Special Transformer Solutions with Structural Optimization and Advanced Processes

Ⅰ. Core Challenges and Innovation Approach​
Traditional transformers are constrained by structural redundancy, material performance bottlenecks, and insufficient process precision, failing to meet demands in specialized scenarios (e.g., space-constrained, high short-circuit risk, harsh environments). This solution achieves performance leaps and scenario adaptability through 3D structural optimization, cutting-edge material upgrades, and precision process innovations.

​II. Key Solution Highlights​
​​(1) Structural Innovation: Modularity and Enhanced Functionality​

1. ​Shell-Type Structure​

• Applications: Urban underground substations, offshore wind power step-up transformers, compact data centers
  
  
• Advantages:
  Uniform magnetic flux distribution, short-circuit withstand capacity ↑30%–40%
  20% smaller volume than core-type structures, ideal for height-limited spaces

2. ​Foil Winding Technology​

• Applicable Types: Distribution transformers, rectifier transformers, mining-specific transformers
• Innovative Value:
  Axial heat dissipation area ↑50%, temperature rise ↓15–20K
  Evenly distributed short-circuit electrodynamic forces, withstand capacity ↑25%

​3. Split Winding/Phase-Shifting Winding​
Core Functions:

• 18-pulse/24-pulse phase-shifting design suppresses 5/7/11th harmonics, THD <3%
• Multi-channel isolated output (e.g., electroplating power supplies), voltage deviation ≤0.5%

​4. Compact Modular Design​
Process Integration:

• Split tank + on-site argon arc welding sealing
• Transport unit weight <80 tons, suitable for mountainous/island terrains

​​(2) Material Innovation: Performance and Sustainability Breakthroughs​

​​(3) Process Innovation: Precision Manufacturing and Lifecycle Assurance​

​1. Vacuum Pressure Impregnation (VPI)​​

• Deep epoxy resin penetration (vacuum level <50Pa)
• Insulation layer porosity ≈0, partial discharge <5pC

2. ​Step-Lap Core Stacking​

• 45° mitered joints laser-aligned, gap <0.1mm
• Results: No-load loss ↓10%–15%, noise ≤55dB(A)

3. ​High-Precision Welding​

• Laser/robotic automated welding
• Weld strength consistency ​>99%​​ Leakage rate <0.1%

4. ​Digital Pre-Integration​

• Built-in fiber-optic temperature (DGA) + vibration sensor interfaces
• Enables real-time health assessment via digital twin systems

​III. Target Achievements​

​IV. Application Scenario Validation​

1. ​Renewable Energy Plants: Shell-type + split winding design → Resolves harmonic disturbances and frequent short-circuit impacts.
2. ​Underground Smart Substations: Fluorinated fluid cooling + compact modularity → Zero fire risk · Maintenance-free for >10 years.
3. ​Offshore Wind Platforms: Lightweight Al alloy + step-lap stacking → Salt mist corrosion resistance · No-load loss <0.15%.