Dry-Type Transformer Connection Bar for Terminal Shielding
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Solution Overview
Problem
Conventional submersible dry-type transformers have high voltage terminals and cables exposed on the front side, making them susceptible to damage from side impacts and increasing the risk of electrical hazards during maintenance, while also occupying more space and being costly to manufacture.
Innovation Solution
The design positions high voltage terminals above or below the transformer, using a connection bar with an insulating body and electrical pathways to create connections between coils, reducing the footprint and enhancing safety by shielding electrical connections from external impacts and environments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If high voltage terminals and cables are exposed on the front side of the transformer, then electrical connections can be easily accessed, but the transformer becomes susceptible to damage from side impacts and electrical hazards increase
Solution Approach 1:
The patent repositions the high voltage terminals from the front side (horizontal dimension) to the top or bottom axial positions (vertical dimension). This dimensional change allows electrical connections to remain accessible while removing them from the impact-prone front side, thereby resolving the contradiction between ease of operation and reliability.
2Ease of operation
If high voltage terminals and cables are exposed on the front side, then connections are readily accessible, but manufacturing costs increase and space occupation increases
Solution Approach 1:
The patent integrates the high voltage terminals directly into the coil structure at the axial ends, merging the terminal function with the coil assembly. This eliminates the need for separate front-side terminal assemblies and complex cable management systems, thereby reducing manufacturing complexity and cost while maintaining electrical accessibility.
3Ease of operation
If conventional front-side terminal configuration is used, then electrical connections are accessible, but the transformer occupies more space
Solution Approach 1:
By moving terminals to the axial top or bottom positions, the patent utilizes the vertical dimension for electrical connections rather than expanding the horizontal footprint. This dimensional reorganization maintains terminal accessibility while compacting the transformer's horizontal occupation space.
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 configuration reduces the transformer's susceptibility to damage, enhances safety for maintenance personnel, and lowers manufacturing costs by simplifying shielding and reducing the need for front-side terminals and cables, while allowing for more efficient thermal dissipation and expanded conductor expansion.
Implementation Method 1
a ground shield embedded within and extending from the electrically insulating body and configured to shield high voltage terminals of each high voltage coil of the transformer
Data Source
Figure 1A
Figure 1B~1C
Figure 2A~2C
AI summary
In some embodiments, a connection bar is provided for connecting multiple high voltage coils of a dry-type transformer along a top or bottom of the dry-type transformer. The connection bar includes (1) an electrically insulating body having a plurality of openings, each opening sized to receive at least one of high voltage terminals of the transformer; (2) an electrical connection pathway within the electrically insulating body configured to create a predetermined electrical connection between multiple high voltage coils of the transformer; (3) external connector terminals embedded within and extending from the electrically insulating body, the external connector terminals connected to the electrical connection pathway; and (4) a ground shield embedded within the electrically insulating body and configured to shield high voltage terminals of each high voltage coil of the transformer. Numerous other aspects are provided.