Transformer Insulation Structure for Partial Discharge Reduction
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Solution Overview
Problem
The uneven electric field strength between high-voltage and low-voltage components in transformers leads to partial discharge and insulation failure, affecting the reliability and heat dissipation of the transformer components, which shortens their service life.
Innovation Solution
A transformer design with a wrapped insulation member around the high-voltage coil, a ground plane on the insulation member, and a voltage uniform layer to balance electric potentials, combined with a simplified connection method through casting, enhances insulation and heat dissipation, reducing the risk of partial discharge and improving safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a solid insulation material is filled between and outside the high-voltage coil and the low-voltage coil, then insulation reliability is improved, but heat dissipation capability deteriorates
Solution Approach 1:
The insulation structure is segmented into two distinct parts: an insulation member that wraps only around the high-voltage coil, and a voltage uniform layer that is disposed between the high-voltage coil and the insulation member. This segmentation allows the low-voltage coil to be exposed and facilitate heat dissipation while maintaining insulation through the dedicated insulation member for the high-voltage coil.
2Reliability
If the insulation material is wrapped around the high-voltage coil and the low-voltage coil, then insulation reliability is improved, but heat dissipation of the low-voltage coil deteriorates
Solution Approach 1:
The insulation member is designed with local quality by wrapping only around the high-voltage coil where insulation is most critical, while leaving the low-voltage coil exposed for heat dissipation. The voltage uniform layer is locally disposed between the high-voltage coil and the insulation member to address specific electric field distribution needs without compromising overall heat dissipation.
3Reliability
If the insulation material is wrapped around the high-voltage coil and the low-voltage coil, then insulation reliability is improved, but installation and maintenance difficulty increases
Solution Approach 1:
The insulation structure is segmented so that the insulation member independently wraps only the high-voltage coil, separating it from the low-voltage coil. This segmentation allows the low-voltage coil to be independently accessed for installation and maintenance without removing insulation material, significantly improving ease of repair while maintaining insulation reliability through the dedicated insulation member.
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 design improves insulation reliability, facilitates heat dissipation, and extends the service life of transformer components while reducing production and maintenance costs, enhancing safety and stability.
Implementation Method 1
the voltage uniform layer is disposed between the high-voltage coil and the insulation member, and the voltage uniform layer is electrically connected to one end of the high-voltage coil
Implementation Method 2
a ground plane is disposed on at least a part of an outer surface of the insulation member
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
This application relates to a transformer and power equipment. The transformer includes: a low-voltage coil (1); a high-voltage coil (2); a magnetic core (3), where at least a part of the magnetic core is penetrated through the low-voltage coil and the high-voltage coil; an insulation member (4) with a ground plane (5) disposed on an outer surface of the insulation member; and a voltage uniform layer (24). The insulation member is wrapped around the high-voltage coil, so that the high-voltage coil is insulated from the low-voltage coil and the magnetic core, heat dissipation of the high-voltage coil, low-voltage coil and the magnetic core can be facilitated, and a service life of the transformer can be prolonged. A structure of the transformer is simplified, so that installation and maintenance of the low-voltage coil and the magnetic core can be facilitated, and processing and maintenance costs of the transformer can be reduced. The voltage uniform layer and the ground plane are used, so that a problem that partial field strength between a high voltage and a low voltage of the transformer is excessively high can be effectively resolved, to reduce a partial discharge, thereby improving long-term insulation reliability. The power equipment includes the foregoing transformer, and an input voltage and/or an output voltage of the power equipment are/is adjusted by using the transformer. Therefore, use performance and an application scope of the power equipment can be increased.