Transformer Feedthrough Assembly With Composite Insulation and Sealing
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Solution Overview
Problem
The production of porcelain for insulation in transformer systems is complex, limited to few suppliers outside Europe, leading to logistical issues such as delivery delays and mechanical vulnerabilities, especially in mechanically exposed environments like wind turbines.
Innovation Solution
A feedthrough kit using an insulating element made of a polyamide and glass fiber mixture, produced by injection molding, which provides high mechanical stability, excellent insulating properties, and easier production, along with a sealing system for secure and watertight connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If porcelain insulating elements are used, then good electrical insulation properties and high weather resistance are achieved, but production is extremely complex, limited to few suppliers outside Europe, and mechanical stability is reduced leading to breakage susceptibility
Solution Approach 1:
The patent changes the material parameters from traditional porcelain to a composite of polyamide and glass fiber, which maintains electrical insulation properties while enabling injection molding production. This material substitution resolves the contradiction by achieving both good insulation and ease of manufacture through different physical and chemical properties.
Solution Approach 2:
The patent uses a composite material consisting of polyamide and glass fiber instead of pure porcelain. The glass fiber reinforcement provides mechanical strength while the polyamide base provides electrical insulation and processability via injection molding, thus resolving the contradiction between reliability and ease of manufacture.
2Reliability
If porcelain insulating elements are used, then high weather resistance is achieved, but mechanical stability is reduced leading to breakage in mechanically exposed environments
Solution Approach 1:
The glass fiber reinforcement in the polyamide composite provides superior mechanical strength and flexibility compared to brittle porcelain, while the polyamide matrix maintains weather resistance. This composite structure resolves the contradiction by combining materials that individually address strength and weather resistance.
Solution Approach 2:
The patent changes the mechanical parameters of the insulating element by using a polymer-composite material system that offers ductility and impact resistance, contrasting with the brittle nature of porcelain. This enables the insulator to withstand mechanical exposure without breakage while maintaining weather resistance.
3Reliability
If porcelain insulating elements are used, then good insulating properties are achieved, but weight is increased and susceptibility to breakage is reduced
Solution Approach 1:
The patent changes the density parameter of the insulating material from high-density porcelain to lower-density polyamide composite, achieving weight reduction while maintaining electrical insulation properties through the polyamide matrix and glass fiber structure.
4Strength
If porcelain insulating elements are used, then high mechanical stability is achieved, but production precision is reduced with tolerances of +- 5 mm
Solution Approach 1:
The patent changes the manufacturing process parameters from complex porcelain firing to injection molding, which provides superior dimensional control and tighter tolerances (+- 0.5 mm) while the glass fiber reinforcement in the composite material maintains the required mechanical 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 kit offers reduced susceptibility to breakage, lower weight, improved CO2 balance, and precise manufacturing, enabling efficient assembly and operation in transformer systems with high currents and mechanical exposure.
Implementation Method 1
the insulating element essentially consists of a mixture of polyamide and glass fibre and is produced by injection moulding
Implementation Method 2
a sealing element which can be inserted between the first stop surface and the outside of the housing wall and can be clamped against the outside of the housing wall by tightening the insulating element to the fixing bolt
Data Source
Figure 1
Figure 2
Figure 3~4a
AI summary
The invention relates to a kit (1) for a feedthrough arrangement for the electrical connection of a transformer system through an opening (2a) in a housing wall (2) of the transformer system, wherein the kit (1) comprises: - at least one electrical conductor (3) for the electrical connection of a power terminal of a transformer system, - at least one first insulating element (4) that can be inserted into the opening (2a) of the housing wall (2) and that has a cylindrical feedthrough opening (4a) for receiving at least part of the main section (3') of the conductor (3), - at least one sealing ring (8) that can be placed on the main section (3') of the conductor (3), wherein the main section (3') of the conductor (3) is provided at least part of the way with a thread (3a) for receiving a screw nut (5) by means of which a sealing ring (8) can be clamped against the insulating element (4) in the inserted state of the conductor (3).