High-Voltage Transformer Insulation Housing Design
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Solution Overview
Problem
High-voltage transformers in the prior art face challenges with weight, manufacturing complexity, and reliability due to the use of heavy cast resins and insulating oils, which lead to increased weight and the risk of defects, especially when using thin winding wires or high voltages.
Innovation Solution
A high-voltage transformer design featuring an insulation housing with a plastic enveloping body that forms an annular gap filled with insulating fluid, allowing for reduced weight, simpler production, and effective electrical insulation without the need for thick wires or excessive insulating oil, using a non-hardening insulating fluid that maintains purity and does not require a separate expansion volume.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cast resin is used for insulation of the secondary winding, then electrical insulation is ensured, but the transformer weight increases and manufacturing complexity increases due to defect risks
Solution Approach 1:
The patent extracts the secondary winding from the cast resin encapsulation and places it in a separate insulating housing filled with insulating oil. This separation removes the need for heavy cast resin while maintaining insulation reliability through the oil-filled environment, directly resolving the contradiction between insulation reliability and weight reduction.
Solution Approach 2:
The insulating oil acts as an intermediary medium between the secondary winding and the external environment, providing electrical insulation without requiring the winding to be embedded in heavy cast resin. The oil-filled insulating housing serves as the intermediary structure that maintains insulation while reducing overall weight.
2Reliability
If cast resin is used for insulation, then electrical insulation is provided, but manufacturing effort increases due to defect risks and production complexity
Solution Approach 1:
By extracting the secondary winding from the cast resin process and housing it separately in an oil-filled insulating housing, the patent eliminates the complex and defect-prone cast resin manufacturing process. The separate housing can be assembled more easily without requiring vacuum casting or pre-impregnation steps.
Solution Approach 2:
The insulating housing with insulating oil provides a simpler, more replaceable insulation solution compared to permanent cast resin encapsulation. If defects occur, the housing can be opened and refilled or replaced more easily than recasting resin, reducing manufacturing effort and improving ease of manufacture.
3Reliability
If insulating oil is used to surround the entire transformer, then electrical insulation is improved, but the transformer weight increases due to the amount of oil and housing required
Solution Approach 1:
Instead of surrounding the entire transformer with insulating oil, the patent applies insulating oil locally only to the secondary winding area within the insulating housing. This localized approach maintains electrical insulation where it is most needed while significantly reducing the total amount of oil required, thereby reducing weight.
Solution Approach 2:
The patent segments the insulation system into two parts: the primary winding area remains without insulating oil, while only the secondary winding is enclosed in an oil-filled insulating housing. This segmentation reduces the overall volume of insulating oil needed compared to complete transformer immersion, directly addressing the weight-insulation contradiction.
4Adaptability or versatility
If thin winding wires are used for the secondary winding, then the transformer can be optimized for high voltage, but compatibility with cast resin insulation is lost due to viscosity issues
Solution Approach 1:
By extracting the thin winding wires from the cast resin encapsulation environment and placing them in an oil-filled housing instead, the patent removes the viscosity compatibility problem. Thin wires can be used for high voltage optimization without needing to be pre-impregnated or requiring complex casting processes.
Solution Approach 2:
The patent changes the insulating medium parameter from cast resin (high viscosity) to insulating oil (lower viscosity), which allows thin winding wires to be used without manufacturing difficulties. The oil can penetrate and surround thin wires more easily during assembly, enabling high voltage optimization with thin wires while maintaining ease of manufacture.
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 achieves significant weight savings, improved reliability, and reduced manufacturing effort, enabling the use of thinner wires and lower material costs, while maintaining effective insulation and extending the lifespan of the insulating fluid, making it suitable for mobile testing devices.
Implementation Method 1
the annular gap between the secondary winding and the enveloping body being filled with an insulating fluid
Implementation Method 2
The magnetic field thus induced in the transformer core then in turn induces a secondary voltage at the at least one secondary winding
Data Source
Figure 1
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Figure 3
AI summary
In a high-voltage transformer (1) for providing an alternating voltage in the kV range, comprising at least one secondary winding (12), which is wound on a coil carrying body (11) surrounding a transformer core (2), an insulation housing (5, 6) encapsulating the secondary winding (12) is provided to electrically insulate the secondary winding (12). Said insulation housing is walled by the coil carrying body (11) carrying the secondary winding (12) and by an enveloping body (14) made of plastic and enveloping the secondary winding (12) so that an annular gap (13) is formed, wherein the annular gap (13) between the secondary winding (12) and the enveloping body (14) is filled with an insulating fluid. The annular gap (13) filled with insulating fluid has a gap width of less than or equal to 20 mm viewed in the cross-section, and the enveloping body (14) has a wall thickness of less than or equal to 20 mm, wherein the plastic is polypropylene, and a separate expansion volume is not provided for the insulating fluid.