Transformer Cooling Assembly for Automated Thermal State Detection
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Solution Overview
Problem
Conventional transformer assemblies, particularly traction transformers in rail vehicles, face overheating issues due to blocked air channels in the heat spreader, leading to inaccurate and time-consuming visual inspections for thermal state determination.
Innovation Solution
A cooling device equipped with temperature sensors for coolant and airstream temperatures, which calculates the thermal state of the transformer by determining the relationship between entering and leaving coolant and airstream temperatures, allowing for accurate thermal state assessment without manual inspection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If visual inspection by human operator is used to detect blocked air channels, then inspection can be performed, but it requires frequent scheduled inspections (loss of time) and has inherent inaccuracy (measurement precision)
Solution Approach 1:
The patent replaces manual visual inspection with an automated optical detection system that uses light sources and sensors to detect blocked air channels. The system shines light through the heat spreader fins and detects blockages automatically, eliminating the need for human operators to physically inspect the transformer assembly.
Solution Approach 2:
The system enables self-monitoring of the transformer assembly by continuously detecting blocked air channels and providing real-time alerts. The automated detection system allows the equipment to monitor its own thermal state without requiring external human intervention or scheduled maintenance inspections.
2Loss of energy
If air channels have small pitch to increase heat dissipation efficiency, then heat dissipation performance is improved, but foreign elements can easily block the air channels (reliability)
Solution Approach 1:
The patent implements preliminary detection of blocked air channels before they cause critical overheating. The optical detection system continuously monitors the air channels and provides early warning of blockages, allowing preventive maintenance to be performed before the blockage becomes severe enough to compromise transformer operation.
Solution Approach 2:
The system provides continuous feedback on the thermal state and air channel condition of the transformer assembly. By monitoring light transmission through the fins and detecting blockages in real-time, the system creates a feedback loop that alerts operators to maintenance needs, enabling timely intervention to maintain optimal heat dissipation 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
Enables precise and automated thermal state monitoring, reducing the risk of overheating and power reduction by detecting thermal de-rating conditions, thus ensuring reliable operation and reducing maintenance time.
Implementation Method 1
heat from the transformer coils is transferred to the coolant
Implementation Method 2
Heat from the coolant is transferred to the heat spreader. The heat spreader comprises a plurality of air channels, usually defined by fins, to enlarge the surface area that contributes to a dissipation of the heat to the ambient air
Data Source
AI summary
A transformer assembly includes an electric transformer, a temperature sensor system, and a computation unit for determining a thermal state of the electric transformer. The electric transformer includes a cooling device having at least one liquid coolant channel to absorb exhaust heat from the electric transformer, a heat spreader for transferring heat from the liquid coolant to a heat dissipation surface of the heat spreader, and an air blower configured to effect an airstream along the heat dissipation surface. The temperature sensor system includes an entering coolant sensor for providing an entering coolant temperature signal, a leaving coolant sensor for providing a leaving coolant temperature signal, an entering airstream sensor providing an entering airstream temperature signal, and a leaving airstream sensor providing a leaving airstream temperature signal. The computation unit is configured to determine a thermal state of the transformer.