcium carbide furnace.
[0030] Reference Figure 2 and Figure 3 The electromagnetic module and the electrical withstand module are bidirectionally electrically connected.
[0031] Specifically, when the multi-strand windings and iron core of the electromagnetic module generate high voltage during the power conversion process, the high-voltage insulation layer and high-voltage bushing of the electrical withstand module respond immediately, suppressing partial discharge by optimizing the electric field distribution to ensure safe transmission of high voltage. The changes in the insulation state of the electrical withstand module under long-term high-voltage environment will be fed back to the electromagnetic module, causing the winding topology to dynamically adjust the current distribution and reduce the electric field strength at weak insulation points to reduce downtime due to faults.
[0032] Reference Figures 2-6 The electromagnetic module includes multi-strand windings and an iron core; the electrical withstand module includes a high-voltage insulation layer and a high-voltage bushing; the winding topology module includes segmented windings and winding supports; the operating condition adaptation module includes a load sensor and a controller; and the voltage regulation and stabilization module includes a voltage regulator switch and a voltage monitor.
[0033] Specifically, the electromagnetic module's multi-strand windings and iron core improve power conversion efficiency through optimized turns ratio and magnetic circuit design. The electrical withstand module's high-voltage insulation layer and high-voltage bushings employ a composite insulation structure, working together to raise the withstand voltage level to over 800kV, supporting high-voltage transmission. The winding topology module's segmented windings reduce winding losses through gradient impedance matching technology. The winding support components are made of high-strength materials, maintaining minimal deformation under high dynamic impact forces to ensure structural stability. The operating condition adaptation module's load sensor collects short-circuit current in real time, and the controller, based on a PID algorithm, can complete voltage regulation decisions quickly. The voltage regulation and stabilization module's voltage regulator switch uses vacuum arc extinguishing for rapid opening and closing. The voltage monitor compares the output with the preset value in real time, automatically adjusting upon detecting deviations, achieving high capacity and high reliability.
[0034] Reference Figure 2 and Figure 4 The segmented windings and multi-strand windings are integrated and wound.
[0035] Specifically, by fitting and arranging the windings together, the current is distributed more evenly among the conductors during transmission, avoiding overheating caused by local current concentration. At the same time, it optimizes the electric field distribution around the windings, reduces local electric field distortion, enhances the insulation reliability during high-voltage transmission, and ensures long-term stable operation under high loads.
[0036] Reference Figure 5 The controller is connected to the load sensor and temperature sensor, and outputs control signals to the voltage regulator and thermal management module.
[0037] Specifically, the controller receives load signals from the load sensor and equipment temperature information from the temperature sensor in real time. By analyzing the signals, it dynamically sends adjustment commands to the voltage regulator to adapt to load fluctuations. At the same time, it outputs control signals to the thermal management module to regulate the cooling intensity, ensuring efficient and reliable power conversion during operation.
[0038] Reference Figure 1 and Figure 5 The input terminal of the load sensor is electrically connected to the output terminal of the external short network. The load sensor collects the current signal of the external short network and transmits it to the controller.
[0039] Specifically, the connection between the load sensor and the external short network allows the sensor to directly capture changes in the current flowing in the short network. When the load sensor transmits these subtle current signals to the controller, the controller can adjust the output voltage of the voltage regulator switch according to the load characteristics contained in the signal, so as to support the continuous and efficient production of the calcium carbide furnace.
[0040] Working Principle: Through the cooperation of the electromagnetic module and the winding topology module, and the integrated winding of multi-strand and segmented windings, the current and voltage distribution is optimized, overcoming the limitations of current and voltage increases. The electrical withstand module connects with the electromagnetic module to support stable high-voltage transmission and prevent insulation breakdown. The voltage regulation and stabilization module receives signals from the operating condition adaptation module and dynamically adjusts the voltage to match load fluctuations. The operating condition adaptation module collects external short-circuit current signals through a load sensor and, in conjunction with the controller, achieves precise control of voltage regulation and heat dissipation. Overall, through energy transfer, load adaptation, and voltage stabilization, it achieves increased transformer capacity, increased calcium carbide furnace production capacity, and reduced operating losses.
[0041] Temperature sensors transmit the collected temperature signals from the electromagnetic module and electrical withstand module to the controller of the operating condition adaptation module. The controller drives the cooling system to dynamically adjust the heat dissipation power based on the preset temperature threshold and load signal. The thermal management module is bidirectionally connected to the electrical withstand module and electromagnetic module to ensure that the hot spot temperature is stable within a safe range under high load, avoiding derating or failure due to overheating, and providing a guarantee for the long-term stable operation of the transformer after capacity expansion.
[0042] Finally, it should be noted that the above description is only a preferred embodiment of the present utility model and is not intended to limit the present utility model. Although the present utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. 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 capacity-enhancing structure for a calcium carbide furnace transformer, comprising an electromagnetic module, a winding topology module, an electrical withstand module, a voltage regulation and stabilization module, an operating condition adaptation module, and a thermal management module, characterized in that: The electromagnetic module is electrically connected to the winding topology module, the winding topology module is electrically connected to the electrical withstand module, the electrical withstand module is electrically connected to the voltage regulation and stabilization module, the voltage regulation and stabilization module is electrically connected to the operating condition adaptation module, and the operating condition adaptation module is electrically connected to the thermal management module.
2. The capacity expansion structure for a calcium carbide furnace transformer according to claim 1, characterized in that: The thermal management module includes a cooling system and a temperature sensor, and the output of the temperature sensor is electrically connected to the input of the operating condition adaptation module.
3. The capacity expansion structure for a calcium carbide furnace transformer according to claim 2, characterized in that: The cooling system is electrically connected to the electrical withstand module and the electromagnetic module, and the thermal management module is bidirectionally electrically connected to the electrical withstand module.
4. The capacity expansion structure for a calcium carbide furnace transformer according to claim 1, characterized in that: The electromagnetic module and the electrical withstand module are bidirectionally electrically connected.
5. The capacity expansion structure for a calcium carbide furnace transformer according to claim 1, characterized in that: The electromagnetic module includes a multi-strand winding and an iron core; the electrical withstand module includes a high-voltage insulation layer and a high-voltage bushing; the winding topology module includes segmented windings and winding supports; the operating condition adaptation module includes a load sensor and a controller; and the voltage regulation and stabilization module includes a voltage regulating switch and a voltage monitor.
6. The capacity expansion structure for a calcium carbide furnace transformer according to claim 5, characterized in that: The segmented windings are integrated with the multi-strand windings.
7. The capacity expansion structure for a calcium carbide furnace transformer according to claim 5, characterized in that: The controller is connected to the load sensor and temperature sensor, and outputs control signals to the voltage regulator switch and thermal management module.
8. The capacity expansion structure for a calcium carbide furnace transformer according to claim 5, characterized in that: The input terminal of the load sensor is electrically connected to the output terminal of the external short network. The load sensor collects the current signal of the external short network and transmits it to the controller.