Double-pole Voltage Transformer Segmented Bushing Design
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Solution Overview
Problem
The existing double-pole voltage transformers with resin insulation face high manufacturing costs due to the use of expensive molds and have a weak mechanical structure at the bushing-body junction, which is prone to cracks from resin shrinkage and temperature changes.
Innovation Solution
A double-pole voltage transformer design featuring a circular central element with circumferential and side sheds, where bushings are detachably joined via truncated cone projections, reducing the stress concentration and using an insulating compound for sealing, thereby lowering manufacturing costs and enhancing mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If insulating bushings and transformer body are connected in one resin cast, then manufacturing is simplified, but mechanical strength at the junction is reduced and cracks may occur
Solution Approach 1:
The transformer is divided into separate components: the resin-cast transformer body and detachable insulating bushings. This segmentation allows the body to be manufactured without complex integrated bushing molds, reducing manufacturing complexity while maintaining structural integrity through the detachable connection design.
Solution Approach 2:
The insulating bushings are extracted as separate detachable components from the transformer body. This extraction eliminates the need for expensive integrated molds and prevents crack formation at the junction, as the bushings can be independently manufactured and attached using projections with cavities that distribute mechanical stress.
2Manufacturing precision
If expensive molds are used for resin casting, then manufacturing precision is improved, but manufacturing cost increases
Solution Approach 1:
The transformer is segmented into the resin-cast body and separately manufactured bushings. This allows the use of simpler, less expensive molds for the body casting while achieving sufficient precision through the modular assembly approach.
Solution Approach 2:
The complex bushing structures are extracted and manufactured separately, eliminating the need for expensive integrated molds that would be required to cast bushings with precise geometric features directly into the transformer body.
3Strength
If bushings are detachably joined with projections, then mechanical strength is increased, but device complexity increases
Solution Approach 1:
The projection and cavity features are merged into the mold design, allowing the joining structures to be formed as integral parts of the casting process. This merging approach maintains structural strength while avoiding additional assembly steps or complex fastening mechanisms.
Data Source
AI summary
The application invention generally deals with a double-pole voltage transformer enclosed in a tight enclosure made in the form of a resin cast comprising a central element integrated with a base and comprising circumferential sheds and two bushings situated above the circumferential sheds on the central element. The central element has the form of a circular cylinder situated with its side wall horizontally on the base plane, and the circumferential sheds are situated around the central element only in the area of the contact between the central element and the base, and above the circumferential sheds there are side elements of the cast forming side sheds, and above the side sheds there is situated a circumferential top shed surrounding a fragment of the side surface of the central element, and the bushings are detachably joined with the central element through projections respectively.