Transformers labeled as "smart" have broad prospects for future development-News-Henan Weichi Electrical Equipment Co., Ltd.

Transformers labeled as "smart" have broad prospects for future development

Time：2025-06-19　Click：449

Only condition-based maintenance based on intelligent online monitoring of transformers holds true practical significance. It not only avoids the blindness and compulsiveness brought by preventive testing and regular maintenance, saving a significant amount of manpower, material resources, and financial resources, but also enhances the power supply reliability of power transmission and transformation equipment, prolongs the service life of transformers, and boasts broad development prospects.

As power grid companies accelerate the construction of a robust and intelligent grid, the advancement of smart transformer technology will significantly propel the development of the intelligent grid. The online monitoring and real-time feedback interaction capabilities of transformers will empower traditional transformers with the wings of intelligent development.

The global transformer monitoring system is experiencing rapid development

According to the global transformer monitoring system market research report released by Technavio, the annual compound growth rate of the global transformer monitoring system market from 2016 to 2020 is as high as 36%. In the Asia-Pacific region, the rapid economic development and population growth are bound to drive the market demand for transformers to strengthen power distribution. These large-scale transformer networks require continuous monitoring to prevent failures during transmission and distribution processes, which could lead to power outages. Therefore, the transformer monitoring market in the Asia-Pacific region holds great potential in the next five years.

Moreover, the electricity demand from industrial, commercial, and residential users continues to grow, stimulating power enterprises to accelerate the expansion and renovation of power grids. The installation of distribution transformers has become a top priority, as it not only expands the distribution range but also upgrades aging transformers, further driving the market demand for monitoring.

It is evident that in the coming years, whether in developed or developing countries, a stable and affordable electricity supply will be crucial for economic growth. Transformers, as key high-cost equipment in the power transmission and distribution system, will play a significant role. Therefore, their operation requires continuous real-time monitoring to ensure stable and reliable power transmission.

The superiority of transformer online monitoring

With the advancement of modern sensing technology, microelectronics, and computer technology, there is a solid foundation for condition monitoring of high-voltage equipment such as transformers. Compared to traditional transformers, smart transformers, equipped with intelligent online monitoring capabilities, are increasingly becoming crucial equipment in the construction of smart grids.

Transformer online monitoring, centered around microprocessing technology, integrates sensors, data collection, communication systems, and data analysis functions. By continuously monitoring state parameters over a period of time, it promptly captures early fault precursor information of transformers and determines the operational status of the transformer based on the trend of transformer parameter changes. Compared to traditional transformers, the intelligent online monitoring function offers several major advantages:

It effectively prevents the occurrence and development of various faults in transformers and reduces the economic losses caused by unexpected power outages. Real-time monitoring of transformers in operation compensates for the deficiencies of conventional testing and inspection methods. Although there are certain limitations in predicting internal sudden faults based on the captured dynamic information of transformers, it remains the most effective technical basis for formulating transformer maintenance plans and holds significant guiding significance.

It possesses high reliability, maintenance-free characteristics, and self-checking functionality. In the event of any issues within the monitor itself, it can automatically emit audible and visual alarm signals. Consequently, it eliminates the issue of misjudgment caused by anomalies in the detection device found in conventional detection methods.

The economic benefits are considerable. The investment cost of a transformer online monitoring system mainly consists of two parts: sensors and intelligent monitoring software. According to statistics from relevant departments both domestically and internationally, the cost of a complete transformer online monitoring system is generally about 1% of the transformer price. However, due to its ability to timely and accurately detect early faults in transformers, the operation and maintenance cost is reduced by 75%. The annual savings are equivalent to 2% of the transformer price, and the service life can be extended by about 10 years. The economic benefits are quite considerable.

Development trend of transformer online monitoring

Based on the current application of transformer online monitoring technology, although there are still some shortcomings such as weak anti-electromagnetic interference capability, short service life, and high price, all these issues will be gradually resolved in the development process due to its unparalleled superiority over conventional detection methods.

From a policy perspective, driven by the demand for smart grid construction and the continuous increase in research and development efforts by various research institutes and online monitoring companies, the application of online monitoring technology is steadily advancing. This not only promotes the transformation of transformer maintenance procedures and management methods, but also inevitably leads to the establishment of a standardized condition-based maintenance management system and the ultimate unification of technical standards.

From an economic perspective, with the strengthening of research and development efforts by domestic manufacturers of online monitoring equipment and software, competition from similar foreign products, and the booming demand for power grids, not only will the prices of their software and hardware products drop significantly, but their cost-effectiveness will also increase substantially.

From a technical perspective, hardware equipment will develop towards a more intelligent direction, with higher maintenance-free capabilities. The adoption of intelligent sensors will effectively suppress electromagnetic interference; with the widespread use of new materials, the service life of devices such as chromatographic analysis permeable membranes will also be extended. Fault analysis software systems will also be organically integrated with information such as offline testing, equipment status, and operational data to carry out comprehensive online diagnosis, and online monitoring data from different systems will be shared through the network.

As power grid companies accelerate the construction of a robust and intelligent grid, the advancement of smart transformer technology will significantly propel the development of the smart grid. The online monitoring and real-time feedback interaction capabilities of transformers will endow traditional transformers with the wings of intelligent development.

Ways to enhance the short-circuit resistance of transformers in power systems

1. Fault analysis of transformers in power systemsA transformer is a device that utilizes the principle of electromagnetic induction to change current. It is widely used in the electric power system. Experiments and investigations have confirmed that faults caused by short circuits in transformers have been seriously affecting the safety and stability of power transmission. Therefore, in order to reduce the probability of faults in the electric power system, it is necessary to conduct a focused analysis and research on the short-circuit capability of transformers. The following provides a specific analysis of the causes leading to short-circuit accidents in transformers:(1) Defects in the structural design of the transformerThe weakness in the short-circuit resistance of transformers is largely attributed to defects in their structural design. Currently, transformer manufacturers in China use static theory to calculate the mechanical forces on transformers. According to static theory, for copper-conductor transformers, the calculated conductor stress should be less than 1600kg/cm2. However, in actual use, the internal dynamics of transformers are complex and variable. Common theoretical values cannot intuitively reflect the actual operating conditions of transformers, making it difficult to meet the requirements for short-circuit resistance. Analyzing the currently common transformer models, low-loss transformers remain the mainstream products. However, there is no consensus among manufacturers on how to achieve low loss in transformers. Additionally, in the design of low-voltage leads for large-capacity transformers, if the fulcrum of the lead is not adequately considered, resulting in a cantilever beam formation, a phase-to-phase short-circuit fault may occur when subjected to the impact of short-circuit current.(II) Poor material qualityThe insulation pressing plate and laminated wood board of the transformer, if not meeting the standard requirements in terms of processing quality and mechanical strength, can also lead to frequent short-circuit failures. Some transformer manufacturers, in order to minimize the loss of winding eddy current, processing difficulties, and production and operation costs, often use thinner wires or ordinary and cheap transposed conductors instead of semi-rigid conductors with stronger mechanical properties during the design process. Although these ordinary and cheap materials can help enterprises reduce production and operation costs, they are unable to meet the anti-short-circuit capability of transformer windings due to the limitations of their material properties. Furthermore, due to the uneven level of domestic manufacturers and the significant gap between their production processes and some advanced foreign technologies, the density of insulation boards is insufficient, which can easily lead to natural shrinkage phenomena and trigger transformer short-circuit failures.(III) There are serious structural issuesSerious structural issues in transformers can also lead to short-circuit faults. Since transformers undergo a series of transportation, lifting, and disassembly processes from manufacturing to deployment, they are inevitably subjected to some impacts. If the internal structure of the transformer is not sturdy, impacts can cause structural issues such as winding displacement and insulation damage, which pose significant safety hazards for future operation.(IV) Issues of transformers operating in a 220kV environmentFor 220kv high-capacity transformers, the connection status of the inner coil is also an important determinant of short-circuit faults. Although the tapping of the inner coil can provide many conveniences for the operation of high-capacity transformers, if the tapping design is not reasonable enough, it can lead to local electric field disorder in the tapping leads, resulting in partial discharge of the transformer.(V) Problems in technology and equipmentIf the manufacturing process and equipment of the transformer cannot effectively ensure the tight winding, pressing, and sheathing of the coil, it will also result in a decrease in short-circuit resistance, thereby causing faults. Moreover, if the insulating pads of the transformer are not sealed or the sealing work is not done properly, the electrodynamic force generated during a short circuit may damage the wire insulation and cause it to break down.When winding the transformer coil, if the tension of the wire is insufficient or due to limitations in technology and equipment, the coil may be wound loosely, leading to a suspended state. This reduces the transformer's resistance to short circuits. If the coil ends are not bound tightly and securely, it can also easily cause short-circuit faults in the transformer. If the gap between the wound coils is too large, resulting in insufficient internal support of the coil, it can cause deformation or collapse of the winding coil, posing significant safety hazards for future operation. Additionally, if the clamping force of the transformer core is insufficient, and effective measurements and appropriate adjustments to the pressure are not made after the core is stacked, it can lead to loose clamping of the core, which is prone to displacement during transportation and collision, causing uneven internal stress in the transformer and resulting in serious consequences.II. Ways to enhance the short-circuit resistance of transformersDue to the crucial role of transformers in the power system, it is imperative to conduct in-depth research on their quality and performance. This article delves into the common causes of transformer short-circuit faults and proposes targeted technical methods to enhance the short-circuit resistance of transformers. The following provides a detailed analysis:(1) Mechanical force calculation and product structure design for improved transformersThe physical structure of a transformer determines its operational performance. Therefore, it is necessary to optimize and improve the mechanical force calculation and product structure design of the transformer, so that the mechanical force distribution of its internal wires can better meet practical requirements and enhance its short-circuit resistance. When designing the structural design of the transformer, a pressure sensor calibrator installed between the pressure plate and the clamping piece can be used to measure the impact force on the winding structure inside the transformer, providing a reliable guarantee for the structural design of the transformer.(II) Short-circuit test of transformerBy conducting short-circuit tests on transformers and analyzing relevant data parameters, a solid foundation is laid for improving the product structure of transformers and enhancing their resistance to short circuits. It is worth noting in this process that conducting short-circuit tests is not only to ensure that the manufacturer's products are qualified, but more importantly, to apply safe and reliable technology to actual production, avoiding the situation where some manufacturers only test and reinforce transformers without promoting technology in actual production.In summary, with the continuous advancement of science and technology, the continuous improvement of power system operation quality, and the widespread operation of ultra-high voltage power transmission and transformation methods, the short-circuit resistance of transformers and the huge losses caused by short circuits have become an important issue that transformer manufacturers and operation units face and urgently need to address. In order to effectively enhance the short-circuit resistance of power system transformers, in addition to requiring manufacturers to make *** improvements in mechanical force calculation and product structural design, attention should also be paid to potential quality hazards in process operations. These issues require high attention from transformer manufacturers and operation units, so as to *** enhance the safety and stability of power system operation.In summary, as the transformation of the power grid progresses, it is imperative to enhance the short-circuit resistance of transformers in the power system to meet development needs. Improving the short-circuit resistance of transformers in the power system not only effectively enhances the safety of mining area power grid operations but also reduces the time required for fault handling, maximizes loss reduction, and prevents accidents, ensuring the safe and stable operation of the power system.

2025-06-19

The company leaders visited China Railway Equipment

At the invitation of China Railway Equipment Company, our company leaders specially led technical management personnel to visit the advanced manufacturing and management practices of China Railway. This visit allowed us to learn from their advanced experience for our company's development and laid a solid foundation for future cooperation.

2025-06-19

News