Transformer Cooling Circuit Inside Coil Windings
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Solution Overview
Problem
Existing electric transformers face overheating issues due to inadequate cooling systems, which can damage windings and affect the transformer's performance.
Innovation Solution
An improved cooling system is implemented by incorporating a cooling circuit that conveys cooling fluid directly inside the coil assemblies, utilizing clamping bars and diffusers to facilitate fluid flow through the windings, enhancing heat dissipation beyond conventional radiator-based systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional radiator-based cooling systems are used, then the transformer structure is simple, but the cooling efficiency is insufficient leading to overheating
Solution Approach 1:
The cooling circuit is nested within the existing transformer structure by integrating it with the clamping bars that are already part of the transformer assembly. The clamping bars serve dual functions: mechanical clamping and fluid conduction, eliminating the need for separate external cooling structures and achieving improved cooling efficiency without proportionally increasing device complexity
Solution Approach 2:
Cooling fluid is introduced as an intermediary medium to transfer heat from the windings to the clamping bars and then to the external environment. This fluid mediator enables efficient heat removal through the existing structural components, resolving the contradiction between simple structure and effective cooling
2Loss of energy
If cooling fluid is conveyed directly inside coil assemblies, then heat dissipation is enhanced, but structural complexity increases due to additional cooling circuits
Solution Approach 1:
The clamping bars are designed to perform multiple functions simultaneously: providing mechanical clamping force to secure the windings and serving as heat conduction pathways for the cooling fluid. This multi-functionality allows enhanced heat dissipation through existing structural elements without adding separate cooling components, thus improving energy loss management without proportionally increasing device complexity
Solution Approach 2:
The cooling circuit is merged with the mechanical clamping structure by integrating fluid conduits into the clamping bars. This combination of cooling and structural functions into a single integrated system enables effective heat dissipation while avoiding the complexity of separate independent cooling and structural systems
3Temperature
If larger radiators are used for better cooling, then cooling performance improves, but the transformer size increases
Solution Approach 1:
The cooling approach transitions from external surface-area-based radiators to an internal volume-based cooling circuit that passes fluid through the core electromagnetic components. This dimensional shift from external to internal cooling allows efficient heat removal without increasing the external footprint of the transformer, maintaining compact size while improving cooling performance
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 provides enhanced cooling efficiency, leading to improved transformer performance, reduced size, and cost-effectiveness compared to traditional designs, while maintaining structural integrity through clamping mechanisms.
Implementation Method 1
a cooling circuit adapted for conveying cooling fluid directly inside said at least one coil assembly
Implementation Method 2
exchanges heat with open air and then returns inside the tank at a lowered temperature
Implementation Method 3
a structure adapted for applying a clamping force on said magnetic core and/or windings
Data Source
AI summary
An electric transformer comprising: a magnetic core; at least one coil assembly which is positioned around a portion of the magnetic core and comprises a plurality of windings; a structure adapted for applying a clamping force on the magnetic core and/or the windings; and a cooling circuit adapted for conveying cooling fluid directly inside the coil assembly.