Transformer Potting Box Insulation Design
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Solution Overview
Problem
The insulation of high-voltage lead-out wires in medium and high-voltage transformers is a challenge due to the complexity, bulkiness, and cost of traditional insulator structures, which are insufficient for achieving effective electrical isolation and voltage level conversion in high-power, high-efficiency applications.
Innovation Solution
A potting box design with an inner and outer wall, support portions for windings, and a potting sealant that encapsulates the windings, creating an air gap for improved insulation and using a silicone rubber heat-shrinkable sleeve to enhance insulation performance and reduce the need for ceramic sleeves, thereby simplifying the structure and reducing volume.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional insulator structure is used for high-voltage lead-out wires, then insulation is achieved, but the structure becomes complicated, bulky, and costly
Solution Approach 1:
The patent combines the insulator and support functions into a single integrated structure. The insulator body serves both as the insulation component and as the support for fixing the lead-out wires, eliminating the need for separate support components and reducing overall structural complexity
Solution Approach 2:
The insulator is designed to perform multiple functions simultaneously: providing electrical insulation between high-voltage and low-voltage windings, mechanically supporting the lead-out wires, and providing structural anchoring within the transformer. This multi-functional design reduces the number of components needed
2Reliability
If traditional insulator structure is used for high-voltage lead-out wires, then insulation is achieved, but the structure becomes bulky
Solution Approach 1:
The patent employs a streamlined insulator design with optimized geometry that reduces volume while maintaining insulation effectiveness. The insulator uses a compact form factor with smooth contours that provide sufficient creepage distance without requiring excessive material or space
Solution Approach 2:
The patent optimizes the insulator's geometric parameters including length, diameter, and shape factors to achieve the minimum necessary volume while satisfying insulation requirements. By carefully controlling the creepage distance and optimizing the electric field distribution through parameter adjustment, the insulator volume is minimized
3Reliability
If sufficient creepage distances are provided between iron core and low-voltage lead-out wires, then insulation is achieved, but the structure becomes complicated and costly
Solution Approach 1:
The patent introduces an insulator as an intermediary component that provides the necessary creepage distance between the iron core and low-voltage lead-out wires. This intermediary structure achieves electrical isolation without requiring complex routing or spacing arrangements of the wires themselves
Solution Approach 2:
The patent achieves the required creepage distance by utilizing the vertical dimension through the insulator's length rather than requiring horizontal spacing between components. This dimensional approach to providing creepage distance simplifies the overall layout and reduces structural complexity
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 the insulation performance of high-voltage and low-voltage lead-out wires, reduces the electric field strength, and enhances mechanical reliability by creating a larger insulation distance and using a soft potting sealant with a hard sealant for mechanical protection, resulting in a more efficient and cost-effective transformer.
Implementation Method 1
A first potting sealant potted in the potting box and encapsulating the first winding and the second winding in the potting box
Implementation Method 2
using a silicone rubber heat-shrinkable sleeve to enhance insulation performance
Data Source
AI summary
A potting box for assembling a transformer comprises an inner wall and an outer wall. The inner wall is sleeved in the outer wall. A bottom plate connected to a bottom portion of the inner wall and a bottom portion of the outer wall to form a potting space for accommodating a first winding and a second winding. An inner side of the outer wall comprises a first support portion for supporting the first winding and an outer side of the inner wall comprises a second support portion for supporting the second winding. An iron core of the transformer penetrates through an inner side of the inner wall.