Sandwich Compensation Block for Air-Core Reactor Settling
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Solution Overview
Problem
Existing air-core reactors experience gap formation due to settling of winding bodies during thermal and mechanical operating loads, necessitating complex and disruptive maintenance to fill these gaps.
Innovation Solution
The introduction of a compensation block with a sandwich structure comprising an upper insulating material block, a lower insulating material block, and an elastomer block, fixed via a form-fitting meshed connection with spider arms, to stabilize winding ends and prevent settling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If winding layers are held by spider blades and spacer strips, then the reactor structure is maintained, but gap formation occurs due to settling under thermal and mechanical loads
Solution Approach 1:
The compensation block is pre-installed between the winding layer and spider blade before the reactor operates. This preliminary positioning allows the block to immediately compensate for any settling that occurs during operation, preventing gap formation from the outset rather than requiring corrective maintenance after gaps form.
Solution Approach 2:
The compensation block acts as an intermediary element between the winding layer and the spider blade. It absorbs the settling movement and maintains continuous contact pressure on the winding layer, preventing gaps without requiring direct modification of the existing spider blade or winding structure.
2Reliability
If gap filling maintenance is performed, then gap formation is corrected, but plant shutdown is required causing loss of productivity
Solution Approach 1:
The compensation block is designed to automatically compensate for gap formation through its elastic deformation under operating conditions. The block continuously adapts to settling without external intervention, making the system self-maintaining during operation and eliminating the need for shutdowns to address gap issues.
Solution Approach 2:
The compensation block utilizes changes in its physical parameters (elastic deformation, compression) to adapt to settling. By allowing the block's compression state to change dynamically during operation, it maintains effective contact pressure on the winding layer without requiring manual adjustment or maintenance intervention.
3Device complexity
If conventional spider blades are used, then the reactor structure is simple, but they cannot prevent settling of winding bodies
Solution Approach 1:
The solution segments the support function by introducing a separate compensation block component distinct from the spider blade structure. This allows the spider blade to maintain its simple structural form while the compensation block provides the additional settling prevention function, keeping the overall system relatively simple while improving stability.
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
Reduces gap formation, minimizing maintenance downtime and ensuring stable operation by preventing settling of winding bodies.
Implementation Method 1
a compensation block with a sandwich structure comprising an upper insulating material block, a lower insulating material block and an elastomer block located therebetween
Data Source
AI summary
A compensation block for air-core inductors or transformers is formed as a sandwich structure. The sandwich structure of the compensation block includes an upper insulating material block, a lower insulating material block, and an elastomer block arranged between the upper and lower insulating material blocks. The novel compensation block allows the formation of gaps due to settlement to be reduced.