Segmented HV Winding Body for Dry Transformer Heat Dissipation
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Solution Overview
Problem
Dry-type transformers face issues such as insulation cracking, poor heat conduction, and harsh operating environments due to the direct winding and casting of high-voltage coils, which affect their fire resistance, aging resistance, and short-circuit resistance.
Innovation Solution
A winding body for high-voltage windings featuring comb-shaped winding plates with varying tooth heights and a ring-shaped auxiliary member, combined with a high-temperature vulcanized silicone rubber insulating layer, provides enhanced mechanical strength, fire resistance, and efficient heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If wires are directly wound on tools to form high-voltage coils and then cast to form high-voltage windings, then the manufacturing process is simple, but the heat dissipation and short-circuit impact resistance are poor
Solution Approach 1:
The high-voltage winding is divided into multiple independent winding plates (first winding plate, second winding plate, etc.) arranged in sequence along the axial direction. Each winding plate contains winding grooves for forming coil sections, creating a segmented structure that improves heat dissipation and mechanical strength while maintaining manufacturing feasibility through modular assembly
Solution Approach 2:
The patent employs composite material construction where winding plates are made from materials with good thermal conductivity and mechanical strength. The combination of multiple winding plates with insulating layers and supporting structures creates a composite system that simultaneously achieves excellent heat dissipation, short-circuit resistance, and ease of manufacture
2Reliability
If high-voltage windings are cast with resin, then the insulation is improved, but insulation cracking and poor heat conduction occur during operation
Solution Approach 1:
The winding structure is segmented into multiple winding plates with insulating layers between them, eliminating the need for bulk resin casting. This segmentation prevents insulation cracking by distributing mechanical stress across multiple thin layers while improving heat conduction through direct thermal paths between adjacent plates and layers
Solution Approach 2:
Different regions of the winding structure have different properties: winding plates provide structural support and heat dissipation, insulating layers provide electrical insulation, and the combination creates local optimization of both thermal and electrical properties throughout the winding assembly
3Reliability
If comb-shaped winding plates with varying tooth heights are used, then mechanical performance and heat dissipation are improved, but device complexity increases
Solution Approach 1:
The comb-shaped winding plates feature varying tooth heights with different regions optimized for specific functions: taller teeth in certain areas enhance mechanical strength and heat dissipation surfaces, while shorter teeth in other areas facilitate wire winding and insulation. This local differentiation improves overall performance without requiring entirely complex structures
Solution Approach 2:
The complex winding plate structure is divided into standardized modular units with repeating patterns of teeth and grooves. Each winding plate follows a consistent design methodology, making the complexity manageable through modular reproduction rather than unique custom designs for each component
Data Source
AI summary
A winding body (1310) for a high-voltage winding (130) includes: a plurality of winding plates (1313), each of the winding plates (1313) being provided with a plurality of winding grooves (1314) to form a plurality of comb teeth on the winding plate (1313); and at least one auxiliary member (5316), the auxiliary member (5316) being ring-shaped, the winding plates (1313) being arranged along a circumferential direction of the auxiliary member (5316), and the auxiliary member (5316) being fixedly connected to the winding plates (1313). A high-voltage winding (130) includes: the foregoing winding body (1310); a high-voltage coil (1320); and a high-voltage insulating layer (1330). A dry-type transformer (10) includes a core (110), a low-voltage winding (120), and the foregoing high-voltage winding (130). The low-voltage winding (120) is sleeved outside the core (110), and the high-voltage winding (130) is sleeved outside the low-voltage winding (120).