Transformer Winding Cooling Ducts for Heat Dissipation
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Solution Overview
Problem
Current winding arrangements for electric transformers face challenges in heat dissipation and size reduction, as axial cooling channels lead to inefficient heat transfer and increased radial dimensions, necessitating larger conductor cross-sections and additional insulation materials to manage temperature.
Innovation Solution
A winding arrangement where cooling ducts extend between pairs of adjacent layers in both axial and tangential directions, forming a cylindrical structure, allowing for a more efficient distribution of cooling channels that reduce the overall size and enhance heat dissipation without increasing the radial dimension.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If axial cooling channels are used in conventional winding arrangements, then cooling function is provided, but heat dissipation efficiency is poor and radial dimensions increase
Solution Approach 1:
The patent transitions from conventional axial cooling channels to oblique cooling channels that extend in both axial and radial directions. This dimensional change allows the cooling channels to penetrate deeper into the winding structure, improving heat dissipation efficiency while avoiding excessive radial dimension increase through optimized channel angle and distribution.
Solution Approach 2:
The cooling channels are segmented into multiple sections extending between different pairs of adjacent layers. This segmentation allows for distributed cooling throughout the winding structure, improving overall heat dissipation efficiency while maintaining compact radial dimensions through strategic placement of multiple smaller cooling zones.
2Temperature
If more cooling channels are added to improve heat dissipation, then cooling effectiveness increases, but the volume and radial dimension of the winding arrangement increase
Solution Approach 1:
By introducing oblique cooling channels with both axial and radial components, the patent achieves more effective heat dissipation from multiple layers simultaneously. This dimensional approach allows fewer channels to serve multiple cooling zones, reducing the overall volume required compared to conventional axial channels that would need to be numerous and densely packed.
Solution Approach 2:
Each oblique cooling channel serves multiple functions: it cools multiple adjacent layers, provides structural support, and maintains electrical insulation. This multi-functionality reduces the total number of channels needed, thereby reducing the overall volume of the winding arrangement while maintaining effective cooling.
3Temperature
If cooling channels are positioned between multiple layers of conductor and insulation, then cooling coverage is improved, but some layers are closer to cooling ducts than others causing uneven cooling
Solution Approach 1:
The patent positions cooling channels at specific locations between selected pairs of adjacent layers, creating localized cooling zones where needed most. This local quality approach ensures that each cooling channel is optimally positioned to cool the specific layers it serves, achieving uniform cooling distribution across the entire winding structure.
Solution Approach 2:
The oblique orientation of cooling channels in both axial and radial directions creates more uniform thermal pathways to the cooling ducts. This dimensional change ensures that heat from different layers travels comparable distances to reach cooling channels, eliminating the uneven cooling distribution problem of conventional axial channels.
4Temperature
If the volume of cooling ducts is increased to improve cooling, then heat dissipation capacity increases, but the radial dimension and overall size of the transformer increase
Solution Approach 1:
The patent utilizes oblique cooling channels that extend in both axial and radial directions, effectively using three-dimensional space more efficiently. This allows increased heat dissipation capacity through enhanced cooling channel geometry and distribution without proportionally increasing the radial dimension, as the cooling channels leverage axial space more effectively.
Solution Approach 2:
The cooling system is segmented into multiple distributed channels rather than one or two large ducts. This segmentation allows for more efficient heat dissipation capacity through increased surface area and better thermal contact with multiple layers, while maintaining compact radial dimensions through optimized channel sizing and distribution.
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 design improves heat dissipation and reduces the size of the winding arrangement, allowing for direct contact with each turn and uniform cooling distribution, thereby minimizing hot zones and optimizing the use of conductor material and insulation.
Implementation Method 1
heat from these layers has to travel a longer way to be dissipated
Implementation Method 2
the cooling channels are usually flowed through by a cooling oil
Implementation Method 3
Due to the Joule effect and additional losses produced by Foucault currents the conductor material heats up
Implementation Method 4
Due to the Joule effect and additional losses produced by Foucault currents the conductor material heats up
Data Source
Figure 1A~2A
Figure 2B~3
Figure 4A
AI summary
Winding arrangement (300) for an electric installation, the winding arrangement (300) comprising an electric conductor (309) and a plurality of cooling ducts (301-304), wherein the electric conductor is coiled up forming several layers (321-327) around an axis (330), wherein: - each cooling duct (301-304) of said plurality of cooling ducts extends between a pair of adjacent layers (321-327) of the coiled electric conductor (309) in axial direction through the winding arrangement (300) and in tangential direction not entirely around the axis (330); the cooling ducts (301-304) of the plurality of cooling ducts are distributed among more than one pair of adjacent layers (321-327) such that the winding arrangement (300) is essentially cylindrical.