On-Load Tap Changer Union-Nut Mounting for Compact Assembly
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Solution Overview
Problem
Existing on-load tap-changers for transformers are time-consuming and expensive to assemble, particularly for smaller units, due to their complex and bulky design.
Innovation Solution
The use of a flange module and union nut for fastening the on-load tap-changer to the transformer, allowing for a simple and compact installation without the need for special tools, using a connection that can be threaded, clipped, or locked, and potentially incorporating insulating materials and seals to prevent oil leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the traditional two-step assembly method (screwing tap-changer head to transformer cover, then screwing tap-changer cover over the assembly) is used, then the connection is secure, but the assembly process is time-consuming and expensive
Solution Approach 1:
The patent combines the tap-changer head and tap-changer cover into a single integrated unit that can be installed in one step. The flange module serves as both the mounting interface and the sealing interface, eliminating the need for separate assembly steps and reducing overall installation time while maintaining secure connection.
Solution Approach 2:
The tap-changer is divided into modular components (flange module, selector assembly, diverter switch) that can be pre-assembled and tested separately, then quickly installed as a complete unit. This modular approach simplifies the final installation process and reduces assembly time on-site.
2Strength
If the traditional bulky design is used, then the structural strength is sufficient, but the device size is large and installation is complex
Solution Approach 1:
The patent employs a nested arrangement where the selector assembly is positioned within the transformer tank, and the flange module is integrated into the tank wall. The diverter switch and other components are arranged in a compact, space-efficient configuration that minimizes the overall device volume while maintaining structural integrity.
Solution Approach 2:
The design transitions from a horizontally extended bulky structure to a vertically oriented compact configuration. The flange module mounts vertically on the transformer cover, and components are arranged in the vertical dimension, reducing the horizontal footprint and overall device volume.
3Reliability
If more assembly steps and components are used, then the connection is more secure, but the assembly process becomes more complex and expensive
Solution Approach 1:
The flange module incorporates self-aligning features and self-sealing mechanisms that automatically ensure proper connection and sealing during installation. The integrated design includes built-in alignment guides and self-adjusting mounting features that eliminate the need for complex alignment procedures and multiple adjustment steps.
Solution Approach 2:
The flange module serves multiple functions simultaneously: it provides the mounting interface for the tap-changer, creates the sealing barrier between the transformer tank and atmosphere, provides structural support, and serves as the electrical insulation barrier. This multi-functionality reduces the number of separate components needed while maintaining connection security.
Data Source
AI summary
An on-load tap-changer provides uninterrupted diverter switch operation between different winding taps of a tap-changing transformer. The on-load tap-changer includes: a flange module; and a union nut. The on-load tap-changer is configured to be fastened to the tap-changing transformer by the union nut and the flange module.