High-voltage bushing with perforated equalization elements
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Solution Overview
Problem
The production of high-voltage bushings is slow due to the time-consuming process of impregnating pre-wound paper and metal films with oil or resin, and existing methods require specific molds for each type of bushing, making the process inefficient and labor-intensive.
Innovation Solution
A bushing design featuring a sheet-like spacer wound in spiral form around a conductor, with electrically conductive or semi-conductive equalization elements having openings to facilitate the penetration of an insulating matrix material, allowing for separate application of these elements to the core, which accelerates the impregnation process and reduces production time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pre-wound paper and metal films are impregnated with oil or resin, then the bushing achieves proper insulation and electrical properties, but the production process becomes slow and time-consuming
Solution Approach 1:
The patent uses porous ceramic spacers instead of traditional paper and metal film windings. These porous spacers allow rapid impregnation with insulating resin while maintaining proper insulation properties, thus resolving the contradiction between achieving reliable insulation and maintaining fast production speed.
Solution Approach 2:
The invention combines ceramic materials with porous structures to create spacers that simultaneously provide mechanical support, electrical insulation, and rapid resin impregnation capabilities. This composite approach enables both high reliability and high productivity in bushing manufacturing.
2Manufacturing precision
If specific molds are made for each type of bushing, then the bushing achieves correct positioning and shape, but the manufacturing process becomes complex and labor-intensive
Solution Approach 1:
The porous ceramic spacers are pre-formed with precise geometries and mounting features before assembly. This preliminary preparation of components with accurate dimensions and positions eliminates the need for complex custom molds for each bushing type, reducing manufacturing complexity while maintaining precision.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach significantly shortens the impregnation process, enhances the penetration of matrix material, and allows for the use of alternative materials and optimized opening designs, resulting in faster production and improved thermo-mechanical properties of the bushing, including reduced curing time and increased thermal conductivity.
Implementation Method 1
the equalization elements have openings, through which openings the matrix material can penetrate
Implementation Method 2
the sheet-like spacer is impregnated with an electrically insulating matrix material
Implementation Method 3
improved thermo-mechanical properties of the bushing, including reduced curing time and increased thermal conductivity
Data Source
AI summary
A high-voltage bushing has a conductor and a core surrounding the conductor, wherein the core comprises a sheet-like spacer, which spacer is impregnated with an electrically insulating matrix material. The spacer is wound in spiral form around an axis, the axis being defined through the shape of the conductor. Thus, a multitude of neighboring layers is formed. The core further comprises equalization elements in appropriate radial distances to the axis. The equalization elements comprise electrically conductive layers, which layers have openings, through which openings the matrix material can penetrate, and in that the equalization elements are applied to the core separately from the spacer. The electrically conductive layers can be net-shaped, grid-shaped, meshed or perforated. The openings are fillable with the matrix material, e.g., a particle-filled resin can be used.