Segmented 3D-Optimized HV Electrodes for Corona Control
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Solution Overview
Problem
High voltage and medium voltage equipment design faces challenges such as expensive manufacturing, limited adaptability to specific sites, and high maintenance costs due to large, inflexible electrode designs that can lead to corona discharges and flashovers, especially in cramped spaces like offshore substations.
Innovation Solution
A method involving 3D design optimization and additive manufacturing to create tailored, segmented high voltage electrodes that can be adapted to specific applications, using non-contact surface scanners and topology optimization to ensure optimal geometry and surface treatment for reduced corona discharge and improved durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If large radius toroid electrodes are used to limit local electric field strength, then corona discharge and flashover are reduced, but manufacturing cost increases and adaptability to cramped spaces decreases
Solution Approach 1:
The electrode is divided into multiple segments that can be assembled together to form the complete toroid structure. This segmentation allows the electrode to be transported and installed in cramped spaces where a single large-piece electrode could not fit, while still achieving the required large radius geometry for corona discharge prevention when assembled.
Solution Approach 2:
The electrode design optimizes the radius locally at different positions around the toroid. By varying the radius according to local electric field requirements rather than using a uniform radius throughout, the design achieves effective corona discharge prevention in critical areas while reducing overall material usage and improving adaptability to space constraints.
2Reliability
If large radius electrodes are designed to ensure adequate spacing from ground planes, then electrical safety is improved, but space utilization in cramped substations deteriorates
Solution Approach 1:
The electrode design utilizes three-dimensional space more efficiently by optimizing the vertical and radial dimensions while minimizing the horizontal footprint. This allows adequate electrical clearance to be maintained in the critical dimensions while reducing the overall volume occupied in cramped substation environments.
Solution Approach 2:
The electrode geometry employs asymmetric radius values at different angular positions around the toroid. This asymmetric design allows the electrode to maintain safe electrical distances from ground planes in critical areas while reducing material usage and volume in areas where space is less constrained.
3Adaptability or versatility
If traditional design methods with manual 3D modeling are used, then design flexibility is maintained, but design efficiency and precision deteriorate
Solution Approach 1:
The design process incorporates automated feedback loops where the software iteratively optimizes electrode geometry parameters based on electric field calculations and design criteria. This automated feedback system maintains design flexibility by allowing parameter adjustment while dramatically improving design efficiency by eliminating manual trial-and-error modeling.
Solution Approach 2:
Manual mechanical 3D modeling processes are replaced with automated computer-aided design software that performs electromagnetic field calculations and geometric optimization automatically. This substitution maintains full design flexibility through software parameter control while improving productivity by eliminating time-consuming manual modeling operations.
Data Source
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AI summary
A method for designing and manufacturing high voltage and/or medium voltage electric components, which comprises receiving electric specifications for the component to be manufactured (501), receiving geometric boundaries for the component to be manufactured (502), producing an initial 3D design of the component to be manufactured (503), optimizing the initial 3D design in accordance with the electric specifications and the geometric boundaries (504), providing a 3D geometry of the optimized 3D design representing the component to be manufactured (505), and manufacturing the component (506).