METHOD FOR MAKING A DRY-TYPE TRANSFORMER, DRY-TYPE TRANSFORMER OBTAINED FROM SAID METHOD, AND DIELECTRIC BARRIER ARRANGEMENT FOR ELECTRICALLY ISOLATING A COIL OF A TRANSFORMER ASSEMBLY

Abstract

A dry-type transformer, comprises a magnetic core, at least one high voltage (HV) winding, and at least one low voltage (LV) winding inductively coupled to the magnetic core. The transformer is made by determining a shape of an electric field that is generated, 3D printing a dielectric structure shaped to conform to the determined shape of the electric field, and mounting the dielectric structure between the HV and LV windings. A dielectric barrier arrangement for electrically isolating a coil of a transformer assembly from a further coil of the transformer assembly or from a core of the transformer assembly comprises a first dielectric structure having a first cylindrical dielectric structure extending along a longitudinal axis (L).

Claims

1. A method for making a dry-type transformer, the transformer comprising a winding assembly including a magnetic core, at least one high voltage winding, and at least one low voltage winding inductively coupled to the magnetic core, the method comprising: determining a shape of an electric field that is generated in the transformer; 3D printing a dielectric structure shaped to be aligned with the shape of the equipotential lines of the electric field; and mounting the dielectric structure between the high voltage and low voltage windings.

2. The method of claim 1, wherein determining a shape of an electric field in the transformer is carried out by performing an finite element method simulation and then adapting the geometry of the dielectric structure to the shape of the equipotential lines of the electric field obtained in the electric simulation.

3. The method of claim 1, wherein the 3D printed dielectric structure is a one-piece structure, preferably wherein the dielectric structure is made by 3D printing polymers or composite materials comprising fibers and polymers.

4. The method of claim 3, wherein the dielectric structure is made by at least one of the Selective Laser Sintering, Fused Deposition Modeling, or Stereolithography 3D printing technologies.

5. A dry-type transformer, comprising at least one first winding, at least one second winding, a magnetic core and at least one 3D printed dielectric structure provided between the at least first and second windings, the dielectric structure comprising at least one cylindrical dielectric screen shaped to be aligned with the shape of the equipotential lines of an electric field that is generated in the transformer, and at least one supporting block to support the dielectric screen and the first winding and/or second winding.

6. A dry-type transformer, comprising at least one first winding, at least one second winding, a magnetic core and at least one 3D printed dielectric structure provided between the at least first and second windings, the dielectric structure comprising at least one cylindrical dielectric screen shaped to be aligned with the shape of the equipotential lines of an electric field that is generated in the transformer, and at least one supporting block to support the dielectric screen and the first winding and/or second winding, made by the method according to claim 1.

7. A dry-type transformer according to claim 5, wherein at least one screen is arranged between the at least one winding, and core yokes, and/or metallic structures.

8. A dry-type transformer according to claim 5, wherein the dielectric structure is printed in one-single piece with no gaps at least between the cylindrical dielectric screen, the supporting blocks and the cylindrical dielectric screen between the windings, and the screen between the at least one winding and core yokes, and/or metallic structures.

9. A dry-type transformer according to claim 5, further including air ducts for directing an airflow from at least one cooling fan and distribute it uniformly at least to the windings.

10. A dry-type transformer according to claim 5, wherein the dielectric structure is made by 3D printing polymers or composite materials comprising fibers and polymers.

11. A dry-type transformer according to claim 5, wherein the first winding defines a longitudinal axis (L), wherein the at least one dielectric structure further comprises a screen, extending at least substantially perpendicular to the longitudinal axis (L) for further electrically isolating the first winding and/or the second winding, preferably wherein the screen is formed directly connected to the at least one supporting block and/or directly connected to the cylindrical dielectric screen of the at least one dielectric structure.

12. A dry-type transformer according to claim 5, wherein the at least one dielectric structure comprises a radially protruding positioning element for radially positioning the at least one dielectric structure relative to a longitudinal axis (L) defined by the first winding.

13. A dry-type transformer according to claim 5, wherein the at least one dielectric structure has at least two cylindrical dielectric screens, comprising a radially inner cylindrical dielectric screen and a radially outer cylindrical dielectric screen, wherein a radial gap or duct is formed between the radially inner cylindrical dielectric screen and the radially outer cylindrical dielectric screen.

14. A dry-type transformer according to claim 13, wherein the at least one dielectric structure further comprises at least one fluid barrier structure that is designed and arranged to close the radial gap or duct in a fluid-tight manner.

15. A dry-type transformer according to claim 5, comprising a first dielectric structure having a first cylindrical dielectric screen, and a second dielectric structure having a second cylindrical dielectric screen, wherein the second cylindrical dielectric screen at least partially coaxially surrounds the first cylindrical dielectric screen, and wherein the design is such that the second dielectric structure is separate from the first dielectric structure.

16. A dry-type transformer of claim 15, wherein the screens of the first and second dielectric structures are arranged at opposite longitudinal ends of the respective first and second dielectric structure, respectively.

17. A dry-type transformer of claim 5, wherein an air duct or fluid duct is formed between the at least one dielectric structure and the coil and/or between the at least one dielectric structure and the further coil and/or between the dielectric structure and the core.

18. The method of claim 2, wherein the 3D printed dielectric structure is a one-piece structure, preferably wherein the dielectric structure is made by 3D printing polymers or composite materials comprising fibers and polymers, and wherein the dielectric structure is made by at least one of the Selective Laser Sintering, Fused Deposition Modeling, or Stereolithography 3D printing technologies.

19. A dry-type transformer according to claim 5, comprising a first dielectric structure having a first cylindrical dielectric screen, and a second dielectric structure having a second cylindrical dielectric screen, wherein the second cylindrical dielectric screen at least partially coaxially surrounds the first cylindrical dielectric screen, wherein the design is such that the second dielectric structure is separate from the first dielectric structure, wherein the screens of the first and second dielectric structures are arranged at opposite longitudinal ends of the respective first and second dielectric structure, respectively, wherein the screens of the first and second dielectric structures are arranged at opposite longitudinal ends of the respective first and second dielectric structure, respectively, and wherein an air duct or fluid duct is formed between the at least one dielectric structure and the coil and/or between the at least one dielectric structure and the further coil and/or between the dielectric structure and the core.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0043] One non-limiting examples of the present disclosure will be described in the following, with reference to the appended drawings, in which:

[0044] FIG. 1 is a diagrammatic rear elevational view of a standard dry-type transformer;

[0045] FIG. 2 is a front elevational view of the standard dry-type transformer in FIG. 1 where equipotential lines in a XZ plane have been depicted

[0046] FIG. 3 is an enlarged side elevational detail view of equipotential lines through supporting blocks;

[0047] FIG. 4 is an enlarged sectional view of equipotential lines through supporting blocks in FIG. 3;

[0048] FIG. 5 is a diagrammatic front elevational view of a dry-type transformer according to the present disclosure;

[0049] FIG. 6 is a representation of an example of a dielectric structure assembly comprising two one-piece 3D printed dielectric structures inserted into one another;

[0050] FIG. 7 is a schematic cross-section of a dielectric barrier arrangement, for example the one of FIG. 6, comprising a first and second dielectric structure according to an embodiment of the present disclosure;

[0051] FIG. 8 is a perspective view of the dielectric barrier arrangement, for example the one of FIG. 6 or 7, wherein the first and second dielectric structures are separated from each other;

[0052] FIG. 9 is a perspective cross-sectional view along line IX-IX indicated in FIG. 7; and

[0053] FIG. 10 is a further schematic cross-section of an embodiment of a corresponding transformer assembly.

DETAILED DESCRIPTION

[0054] Reference is first made to the non-limiting example shown in figures of the drawings where a dry-type transformer 100 has been illustrated. As shown in figures, the dry-type transformer 100 comprises a winding assembly including a first winding 110, that is a high voltage winding (HV winding), a second winding 120, that is a low voltage winding (LV winding), and a magnetic core 180 around which the HV and LV windings 110, 120 are arranged.

[0055] The HV and LV windings 110, 120 are fitted between a top structure 200 and a bottom structure 250 of the transformer 100. The top and bottom structures 200, 250 have associated corresponding top and bottom core yokes 210, 260, respectively.

[0056] Reference is now made to FIGS. 2-4 of the drawings where the equipotential lines of the dielectric field generated in the transformer 100 are shown. Equipotential lines are perpendicular to the electric field vector and determines the region in the space where every point has the same dielectric potential. The spacing between the lines describes the intensity of the electric field in the transformer. The shape of the electric field depends on the configuration of the transformer 100 and is determined by a 3D simulation from which a dielectric structure 130 is suitably designed. From that 3D simulation of the shape of the electric field a dielectric structure 130 is 3D printed into a single piece by 3D printing polymers or composite materials comprising fibers and polymers and through any of Selective Laser Sintering (SLS), or Fused Deposition Modeling (FDM), or stereolithography (SLA) 3D printing technologies. Other 3D printing technologies are not ruled out.

[0057] The shape of the resulting 3D printed dielectric structure 130 closely conforms to the shape of the electric field that has been previously determined in the simulation. The geometry of the dielectric structure 130 is tuned where necessary before being 3D printed.

[0058] FIG. 6 shows one example of a dielectric structure assembly 300 comprising a first one-piece 3D printed dielectric structure 130 and a second one-piece 3D printed dielectric structure 130 which is inserted upside down inside the first one-piece 3D printed dielectric structure 130. The 3D printed dielectric structure 130 comprises a cylindrical dielectric screen 135 that is arranged between the HV winding 110 and the LV winding 120. The dielectric structure 130 further includes a corresponding screen 160, 170 arranged between the windings 110, 120 and the core yokes 210, 260, and/or metallic structures (200). Also, the one-piece 3D printed dielectric structure 130 includes top and bottom supporting blocks 140, 150 arranged to support the dielectric screen 135 and the HV and LV windings 110, 120. Since the 3D printed dielectric structure 130 is a one-piece structure, no gaps are present, that is, the cylindrical dielectric screen 135, 160, 170 and the supporting blocks 140, 150 of the dielectric structure 130 have no gaps, openings or discontinuities.

[0059] The 3D dielectric structure 130 is 3D includes air ducts (not shown). Such air ducts are suitably designed to direct an airflow from external cooling fans (not shown) into the HV and LV windings 110, 120 and the magnetic core 180 in a distributed and uniform manner for efficient cooling of the transformer 100.

[0060] FIG. 7 is a schematic cross-section of a transformer according to an embodiment of the present disclosure. FIG. 8 is a perspective view of a first and a second dielectric structure of the transformer. The first and second dielectric structure are suited for electrically isolating a coil 2 of the transformer from a further coil 4 of the transformer or from a core 6 of the transformer. Unless otherwise stated in the following, the transformer of the transformer assembly may be structured as the above described transformer 100 and may comprise corresponding features, as discussed herein above.

[0061] The coil 2 may be a low voltage winding, and the further coil 4 may be a high-voltage winding. The core 6 may comprise a lower yoke and an upper yoke, for example the bottom core yoke 260 and the top core yoke 210, and a column extending between the lower and the upper yoke. The coil 2 and the further coil 4 particularly surround the column of the core 6.

[0062] The first dielectric structure 10 comprises a first cylindrical dielectric structure 12 extending along a longitudinal axis L. The second dielectric structure comprises a second cylindrical dielectric structure 22 extending along the longitudinal axis L. The longitudinal axis L extends through the column of the core 6.

[0063] The second cylindrical dielectric structure 22 at least partially coaxially surrounds the first cylindrical dielectric structure 12. Alternatively, the first cylindrical dielectric structure may at least partially coaxially surround the second cylindrical dielectric structure. In other words, the second cylindrical dielectric structure 22 and the first cylindrical dielectric structure 12 overlap as seen along the longitudinal axis L. For example, at least one half of the length of the second cylindrical dielectric structure 22 seen along the longitudinal axis L may overlap with at least one half of the length of the first cylindrical dielectric structure 12.

[0064] The dielectric barrier arrangement is designed such that the second dielectric structure 20 is separate from the first dielectric structure 10.

[0065] The first dielectric structure 10 and/or the second dielectric structure 20 may each be a one-piece or integral structure. Preferably, the first dielectric structure 10 and/or the second dielectric structure 20 is manufactured by 3D printing.

[0066] In some embodiments, the first cylindrical dielectric structure 12 and/or the second cylindrical dielectric structure 22 comprises a radially protruding positioning element 18 for radially positioning the second cylindrical dielectric structure 22 relative to the first cylindrical dielectric structure 12. This may facilitates the assembling of the transformer further. The radially protruding element 18 particularly extends, with respect to the longitudinal axis L, circumferentially in closed ring-like manner. In this way, a fluid flow between the first and second cylindrical dielectric structure 12, 22 may be effectively prevented or at least significantly reduced.

[0067] In particular, one dielectric structure 10; 20 may be inserted upside down inside the other dielectric structure 20; 10.

[0068] FIG. 9 is a perspective cross-sectional view through cylindrical dielectric structures 12 and 22 along line IX-IX indicated in FIG. 7. As seen for example in this figure, the first cylindrical dielectric structure 12 may be, at least partly, double-walled with a radially inner and a radially outer cylindrical dielectric screen. FIG. 10 is a schematic cross-sectional view showing a corresponding radially inner cylindrical dielectric screen 1210 of the first cylindrical dielectric structure 12, a radially outer cylindrical dielectric screen 1212 of the first cylindrical dielectric structure 12, a radially inner cylindrical dielectric screen 2210 of the second cylindrical dielectric structure 22, and a radially outer cylindrical dielectric screen 2212 of the second cylindrical dielectric structure 22.

[0069] Further, the first dielectric structure 10 particularly has at least one fluid barrier element 1214 extending circumferentially, wherein the at least one fluid barrier element 1214 is designed and arranged to close a radial gap formed between the radially inner cylindrical dielectric screen 1210 and the radially outer cylindrical dielectric screen 1212 of the first tubular section 12 in a fluid-tight manner. Similarly, the second dielectric structure 20 particularly has at least one fluid barrier element 2214 extending circumferentially, wherein the at least one fluid barrier element 2214 is designed and arranged to close a radial gap formed between the radially inner cylindrical dielectric screen 2210 and the radially outer cylindrical dielectric screen 2212 of the second tubular section 22 in a fluid-tight manner.

[0070] More generally, the first cylindrical dielectric structure 12 and/or the second cylindrical dielectric structure 22 may have at least two cylindrical dielectric screens, for example three, four, five, six or even more corresponding cylindrical dielectric screens. Between each pair of adjacent cylindrical dielectric screens, a radial gap may be formed which is closed by a corresponding fluid barrier element.

[0071] As can be seen in FIG. 10, a first cooling fluid duct 40 may be formed between the dielectric barrier arrangement and the coil 2 and a second cooling fluid duct 42 may be formed between the dielectric barrier arrangement and the further coil. Thus, an effective cooling of the coil and the further coil is enabled. Corresponding cooling fluid flows are indicated in FIG. 10 by arrows. A fluid flow inlet and a fluid flow outlet may be formed for example between supporting blocks.

[0072] Further, the first dielectric structure 10 and/or the second dielectric structure 20 may include a fluid opening 15 that is in fluid communication with the first or second fluid duct 40, 42.

[0073] As can be seen in FIG. 10, the coil 2 may comprise a conductor 2001 and an isolation member 2002 at least partly surrounding the conductor 2001 for isolating the conductor 2001. The isolation member 2002 may be made for example from epoxy resin. Similar, the further coil 4 may comprise a conductor 4001 and an isolation member 4002 at least partly surrounding the conductor 4001 for isolating the conductor 4001. The isolation member 4002 may be made for example from epoxy resin. The dielectric structure, which is preferably not made of ceramic, is separate from such isolation member and, preferably, made of a different material than the isolation member.

[0074] The first dielectric structure 10 further comprises a sleeve-like screen 14 extending at least substantially perpendicular to the longitudinal axis L for further electrically isolating the coil 2 and/or the further coil 4. The screen 14 is preferably sheet-like shaped, extending perpendicular to the longitudinal axis L. Similar, the second dielectric structure 20 further comprises a sleeve-like screen 24 extending at least substantially perpendicular to the longitudinal axis L for further electrically isolating the coil 2 and/or the further coil 4. The screen 24 of the second dielectric structure 20 is preferably sheet-like shaped, extending perpendicular to the longitudinal axis L.

[0075] Preferably, the screens 14, 24 of the first and second dielectric structures 10, 20 are arranged at opposite longitudinal ends of the respective first and second dielectric structure 10, 20, respectively. In other words, the screen 14 of the first dielectric structure 10 and the screen 24 of the second dielectric structure are arranged at opposite ends of the dielectric barrier arrangement.

[0076] The screen 14 of the first dielectric structure 10 preferably includes a supporting block 17 for supporting the coil 2 or the further coil 4. Similar, the screen 24 of the second dielectric structure 20 preferably includes a supporting block 27 for supporting the coil 2 or the further coil 4.

[0077] The invention furthermore relates, for example, to the following additional and/or alternative aspects:

[0078] 1. A method for making a dry-type transformer (100), the transformer (100) comprising a winding assembly including a magnetic core (180), at least one high voltage winding (110), and at least one low voltage winding (120) inductively coupled to the magnetic core (180), the method comprising: [0079] determining a shape of an electric field that is generated in the transformer (100); [0080] 3D printing a dielectric structure (130) shaped to conform to the determined shape of the electric field; and [0081] mounting the dielectric structure (130) between the high voltage and low voltage windings (110, 120).

[0082] 2. The method of aspect 1, wherein determining a shape of an electric field in the transformer is carried out by performing an electric finite element method simulation and then adapting the geometry of the dielectric structure (130) to the shape of the equipotential lines of the electric field obtained in the electric simulation.

[0083] 3. The method of aspect 1 or 2, wherein it further comprises: [0084] tuning the geometry of the dielectric structure (130) before being printed.

[0085] 4. The method of any of the preceding aspects, wherein the 3D printed dielectric structure (130) is a one-piece structure.

[0086] 5. The method of preceding aspect 4, wherein the dielectric structure (130) is made by 3D printing polymers or composite materials comprising fibers and polymers.

[0087] 6. The method of preceding aspects 4 or 5, wherein the dielectric structure (130) is made by at least one of the Selective Laser Sintering, Fused Deposition Modeling, or Stereolithography 3D printing technologies.

[0088] 7. A dry-type transformer (100), comprising at least one first winding (110, 2), at least one second winding (120, 4), and at least one 3D printed dielectric structure (130, 10, 20) provided between the at least first and second windings (110, 120, 2, 4), the dielectric structure (130, 10, 20) comprising at least one cylindrical dielectric screen (135, 12, 22) shaped to closely conform to a shape of an electric field that is generated in the transformer (100), and at least one supporting block (140, 150, 17, 27) to support the dielectric screen (135, 10, 20) and the first winding (110, 2) and/or second winding (120, 4).

[0089] 8. A dry-type transformer (100) of aspect 7, made by the method according to any one of aspects 1 to 6.

[0090] 9. A dry-type transformer (100) according to aspect 7 or 8, wherein at least one screen (160, 170, 14, 24) is arranged between the at least one winding (110, 120, 2, 4), and core yokes (210, 260), and/or metallic structures.

[0091] 10. A dry-type transformer (100) according to any of the aspects 7-9, wherein the dielectric structure (130, 10, 20) is printed in one-single piece with no gaps at least between the cylindrical dielectric screen (135, 12, 22), the supporting blocks (140, 150, 17, 27) and the cylindrical dielectric screen (135, 12, 22) between the windings (110, 120, 2, 4), and the screen (160, 170, 17, 27) between the at least one winding (110, 120, 2, 4) and core yokes (210, 260), and/or metallic structures (200).

[0092] 11. A dry-type transformer (100) according to any of the aspects 7-10, further including air ducts (40, 42) for directing an airflow from at least one cooling fan and distribute it uniformly at least to the windings (110, 120, 2, 4).

[0093] 12. A dry-type transformer (100) according to any of the aspects 7-11, wherein the dielectric structure (130, 10, 20) is made by 3D printing polymers or composite materials comprising fibers and polymers.

[0094] 13. A dry-type transformer according to any of the aspects 7-12, wherein the dielectric structure (130, 10, 20) is made by at least one of the Selective Laser Sintering, Fused Deposition Modeling, or Stereolithography 3D printing technologies.

[0095] 14. A dry-type transformer according to any of the aspects 7-13, wherein the first winding (110, 2) defines a longitudinal axis (L), wherein the at least one dielectric structure (130, 10, 20) further comprises a screen (160, 170, 14, 24), extending at least substantially perpendicular to the longitudinal axis (L) for further electrically isolating the first winding (110, 2) and/or the second winding (120, 4), preferably wherein the screen (160, 170, 14, 24) is formed directly connected to the at least one supporting block (140, 150, 17, 27).

[0096] 15. A dry-type transformer according to any of the aspects 7-14, wherein the at least one dielectric structure (130, 10, 20) comprises a radially protruding positioning element (18) for radially positioning the at least one dielectric structure (130, 10, 20) relative to a longitudinal axis (L) defined by the first winding (110) and/or for closing a fluid duct.

[0097] 16. A dry-type transformer according to any of the aspects 7-15, wherein the at least one dielectric structure (130, 10, 20) has at least two cylindrical dielectric screens, comprising a radially inner cylindrical dielectric screen (1210, 2210) and a radially outer cylindrical dielectric screen (1212, 2212), wherein a radial gap or duct (16) is formed between the radially inner cylindrical dielectric screen (1210, 2210) and the radially outer cylindrical dielectric screen (1212, 2212).

[0098] 17. A dry-type transformer according to aspect 16, wherein the at least one dielectric structure (130, 10, 20) further comprises at least one fluid barrier structure (1214, 2212) that is designed and arranged to close the radial gap or duct (16) in a fluid-tight manner.

[0099] 18. A dry-type transformer according to any of the aspects 7-15, wherein the at least one dielectric structure (130, 10, 20) further includes a fluid opening (15) fluidly connected to a fluid or air duct (40, 42) of the transformer.

[0100] 19. A dry-type transformer according to any of the aspects 7-18, comprising a first dielectric structure (130, 10) having a first cylindrical dielectric screen (12), and a second dielectric structure (130, 20) having a second cylindrical dielectric screen (22), wherein the second cylindrical dielectric screen (22; 135) at least partially coaxially surrounds the first cylindrical dielectric screen (12; 135), wherein the design is such that the second dielectric structure (20; 130) is separate from the first dielectric structure (10; 130).

[0101] 20. A dry-type transformer of aspect 19, wherein the screens (24, 14; 160, 170) of the first and second dielectric structures (10, 20; 130) are arranged at opposite longitudinal ends of the respective first and second dielectric structure (10, 20; 130), respectively.

[0102] 21. A dry-type transformer of any of the aspects 7-20, wherein an air duct or fluid duct (40, 42) is formed between the at least one dielectric structure (130, 10, 20) and the coil (2) and/or between the at least one dielectric structure (130, 10, 20) and the further coil (4) and/or between the dielectric structure (130, 10, 20) and the core (6).

[0103] Although only a number of examples have been disclosed herein, other alternatives, modifications, uses and/or equivalents thereof are possible. Furthermore, all possible combinations of the described examples are also included herein. Thus, the scope of the present disclosure should not be limited by particular examples but should be determined only by a fair reading of the claims that follow. Reference signs related to drawings placed in parentheses in the claims are solely for attempting to increase the intelligibility of the claim and shall not be construed as limiting the scope.