FRP Transformer Tank Structure to Eliminate Stray Current and Rust
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Solution Overview
Problem
Transformer tanks made of mild steel face issues such as overheating due to stray flux, leak-prone flanged joints, dielectric clearance issues, and rusting, which affect their efficacy over time.
Innovation Solution
A transformer tank constructed from fibre reinforced polymer (FRP) with embedded metallic inserts and reinforced lifting lugs, featuring a non-metallic, corrosion-resistant design that eliminates stray current circulation and reduces weight, while maintaining structural integrity through metal framing and integrated bushings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If mild steel is used for transformer tank construction, then structural strength and rigidity are achieved, but the tank becomes prone to rust and corrosion over time
Solution Approach 1:
The patent employs fibre reinforced polymer (FRP) composite material consisting of glass fibres embedded in a polymer resin matrix. This composite structure provides both the required mechanical strength from the glass fibres and corrosion resistance from the polymer matrix, eliminating the rust issues associated with mild steel while maintaining structural integrity.
2Ease of manufacture
If mild steel is used for transformer tank, then manufacturing capability is maintained, but stray flux causes overheating issues
Solution Approach 1:
The patent removes the metallic component entirely from the tank construction, replacing mild steel with non-conductive FRP material. This extraction of the conductive property eliminates the stray flux circulation path that causes overheating in steel tanks, while the manufacturing process is adapted to work with composite materials through techniques like fibre placement and resin injection.
3Reliability
If FRP material is used for transformer tank, then corrosion resistance and weight reduction are achieved, but structural integrity must be maintained
Solution Approach 1:
The FRP composite structure uses glass fibres providing tensile strength and rigidity while the polymer resin matrix provides compression strength and binds the fibres together. This combination creates a material that is both corrosion-resistant and structurally sound, capable of withstanding the mechanical loads and environmental conditions transformer tanks face.
Solution Approach 2:
The patent incorporates corrugated or ribbed structures into the FRP tank walls, creating curved reinforcement patterns that increase structural rigidity and resistance to external pressure without adding significant weight. These geometric features enhance the load-bearing capacity of the composite material.
4Weight of stationary object
If FRP is used instead of steel, then weight is reduced by up to a quarter, but connection and assembly methods must be adapted
Solution Approach 1:
The transformer tank is divided into modular sections that can be manufactured separately and then assembled together. The FRP components use integrated connection features such as molded-in attachment points and interlocking joints, eliminating the need for welding or heavy bolting required with steel, and simplifying the assembly process for the lighter composite sections.
Data Source
AI summary
A transformer tank is made of a fibre reinforced polymer (FRP) and therefore there may be no stray current circulation on the walls of the tank, and the FRP may not rust or corrode over time. A transformer tank assembly includes: a front wall; a right wall adjacent the front wall; a left wall adjacent the front wall and opposite the right wall; a back wall adjacent the right wall and left wall and opposite the front wall; and a base connected to each said wall. Each wall is connected to its adjacent neighbors thereby defining together defining a tank. A top cover may be included, for example detachably coupled to a top of the tank.