Open-Close Current Transformer Structure for Compact Outdoor Accuracy
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Solution Overview
Problem
Existing outdoor open-close type current transformers suffer from large size, high material waste, poor accuracy due to fixed coil turns, inconsistent thermal and cold coefficients of iron core and epoxy, and inadequate protection against environmental factors.
Innovation Solution
A compact outdoor open-close type current transformer design featuring a semi-annular transformer shell with a compact winding structure, special screws to prevent falling, and enhanced cable fixation, addressing issues of size, accuracy, and environmental protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the transformer uses a traditional full-annular structure with iron core wrapped by insulating adhesive tape and filled with epoxy, then the transformer provides complete magnetic path and structural integrity, but the transformer size becomes large and material waste increases
Solution Approach 1:
The patent divides the traditional full-annular iron core into two separate semi-annular iron core pieces (first and second semi-annular iron core pieces). These segmented cores are positioned on opposite sides of the winding, eliminating the need for insulating adhesive tape between core segments and reducing overall material usage while maintaining magnetic circuit functionality.
Solution Approach 2:
The patent repositions the semi-annular iron core pieces from a concentric arrangement to a face-to-face arrangement on opposite sides of the winding. This dimensional reconfiguration creates a more compact structure that reduces the transformer's overall volume while maintaining the complete magnetic path through the winding.
2Manufacturing precision
If the coil is wound and sealed with epoxy before cutting, then the transformer structure is complete and sealed, but the number of turns cannot be adjusted and accuracy deteriorates
Solution Approach 1:
The patent performs the cutting operation on the winding before the epoxy sealing process. By pre-cutting the winding to the required number of turns and then applying epoxy to seal the ends, the design allows for precise adjustment of coil turns while maintaining structural integrity and sealing. This sequence reversal enables both manufacturing flexibility and measurement precision.
3Stability of the object's composition
If the iron core is filled and sealed with epoxy after winding, then the transformer structure is consolidated, but the inconsistent thermal and cold coefficients between iron core and epoxy affect transformer consistency in temperature-varying environments
Solution Approach 1:
The patent removes the insulating adhesive tape that would traditionally be placed between iron core segments. By eliminating this intermediate material with different thermal properties, the design reduces thermal interface resistance and minimizes thermal expansion mismatches, thereby improving thermal consistency across the iron core assembly in varying temperature conditions.
4Object-affected harmful factors
If silica gel is simply added to the end face of the transformer for protection, then the transformer has basic environmental protection, but the protection effect is insufficient
Solution Approach 1:
The patent combines multiple protective materials with complementary properties: epoxy resin provides structural sealing and moisture barrier, while silica gel provides humidity absorption and shock resistance. This composite protection system addresses multiple environmental factors simultaneously, significantly improving the transformer's reliability in harsh outdoor conditions compared to using silica gel alone.
5Reliability
If the transformer uses conventional cable fixation methods, then the cable can be connected, but the cable is easy to loosen during operation
Solution Approach 1:
The patent integrates the cable fixing structure with the transformer housing by incorporating a fixing groove directly into the housing structure. The cable is positioned in this groove and secured with fixing glue, merging the cable management function with the structural housing. This integrated approach prevents cable loosening during operation while maintaining ease of installation through the built-in groove guidance.
6Reliability
If the transformer uses small screws for assembly, then the assembly is compact, but screws can easily fall off during high-altitude operation
Solution Approach 1:
The patent introduces a fixing groove as an intermediary structure between the screw and the transformer housing. This groove provides a mechanical constraint that prevents screw rotation and potential falling off during high-altitude operation. The groove acts as a mediator that enhances screw retention without requiring larger or more complex fastening mechanisms, thereby maintaining the transformer's compact design.
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 improves cable fixation reliability, prevents screws from falling off at high altitudes, reduces material waste, enhances accuracy by allowing adjustable coil turns, and provides better thermal and cold consistency, resulting in a more efficient and reliable transformer.
Implementation Method 1
a winding wire is arranged on the outer contour of the lower half hollow framework
Data Source
AI summary
The invention discloses a compact outdoor open-close type current transformer which comprises a transformer shell formed by butt joint of an upper half housing and a lower half housing, wherein an upper half hollow framework and a lower half hollow framework are arranged in the transformer shell, an upper half iron core is arranged in the upper half hollow framework, a lower half iron core is arranged in the lower half hollow framework, and a spring jacking piece is arranged between the upper half hollow framework and the upper half iron core; a winding wire is arranged on the lower half hollow framework, a framework baffle and a sealing gasket connected to the framework baffle are arranged at the butt joint of the upper half hollow framework and the lower half hollow framework, and the framework baffle and the sealing gasket after being connected are respectively and correspondingly embedded in a guide positioning groove arranged in the upper half housing and the lower half housing; and inner spaces of the upper half housing and the lower half housing are filled with epoxy resin, a pair of lug hole plates, and a pressing plate and bolts for connecting the lug hole plates are arranged on the transformer shell. According to the invention, the fixing reliability between a cable and the transformer is improved, and screws can be prevented from falling off during high-altitude operation.