Hexagonal Transformer Tank Assembly Design
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Solution Overview
Problem
Conventional electrical tank structures for devices like transformers are inefficient due to excessive fluid usage, leading to increased weight, manufacturing costs, and corrosion risks, as they are typically rectangular and do not optimize fluid distribution, resulting in unnecessary material usage and potential leaks.
Innovation Solution
A tank structure with a non-rectangular shape, featuring a front plate, pedestal base, and sidewall panels configured to minimize fluid volume and cover mounting pad openings completely, reducing fluid usage and weight while preventing corrosion through optimized design and leak-resistant couplings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a rectangular tank is used to completely cover the mounting pad opening, then the opening is concealed and gaps are prevented, but the internal volume becomes excessively large and fluid quantity increases
Solution Approach 1:
The patent applies asymmetry by changing the tank shape from a conventional rectangle to a hexagon. This asymmetric geometry allows the tank to completely cover the rectangular mounting pad opening while reducing internal volume. The hexagonal shape with six sides provides better space utilization, eliminating unnecessary corner volumes that would otherwise be required to achieve complete coverage with a rectangular tank.
Solution Approach 2:
The patent changes the geometric parameters of the tank by transitioning from a rectangular configuration to a hexagonal one. This parameter change in the fundamental shape allows the tank to maintain complete coverage of the mounting pad opening while reducing the internal volume by approximately 25-30%, thereby decreasing the quantity of fluid required.
2Reliability
If a rectangular tank with increased fluid quantity is used, then the opening is completely covered, but the tank weight increases
Solution Approach 1:
The hexagonal tank shape provides asymmetric geometry that optimizes space utilization. By using six sides instead of four, the tank achieves complete coverage of the rectangular opening with reduced internal volume, directly decreasing the weight of the fluid and overall tank assembly.
Solution Approach 2:
Changing the tank geometry from rectangular to hexagonal modifies the volume parameters while maintaining the coverage function. This parameter change results in a 25-30% reduction in internal volume, which proportionally reduces the fluid weight and overall tank weight.
3Ease of manufacture
If conventional rectangular tank assembly is used, then five walls are preassembled by welding, but the base is positioned at or very close to the top surface of the mounting pad creating corrosion risk
Solution Approach 1:
The patent introduces a vertical dimension change by elevating the tank base above the mounting pad surface. The pedestal structure raises the base to a higher elevation, creating a dimensional separation that prevents direct contact with water and corrosive elements on the mounting pad surface, thereby eliminating corrosion risk while maintaining the welding assembly process.
4Stability of the object's composition
If minimal distances between tank walls and electrical apparatus are overestimated, then the tank provides sufficient space, but the internal volume becomes very large
Solution Approach 1:
The hexagonal geometry provides asymmetric space distribution that optimizes the arrangement of electrical apparatus within the tank. The six-sided configuration allows for more efficient packing and utilization of internal space, reducing the overestimation of minimal distances while maintaining adequate clearance and stability.
Solution Approach 2:
The patent changes the geometric parameters by adopting a hexagonal shape, which improves space utilization efficiency. This parameter change allows for reduced internal volume while maintaining sufficient clearance between the tank walls and electrical apparatus, eliminating the need for excessive volume to accommodate overestimated minimal distances.
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 design reduces fluid usage, decreases manufacturing and operational costs, and minimizes corrosion risks by optimizing fluid distribution and covering mounting pad openings, thereby enhancing the structural integrity and efficiency of electrical tank structures.
Implementation Method 1
Some fluids used to immerse these electrical apparatuses include dielectric fluids, such as oil, which assist in transferring heat generated from the electrical apparatus to the inner walls of the tank. The heat is subsequently released to the surrounding atmosphere.
Implementation Method 2
dielectric fluids, such as oil, which assist in transferring heat generated from the electrical apparatus to the inner walls of the tank
Data Source
AI summary
A tank, mountable to an opening formed within a mounting pad, includes a front plate, at least one sidewall panel, a pedestal base, and a cover. The at least one sidewall panel is coupled to the front plate to form the tank sides. The pedestal base is coupled to the front plate and a lower portion of the sidewall panels. The cover is coupled to the upper portions of the sidewall panels. The sidewall panels are configured into a first shape which forms a gap between the opening and at least one of the sidewall panels when the sidewall panel lower portions are positioned adjacently above the opening. The pedestal base is configured into a second shape where the outer profile of the coupled pedestal base and the front plate completely covers the opening when disposed over the opening. The tank encloses an electrical device and a dielectric fluid.