Transformer Insulation Member with Oriented Spacers

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Solution Overview

Problem

Existing transformer insulation systems are inefficient in cooling, particularly at areas near the outlet of cooling fluids, leading to increased maintenance and manufacturing costs, and reliance on pumps for fluid circulation, which can result in reduced reliability during power outages.

Innovation Solution

An insulation member with a flat base and discrete spacers oriented at specific angles to enhance fluid circulation, promoting auto-circulation and convective heat transfer, eliminating the need for pumps and allowing the use of various cooling fluids, including environmentally friendly options.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If pumps are used to force the circulation of cooling fluid, then the cooling effectiveness is improved, but the device complexity and maintenance costs increase

Engineering Contradiction:

Improvecooling effectivenessVSAvoiddevice complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The insulation member's structure enables the cooling fluid to circulate automatically through the transformer without requiring external pumps. The spacers create channels that guide the fluid flow path, allowing the system to self-regulate cooling fluid circulation based on natural convection and temperature differential-driven flow.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent removes the pump component from the cooling system by integrating flow-guiding spacers directly into the insulation member. This extraction of the active pumping mechanism while maintaining cooling functionality simplifies the overall device structure and reduces maintenance requirements.

Inventive Principle:

Principle #2Taking out (Extraction)

2Temperature

If pumps are used to force the circulation of cooling fluid, then the cooling effectiveness is improved, but the manufacturing costs increase

Engineering Contradiction:

Improvecooling effectivenessVSAvoidmanufacturing costs

Core Design Contradiction:

TemperatureVSEase of manufacture

Solution Approach 1:

The patent combines the insulation function and the flow guidance function into a single integrated member. The spacers are incorporated directly into the insulation member structure, merging two functions (insulation and flow management) that would traditionally require separate components, thereby reducing manufacturing complexity and costs.

Inventive Principle:

Principle #5Merging (Combining)

3Loss of energy

If cooling fluid flows through windings, then heat is removed from coils, but the cooling fluid temperature increases progressively

Engineering Contradiction:

Improveheat removalVSAvoidcooling fluid temperature

Core Design Contradiction:

Loss of energyVSTemperature

Solution Approach 1:

The insulation member is divided into multiple zones with spacers arranged at different orientations (first zone: 0-30 degrees, second zone: 30-60 degrees, third zone: 60-90 degrees). This segmentation creates multiple flow paths with varying resistance, distributing the cooling fluid flow more evenly across different regions of the coil assembly, which helps maintain more uniform cooling effectiveness throughout the system.

Inventive Principle:

Principle #1Segmentation

4Loss of energy

If spacers are arranged to allow cooling fluid circulation, then heat transfer is improved, but the insulation member complexity increases

Engineering Contradiction:

Improveheat transferVSAvoidinsulation member complexity

Core Design Contradiction:

Loss of energyVSDevice complexity

Solution Approach 1:

Different zones of the insulation member have spacers oriented at different angles tailored to the local cooling requirements. The first zone has spacers at 0-30 degrees, the second zone at 30-60 degrees, and the third zone at 60-90 degrees. This local differentiation optimizes heat transfer in each specific region while the overall structure remains integrated and manufacturable.

Inventive Principle:

Principle #3Local quality

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 solution effectively cools transformer coils, reducing maintenance and manufacturing costs, and ensuring transformer reliability by enhancing fluid circulation and heat transfer without the need for pumps, while accommodating different fluid densities and viscosities.

Implementation Method 1

The local speed of the cooling fluid is increased and the auto-circulation of the cooling fluid is promoted. The convective heat transference may therefore be enhanced

Methodology Applied

Scientific EffectConvection: Convection

Implementation Method 2

use cooling systems use a cooling fluid such as mineral oil or cooled air to remove the heat produced by the coil windings

Methodology Applied

Scientific EffectHeat transfer: Convection

Data Source

PatentEP3991187B1An insulation member

Publication Date: 2023.05.31 HITACHI ENERGY LTD

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AI summary

An insulation member for being arranged adjacent to a transformer coil is provided. The insulation member comprises a flat base comprising a first half and a second half defined along a symmetry plane and a plurality of discrete spacers projecting from the plane of the base. The spacers are attached to the first and second halves for allowing a cooling fluid to circulate between the coil and the flat base. The first half comprises at least four zones, each zone having spacers arranged according to a predetermined orientation with respect to an orientation axis. The orientation of spacers between adjacent zones is different. The spacers at a first zone are oriented at an angle of between (120 – 150) degrees, in a second zone at between (80 – 100) degrees, in a third zone at between (30).