Thermal Barrier Segmentation for High-Temperature Electrical Devices
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Solution Overview
Problem
Conventional electrical devices connected to high-voltage networks face limitations in operating at higher temperatures due to the use of conventional insulating materials, which are cost-intensive and do not fully utilize the thermal resistance of alternative insulating fluids like ester or silicone oils.
Innovation Solution
The implementation of a thermal barrier that creates separate cooling spaces for partial windings, each with its own cooling unit, allowing for different temperature settings and the use of insulating materials tailored to specific temperature zones, enabling operation at higher temperatures while maintaining cost-effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional insulating materials are used in electrical devices, then the device can be manufactured cost-effectively, but the operating temperature is limited and cannot fully utilize the thermal resistance of alternative insulating fluids
Solution Approach 1:
The electrical device is divided into multiple cooling spaces separated by thermal barriers, with each space containing partial windings and equipped with independent cooling units. This segmentation allows different temperature zones to be created, enabling the use of alternative insulating fluids at higher temperatures in specific regions while maintaining cost-effectiveness through targeted application of high-temperature materials only where necessary.
Solution Approach 2:
Different insulating materials are applied locally in different cooling spaces based on temperature requirements. High-temperature insulating materials are used only in regions where high temperatures are required, while conventional materials are used in other regions. This local differentiation allows the device to operate at higher temperatures in critical areas without incurring the full cost of using high-temperature materials throughout the entire device.
2Temperature
If hybrid solutions with both high-temperature materials and conventional materials are used, then some high-temperature operation is possible, but the operating temperature remains considerably below what would be possible with exclusive use of high-temperature materials
Solution Approach 1:
The insulation system is segmented into distinct cooling spaces with thermal barriers, allowing each space to be optimized independently. This segmentation simplifies the overall system design by creating clear boundaries between high-temperature and conventional material zones, making the hybrid solution more manageable and efficient compared to a mixed approach without clear separation.
Solution Approach 2:
Thermal barriers serve as intermediaries between high-temperature cooling spaces and conventional cooling spaces. These barriers enable the hybrid insulation system to function effectively by preventing thermal interference between the two material types, thereby simplifying the overall system architecture and improving operational temperature capabilities.
3Temperature
If a single cooling unit is used for the entire electrical device, then the cooling system is simple, but different partial windings cannot be operated in different temperature sections
Solution Approach 1:
The cooling device is segmented into multiple independent cooling units, with each unit responsible for a specific cooling space. This segmentation enables different temperature settings in different regions of the electrical device, allowing partial windings to be operated in different temperature sections. The modular nature of this segmentation keeps each cooling unit relatively simple while achieving complex temperature distribution across the entire device.
Solution Approach 2:
Each cooling unit provides localized temperature control for its associated cooling space and partial windings. This local quality approach allows each cooling unit to be designed and operated independently with optimal parameters for its specific region, simplifying the design of individual units while achieving sophisticated overall temperature management through the combination of multiple specialized units.
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 solution allows for efficient operation at higher temperatures, reduces material costs, and enables a more compact design by optimizing cooling efficiency and material selection based on hotspot temperatures, thereby enhancing the performance and reliability of electrical devices.
Implementation Method 1
a cooling device for cooling the insulating fluid... the insulating oil heated during operation is guided, in order to remove the heat, via a cooling device
Implementation Method 2
at least one thermal barrier which delimits cooling spaces
Implementation Method 3
an active part which is arranged in the vessel and which has a magnetizable core and partial windings for generating a magnetic field in the core
Data Source
AI summary
An electrical device connects to a high-voltage network and has a vessel, which is filled with an insulating fluid, an active part, which is arranged in the vessel and which has a magnetizable core and partial windings for producing a magnetic field in the core, and a cooling apparatus for cooling the insulating fluid. The electrical device is economical and at the same time can be operated at higher temperatures. This is achieved by use of at least one thermal barrier, which delimits cooling spaces, in each of which at least one partial winding is arranged. The cooling apparatus has at least two cooling units and each cooling unit being configured to cool an associated partial winding.