Segmented Transformer Windings for Dielectric Test Maintenance
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Solution Overview
Problem
Existing single-phase transformers for dielectric tests are bulky and require replacement of entire windings upon damage, leading to increased intervention times and costs, especially for high insulation classes like 400/500 kV, which complicates maintenance and is economically disadvantageous.
Innovation Solution
The transformer features 'cigar' windings composed of independent elementary coils with electrical connections that allow for smaller coil sizes, enabling the replacement of only the damaged coil instead of the entire winding, simplifying maintenance and assembly while maintaining equivalent electrical performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional single-stage cigar windings are used in transformers for dielectric tests, then the transformer can achieve the required electrical performance and insulation class (e.g., 400/500 kV), but the windings become huge in size and complicate fitting operations, making maintenance and repair difficult and expensive
Solution Approach 1:
The patent divides the traditional single-stage winding into multiple independent elementary coils (first elementary coil, second elementary coil, etc.) that can be separately manufactured, assembled, and replaced. Each elementary coil is wound on a separate former and then assembled together to form the complete winding structure, thereby reducing the complexity of fitting operations while maintaining the required electrical performance and insulation class.
2Power
If traditional single-stage cigar windings are used, then the transformer achieves required power output, but any damage to the winding requires replacement of the entire winding, increasing intervention times and costs
Solution Approach 1:
The winding is segmented into multiple independent elementary coils that are electrically connected in series or parallel. If one elementary coil becomes damaged, only that specific coil needs to be replaced rather than the entire winding, significantly reducing intervention time and costs while maintaining the required power output through the remaining functional coils.
Solution Approach 2:
The modular elementary coil design allows for selective replacement of only the damaged component (individual coil) while retaining and reusing the undamaged elementary coils. This approach recovers the functional value of intact components and avoids the waste and cost associated with replacing the entire winding assembly.
3Reliability
If traditional continuous windings are used, then the transformer achieves required insulation levels, but the overall size of the containment case increases
Solution Approach 1:
By dividing the winding into multiple compact elementary coils with independent formers, the overall volume required for the containment case is reduced compared to a single continuous winding structure. The segmented design allows for more efficient space utilization while maintaining the required insulation levels through proper spacing and insulation materials between the elementary coils.
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
This design reduces maintenance and repair costs, allows for quicker interventions, and maintains competitive pricing by enabling the use of current technologies, addressing the bulkiness and high replacement costs of traditional transformers.
Implementation Method 1
a transformer is a static machine operating in alternating current suitable to convert the parameters of output voltage and electric current with reference to those input ones
Implementation Method 2
two or more inductor circuits, called primary windings and secondary winding, mutually coupled each other through a common magnetic flux
Implementation Method 3
dispose the power dissipated both in the ferromagnetic core, due to hysteresis and parasitic currents
Implementation Method 4
power dissipated both in the ferromagnetic core, due to hysteresis and parasitic currents, and in the windings due to Joule effect
Data Source
Figure 1
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AI summary
An optimized transformer (1), in particular for carrying out dielectric tests, comprising a containment case (2) which is placed on a support structure, a magnetic core (3) placed inside the containment case (2), a primary winding (4), coupled with the magnetic core (3) and a secondary winding (6), magnetically coupled with the primary winding (4) through the magnetic core (3). At least one between the primary winding (4) and the secondary winding (6) comprises a plurality of layers (8) facing one another, defining linear directions (Y) substantially parallel each other, each layer (8) including a plurality of elementary coils independent one from another, electrically connected each other.