Dielectric Cooling Tubes for Transformer Winding Temperature Control
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Solution Overview
Problem
Non-liquid immersed transformers face temperature rise issues during operation, which affect their performance and lifespan, particularly at higher voltages, where existing cooling methods like air cooling and metallic serpentine solutions are inefficient.
Innovation Solution
Incorporating dielectric cooling tubes made of dielectric material, continuously wound in loops around the magnetic core within the coil windings, utilizing dielectric fluid to cool the windings, and optionally connected to an external cooling circuit with a pump and heat-exchanger, allowing for efficient heat dissipation without voltage drops.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If air cooling or metallic serpentine solutions are used in non-liquid immersed transformers, then the transformer structure is simpler, but the cooling efficiency is insufficient especially at higher voltages
Solution Approach 1:
The patent introduces dielectric fluid as an intermediary cooling medium that flows through dielectric cooling tubes positioned inside the coil windings. This intermediary system enables efficient heat transfer from the windings to the cooling fluid, resolving the insufficient cooling efficiency of direct air cooling or metallic serpentine methods while maintaining electrical insulation through the use of dielectric materials.
Solution Approach 2:
The dielectric cooling tubes are nested inside the coil windings, with the cooling tubes positioned within the spaces between turns of the winding. This nested arrangement maximizes the cooling surface area in contact with the windings while maintaining a compact transformer structure, thereby improving cooling efficiency without significantly increasing the overall transformer size.
2Temperature
If dielectric cooling tubes are placed inside coil windings, then cooling efficiency improves, but the manufacturing complexity increases
Solution Approach 1:
The cooling system is segmented into multiple separate dielectric cooling tubes that can be independently manufactured and then installed within the coil windings. This segmentation allows for simplified manufacturing of individual tube components and facilitates easier installation and maintenance compared to a single integrated cooling system, thereby reducing overall manufacturing complexity while maintaining effective cooling.
3Temperature
If metallic serpentines are used for cooling, then cooling effectiveness improves, but insulation requirements increase due to grounding needs
Solution Approach 1:
The patent changes the material parameter of the cooling tubes from conductive metal to dielectric material. This parameter change eliminates the need for grounding and complex insulation systems required by metallic serpentines, while maintaining effective heat transfer capabilities through the dielectric walls of the cooling tubes. The dielectric material allows direct placement inside the windings without creating electrical insulation problems.
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 solution effectively reduces temperature rises, enhancing the performance and lifespan of transformers, especially at higher voltages, while simplifying manufacturing and reducing costs by avoiding complex fittings and connections.
Implementation Method 1
cool down the coil winding using dielectric fluid flowing through the cooling tube
Implementation Method 2
dielectric fluid flowing through the cooling tube made of dielectric material
Implementation Method 3
at least one cooling tube made of dielectric material arranged inside at least one of the coil windings
Data Source
AI summary
A non-liquid immersed transformer including a magnetic core having a winding axis and at least two coil windings wound around the magnetic core along the winding axis. One or more cooling tubes made of dielectric material are arranged inside at least one of the coil windings to cool down the coil winding using dielectric fluid flowing through the dielectric cooling tubes. Each cooling tube is wound continuously forming one or more complete loops around the core.