Dry-Type Transformer Winding Spacers for Mechanical Stability
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Solution Overview
Problem
Existing dry-type transformers face issues with interference and mechanical stress due to temperature fluctuations and magnetic flux, leading to potential winding deformations and breakages, especially when insulation is insufficiently reinforced.
Innovation Solution
Mechanically reinforced spacers with high-strength, electrically non-conductive fibers are placed between high-voltage and low-voltage windings to maintain a defined distance, using a method where fiber structures are integrated into moldings and surrounded by a casting compound to enhance mechanical stability and prevent deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the distance between high-voltage winding and low-voltage winding is reduced to minimize interference, then the transformer size is reduced, but the insulation reliability deteriorates and the risk of interference increases
Solution Approach 1:
The patent introduces spacers as intermediary elements positioned between the high-voltage and low-voltage windings. These spacers maintain a defined distance between the windings, preventing direct contact and ensuring reliable insulation while allowing the transformer to have a compact design. The spacers act as mediators that enable close winding placement without compromising insulation reliability.
2Stability of the object's composition
If the clamping pressure of windings is increased to prevent deformation, then the mechanical stability is improved, but the risk of winding breakage increases due to excessive stress
Solution Approach 1:
The patent divides the winding structure into segments by introducing spacers at multiple positions between the high-voltage and low-voltage windings. This segmentation distributes the mechanical forces and clamping pressure across multiple support points, preventing concentration of stress that could lead to winding breakage while maintaining overall winding stability and preventing deformation.
3Reliability
If the insulation between windings is maximized to prevent interference, then the reliability is improved, but the transformer size increases
Solution Approach 1:
The patent employs thin spacer structures that provide effective insulation between the windings without adding significant volume. These spacers function as thin film barriers that maintain reliable insulation while minimizing the increase in transformer size, achieving a balance between insulation reliability and compact dimensions.
4Ease of manufacture
If the spacers are made from simple material to reduce cost, then the manufacturing cost is reduced, but the mechanical reinforcement capability deteriorates
Solution Approach 1:
The patent employs spacers made from fiber-reinforced plastic composite materials, which combine the cost-effectiveness of plastic with the mechanical strength of embedded fibers. This composite material approach provides the necessary mechanical reinforcement to withstand thermal expansion forces and maintain winding stability while remaining economically viable for manufacturing.
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 effectively prevents interference and mechanical stress, ensuring reliable operation by maintaining a consistent distance between windings and distributing forces uniformly, thereby preventing winding deformations and breakages.
Implementation Method 1
disposing a fiber structure, that mechanically reinforces the spacers and includes high-strength, electrically non-conductive fibers, into contact with the positioned moldings for the spacers
Implementation Method 2
casting the moldings with a casting compound to at least partially surround and anchor the fiber structure moldings that are positioned at defined distances from one another for the spacers
Implementation Method 3
the high-voltage winding and the low-voltage winding have a defined distance from one another, and spacers are arranged between the windings and maintain said defined distance
Implementation Method 4
at least one high-voltage winding and one low-voltage winding, wherein the windings are operatively connected to one another by an electromagnetic field
Data Source
AI summary
A dry-type transformer includes at least one high-voltage winding and one low-voltage winding. The windings are operatively connected to one another by an electromagnetic field, and each winding is constructed from winding conductors, wherein the high-voltage winding and the low-voltage winding have a defined distance from one another, and spacers are arranged between the windings and maintain the defined distance.