Research on the Influence of Compression and Offset of Cushion Blocks on the Axial Strength of Transformers

• Published in: Applied sciences Vol. 13; no. 24; p. 13289
• Main Authors: Sun, Lu, Gao, Shuguo, Li, Tianran, Yao, Jiaxin, Wang, Ping, Zhu, Jianhao
• Format: Journal Article
• Language: English
• Published: Basel MDPI AG 01.12.2023
• Subjects: Analysis; axial bending stress; Bending stresses; Circuits; cushion blocks; Electric transformers; Electromagnetism; power transformers; short-circuit impacts; Simulation; winding strength; Wire; China
• DOI: 10.3390/app132413289
• ISSN: 2076-3417

The instability of the winding-cushion structure is one of the primary causes of transformer failures. Insulation cushion compression and offset are the predominant forms leading to structural instability. Therefore, this paper, using the SFSZ7-31500/110 transformer as an example, first derives the theoretical formula for mechanical stress calculation. It clarifies the key influencing parameters of the winding-cushion block structure on the axial bending stress of the winding. Subsequently, an electromagnetic force finite element calculation model is established to obtain the axial force distribution in the winding and the distribution of unbalanced displacement during short-circuit processes. Based on the force and offset distribution, a specific cushion block compression and offset test platform is constructed. By setting different cushion block variables, the effects of cushion block unbalanced height and cushion block offset on the winding’s bending elastic modulus are determined. Finally, a simulation model for stress calculation of the winding-cushion block structure is established, revealing the influence pattern of cushion block compression and offset instability on the axial strength of the winding. The results of this study indicate that the greater the uneven cushion block height, the lower the axial strength of the winding. Under the same cushion block offset angle, winding structures with non-uniform cushion block offsets exhibit the worst axial stability. When the offset angles are 30°, 45°, and 60°, the maximum axial bending stress of the winding increases by 1.73%, 3.46%, and 7.82%, respectively. Increasing the offset angle exacerbates the decrease in the axial strength of the winding up to a certain extent. The findings in this study have significant implications for enhancing a transformer’s short-circuit resistance.