Especial na mga Solusyon ng Transformer na may Pag-optimize ng Struktura at Advanced na Proseso
Ⅰ. Pangunahing Hamon at Paglalakbay sa Inobasyon
Ang mga tradisyunal na transformer ay nahahadlangan ng struktural na redundansiya, botelya ng pagganap ng materyales, at hindi sapat na presisyon ng proseso, kaya hindi ito nasasakop ang mga espesyal na pangangailangan (hal. may limitadong espasyo, mataas na panganib ng maikling circuit, masamang kapaligiran). Ang solusyong ito ay nagpapahusay ng pagganap at adaptabilidad sa iba't ibang sitwasyon sa pamamagitan ng 3D structural optimization, pagbabago ng materyales, at inobatibong proseso.
II. Mga Pinakamahalagang Katangian ng Solusyon
(1) Struktural na Inobasyon: Modularidad at Pinalaking Funcionalidad
1. Shell-Type Structure
- Paggamit: Underground substation sa lungsod, offshore wind power step-up transformers, maliit na data centers
- Mga Advantages:
Pantay na distribusyon ng magnetic flux, kakayahang tumahan ng maikling circuit ↑30%–40%
20% mas maliit na volume kaysa sa core-type structures, ideal para sa may limitadong taas na espasyo
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
|
Kategorya ng Materyales |
Innovative Application |
Performance Advantages |
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Bagong Insulation |
Nomex® paper + DDP film composite system |
Class H heat resistance (180°C) · Dielectric strength ↑20% |
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Eco-Cooling Medium |
Natural ester (FR3™)/Fluorinated fluid (Novec™) |
Ignition point >300°C · Biodegradability >98% |
|
Ligtas na Struktura |
High-strength Al alloy (Series 6) for tanks |
Weight ↓30% · Corrosion-resistant lifespan +15 years |
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Typical Scenarios: |
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• Fluorinated fluid cooling: Data center immersion transformers (Fire Class F0) |
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• Natural ester oil: Subway tunnel transformers (zero toxic leakage risk) |
(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
|
Dimension |
Traditional Solution |
This Solution |
|
Space Efficiency |
Bulky volume |
Footprint ↓25%–40% |
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Short-Circuit Withstand |
25kA/2s |
35kA/3s withstand |
|
Eco-Friendliness |
Mineral oil (pollution risk) |
100% biodegradable · Carbon footprint ↓60% |
|
Lifecycle Cost |
High maintenance |
Predictive maintenance · Failure rate↓45% |
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Extreme Environment |
-40℃~+40℃ |
Stable operation at -50℃~+65℃ |
IV. Application Scenario Validation
- Renewable Energy Plants: Shell-type + split winding design → Resolves harmonic disturbances and frequent short-circuit impacts.
- Underground Smart Substations: Fluorinated fluid cooling + compact modularity → Zero fire risk · Maintenance-free for >10 years.
- Offshore Wind Platforms: Lightweight Al alloy + step-lap stacking → Salt mist corrosion resistance · No-load loss <0.15%.
