Ground-Buried Solid Insulation Transformer Manufacturing
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Solution Overview
Problem
Existing solid type and dry type transformers face issues with thermal diffusion, leading to hot spots and mechanical instability, and are prone to electrical arcs and corrosion when buried underground, causing potential explosions and environmental contamination.
Innovation Solution
A manufacturing method for a ground-buried solid insulation transformer that involves forming an inner window in a coil form, winding low and high voltage coils, applying glass fiber, injecting epoxy resin, and using a conductive mesh with a shielding shell filled with silicone or high molecular weight compounds to prevent electrical shocks and corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If solid type dielectric material is used in ground-buried transformer, then environmental contamination is prevented, but corrosion resistance against ground surrounding is insufficient
Solution Approach 1:
The patent uses a composite structure combining solid insulation material with corrosion-resistant coating materials (epoxy resin, polyurethane, zinc-rich primer) to simultaneously achieve environmental protection and corrosion resistance. The multi-layer coating system provides both dielectric insulation and chemical resistance against ground surrounding.
Solution Approach 2:
The patent modifies the chemical composition and physical properties of the coating materials to enhance corrosion resistance. Specific parameters such as coating thickness, cross-linking density of epoxy resin, and zinc content in primer are optimized to provide adequate protection against ground corrosion while maintaining electrical insulation properties.
2Reliability
If protective enclosure is added to eliminate electric shock risks, then safety is improved, but space requirement increases
Solution Approach 1:
The patent merges the protective enclosure function with the transformer tank itself. The tank is designed to provide both mechanical protection and electrical insulation, eliminating the need for separate protective enclosures. The solid insulation material surrounding the windings also serves as the protective barrier.
Solution Approach 2:
The transformer tank and solid insulation system perform multiple functions simultaneously: mechanical containment, electrical insulation, thermal management, and corrosion protection. This multi-functionality eliminates the need for additional protective structures that would increase space requirements.
3Reliability
If dielectric cast resin material is used for large transformer, then insulation performance is improved, but uniform curing becomes difficult
Solution Approach 1:
The patent divides the curing process into multiple stages with different temperature profiles. The curing is performed in segments (initial cure, intermediate cure, final cure) allowing heat to distribute uniformly throughout the large transformer structure, preventing thermal gradients and ensuring uniform physical properties.
Solution Approach 2:
The patent employs periodic heating and holding cycles during the curing process. Temperature is increased in stages, held at each stage to allow uniform heat distribution, then increased further. This periodic action ensures complete and uniform curing throughout the large transformer volume.
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 method prevents electrical shocks and mechanical instability, ensuring the transformer's stability and preventing corrosion when buried underground, thereby avoiding transformer failure and environmental contamination.
Implementation Method 1
injecting epoxy resin and hardener between the second coil part and the second mold, and automatically casting and curing thereof
Implementation Method 2
connecting the fifth coil part to a conductive mesh and shielding thereof
Implementation Method 3
filling silicone or high molecular weight compound between the fifth coil part and the shell
Data Source
AI summary
A manufacturing method of ground-buried-type solid insulation transformer includes producing a coil form into which an inner window is formed; winding a low voltage coil and a high voltage coil on the coil form to produce a first coil part; winding glass fiber on the first coil part to produce a second coil part and assembling a first mold into the inner window and then pre-heating the second coil part; putting the second coil part into a second mold and injecting epoxy resin and hardener between the second coil part and the second mold, and automatically molding and curing thereof under predetermined speed, vacuum, pressure and temperature to produce a third coil part on outer circumference of which an epoxy layer is formed; separating the first mold from the inner window of the third coil part and then after-treating and curing the third coil part; cooling the after-treated and cured third coil part and sanding and washing the epoxy layer, and applying semi-conductive coating material to the sanded part to produce a fourth coil part; assembling a core to the fourth coil part to produce a fifth coil part and testing the fifth coil part; and connecting the fifth coil part to a conductive mesh and shielding thereof, and then sealing outer side of the fifth coil part and filling silicone or high molecular weight compound between the fifth coil part and a shell to manufacturing the transformer.