Modular Transformer Winding Clamping System
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing clamping devices for power transformer windings are costly and inflexible due to the need for highly variable insulation spacings and sizes, with limited adaptability to different winding diameters and thermal expansion, and often compromise mechanical strength and ventilation efficiency.
Innovation Solution
A modular clamping system using interlocking base blocks, bolt holders, and centering elements with rubber pads, allowing for adjustable thickness and improved mechanical strength, surface resistance, and ventilation efficiency, similar to the LEGO brick concept, with elements that can be reused to accommodate a wide range of winding diameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If clamping devices are specially designed to fit the size of the transformer and its windings with highly variable insulation spacings, then the positioning accuracy and mechanical clamping are improved, but the manufacturing cost and stock management complexity increase
Solution Approach 1:
The clamping device is divided into multiple modular elements of the same type that can be stacked in series. Each element has a standardized thickness, and by varying the number of elements stacked, different total thicknesses are achieved to accommodate highly variable insulation spacings. This segmentation allows a single standardized part design to replace multiple custom-designed clamping devices.
Solution Approach 2:
A single type of modular element is designed to serve multiple functions: providing mechanical clamping, ensuring electric insulation through stacked thickness, and accommodating variable winding sizes. The universal design eliminates the need for different types of clamping devices for different transformer configurations.
2Adaptability or versatility
If modular clamping devices are used with elements of different thicknesses to adapt to various needs, then the adaptability to different winding diameters is improved, but the device structure becomes more complex and mechanical strength decreases
Solution Approach 1:
Instead of using elements of different thicknesses, the solution segments the clamping device into multiple elements of identical thickness that are stacked in series. The desired total thickness is achieved by varying the number of stacked elements, not by using differently sized components. This maintains structural simplicity and mechanical strength while providing adaptability.
3Adaptability or versatility
If compound clamping devices with interlocked elements are used to obtain different combined thicknesses, then the adaptability to various insulation spacings is improved, but the structure becomes particularly complex and mechanical strength is reduced
Solution Approach 1:
Multiple elements of the same type are combined through stacking to achieve different total thicknesses. The elements are designed with complementary profiles that allow them to interlock when stacked, creating a unified structure that maintains mechanical strength. This merging approach avoids the complexity of compound devices with differently sized elements.
4Reliability
If clamping devices are designed with controlled elasticity to absorb thermal expansion and damp vibrations, then the thermal expansion compensation and vibration damping are improved, but the device complexity increases
Solution Approach 1:
The elastic properties of the clamping device are adjusted by changing the material composition and the number of stacked elements. Different materials with varying elastic moduli can be selected, and the overall elasticity of the device can be tuned by the number of elements in the stack. This allows controlled elasticity for thermal expansion compensation and vibration damping without requiring complex additional mechanisms.
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 modular system reduces manufacturing costs and complexity by minimizing the number of parts, providing robust clamping with adjustable thickness, maintaining efficient ventilation, and enhancing surface insulation resistance, while accommodating various winding sizes and thermal expansions.
Implementation Method 1
the clamping devices shall have a certain controlled elasticity to absorb the different thermal expansion of the windings during operation and to damp vibrations
Implementation Method 2
to damp vibrations, which will thence not be transferred to the whole structure
Data Source
Figure 1~7
Figure 8~12
Figure 13
AI summary
A modular device for clamping the windings of a transformer in which two parallel sides (2, 3) of an elongate base block, extending downwards to form an elongate lower housing open at its ends, have identical upper external toothings and lower internal toothings (7, 8, 9, 10), the distance W2 between the two opposite upper toothings (7, 8) being equal to the distance W2 between the two facing lower toothings (9, 10) so that a plurality of said base blocks can be interlocked together in stacked relationship, possibly in staggered positions in the direction of length, and a winding guide element (19) and a bolt-carrying element (11) having the same transverse profile as the base block, with identical toothings, can also be interlocked in stacked relationship to a base block.