Transformer or reactor cooled by an insulating agent

Abstract: Transformer or reactor with a winding of a sheet-formed conductor material wherein the winding comprises a cooling element arranged between two consecutive winding turns and wherein the conductor material, within a region nearest the cooling element, in the axial direction of the winding has a decreasing width for each winding turn towards both the inner and outer cylindrical surfaces of the cooling element.

Description: The present invention relates to a sheet-wound transformer or reactor cooled by an insulating agent. The transformer or reactor comprises a core of magnetic material with at least one leg and one yoke, at least one winding arranged substantially concentrically around the core leg and built up of several turns of a conductor sheet wound one above the other, the conductor sheet being composed of a metal foil and an insulating film arranged at least on one side. The transformer or reactor further comprises at least one cooling element arranged between two consecutive winding turns. In transformers and reactors with sheet-wound or foil-wound windings, problems may arise due to increased electric current densities towards the edges of the sheet. This uneven current density is due to a heavy displacement of current, which results in heavy additional losses as well as in powerful localized heating of the sheet edges. The current displacement is caused by the fact that the substantially axial magnetic leakage flux extending through the winding is deflected at the ends of the windings more or less in radial direction instead of continuing axially, i.e. parallel with the leg, and passing into the yokes. This causes the axial ends of the windings to be traversed by a magnetic flux with a radial component which generates eddy currents in the conductor sheet which cause losses in addition to the unavoidable ohmic losses in case of equal distribution of the current across the entire cross-section of the conductor sheet. To reduce these eddy current losses, several solutions have been proposed, one of which is described in SE-A-418 234. Here a method is described which is characterized in that the conductor sheet at its axial end portions, at least in a region at the periphery of the winding, follows a funnel-shaped double-curved surface. Another method is described in SE-A-428 979, which is characterized in that the cooling channels include spacers which exhibit an increasing thickness towards the end surfaces of the winding. The double curvature which is needed to reduce the effect of the current displacement is necessary above all in those parts of the sheet winding which, viewed in a radial direction, are furthest away from the axial centre line of the winding. For practical reasons, sheet windings are therefore sometimes formed with an end surface in a plane perpendicular to the centre line for that part of the winding which, viewed in a radial direction, lies nearest the axial centre line of the winding. These parts will be referred to below as the central parts of the sheet winding, while those parts mentioned before will be referred to below as the peripheral parts of the sheet winding. Another known electrical phenomenon is that high electric field strengths arise at sharp edges or pointed projections, and these field strengths may cause corona and electric flashover. Reducing these field strength concentrations by increasing the radius of curvature of the edges or projections in different ways belongs to the state of the art. The GB-A-995 168 describes specific problems which come up with high-tension dry transformers due to the long spark-over distances in air. The document suggests a high-tension winding consisting of a number of coils stacked upon one another, each coil comprising a normal winding of wire arranged in several layers. Since these coils are connected in series, the highest voltage will occur at one of the two axial ends of the high-tension winding. To reduce the required insulating distances at this end of the winding a combination of measures is suggested consisting of the simultaneous use of a pressure ring, a capacitor ring, and a voltage barrier which surrounds three sides of the axial end of the winding. In order not to waste valuable space for the winding, the coils at the axial end of the winding which are covered on their inner side by said voltage barrier exhibit from coil to coil in the direction to the winding's axial end increased inner diameters while their radial thicknesses decrease. The FR-A-1 431 870 deals with a transformer which is operated at extremely low temperatures which allow the use of liquid hydrogen as coolant and dielectric medium. The winding of this transformer consists of extremely thin sheet-formed conductor material. The specific demands are due to the fact that an increase in temperature of the conductor material has to be suppressed, because it would result in an extreme relative increase of the resistivity of the conductor material. Therefore, thickness of the sheet material is not greater than some ten micrometers, and an extreme number of axial cooling channel are provided. The axial length of the conductive turns of the sheet material decreases radially from the inside to the outside of the winding while the insolation layers have no reduced axial length, and the removed conductor parts are not replaced by insulating strips. In existing sheet winding designs, a potentially dangerous region, with respect to corona and possibly electric flashover, exists in those parts of a sheet winding which adjoin both sides of a cooling channel. This is true both for those parts of the sheet winding which comprise the central and the peripheral parts. The reason is that for the central parts of the sheet winding, the end surface of the sheet winding forms a right angle with the internal and external walls of the cooling channels, that is, the sheet winding forms a right-angled edge. For the peripheral parts of the sheet winding the risk of corona and discharge will be even greater since the end surface of the sheet winding forms an angle with the cylindrical surfaces of the cooling channels, especially with the internal cylindrical surfaces, which is smaller than a right angle, that is, the sheet winding forms an even more acute angle with the cooling channels. This is shown very clearly in the accompanying drawings. These drawings show in Figure 1 a section of a sheet winding seen in a direction parallel to the axial centre line of the winding, Figure 2 a section at the peripheral part of a sheet winding, perpendicular to the section in Figure 1. The figure shows how the metal foil, the insulation tape, etc., are formed around a cooling channel according to the state of the art, Figure 3 the same section as Figure 2, but with a design according to the invention. Figure 1 shows, viewed in a plane perpendicular to the axial centre line of the winding, those parts of a sheet winding which adjoin a cooling element 1. The cooling element consists of a curved insulation plate, often called cooling mat, provided which slots 2, 3 etc., manufactured by sawing or milling, around the whole winding: These slots are provided to be passed by the cooling agent. The figure also shows some of the sheet layers 4 and 5 positioned inside and outside the cooling element. To transfer the sheet layer 7 lying immediately inside the cooling element to the sheet layer 6 lying immediately outside the cooling element, the cooling mat is provided with a bevelled opening 8. The axial centre line of the sheet winding is indicated at 9. The state of the art as regards the design of the sheet winding on both sides of a cooling channel is shown in more detail in Figure 2, which shows parts of a plane A-A through the axial centre line 9 of the sheet winding. The figure shows how each sheet layer consists of a metal foil 10 which, in the example shown, is surrounded on both sides by insulating foils 11 and 12. Since the axial length of the metal foil is shorter than the axial length of the coil, an edge strip 13 of insulating material is introduced between the insulating foils, at the two ends of the sheet winding. As is clear from the figure, the end surface of the sheet winding will therefore, at the peripheral part of the winding, form an acute angle α smaller than a right angle with the lateral (generated) surfaces of the cooling elements. At the continuous transition towards the central part of the winding, the angle α of the pointed,edge, that is, the angle between the plane of the end surface of the sheet winding and the lateral end surfaces of the cooling elements, will approach a right angle. Concurrently with increased voltages on transformers and reactors, the risk of corona and flashover will then increase, especially at the double-curved part of the winding. The invention is clear from Figure 3, which shows the same sectional view as Figure 2. To avoid the high field strengths which arise at the above-mentioned acute and right angles, a reduction of the width of the metal foil takes place in the axial direction towards both the internal and external lateral surfaces of the cooling element. This will cause the edge of the sheet winding with its electrical potential towards the cooling element to become bevelled to an extent corresponding to a considerably greater radius of curvature, whereby the risks of corona and flashover can be considerably reduced. To maintain the axial length of the sheet winding at the cooling element, the axial width of the edge strip is at the same time extended to an extent corresponding to the decrease of the foil length. The bevelling can be performed in a plurality of different ways, and the envelope to the bevelled metal foil layers may have a varying curve shape. To avoid discontinuities in the envelope, there should be a near tangential approach both to the end surface of the central part of the metal foil winding and to the lateral surfaces of the cooling element. To obtain a symmetrical field strength distribution towards the pointed edge, the bevelling should, in addition, be mirror-symmetrical around the bisector 14 of the angle α. In a preferred embodiment, the envelope consists of an arc with its centre on the bisector 14. In this case, it is then completely correct to talk about the radius of curvature of the envelope. The magnitude of the radius of curvature in a concrete case is determined by many factors, such as the voltage level, the value of the angle, safety margins, etc. However, the envelope need not be formed as an arc to attain satisfactory and sufficient safety against corona and flashover, nor need it be symmetrically formed around the bisector. It may, for example, be formed as parts of a parabola, an ellipse or a hyperbola or change from one curve shape to another. For practical reasons, the connection to the cooling element may, for example, take place in the form of a straight curve. It should be pointed out here that no significant increase of the electric field strength arises if the connection is slightly discontinuous instead of tangential. Independently of the curve shape of the envelope, however, it is practical, both for designing and quantifying the curve, to define it with the aid of a "radius of curvature", which must not be smaller than a certain given measure. As indicated above, the currently permissible smallest radius of curvature depends on several factors, such as the voltage level, the value of the angle, safety margins etc. As a realistic value of the radius of curvature for transformers and reactors, it can be said that it should not be below 1 mm.

Claims: Transformer or reactor comprising a core of magnetic material with at least one leg and one yoke and at least one winding (4, 5) of sheet-formed conductor material in the form of metal foil (10) arranged substantially concentrically around the leg, at least one side of the conductor sheet being provided with an insulation film (11, 12), which has a width in the axial direction of the winding which is greater than the width of the conductor sheet, with an edge strip (13) arranged at the edges of the winding and in the axial extension of the conductor sheet, which edge strip (13) has an axial width corresponding to the difference between the width of the conductor sheet and the width of the insulation film (11, 12), and with at least one cooling element (1) arranged between two consecutive winding turns of the winding, characterized in that the axial length of the metal foil (10) within a region nearest the cooling element(s) (1) decreases for each winding turn towards both the inner and outer cylindrical surfaces of the cooling elements (1). Transformer or reactor according to claim 1, characterized in that the axial length of the metal foil (10) within a region nearest the cooling element (1) decreases for each winding turn towards both the inner and outer cylindrical surfaces of the cooling element (1) in such a way that a curve interconnecting the edges of the metal foil (10) is defined with the aid of a radius of curvature. Transformer or reactor according to claim 2, characterized in that the axial length of the metal foil (10) within a region nearest the cooling element (1) decreases for each winding turn towards both the inner and outer cylindrical surfaces of the cooling element (1) in such a way that a curve interconnecting the edges of the metal foil (10) has a radius of curvature which is equal to or greater than 1 mm. Transformer or reactor according to any of the preceding claims, characterized in that the axial length of the metal foil (10) within a region nearest the cooling element (1) decreases for each winding turn towards both the inner and outer cylindrical surfaces of the cooling element (1) in such a way that a curve interconnecting the edges of the metal foil (10) tangentially adjoins both the end surface of the metal foil winding and the inner and outer cylindrical surface of the cooling element (1). Transformer or reactor according to any of the preceding claims, characterized in that the axial length of the metal foil (10) within a region nearest the cooling element (1) decreases for each winding turn towards both the inner and outer cylindrical surfaces of the cooling element (1) in such a way that a curve interconnection the edges of the metal foil (10) constitutes a circular arc. transformer according to any of the preceding claims, characterized in that said at least one winding (4,5) is formed with double-curved axial ends.

Inventors: FORSBERG ERIK, PETERSSON SOEREN, FORSBERG, ERIK, PETERSSON, SOEREN, Petersson, Sören
Applicants: ASEA BROWN BOVERI, ASEA BROWN BOVERI AB
Application year: 1992
Main classification: H01F27
IPC codes: H01F27