Transformer Press-Clamp Sensor Alignment
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Solution Overview
Problem
Existing clamping systems for electric transformers lack the ability to accurately measure and adjust the clamping force, leading to potential damage and erroneous measurements due to misalignment of the ring-shaped clamping force sensor, which can result in inadequate pressure maintenance and increased risk of mechanical and electrical stress during short circuit events.
Innovation Solution
A press-clamp configuration with an upper plate and a concentric nut, a lower plate with a cavity housing a ring-shaped clamping force sensor, and concentric circular protrusions to ensure the sensor's alignment, allowing for precise measurement and adjustment of the clamping force using optoelectric or piezoelectric sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a ring-shaped clamping force sensor is incorporated into the press-clamp, then the ability to measure and adjust clamping force is improved, but the risk of sensor misalignment and damage increases
Solution Approach 1:
A concentric alignment structure acts as an intermediary mechanism between the upper and lower plates, ensuring the ring-shaped sensor body remains perfectly centered during assembly and operation. This mediator prevents misalignment without requiring complex adjustment procedures or sacrificing sensor accessibility.
Solution Approach 2:
The alignment structure employs asymmetric geometric features (protrusions and recesses) that guide the sensor into a unique concentric position. This asymmetric design eliminates the possibility of incorrect sensor placement while maintaining simple overall structure and easy manufacturability.
2Strength
If rigid clamping systems are used to compress windings, then the ability to resist mechanical and electrical vibrations is improved, but the ability to maintain constant pressure over time deteriorates due to material degradation
Solution Approach 1:
The clamping system transitions from a static rigid structure to a dynamic adjustable system. The ability to periodically retighten and readjust the clamping force allows the system to adapt to material degradation over time, maintaining optimal pressure levels throughout the transformer's operational life.
Solution Approach 2:
The clamping force sensor provides continuous feedback on the actual pressure applied to the windings. This feedback enables operators to monitor pressure levels and perform maintenance adjustments at optimal intervals, preventing both under-clamping and excessive maintenance.
3Measurement precision
If clamping force sensors are incorporated into existing press-clamp designs, then the ability to monitor compression is improved, but the complexity of the device increases and manufacturing becomes more difficult
Solution Approach 1:
The press-clamp is divided into modular components (upper plate, lower plate, alignment structure, sensor) that can be independently manufactured and assembled. This segmentation simplifies the manufacturing of each individual part while enabling precise sensor integration through the alignment features.
Solution Approach 2:
The alignment structure serves multiple functions simultaneously: it guides sensor installation, ensures concentric positioning, prevents sensor damage, and maintains structural integrity. This multi-functionality reduces the need for additional separate components, keeping the overall device complexity manageable.
4Reliability
If scheduled maintenance is performed on clamping systems, then the ability to compensate for pressure loss is improved, but the cost and downtime increase when maintenance is performed too early or too late
Solution Approach 1:
The clamping force sensor provides real-time feedback on the actual compression force applied to the windings. This enables condition-based maintenance scheduling, where maintenance is performed only when actually needed based on measured pressure levels, optimizing the balance between reliability and operational downtime.
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
This configuration ensures accurate measurement and application of clamping force, maintaining optimal winding compression and stress absorption, reducing the risk of power failures and maintenance costs by providing real-time monitoring and adjustment capabilities.
Implementation Method 1
clamping force sensors have been incorporated into the clamping systems... which measure the contact pressure or clamping force exerted on the winding by the clamping system
Implementation Method 2
allowing for precise measurement and adjustment of the clamping force using optoelectric or piezoelectric sensors
Data Source
AI summary
A press-clamp for an electric transformer winding formed by an upper plate having a free inner face with a first concentric circular protrusion, and an outer face joined to a concentric nut that can be screwed along a threaded bolt; a clamping force sensor having a ring-shaped body; and a lower plate having a peripheral wall defining a cavity with a second concentric protrusion and housing the ring-shaped body of the clamping force sensor and the upper plate by its inner face, the ring-shaped body of the clamping force sensor placed concentrically when aligned with the first protrusion and the second protrusion.