Current Transformer Unit With Dielectric Air Space
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Solution Overview
Problem
High voltage transformers face challenges with partial discharge due to air voids between dielectric layers, leading to electrical breakdown and signal fidelity issues, which are difficult and costly to address through conventional methods like vacuum filling or increasing dielectric thickness, especially in compact applications.
Innovation Solution
A transformer unit with a dielectric housing and magnetic core configuration that creates a dielectric air space between the magnetic core and coils, using positioning portions to maintain a minimum air distance and reduce electrical field strength, thereby eliminating or reducing partial discharge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a dielectric layer is positioned against and surrounds the magnetic core with coils wound directly over it, then the insulation protection is provided, but small air spaces or voids are created between coil windings and dielectric layer which favor partial discharge
Solution Approach 1:
The invention extracts the harmful air voids from the dielectric layer by creating a dedicated dielectric air space between the magnetic core and coil windings. This is achieved by positioning the coils at a distance from the core using support structures, thereby eliminating the voids that would otherwise form between tightly wound coils and the dielectric layer, and removing the source of partial discharge
Solution Approach 2:
The invention introduces an intermediary dielectric air space between the magnetic core and coil windings. This air space acts as a mediator that provides dielectric separation and prevents direct contact between coils and the core, thereby eliminating partial discharge while maintaining insulation protection
2Reliability
If the dielectric layer thickness is increased to eliminate partial discharge, then partial discharge is reduced, but the device volume, mass and cost increase
Solution Approach 1:
The invention segments the dielectric structure into two distinct parts: a thin dielectric layer surrounding the magnetic core for protection, and a separate dielectric air space between the core and coils. This segmentation allows the thin layer to provide insulation while the air space eliminates partial discharge, avoiding the need for a single thick dielectric layer that would increase volume
3Reliability
If conventional methods like vacuum filling or increasing dielectric thickness are used to address partial discharge, then partial discharge is reduced, but the manufacturing complexity and cost increase
Solution Approach 1:
The invention performs preliminary action by pre-positioning the coil windings at a specific distance from the magnetic core using support structures during manufacturing. This preliminary positioning creates the dielectric air space before the transformer is put into service, eliminating the need for post-manufacturing processes like vacuum filling or complex dielectric application
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
The solution provides a compact, economical, and reliable transformer unit that effectively reduces partial discharge, ensuring stable signal transmission and power transfer across high voltage differences, while being easy to produce and assemble, even in limited spaces.
Implementation Method 1
there may be a phenomenon of partial discharge that could eventually lead to an electrical breakdown or have an adverse effect on the performance of the transformer
Implementation Method 2
provides a dielectric separation that should withstand breakdown of the dielectric due to the voltage difference
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A transformer (3, 3') including a housing (6), a magnetic core (10, 10') and transformer coils (12, 12') wound around the housing. The housing (6) defines a magnetic core receiving cavity (20, 20') in which the magnetic core (10, 10') is mounted. The housing further comprises positioning portions (8) projecting from walls of the housing in the magnetic core receiving cavity, configured to position the magnetic core in the magnetic core receiving cavity to form a dielectric air space (15, 15') between the magnetic core and the transformer coil.