Encapsulated Transformer Coil with Corrugated Cooling Ducts
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Solution Overview
Problem
Current transformer coil designs for underground mining environments face issues with mechanical stress, coil distortion during short circuits, and inadequate cooling due to environmental contaminants like moisture and coal dust, leading to phase-to-phase and phase-to-ground failures.
Innovation Solution
The development of a wet wound transformer coil with corrugated insulating material as cooling ducts, encapsulated in resin, which provides a mechanically robust construction and seals out environmental contaminants, using a resin impregnated outer layer and fiberglass reinforcing materials to prevent winding displacement and improve dielectric performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional open wound construction with duct sticks is used, then manufacturing is simpler, but the transformer coils cannot withstand extreme mechanical stresses during short circuits
Solution Approach 1:
The patent applies composite materials by combining resin-impregnated winding layers with fiberglass reinforcing materials to create a mechanically robust coil construction. This composite structure provides the necessary strength to withstand extreme mechanical stresses during short circuits while maintaining manufacturing feasibility.
Solution Approach 2:
The patent uses resin-impregnated winding layers that form a flexible yet strong encapsulation around the coil windings. This resin matrix acts as a binding medium that holds the fiberglass reinforcement and windings together, providing mechanical strength while allowing the coil to flex slightly under stress without catastrophic failure.
2Area of stationary object
If reduced spacing between adjacent transformer coils is used to save real estate, then space utilization improves, but phase-to-phase failure risk increases due to coil distortion
Solution Approach 1:
The patent applies preliminary anti-action by pre-installing fiberglass reinforcing materials within the resin-impregnated winding layers before the coil is subjected to short circuit forces. This reinforcement structure proactively counteracts the outward radial forces that occur during short circuits, preventing coil distortion before it can compromise the electrical clearance between adjacent phases.
3Temperature
If duct sticks are used to create air cooling ducts, then cooling passages are formed, but the duct sticks loosen and fall out during operation reducing cooling efficiency
Solution Approach 1:
The patent merges the cooling duct function with the structural winding layers by forming duct passages directly within the resin-impregnated composite structure. The cooling ducts are integrated into the coil construction itself rather than being separate components, ensuring they remain stable and functional throughout the transformer's operational life.
4Reliability
If wet wound construction with resin encapsulation is used, then mechanical robustness and environmental sealing improve, but manufacturing complexity increases
Solution Approach 1:
The patent applies parameter changes by transforming the manufacturing process to use wet wound construction with resin encapsulation. This involves changing the physical state of the resin (applying it in liquid form during winding) and then transforming it again during curing to create a solid, environmentally sealed structure. This parameter transformation enables both mechanical robustness and environmental protection.
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 withstands extreme mechanical stresses, prevents coil distortion, and enhances cooling efficiency, reducing the risk of phase-to-phase and phase-to-ground failures while maintaining electrical clearance and impedance stability.
Implementation Method 1
encapsulated with a resin material... resin impregnated outer layer covering the circumference of the transformer coil to produce an oval mechanically robust construction preventing winding displacement and sealing out environmental contaminants
Implementation Method 2
corrugated insulating material as cooling ducts... forming the primary winding including primary wire layers wound around the barrier insulating layer and insulation layer... to form cooling ducts
Implementation Method 3
mechanically robust construction preventing winding displacement... capable of withstanding extreme mechanical stresses in an underground mining environment
Data Source
AI summary
Methods and devices for an extreme duty transformer with wet wound primary and secondary winding encapsulated with a resin and having corrugated insulating material as cooling ducts as a transformer capable of withstanding extreme mechanical stresses in an underground mining environment. The method includes providing a resin impregnated rectangular winding form, forming a secondary winding with alternating layers of magnet wire with a resin impregnated insulating collar above and below the magnet wire and corrugated insulating material extending the full or partial circumference and width of the coil. An insulating layer of corrugated material and resin impregnated insulation is wound to separate the primary from the secondary windings. The primary winding is wound with alternating magnet wire layers and resin impregnated insulation layers and a resin impregnated outer layer covers the circumference of the coil to produce an oval mechanically robust construction preventing winding displacement and sealing out environmental contaminants.