Disassembled Transformer Core Erection Using Portal Lifter
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Solution Overview
Problem
The existing transformer transportation and assembly methods require significant time, space, and cost due to the need for multiple heavy machines and large installation spaces, and are weather-dependent, making them inefficient and costly for installing large capacity transformers in challenging locations.
Innovation Solution
A disassembled transportation method where a U-shaped iron core is transported in a sideways attitude and reassembled using a portal lifter with extensible booms and a beam to erect the core, reducing the need for large heavy devices and allowing assembly in a smaller space without a dedicated clean house, enabling faster and more cost-effective installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple heavy machines are used to hoist and erect the U-shaped iron core tank, then the iron core can be assembled and erected, but the installation space required increases and the rental cost increases
Solution Approach 1:
The iron core is divided into multiple U-shaped iron cores, each housed in a separate tank. These smaller tanks can be transported and assembled individually in limited space, then connected to form the complete transformer core structure
Solution Approach 2:
The U-shaped iron core is nested within the erection tank during transport. The tank serves as a protective container that also defines the assembly space, eliminating the need for separate clean rooms or large assembly halls
2Reliability
If multiple heavy machines are used to hoist and erect the U-shaped iron core tank, then the iron core can be assembled and erected, but the rental cost increases
Solution Approach 1:
The erection tank serves multiple functions: it protects the iron core during transport, provides a controlled assembly environment, and acts as the final housing structure. This eliminates the need for separate clean rooms, assembly halls, and multiple heavy lifting devices
Solution Approach 2:
The erection tank is designed to be self-contained, providing its own protective environment and assembly space. The tank structure itself becomes the workspace, eliminating the need for external heavy machinery and dedicated assembly facilities
3Manufacturing precision
If the U-shaped iron core is assembled in a conventional assembling room with dehumidification and dust removal, then the assembly quality is maintained, but the installation time increases
Solution Approach 1:
The erection tank is prepared in advance with the necessary assembly environment. The tank can be pre-positioned and pre-prepared for assembly, eliminating the time required to build and prepare separate clean rooms or assembly halls on-site
Solution Approach 2:
The assembly environment parameters (temperature, humidity, cleanliness) are controlled within the erection tank rather than requiring a separate controlled environment facility. This allows assembly to proceed in the tank itself without additional preparation time
4Length of moving object
If the U-shaped iron core is disassembled into smaller parts (leg iron core and lower-yoke iron core), then the transportation size is reduced, but the assembly complexity increases
Solution Approach 1:
The iron core is segmented into transportable components (leg iron cores and lower-yoke iron cores) that fit within the erection tank. These segments are designed to be assembled in a predetermined sequence using simple connection operations, maintaining simplicity despite the divided structure
Data Source
AI summary
A transformer transporting/assembling method comprises a transportation step of transporting a U-shaped iron core with an iron plate horizontally extending to a place near an installation site and an erection step of erecting the U-shaped iron core together with an erection tank from a state that the iron plate extends horizontally to a state that the iron plate extend vertically, with the U-shaped iron core contained in the erection tank. The erection step includes a sub-step in which a portal lifter composed of two booms which are vertically expandable and parallel movable with a predetermined distance therebetween and between which the erection tank is disposed and a beam horizontally connecting the two booms and vertically moved as the booms expands or contracts is used, the beam supports the erection tank through a flexible member at predetermined support portions, and the beam is vertically moved by expanding/contracting the booms.