Transformer Conductor Connection with Radial Shield Insulation
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Solution Overview
Problem
In compact transformer designs, the close spacing of connection conductors poses challenges in providing adequate insulation and preventing creepage currents, as existing solutions are complex and difficult to implement in confined spaces.
Innovation Solution
A conductor connection piece with radially protruding screens, coated with electrically non-conductive material, such as epoxy, polyester, or acrylic resin, to ensure electrical insulation and increased creepage distances, using methods like spot welding, soldering, or conductive adhesives, and a four-step production process involving screen attachment and powder coating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If connection conductors are arranged at a small distance from one another in compact transformer designs, then space utilization is improved, but insulation reliability deteriorates due to insufficient creepage distances and risk of leakage currents
Solution Approach 1:
The invention extends the insulation solution from a two-dimensional surface coating to a three-dimensional structure by adding radially protruding screens that create additional spatial layers. These screens protrude perpendicular to the conductor surface, effectively increasing the creepage distance in the radial dimension while maintaining compact axial spacing, thus resolving the contradiction between space utilization and insulation reliability.
Solution Approach 2:
The radially protruding screens act as intermediary elements between conductors at different potentials. These screens, coated with electrically non-conductive material, serve as intermediate barriers that prevent direct surface creepage paths while maintaining the compact overall structure, thereby enabling safe close spacing of conductors.
2Reliability
If conventional insulation methods such as insulating tubes or wound insulation are used, then insulation is provided, but device complexity and difficulty of implementation in confined spaces increase
Solution Approach 1:
The invention merges the insulation function with the conductor structure itself by integrating radially protruding screens that are directly connected to the conductor. This unified structure eliminates the need for separate insulating components like tubes or wound insulation, simplifying implementation while maintaining reliable insulation in confined spaces.
Solution Approach 2:
The radially protruding screens are coated with a thin film of electrically non-conductive material (such as powder coating), creating an effective insulation layer that conforms to the conductor geometry. This thin film approach provides reliable insulation without the bulk and complexity of conventional insulating structures.
3Reliability
If radially protruding screens are added to increase creepage distances, then insulation effectiveness is improved, but manufacturing complexity increases
Solution Approach 1:
The invention changes the manufacturing approach by using powder coating technology, which allows the insulating material to be applied in a molten state that automatically conforms to complex conductor geometries including radially protruding screens. This parameter change (applying coating at elevated temperature) simplifies manufacturing by eliminating the need for precise pre-forming of complex insulated shapes.
Solution Approach 2:
The solution uses composite construction combining conductive material for the screens with electrically non-conductive powder coating material. This composite approach allows the insulating property to be added to the conductive structure through surface treatment rather than requiring complex integration of separate insulating components.
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 effectively isolates conductors from different potentials and prevents leakage currents by enhancing creepage distances and reducing stress concentrations, ensuring electrical safety and reliability in compact transformer designs.
Implementation Method 1
The insulation of the connection piece including the at least one radially protruding shield is advantageously formed by a powder coating layer made of electrically non-conductive material
Implementation Method 2
the existing creepage distance is corresponding to the radial extension of the screen from the conductor surface elevated
Implementation Method 3
This can be done by welding or soldering or also by means of conductive adhesive
Implementation Method 4
This can be done by welding or soldering or also by means of conductive adhesive
Data Source
AI summary
The invention relates to a conductor connection (19) on transformers, in particular on dry transformers, and a method for the production thereof, with a connection piece (12) which is formed by a conductor (14) made from an electrically conductive material, which is conductively connected to one end of a winding of the transformer, the connection piece (12) being arranged at a short distance from a further connection piece (12) with a different potential, and at least sections of the connection piece over the circumference thereof having been provided with electrical insulation (18), the conductor (14) which forms the connection piece (12) having been provided with at least one radially protruding shield (16), the connection region of which is connected over the entire circumference to the conductor (14), and the conductor (14) as well as the at least one radially protruding shield (16) having been provided with insulation (18).