Radiator Flute Geometry for High-Viscosity Transformer Oil Flow
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Solution Overview
Problem
Existing radiator designs for transformers face structural integrity concerns and inefficiencies in heat dissipation, particularly with high-viscosity ester-based oils, leading to premature failure and increased operational costs due to excessive oil consumption and thermal performance limitations.
Innovation Solution
A heat dissipating element with a body featuring a top, middle, and bottom portion, including a plurality of flutes that diverge laterally outward from the inlet and converge inwardly toward the outlet, providing a continuous channel for fluid flow, and made from corrugated sheet surfaces, allowing for improved heat transfer and accommodating high-viscosity ester oils.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If tubular-type radiators with straight tubes are used, then structural integrity is maintained, but heat dissipation efficiency deteriorates due to limited exposure to cool air
Solution Approach 1:
The patent applies curvature by replacing straight tubes with curved tubes that have a specific arc shape. The curved tubes extend along an arc from the first end to the second end, increasing the surface area exposed to cool air while maintaining structural integrity. This curvature allows better heat dissipation efficiency without compromising the strength of the radiator structure.
2Temperature
If the number of tubes and tube length are increased to achieve required thermal performance, then heat dissipation efficiency improves, but device complexity and manufacturing cost increase
Solution Approach 1:
The curved tube design increases the effective heat dissipation surface area within the same spatial footprint, reducing the number of tubes required to achieve the same thermal performance. The arc-shaped configuration allows each tube to expose more surface area to the surrounding cool air, thereby improving heat dissipation efficiency without proportionally increasing the number of tubes or overall complexity.
3Loss of substance
If small hydraulic dimensions are used in radiators for high-viscosity ester-based oil, then oil consumption is reduced, but frictional losses increase and thermal performance deteriorates
Solution Approach 1:
The patent optimizes the hydraulic dimensions of the curved tubes by adjusting parameters such as tube diameter, wall thickness, and curvature radius. This allows achieving a balance where the hydraulic dimensions are sufficiently large to minimize frictional losses for high-viscosity ester-based oil, while still maintaining efficient heat dissipation and preventing excessive oil consumption.
4Strength
If welding is used to connect tubes to top and lower sides, then structural strength is improved, but structural integrity concerns arise due to potential weak points
Solution Approach 1:
The patent integrates the tube connections directly into the top and lower sides of the radiator body through forming processes, merging the tube structure with the main body. This eliminates separate welding joints and potential weak points, creating a more reliable structure with improved structural integrity while maintaining the necessary connection strength.
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
Enhances thermal performance by reducing frictional losses and enabling efficient heat dissipation, extending the life of transformers and reducing operational costs through optimized fluid flow and increased surface area for heat transfer.
Implementation Method 1
Each of the plurality of flutes provides a continuous channel to allow for flow of a fluid therein
Implementation Method 2
made from corrugated sheet surfaces, allowing for improved heat transfer and accommodating high-viscosity ester oils
Implementation Method 3
Air passes around the outside of the tubes, absorbing heat from the oil (or water) in passing
Data Source
AI summary
A heat dissipating element for a radiator for better thermal performance by dissipating more heat from high viscous oil filled transformer and a method of manufacturing therefor are disclosed. The heat dissipating element comprises a plurality of flutes defined in a body thereof, with a transverse section of each flute representing two trapezium mirrored to each other along a base. The heat dissipating element comprises an inlet port in a top portion of the body to receive the fluid and supply the fluid to each of the plurality of flutes, and an outlet port in a bottom portion of the body to collect the fluid from each of the plurality of flutes. The plurality of flutes are extending longitudinally downwards and diverging laterally outwards from the inlet port, extending longitudinally downwards in a middle portion of the body, and extending longitudinally downwards and converging laterally inwards towards the outlet port.