High-Efficiency Thermal Management Solution for Special Transformers Guaranteeing Core Performance & Extending Equipment Lifespan

Ⅰ. Core Perspective

Addressing heat accumulation challenges in special transformers under severe operating conditions, this solution proposes systematic thermal dissipation and temperature control optimization strategies:

• Extreme Loading: Continuous overload, impact loads.

• High Harmonic Pollution: Additional losses caused by non-linear loads.

• High Ambient Temperatures: Outdoor/enclosed spaces with sustained ambient temperatures ≥40°C.

II. Key Solution Points

(A) Precision Thermal Simulation & Design Optimization

1. Thermal Digital Twin Model

• Utilizes CFD software (FloTHERM/Star-CCM+) to build a 3D thermal-fluid coupling model.

• Accurately simulates oil flow paths, winding hot-spot distribution, and radiator efficiency.

• Outputs optimized schemes: Achieves >15% hotspot temperature reduction through heat dissipation structure adjustments.

(B) Customized Cooling System Design

(C) Oil Flow Control Optimization

• Enhanced Oil Guiding Design:

A[Oil Inlet] --> B[Silicon Steel Guide Channels]

B --> C[Axial Winding Oil Ducts]

C --> D[Hotspot Reinforced Spray Nozzles]

D --> E[Top Oil Outlet]

• Achieves ≥300% increase in oil flow velocity in hotspot regions, resulting in 8-12K temperature reduction.

(D) Intelligent Temperature Control System

III. Target Outcomes & Verification Standards

1. Temperature Control

• Winding Hotspot Temperature: ≤95°C (rated load) / ≤115°C (2-hour emergency overload)

• Top Oil Temperature Rise: ≤45K (compliant with IEC 60076-7)

2. Lifespan Assurance

• Based on the 10°C Rule (Montsinger's Rule):L = L₀ × 2^[(98°C - T_hotspot)/6]

• Ensures insulation thermal aging <20% over the 30-year design lifespan.

3. Efficiency Improvement

• Reduced No-Load Losses: 12% reduction (low eddy current design)

• Cooling System Energy Consumption: <5% of total losses

IV. Typical Application Scenarios