OLTC Interface Barrier Suspension for Transformer Drying
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Solution Overview
Problem
The manual assembly of electromagnetic induction devices with On-Load Tap Changers is time-consuming and exposes workers to hazardous conditions, and there is a risk of moisture absorption by cellulose-based electrical insulation during the drying process.
Innovation Solution
The method involves suspending the OLTC interface barrier arrangement from the electromagnetic induction device using suspension means, allowing it to be connected and dried separately before final assembly, reducing manual labor and hazardous exposure, and ensuring faster sealing post-drying.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual assembly is used for connecting OLTC interface barrier arrangement to windings and tap changer mechanism, then assembly flexibility and adaptability are maintained, but assembly time increases and workers are exposed to hazardous conditions
Solution Approach 1:
The manufacturing process is divided into separate stages: drying process for moisture removal, and final assembly for connecting electrical connections. This segmentation allows the drying process to be completed independently before assembly, reducing overall assembly time while maintaining quality requirements.
Solution Approach 2:
The drying process is performed as a preliminary action before final assembly. By removing moisture from the electrical insulation system in advance, the subsequent assembly process can proceed faster without compromising dielectric withstand strength, thus reducing both assembly time and hazardous exposure.
2Reliability
If manual assembly is performed in hot and dry atmosphere or with kerosene vapour-soaked insulation, then electrical insulation quality is maintained, but worker safety deteriorates due to hazardous exposure
Solution Approach 1:
The drying process is performed in advance before final assembly, eliminating the need for workers to perform assembly operations in hot and dry atmospheres or with kerosene vapour. This preliminary treatment maintains dielectric withstand strength while removing hazardous working conditions from the assembly process.
Solution Approach 2:
The hazardous drying environment is extracted from the assembly process. By completing drying separately before assembly, the harmful factors (heat, dry atmosphere, kerosene vapour) are removed from the workspace where workers perform final assembly, protecting worker safety while maintaining insulation quality.
3Ease of manufacture
If extended assembly time is allowed for manual connection, then assembly completeness is ensured, but moisture absorption risk increases in the not yet sealed device
Solution Approach 1:
The drying process is performed as a preliminary action that removes moisture from the electrical insulation system before final assembly. This ensures that even though assembly operations take time, the insulation material starts in a low-moisture state and can be sealed sooner, reducing the window for moisture absorption while maintaining assembly completeness.
Solution Approach 2:
The process is segmented into drying phase and assembly phase. During the drying phase, moisture is removed from insulation materials. During the assembly phase, connections are made and the device is sealed. This segmentation allows the device to be sealed sooner after drying, minimizing the time window for moisture absorption while ensuring complete assembly.
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 approach shortens assembly time, reduces hazardous exposure, and minimizes moisture absorption risks, leading to a more efficient and safer manufacturing process for electromagnetic induction devices.
Implementation Method 1
The drying process may involve subjecting the electrical insulation system to vacuum and heating
Implementation Method 2
The drying process may involve subjecting the electrical insulation system to vacuum and heating
Implementation Method 3
The OLTC interface barrier arrangement is provided with a first set of electrical connections arranged to be connected to the windings and a second set of electrical connections arranged to be connected to the OLTC unit
Data Source
AI summary
A method of manufacturing an electromagnetic induction device with On-Load Tap Changer. The method includes: a) providing an electromagnetic core with windings, b) suspending an OLTC insulation barrier from the electromagnetic induction device by a suspension, wherein the OLTC interface barrier arrangement is arranged to act as a barrier between an electromagnetic core housing and an OLTC, and wherein the OLTC interface barrier arrangement is provided with a first set of electrical connections arranged to be connected to the windings and a second set of electrical connections arranged to be connected to the OLTC, c) connecting the first set of electrical connections to the windings, and d) subjecting the windings and the OLTC interface barrier arrangement to a drying process.