Cost-Effective AIS Voltage Transformer Solution: Optimized Modular Design Enables Grid Cost Reduction and Efficiency Enhancement

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I. Industry Pain Points: Limitations of Traditional Solutions​
In county-level distribution grids and infrastructure projects in developing countries, traditional Air-Insulated Switchgear Voltage Transformers (AIS VTs) face two core challenges:

1. ​High Customization Costs: Independent housing and winding designs are required for different voltage classes (66kV/110kV/220kV), resulting in inflated R&D and manufacturing costs.
2. ​Spare Parts Inventory Pressure: Multiple VT specifications necessitate large stocks of dedicated spare parts, tying up capital and reducing maintenance efficiency.

​II. Innovative Solution: Modular Design Drives Full-Lifecycle Cost Optimization​

1. ​Standardized Voltage Module​
   • Core Technology: Replaceable coil bobbin frame design enables compatibility with 66kV/110kV/220kV in a single housing.
   • Economic Value:
   o 30% reduction in housing mold development costs;
   o 25% increase in production efficiency through streamlined manufacturing.
2. ​Detachable Secondary Terminal Box​
   • Rapid Replacement Design:
   o Standardized interfaces enable field replacement in <1 hour (vs. ≥7 days for factory repair in traditional solutions);
   o Supports individual faulty component replacement, avoiding whole-unit scrapping.
   • Maintenance Cost Optimization:
   o 60% reduction in spare part types, decreasing inventory costs by 45%;
   o 80% shorter power outage time, enhancing supply reliability.
3. ​Material Innovation: Aluminum Windings + Epoxy Resin Casting​
   • Lightweight & Cost Control:
   o Aluminum windings replace copper, reducing material costs by 25%;
   o Vacuum epoxy resin casting ensures insulation strength (power frequency withstand voltage ≥3kV/mm).
   • Performance Validation:
   o Temperature rise test ≤65K (IEC 60044 Standard);
   o Accuracy Class 0.2, meeting dual requirements for metering and protection.

​III. Application Scenarios and Quantified Value​

​IV. Core Advantages Summary​
• ​Procurement Cost Optimization: 20% lower initial investment, ROI period shortened to 3 years;
• ​Full-Lifecycle Cost Control: Spare parts commonality + modular replacement reduces Life Cycle Cost (LCC) by 35%;
• ​Enhanced Sustainability: Aluminum windings cut carbon footprint by 30%, epoxy resin achieves 90% recyclability.