Instrument Transformer Paste Insulation Automation
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Solution Overview
Problem
The manual taping process for insulating instrument transformers with kraft paper is time-consuming, costly, and prone to human errors, making automation difficult and expensive, especially for complex shapes, which can lead to faults and irreversible damage.
Innovation Solution
The use of a paste or pulp as an isolation material, comprising particles and a solvent, allows for automated filling and reduces manual labor, providing effective electrical insulation with improved handling and production efficiency, using materials like paper material, cellulose, and silicon, and solvents such as ionic liquids, which enhance electrical properties and reduce manufacturing time and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual taping with kraft paper is used for insulation, then electrical insulation is achieved, but production time increases and costs rise
Solution Approach 1:
The patent changes the physical state of the insulation material from solid sheets (kraft paper) to a flowable paste or pulp suspension. This parameter change allows the insulation material to be applied in a fluid state that can automatically fill complex geometries, then solidifies upon drying or curing, thereby enabling automation while maintaining insulation effectiveness.
Solution Approach 2:
The patent utilizes the flowable nature of the paste or pulp suspension to enable automated filling processes. The suspension can be pumped and injected into the housing, automatically conforming to complex shapes without manual intervention, replacing the manual taping process with a hydraulic/pneumatic delivery system.
2Reliability
If manual taping with kraft paper is used for insulation, then electrical insulation is achieved, but manufacturing costs increase due to manpower
Solution Approach 1:
The paste or pulp insulation material is self-applying through automated filling systems. The material flows into position under its own properties (viscosity, gravity, or pump pressure) and automatically conforms to the housing geometry, eliminating the need for manual labor and reducing dependency on skilled workers.
Solution Approach 2:
The patent replaces the manual mechanical taping process with an automated material delivery system. The paste or pulp suspension is delivered through pumps and hoses, and the material itself performs the insulation function without requiring manual manipulation, thereby substituting human mechanical action with an automated material flow system.
3Productivity
If automation of taping is attempted for complex shapes, then productivity may improve, but device complexity and costs increase
Solution Approach 1:
The patent changes the insulation material from rigid sheets to a flowable paste or pulp suspension, which can adapt to any geometry. This parameter change eliminates the need for complex automation equipment designed to handle specific shapes, as the material itself adapts to complex geometries through its flowable state.
Solution Approach 2:
This principle is not directly applicable to the core insulation mechanism. The patent achieves automation through the flowable properties of the paste or pulp suspension rather than through chemical acceleration or oxidation processes.
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 paste or pulp insulation method significantly reduces production time and costs, minimizes faults, and achieves reliable electrical isolation for high voltage applications up to 1200 kV, enabling fully automated processes and improved handling, resulting in cost-effective and efficient high current and voltage conversion.
Implementation Method 1
The active part is electrically insulated by an isolation material from the housing of the instrument transformer. The isolation material comprises or is a paste and/or pulp.
Implementation Method 2
The measuring assembly comprises for example windings arranged around an electric conductor, which can be used to measure a current in the conductor by magnetic induction in the windings.
Data Source
AI summary
An instrument transformer for high current and/or high voltage conversion includes a housing and at least an active part, which is electrically insulated by an isolation material. The isolation material includes or is a paste and/or pulp. A method for producing the instrument transformer includes the filling of a housing of the instrument transformer with paste and/or pulp, particularly with paste and/or pulp including paper material and/or cellulose, solved in a solvent, particularly at least one ionic liquid.