REINFORCED TRANSFORMER CORE FRAME AND MANUFACTURING METHOD

Abstract

A transformer core frame is provided with a reinforcement structure to form a reinforced transformer core frame. The reinforcement structure comprises one or several reinforcement panels comprising a honeycomb structure and affixed to the transformer core frame. A method of producing a reinforced transformer core frame is also described.

Claims

1. A reinforced transformer core frame, comprising: a transformer core frame; and a reinforcement structure, wherein the reinforcement structure comprises one or several reinforcement panels comprising a honeycomb structure and affixed to the transformer core frame.

2. The reinforced transformer core frame of claim 1, wherein the transformer core frame has a first side wall, a second side wall, a top wall, and a bottom wall, and wherein a first reinforcement panel comprising the honeycomb structure is affixed to the first side wall and a second reinforcement panel comprising the honeycomb structure is affixed to the second side wall.

3. The reinforced transformer core frame of claim 2, wherein the first reinforcement panel is affixed to an inner surface of the first side wall and the second reinforcement panel is affixed to an inner surface of the second side wall.

4. The reinforced transformer core frame of claim 3, wherein the first reinforcement panel and the second reinforcement panel abut on an inner surface of the bottom wall or an inner surface of the top wall, and/or wherein the first reinforcement panel and the second reinforcement panel are affixed to the inner surface of the bottom wall or the inner surface of the top wall.

5. The reinforced transformer core frame of claim 2, wherein the first reinforcement panel is affixed to an outer surface of the first side wall and the second reinforcement panel is affixed to an outer surface of the second side wall.

6. The reinforced transformer core frame of claim 5, wherein the honeycomb structure comprises walls defining a plurality of cells, wherein the walls have fluid communication openings formed therein.

7. The reinforced transformer core frame of claim 6, wherein cells of the honeycomb structure are filled with a liquid, optionally with a transformer insulation liquid, optionally with an insulation oil.

8. The reinforced transformer core frame of claim 7, wherein each of the one or several reinforcement panels comprises at least one skin layer adhered to the honeycomb structure.

9. The reinforced transformer core frame of claim 8, wherein each of the one or several reinforcement panels respectively is a composite sandwich panel comprising first and second skin layers, with the honeycomb structure sandwiched between the first and second skin layers.

10. The reinforced transformer core frame of claim 8, wherein each of the one or several reinforcement panels has only one skin layer arranged such that the honeycomb structure is sandwiched between the skin layer and the transformer core frame.

11. The reinforced transformer core frame of claim 10, wherein the one or several reinforcement panels are affixed to the transformer core frame by rivets, bolts, welds or by an adhesive.

12. A transformer, comprising: a wound core, and the reinforced transformer core frame of claim 1 that surrounds the wound core and on which the wound core is supported; optionally wherein the transformer has a tank in which an insulation liquid is disposed, wherein the reinforced transformer core frame is positioned within the tank and cells of the honeycomb structure are at least partially filled with the insulation liquid.

13. A method of producing a reinforced transformer core frame, comprising: affixing one or several reinforcement panels to a transformer core frame, wherein each of the one or several reinforcement panels comprises a honeycomb structure.

14. The method of claim 13, wherein each of the one or several reinforcement panels is a pre-fabricated panel that is affixed to the transformer core frame as an integral unit.

15. Use of one or several reinforcement panels comprising a honeycomb structure and affixed to a transformer core frame for preventing crack formation in the reinforced transformer core frame when short circuit testing is performed.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0097] The subject-matter of the invention will be explained in more detail with reference to preferred exemplary embodiments which are illustrated in the attached drawings, in which:

[0098] FIG. 1 is a schematic view of a reinforced transformer core frame according to an embodiment and a wound core received therein.

[0099] FIG. 2A is a schematic view of a reinforcement panel that may be used in embodiments of the invention, and FIG. 2B a schematic partial view of a reinforced transformer core frame that comprises the reinforcement panel.

[0100] FIG. 3A is a schematic view of a reinforcement panel that may be used in embodiments of the invention, and FIG. 3B a schematic partial view of a reinforced transformer core frame that comprises the reinforcement panel.

[0101] FIG. 4 is a schematic partial view of a reinforced transformer core frame according to an embodiment.

[0102] FIG. 5 is a schematic partial perspective view of a reinforcement structure of a reinforced transformer core frame according to an embodiment.

[0103] FIG. 6 is a schematic cross-sectional view of a transformer comprising a reinforced transformer core frame according to an embodiment.

DETAILED DESCRIPTION OF EMBODIMENTS

[0104] Example embodiments of the invention will be described with reference to the drawings in which identical or similar reference signs designate identical or similar elements. While some embodiments will be described in the context of a distribution transformer, the embodiments are not limited thereto. The features of embodiments may be combined with each other, unless specifically noted otherwise.

[0105] According to embodiments of the invention, composite panels having a structure that defines a plurality of cells, such as a honeycomb structure, and at least one skin layer attached to the honeycomb structure are used as reinforcement affixed to side walls (i.e., the shorter walls) of a transformer core frame.

[0106] FIG. 1 shows a partial view of a transformer 10 having a transformer core frame 20 and a wound core 11. The wound core 11 has various yokes. The transformer core frame 20 has a first side wall 21, a second side wall 22, a bottom wall 23 and a top wall 24. The transformer core frame 20 may be operative to clamp and compress yokes of the core at the top and bottom, thereby holding the core together. The transformer core frame 20 may be made of metal, in particular stainless steel.

[0107] Without any reinforcement of the transformer core frame 20, some of the walls of the transformer core frame 20 may be subject to the risk of crack formation when the active part of the transformer exerts electro-dynamical forces onto the transformer core frame 20. This applies in particular to situations such as short circuit testing, where the shorter walls, i.e., the side walls 21, 22, may be prone to exhibiting crack formation.

[0108] For improved stability and in order to mitigate the risk of such crack formation, a first reinforcement panel 31 is affixed to the first side wall 21 and a second reinforcement panel 32 is affixed to the second side wall 22. While only a single reinforcement panel 31, 32 is shown on each of the side walls 21, 22, plural separate reinforcement panels may be affixed to one side wall. The reinforcement panel(s) may be attached on one or several of the side walls 21, 22, the bottom wall 23, and/or the top wall 24, as will be explained in more detail below.

[0109] The transformer core frame 20 with the reinforcement panels 31, 32 affixed thereto is also referred to as “reinforced transformer core frame” herein.

[0110] The reinforcement panels 31, 32 respectively are composite panels having a honeycomb structure and at least one skin layer adhered to the honeycomb structure. The reinforcement panels 31, 32 may have a sandwich configuration with two skin layers (as will be explained in more detail with reference to FIGS. 2A and 2B) or with just one skin layer that sandwiches the honeycomb structure between the skin layer and a surface of one of the walls of the transformer core frame (as will be explained in more detail with reference to FIGS. 3A and 3B).

[0111] The reinforcement panels 31, 32 may be affixed to the side walls 21, 22 of the transformer core frame by means of rivets, bolts, welds, and/or by means of adhesive.

[0112] FIG. 2A is a perspective view of a reinforcement panel 31. The reinforcement panel 31 with the structure depicted in FIG. 2A may be affixed on plural walls of the transformer core frame, such as side walls 21, 22, bottom wall 23, and/or top wall 24.

[0113] The reinforcement panel 31 has a two skin layers 42, 43 provided on opposite sides in the width direction of the reinforcement panel 31. The honeycomb structure 41 is sandwiched between the skin layers 42, 43. The skin layers 42, 43 may be attached to the honeycomb structure 41 (which is a honeycomb core sandwiched between the skin layers) by an adhesive layer, without being limited thereto.

[0114] FIG. 2B is a perspective partial view of the reinforced transformer core frame, in which the reinforcement panel 31 is affixed to the side wall 21 such that the skin layer 43 is in close abutment with the side wall 21 along the planar extension of the skin layer 43.

[0115] The reinforcement panel 31 having two skin layers 42, 43 may be affixed to the side wall 21 by riveting, bolting, welding or gluing, for example.

[0116] FIG. 3A is a perspective view of a reinforcement panel 31. The reinforcement panel 31 with the structure depicted in FIG. 3A may be affixed on plural walls of the transformer core frame, such as side walls 21, 22, bottom wall 23, and/or top wall 24. The reinforcement panel 31 has a single skin layer 42 attached to the honeycomb structure 41 by an adhesive layer, without being limited thereto.

[0117] FIG. 3B is a perspective partial view of the reinforced transformer core frame, in which the reinforcement panel 31 is affixed to the side wall 21 such that the skin layer 42 and the side wall 21 sandwich the honeycomb structure 41 therebetween.

[0118] The reinforcement panel 31 having a single skin layer 42 may be affixed to the side wall 21 using an adhesive or using other techniques. In the reinforced transformer core frame structure, the honeycomb structure 41 is adhered to the side wall 21 such that no skin layer is interposed between the honeycomb structure 41 and the side wall 21. Other techniques may be used for attaching the honeycomb structure 41 to the side wall 21, such as riveting, bolting, or welding.

[0119] It will be appreciated that, when using panels having a single skin layer only, the side wall 21 of the transformer core frame operates to sandwich the honeycomb structure 41 between the side wall 21 and the skin layer 42. As indicated by solid black arrows in FIG. 3B, the side wall 21 may act as an axial end face of the cells of the honeycomb structure. I.e., the side wall 21 of the transformer core frame itself has a function that is similar to that of a skin layer opposing the skin layer 42 of the reinforcement panel 31.

[0120] While FIGS. 1 to 3 are views of reinforced transformer core frames in which the reinforcement panel is affixed on an outer side of the reinforced transformer core frame, reinforcement panels comprising a honeycomb structure may alternatively or additionally be affixed on an inner side of the reinforced transformer core frame.

[0121] FIG. 4 is a schematic partial view of a reinforced transformer core frame, with a reinforcement panel 31 being affixed to an inner surface of the first side wall 21. A similar construction may be used on the opposite second side wall 22 (not shown in FIG. 4). The reinforcement panel 31 may be affixed to the inner surface of the side wall 21 by riveting and/or gluing. A fixation area 51 between the reinforcement panel 31 and the side wall 21 may be formed along the major face of the reinforcement panel 31.

[0122] The reinforcement panel 31 may optionally also be affixed to an inner surface of the bottom wall 23 and/or an inner surface of the top wall 24. A further fixation area 52 between the reinforcement panel 31 and the bottom wall 23 may be formed along a minor face of the reinforcement panel 31. Alternatively or additionally, a further fixation area between the reinforcement panel 31 and the top wall 24 may be formed along another minor face of the reinforcement panel 31.

[0123] When the reinforcement panel 31 is provided on the inner side of the transformer core frame, it can act as an interconnection between side and bottom walls, further increasing robustness of the construction.

[0124] The side wall 21 has a planar major portion and integral bent edge portions that extend transversely to the planar major portion along the vertical edges of the planar major portion. Part or all of the reinforcement panel 31 may be arranged between the bent edge portions of the side wall 21.

[0125] The bottom wall 23 may a planar major portion and integral bent edge portions that extend transversely to the planar major portion, and part of the reinforcement panel 31 may be arranged between the bent edge portions of the bottom wall 23.

[0126] Part or all of the reinforcement panel 31 may be made of an electrically insulating material. For illustration, one or two skin layers and/or the honeycomb structure may be made of an electrically insulating material. In some examples, only the skin layer closer to the wound core (but not the skin layer closer to the side wall 21) may be made of an electrically insulating material. The use of insulating materials in the reinforcement panel 31 allows the reinforcement panel 31 to also provide electrical insulation. The amount of conventional insulating materials that are normally provided, such as pressboards, on the inner sides of the transformer core frame may thereby be reduced or eliminated along the side walls 21, 22.

[0127] Various materials can be used for skins and/or of the cores of the composite panel 31. For illustration, the honeycomb structure 41 may comprise or may be formed of at least one of: aluminum, stainless steel, Nomex®, Kevlar®, polypropylene, polycarbonate, without being limited thereto. The at least one skin layer 42, 43 may comprise or may be formed of at least one of: aluminum, stainless steel, high pressure laminate, glass/epoxy prepreg, fiberglass, without being limited thereto. The at least one skin layer 42, 43 may be adhered to the honeycomb structure 41 using an adhesive that is commercial grade toughened epoxy or modified epoxy film adhesive. It will be appreciated that these materials are only exemplary.

[0128] The characteristics of the reinforcement panel(s) 31, 32 may be customized by appropriately dimensioning the skin layers (e.g., skin layer thickness) and/or the honeycomb structure (e.g., the wall thickness, the cross-sectional area of the honeycomb cells, and/or the length of the honeycomb cells) and/or by appropriate selection of materials.

[0129] It will be appreciated that the reinforcement panel(s) 31, 32 may be selected according to the transformer rating and may be pre-manufactured for subsequent affixation to the transformer core frame. This allows few sizes of ready-made reinforcement panels to be stocked and used in modular fashion. In this case, several reinforcement panels (e.g., two, three, four, or more than four reinforcement panels) may be attached to a first side wall 21 of the transformer core frame, and several additional reinforcement panels (e.g., two, three, four, or more than four reinforcement panels) may be attached to a second side wall 22 of the transformer core frame.

[0130] The types and numbers of reinforcement panels to be used may be selected in accordance with the transformer specifications, e.g., in dependence on the transformer rating.

[0131] The walls defining the honeycomb cells of the reinforcement panel(s) may be provided with fluid communication openings. The fluid communication openings may allow a liquid to enter into the cells, preferably all cells, of the honeycomb structure while allowing gas to exit the cells of the honeycomb structure.

[0132] Preferably, for each cell of the reinforcement panel(s), the wall surrounding the cell has at least one, preferably at least two fluid communication openings. The wall surrounding the cell may consist of six essentially rectangular panels that are angled relative to each other to form the hexagonal cell, and one or more fluid communication openings may be provided in each one of the six panels.

[0133] FIG. 5 shows a honeycomb structure 41 of a reinforcement panel. It will be appreciated the honeycomb structure 41 as described with reference to FIG. 5 may be used for any reinforcement panel, e.g., on reinforcement panel(s) 31 affixed to the side walls 21, 22, bottom wall 23, and/or top wall 24.

[0134] The honeycomb structure 41 has walls 61, 62 defining the hexagonal cells. Fluid communication openings 64, 65 are formed in the walls 61, 62.

[0135] The fluid communication openings may include fluid communication openings 64 that allow an insulation liquid to pass between adjacent cells in the honeycomb structure of the same reinforcement panel.

[0136] The fluid communication openings may include fluid communication openings 65 provided in outer walls 62 of the honeycomb structure 41 that allow the insulation liquid to pass from a cell in the honeycomb structure of the same reinforcement panel to a cell in an adjacent reinforcement panel.

[0137] The fluid communication openings 64, 65 do not only allow insulation liquid to enter the cells and/or to pass between the cells, but also allow gas that may initially be contained within the cells to exit the reinforcement panel.

[0138] In this way, the stability of the reinforcement structure may be further enhanced by reducing, in particular essentially eliminating, a hydrostatic pressure difference between the inside and outside of a reinforcement panel. The hydrostatic pressure present at any location on the inner surface of a skin layer may be caused to become equal to the hydrostatic pressure present at the corresponding location on the outer surface of the skin layer.

[0139] FIG. 6 shows a transformer 10 comprising a reinforced transformer core frame according to an embodiment. The transformer 10 has a tank 70. The reinforced transformer core frame having the transformer core frame 20 and the reinforcement panels 31 attached thereto is positioned in the tank. The reinforcement panels 31 may be affixed to the side, bottom and/or top walls of the transformer core frame 20.

[0140] The reinforcement panel(s) 31 includes a honeycomb structure that has walls defining the hexagonal cells, with fluid communication openings being formed in the walls. The fluid communication openings may communicate, directly or indirectly, the interior of all cells of the honeycomb structure with the tank volume surrounding the reinforcement panel(s).

[0141] When the tank 70 is filled with an insulation liquid, the insulation liquid enters the cells of the honeycomb structure. Concurrently, gas (typically air) is driven out from the cells of the honeycomb structure. An equalization in hydrostatic pressure can be attained, such that the pressure differential in hydrostatic pressure across the skin layer of the reinforcement panel is equal to zero.

[0142] Various effects and advantages are attained by the reinforced transformer core frame, the method, and the use according to the invention.

[0143] A weight reduction can be attained compared to stiffeners conventionally considered for reinforcing transformer core frames. It will be appreciated that the weight reduction is particularly pronounced in the state in which the reinforced transformer core frame is mounted in a transformer tank, and the cells of the honeycomb core are still filled with gas. This is an important advantage, because the weight reduction is pronounced in the state in which the transformer core frame may have to be transported and/or handled for assembly.

[0144] The assembly of the reinforcement panels to the transformer core frame is simplified. This applies in particular when riveting or bolting is used for affixing the reinforcement panels to the transformer core frame.

[0145] When the reinforcement panels are placed on the inner side of the transformer core frame and are affixed thereto by, e.g., gluing, an interconnection between bottom and side walls of the frame can be assured, leading to a further increase in stiffness. Further, a skin of the reinforcement panel facing towards the wound core and, optionally, the honeycomb structure and/or the other skin, may be formed from insulating material, allowing the conventional pressboard insulation along the side walls to be reduced or eliminated.

[0146] The reinforced transformer core frame can be applicable to all wound core frames types, where additional reinforcement is desired. Embodiments of the invention may be used for, e.g., distribution transformers.

[0147] While the invention has been described in detail in the drawings and foregoing description, such description is to be considered illustrative or exemplary and not restrictive. Variations to the disclosed embodiments can be understood and effected by those skilled in the art and practicing the claimed invention, from a study of the drawings, the disclosure, and the appended claims. In the claims, the word “comprising” does not exclude other elements or steps, and the indefinite article “a” or “an” does not exclude a plurality. The mere fact that certain elements or steps are recited in distinct claims does not indicate that a combination of these elements or steps cannot be used to advantage, specifically, in addition to the actual claim dependency, any further meaningful claim combination shall be considered disclosed.