Dry-Type Transformer Winding Cooling With Turbulence Grooves
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Solution Overview
Problem
Dry-type transformers suffer from insufficient heat dissipation capability, leading to failures due to excessive temperatures that degrade insulation materials and reduce operational reliability.
Innovation Solution
The transformer design incorporates support strips with alternating cross sections and grooves to enhance airflow turbulence, vortex generators on the insulation cylinder to disrupt airflow boundaries, and heat-dissipating channels with varying cross sections to improve heat transfer, all while maintaining structural integrity and insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If natural convection and forced air cooling by fans are used for heat dissipation, then heat dissipation capability is improved, but heat dissipation capacity remains insufficient leading to transformer failures
Solution Approach 1:
The support strips are designed with a porous structure containing multiple through-holes, allowing airflow to pass through the low-voltage winding body. This porous configuration enhances heat dissipation by creating additional cooling pathways while maintaining structural support, directly addressing the insufficient heat dissipation capacity that leads to transformer failures
Solution Approach 2:
The support strips feature non-uniform thickness distribution with different first and second thicknesses, creating regions of varying thermal and mechanical properties. This local quality variation optimizes both structural support in critical areas and heat dissipation in other regions, resolving the contradiction between maintaining transformer reliability and improving heat dissipation capability
2Strength
If support strips with large contact area are used, then structural support is improved, but heat dissipation area is reduced
Solution Approach 1:
The support strips incorporate multiple through-holes creating a porous structure that reduces the solid contact area with the low-voltage winding body. This decreases thermal resistance and increases the effective heat dissipation area while the remaining solid portions maintain sufficient mechanical support strength
Solution Approach 2:
The support strips utilize composite structure with varying thickness regions (first thickness and second thickness) that combine high-strength zones for structural support with thinner zones for enhanced heat dissipation, resolving the contradiction between support strength and heat dissipation area
3Stability of the object's composition
If laminar airflow is maintained, then flow stability is improved, but heat transfer efficiency is reduced due to thick boundary layer
Solution Approach 1:
The porous support strips with through-holes disrupt the laminar airflow pattern as air passes through the low-voltage winding body. This disruption creates turbulence that thinns the boundary layer and enhances convective heat transfer efficiency while the overall airflow direction remains stable
Solution Approach 2:
The rounded corners and curved surfaces of the support strips create flow separation and reattachment patterns that generate controlled turbulence. This curvature-induced turbulence disrupts the thick boundary layer associated with laminar flow, improving heat transfer efficiency while maintaining flow stability
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 enhanced design reduces overall temperature rise by approximately 5-10°C, improving heat dissipation and reducing the risk of transformer failures by ensuring uniform heat distribution and efficient heat removal.
Implementation Method 1
The dry-type transformer mainly rely on natural convection and forced air cooling by fans for heat dissipation
Implementation Method 2
During operation, the windings and the iron core may generate losses, and heat may be produced inside
Implementation Method 3
a plurality of first grooves are provided on a side wall of each of the plurality of support strips, and the plurality of first grooves are distributed at intervals along a longitudinal direction of the side wall
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The present application provides a dry-type transformer, the dry-type transformer includes a base body, an iron core, a winding unit, and a fan. The winding unit and the fan are mounted on the base body, the winding unit includes a high-voltage winding, an insulation cylinder, and a low-voltage winding which are sequentially nested from outside to inside. The low-voltage winding includes a low-voltage winding body and a plurality of support strips, the low-voltage winding body is cylindrical, the plurality of support strips are arranged in the low-voltage winding body, and the plurality of support strips are distributed at intervals; a plurality of first grooves are provided on a side wall of the support strip and distributed at intervals along a longitudinal direction of the side wall, alleviating a technical problem of the dry-type transformer failures due to insufficient heat dissipation capability.