Dry-Type Transformer Shielding Structure to Eliminate Coil Air Gaps
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Solution Overview
Problem
Existing dry-type transformers have a large size due to the need for air gaps between coils for insulation, which can lead to electrical aging from partial discharge, and their winding processes are complex and require high maintenance.
Innovation Solution
A dry-type transformer design that eliminates air gaps by using a shielding component with conducting layers and solid insulation layers to confine electric fields, and a winding method that involves preparing a preform with sequential conducting layers and pouring insulation material in a vacuum to reduce size and prevent partial discharge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If air gaps are reserved between coils for insulation in dry-type transformer, then insulation reliability is improved, but transformer size increases
Solution Approach 1:
A shielding component comprising multiple conducting layers (first, second, third, and fourth conducting layers) is introduced as an intermediary structure between the first coil and second coil. These conducting layers are hermetically connected and equipotentially bonded to the respective coils, creating controlled electric field paths that eliminate the need for large air gaps while maintaining insulation reliability.
Solution Approach 2:
The patent changes the electrical field distribution parameters by using solid insulation layers between conducting layers and coils. This allows the electric field to be confined within specific regions, enabling reduced spacing between coils while maintaining insulation performance. The solid insulation layers transform the insulation approach from relying on air gaps to using controlled solid dielectric barriers.
2Reliability
If air gaps are reserved between coils for insulation, then insulation reliability is improved, but partial discharge occurs causing electrical aging
Solution Approach 1:
The shielding component with multiple conducting layers acts as an intermediary that controls and confines electric fields. By hermetically connecting and equipotentially bonding these layers to the coils, the patent creates controlled electric field paths that prevent field concentration at coil surfaces, thereby eliminating conditions that lead to partial discharge and electrical aging of insulation materials.
Solution Approach 2:
The patent changes the electric field distribution parameters by introducing conducting layers with solid insulation between them. This transforms the electric field from an uncontrolled distribution in air gaps to a confined distribution within solid insulation layers, preventing field intensification that would cause partial discharge and subsequent insulation aging.
3Reliability
If complex winding process is used to achieve proper insulation, then insulation reliability is improved, but manufacturing complexity increases
Solution Approach 1:
The shielding component is designed and prepared as a pre-assembled structure with conducting layers and solid insulation layers already in place. This preliminary preparation allows the component to be installed as a complete insulation system between coils, eliminating the need for complex multi-step winding processes and simplifying manufacturing while maintaining insulation reliability.
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 reduces the size of the dry-type transformer while maintaining insulation reliability, preventing electrical aging from partial discharge and simplifying the winding process, thereby lowering production costs and complexity.
Implementation Method 1
an electric field generated between the first coil and the second coil can be completely limited within the solid insulation layers between the first conducting layer and the second conducting layer and between the third conducting layer and the fourth conducting layer
Implementation Method 2
the first conducting layer and the fourth conducting layer are hermetically connected and both are equipotentially bonded to the first coil, and the second conducting layer and the third conducting layer are hermetically connected and both are equipotentially bonded to the second coil
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
This application provides a dry-type transformer and a winding method thereof. The dry-type transformer includes a magnetic core (11), a first coil (12), a second coil (13), and a shielding component (14). The first coil (12) is disposed around the exterior of the magnetic core (11), and the second coil (13) is disposed around the exterior of the first coil (12). In a direction from the iron core to the second coil, the shielding component includes a first conducting layer (141), a second conducting layer (142), a third conducting layer (143), and a fourth conducting layer (144) that are sequentially disposed at intervals, the first coil is disposed between the magnetic core and the first conducting layer, and the second coil is disposed between the second conducting layer and the third conducting layer. On one side of an axial direction of the iron core, the first conducting layer (141) and the fourth conducting layer (144) are hermetically connected and both are equipotentially bonded to the first coil (12), and the second conducting layer (142) and the third conducting layer (143) are hermetically connected and both are equipotentially bonded to the second coil (13). The first conducting layer and the second conducting layer, and the third conducting layer and the fourth conducting layer are each connected by using a solid insulation layer (15).