Insulating Transformers With Flexible Dielectric Screens

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Solution Overview

Problem

Current insulation methods for dry-type transformers, especially above 12 kV, are costly and mechanically inadequate, and existing solutions like angle rings or collars are not suitable due to high expense and complexity, with supporting blocks being a weak point under high voltage differences.

Innovation Solution

The introduction of insulating modules with flexible L-shape screens that integrate with cylindrical barriers, providing enhanced creepage distance and structural integrity, and can be made from resin materials for improved insulation properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If insulating barriers are added to improve insulation performance, then the voltage support capability is improved, but the device complexity and manufacturing cost increase

Engineering Contradiction:

Improveinsulation performanceVSAvoidstructure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines multiple insulating functions into a single integrated insulating barrier structure that includes both vertical barriers between windings and horizontal screens within supporting blocks. This merging approach provides comprehensive insulation performance while reducing the number of separate components needed, thereby managing complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The insulating barrier is segmented into multiple functional portions: vertical barriers positioned between HV and LV windings to prevent direct discharge, and horizontal screens integrated into supporting blocks to increase creepage distance. This segmentation allows each portion to address specific insulation challenges systematically.

Inventive Principle:

Principle #1Segmentation

2Reliability

If conventional insulating materials like angle rings or collars are used, then insulation coverage is improved, but the manufacturing cost and complexity increase significantly

Engineering Contradiction:

Improveinsulation coverageVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces expensive conventional insulating materials like angle rings and collars with a cost-effective insulating barrier made from readily available materials such as G10 or similar composite materials. This substitution maintains adequate insulation coverage while significantly reducing manufacturing costs.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The insulating barrier is designed with adjustable parameters including thickness, height, and horizontal screen positioning that can be optimized based on specific voltage levels and transformer configurations. This flexibility allows the same basic structure to serve multiple applications without requiring custom-designed expensive components.

Inventive Principle:

Principle #35Parameter changes

3Strength

If supporting blocks are used to separate coils, then mechanical support is improved, but the insulation performance under high voltage differences deteriorates

Engineering Contradiction:

Improvemechanical supportVSAvoidinsulation performance

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent merges the mechanical support function and insulation function into a single integrated component by integrating horizontal screens directly into the supporting blocks. This combination allows the supporting block to simultaneously provide mechanical support and enhanced insulation performance under high voltage differences.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent adds a horizontal dimension to insulation by incorporating screens within supporting blocks, complementing the vertical insulation barriers. This multi-dimensional approach to insulation strengthens the overall insulation system while maintaining mechanical support functionality.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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

This solution offers a cost-effective and mechanically robust insulation system that effectively breaks direct discharge paths and increases insulation levels, making it suitable for higher voltage applications like 72.5 kV or 123 kV without the need for complex or expensive components.

Implementation Method 1

The insulating module may include a dielectric screen and a supporting block. The supporting block may support the dielectric screen over a first winding of the transformer.

Methodology Applied

Scientific EffectDielectric insulation: Dielectric

Data Source

PatentUS11355278B2Insulating transformers

Publication Date: 2022.06.07 HITACHI ENERGY LTD

AI summary

Dry-type transformers with insulating modules are disclosed. Example insulating modules include dielectric screens and supporting blocks. The supporting blocks support the dielectric screens over windings of the transformer. The dielectric screens have first substantially even portions configured to adapt in spaces defined by corresponding cylindrical barriers arranged between first and second windings of the transformers and second substantially even portions, transversal to the first portions and to the first windings of the transformers and extending outwards from the first portions and beyond the supporting blocks. The dielectric screens partly extend around a winding.