Condenser Core Fastening Structure for Stable Bushing Connections
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Solution Overview
Problem
High voltage bushings face challenges in reducing the risk of partial discharge and ensuring reliable operation, particularly during the manufacturing and curing processes of resin-impregnated paper condenser cores, where mechanical and electrical connections are prone to stress and movement.
Innovation Solution
A condenser core design featuring an electrically insulating body with a longitudinal through hole, multiple insulated conductive foils, and a fastening device that securely connects a potential electrical conductor to the main electrical conductor, using a fastener and washer to maintain the electrical connection and reduce electric field enhancement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If resin impregnation and curing is used to produce RIP condenser cores, then electrical insulation and field distribution are improved, but mechanical stress and movement during manufacturing cause unreliable electrical connections
Solution Approach 1:
The electrical connection components (contact element, fastening device) are installed and secured to the conductor before the resin impregnation and curing process begins. This preliminary positioning ensures that when the resin is applied and cured, the connection is already established and protected from the mechanical stresses of the manufacturing process, preventing movement and maintaining reliability.
Solution Approach 2:
The fastening device and clamping mechanism are designed to provide pre-compression and mechanical restraint to the electrical connection components before the resin curing process generates thermal expansion and contraction stresses. This beforehand cushioning counteracts the mechanical stress that would otherwise cause movement or disconnection during manufacturing.
2Reliability
If conventional connection methods are used without fastening devices, then device complexity is reduced, but partial discharge risk increases due to unstable connections
Solution Approach 1:
A fastening device acts as an intermediary mechanical element between the conductor and the electrical connection components. This intermediary provides a secure mounting structure that stabilizes the connection, preventing movement and partial discharge, while isolating the complexity of the fastening mechanism from the main condenser core structure.
Solution Approach 2:
The fastening device is designed to be self-contained and self-securing, using simple clamping or screw mechanisms that automatically maintain proper connection pressure without requiring external adjustment or monitoring systems. The connection element itself provides the fastening function, combining electrical connection and mechanical securing in a single integrated component.
3Object-affected harmful factors
If multiple foils are used to smoothen electric field distribution, then electric breakdown risk is reduced, but manufacturing complexity and assembly difficulty increase
Solution Approach 1:
Multiple conductive foils are combined and integrated into a single condenser core structure, where the foils are positioned at different radial distances from the conductor. This merging creates a graduated shielding effect that progressively smoothes the electric field distribution from the high-field region near the conductor to the lower-field regions outward, reducing breakdown risk while maintaining a unified structural design.
Data Source
AI summary
A condenser core for being positioned around a high voltage main electrical conductor, the condenser core including an electrically insulating body; a longitudinal through hole for accommodating the main electrical conductor; a plurality of electrically conductive foils encircling the through hole and being surrounded by the body such that each foil is insulated from any other of the foils; a potential electrical conductor for establishing an electrical connection between one of the foils and the main electrical conductor when the main electrical conductor is accommodated in the through hole; and a fastening device configured to mechanically connect the potential electrical conductor to the main electrical conductor when the main electrical conductor is accommodated in the through hole. A bushing, a high voltage application and a method of producing a bushing are also provided.