High-Efficiency Thermal Management Solution for Special Transformers Guaranteeing Core Performance & Extending Equipment Lifespan

Ⅰ. Core Perspective​

Addressing heat accumulation challenges in special transformers under severe operating conditions, this solution proposes systematic thermal dissipation and temperature control optimization strategies:

• ​Extreme Loading:​​ Continuous overload, impact loads.
• ​High Harmonic Pollution:​​ Additional losses caused by non-linear loads.
• ​High Ambient Temperatures:​​ Outdoor/enclosed spaces with sustained ambient temperatures ≥40°C.

​II. Key Solution Points​

​​(A) Precision Thermal Simulation & Design Optimization​

1. ​Thermal Digital Twin Model​
• Utilizes CFD software (FloTHERM/Star-CCM+) to build a 3D thermal-fluid coupling model.
• Accurately simulates oil flow paths, winding hot-spot distribution, and radiator efficiency.
• Outputs optimized schemes: Achieves >15% hotspot temperature reduction through heat dissipation structure adjustments.

​​(B) Customized Cooling System Design​

​​(C) Oil Flow Control Optimization​

• ​Enhanced Oil Guiding Design:​​

A[Oil Inlet] --> B[Silicon Steel Guide Channels]

B --> C[Axial Winding Oil Ducts]

C --> D[Hotspot Reinforced Spray Nozzles]

D --> E[Top Oil Outlet]

• Achieves ≥300% increase in oil flow velocity in hotspot regions, resulting in 8-12K temperature reduction.

​​(D) Intelligent Temperature Control System​

​III. Target Outcomes & Verification Standards​

1. ​Temperature Control​
• Winding Hotspot Temperature: ≤95°C (rated load) / ≤115°C (2-hour emergency overload)
• Top Oil Temperature Rise: ≤45K (compliant with IEC 60076-7)
2. ​Lifespan Assurance​
• Based on the 10°C Rule (Montsinger's Rule):L = L₀ × 2^[(98°C - T_hotspot)/6]
• Ensures insulation thermal aging <20% over the 30-year design lifespan.
3. ​Efficiency Improvement​
• Reduced No-Load Losses: 12% reduction (low eddy current design)
• Cooling System Energy Consumption: <5% of total losses

​IV. Typical Application Scenarios​