Thin-Film UHF Sensor Integration in Composite Bushings

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Solution Overview

Problem

The existing methods for measuring partial discharges in composite bushings within Gas Insulated Switchgear (GIS) face challenges due to the difficulty in installing ultra high frequency (UHF) sensors, noise interference, and the risk of flashover accidents, which can lead to safety hazards.

Innovation Solution

A method involving the integration of a thin-film UHF sensor within a fiberglass reinforced plastics (FRP) tube, coated with silicone rubber, allowing for the measurement of partial discharges and preventing safety accidents by providing a compact and reliable sensing solution.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If a UHF sensor is installed in a composite bushing to measure partial discharge, then measurement capability is improved, but installation difficulty increases due to the bushing structure

Engineering Contradiction:

Improvepartial discharge measurementVSAvoidsensor installation

Core Design Contradiction:

Measurement precisionVSEase of operation

Solution Approach 1:

The patent uses a thin-film UHF sensor that can be flexibly applied to the inner surface of the composite bushing. This thin-film design allows the sensor to conform to the curved surface of the bushing, making installation feasible without complex mounting structures while maintaining measurement capability

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The UHF sensor is integrated within the composite bushing structure itself, nesting the sensing element inside the bushing wall. This nested configuration allows the sensor to be positioned optimally for detecting partial discharge while being protected by the bushing structure

Inventive Principle:

Principle #7Nested doll (Nesting)

2Ease of operation

If a UHF sensor is externally installed on the composite bushing, then installation is simpler, but measurement accuracy deteriorates due to noise interference

Engineering Contradiction:

Improvesensor installationVSAvoidpartial discharge measurement accuracy

Core Design Contradiction:

Ease of operationVSMeasurement precision

Solution Approach 1:

The sensor is nested within the composite bushing structure, placing it in close proximity to the discharge source while being shielded from external electromagnetic noise. This internal positioning significantly improves signal-to-noise ratio compared to external installation

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The thin-film sensor design allows it to be positioned very close to the discharge path within the bushing, maximizing the detection of partial discharge signals while the composite bushing material provides natural shielding from external interference

Inventive Principle:

Principle #30Flexible shells and thin films

3Reliability

If the inner circumferential surface of the flange is processed to be rough to enhance air-tightness, then gas sealing is improved, but adhesive surface durability deteriorates due to temperature changes

Engineering Contradiction:

Improvegas air-tightnessVSAvoidadhesive surface durability

Core Design Contradiction:

ReliabilityVSDuration of action of stationary object

Solution Approach 1:

The patent changes the surface parameter from rough to smooth, and introduces a primer coating layer that provides both sealing and temperature resistance functions, resolving the contradiction between air-tightness and adhesive durability under temperature variations

Inventive Principle:

Principle #35Parameter changes

4Measurement precision

If a thin-film UHF sensor is integrated within the FRP tube, then measurement accuracy is improved, but manufacturing complexity increases

Engineering Contradiction:

Improvepartial discharge detectionVSAvoidmanufacturing process

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The thin-film UHF sensor is incorporated into the FRP tube during the manufacturing process itself, rather than installing it separately afterward. This preliminary integration ensures proper positioning and bonding while streamlining the overall manufacturing workflow

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The thin-film nature of the sensor allows it to be easily applied to the FRP tube surface during manufacturing, and the primer coating provides a simple bonding mechanism that does not require complex assembly steps

Inventive Principle:

Principle #30Flexible shells and thin films

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

The solution enables accurate measurement of partial discharges within composite bushings, reducing the risk of flashover and enhancing the reliability of GIS systems by providing a compact and noise-resistant UHF sensor installation.

Implementation Method 1

When a discharge is initiated in a bushing that is one of constituent parts of the GIS, wideband electromagnetic waves may occur

Methodology Applied

Scientific EffectElectromagnetic radiation detection: Electromagnetic Induction

Implementation Method 2

performing primer coating on the FRP tube

Methodology Applied

Scientific EffectAdhesion: Adhesive

Data Source

PatentUS8981784B2Method for manufacturing a composite bushing, and partial discharge diagnostic system for composite bushing

Publication Date: 2015.03.17 HYOSUNG HEAVY IND CORP

AI summary

Disclosed are a method of manufacturing a composite bushing and a diagnostic system for the partial discharge of the composite bushing that may provide a thin-film ultra high frequency (UHF) sensor to a composite bushing, thereby measuring a partial discharge of a composite bushing and preventing a safety accident of the composite bushing that may occur due to the partial discharge.