Transformer Insulation Test Rig With Adjustable Core and Shield Spacing
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Solution Overview
Problem
Conventional transformer insulation property testing is performed after manufacturing, leading to significant cost and time losses due to repeated manufacturing processes and inability to detect design errors or potential oscillation phenomena during the manufacturing process.
Innovation Solution
A device for testing insulation properties during the transformer manufacturing process, featuring a low-voltage and high-voltage winding part arrangement with an adjustable iron core and shield parts, allowing for height and interval adjustments to simulate the transformer's insulation properties, enabling early detection of issues and reducing manufacturing errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If insulation distance is reduced to decrease transformer weight, then weight is reduced, but insulation properties deteriorate
Solution Approach 1:
The patent applies preliminary action by performing insulation property tests on the winding part during the manufacturing process, before the transformer is fully assembled. This allows insulation issues to be detected and corrected in advance, preventing the need to redesign insulation structures that would otherwise require increased insulation distances and additional weight.
Solution Approach 2:
The patent uses a test device that creates a simplified copy of the actual transformer insulation structure. The test device includes a test iron core and test winding part that replicate the insulation configuration, allowing insulation properties to be verified without requiring the full transformer assembly, thus maintaining compact insulation design while ensuring reliability.
2Reliability
If insulation property test is performed after transformer manufacturing, then complete transformer can be tested, but manufacturing time and cost increase due to repeated manufacturing
Solution Approach 1:
The patent performs insulation property tests on the winding part during the manufacturing process, before final assembly. This preliminary testing allows insulation issues to be detected early, eliminating the need to disassemble and redesign the entire transformer, thus significantly reducing manufacturing time and avoiding repeated manufacturing cycles.
Solution Approach 2:
The patent segments the testing process from the final assembled transformer and applies it to the winding part independently during manufacturing. This segmentation allows insulation testing to be performed on a smaller, more manageable component, enabling faster testing and iteration without requiring the complete transformer to be assembled and disassembled multiple times.
3Manufacturing precision
If insulation analysis techniques or CAE are used to secure insulation standards, then insulation design consistency is improved, but it remains impossible to check insulation problems in advance during manufacturing
Solution Approach 1:
The patent implements self-service by enabling direct physical measurement of insulation properties on the actual winding part during manufacturing, rather than relying solely on computer simulations or theoretical calculations. This empirical approach allows real verification of insulation performance, combining design consistency with actual problem detection capability.
Solution Approach 2:
The patent changes the testing parameter from theoretical calculations (CAE) to actual physical measurement during manufacturing. By measuring real insulation properties on the manufactured winding part, the system transitions from predictive modeling to empirical verification, enabling actual insulation problems to be detected and corrected during the manufacturing process.
4Manufacturing precision
If conventional insulation check methods measuring insulation thickness and distance are used, then manufacturing errors are reduced, but design errors cannot be reduced
Solution Approach 1:
The patent replaces mechanical measurement methods (physical thickness and distance measurements) with electrical measurement methods. By applying voltage and measuring insulation properties electrically, the system can detect not only manufacturing errors in dimensions but also design errors in insulation configuration and material selection, providing comprehensive validation.
Solution Approach 2:
The patent changes the measurement parameter from geometric dimensions (thickness and distance) to electrical properties (insulation performance). This parameter change enables detection of both manufacturing errors and design errors, as electrical insulation testing reveals functional performance issues that dimensional measurements cannot detect.
Data Source
AI summary
A device for testing insulation properties of a transformer may be provided by: a low-voltage winding part and a high-voltage winding part that are arranged concentrically with each other; an iron core for testing combined with the low-voltage winding part and the high-voltage winding part and adjustable in height according to the height of low-voltage winding part and the high-voltage winding part; a low-voltage terminal part connected to both ends of the winding of the low-voltage winding part; and a high-voltage terminal part connected to both ends of the winding of the high-voltage winding part.