The Core Challenge: Thermal Sensitivity of Amorphous Alloys
Amorphous alloy ribbons (0.03mm thick, 1/10 of silicon steel) exhibit critical thermal behavior:
- 65℃ Threshold: Beyond this, no-load loss surges by >15%
- Edge Hotspots: Eddy current concentration causes 20-30℃ higher temperature at core edges
Conventional Cooling Pitfalls: Continuous fan operation wastes energy (3% of total loss) and attracts dust, degrading insulation.
Four “Decision Layers” of the Smart Fan System
uses triple-sensor logic:
Sensor | Location | Trigger Threshold | Fan Response |
PT100 RTD | LV Winding Hotspot | 120℃ | Activate axial fans (full power) |
Infrared Probe | Amorphous Core Gaps | 70℃ | Reduce fan speed to 50% |
Ambient Sensor | Transformer Room Top | 40℃+60% RH | Preemptive startup to avoid condensation |
Key Innovation: Automatic air inlet sealing when fans stop
Physics Insight: How 25% Cooling Efficiency Gain Achieved?
Computational Fluid Dynamics (CFD)-optimized airflow:
Heat Dissipation (Q) = h · A · ΔT
Where:
h = Convective heat transfer coefficient (fan-speed dependent)
A = Effective cooling area (3.2x expansion when fans on)
ΔT = Temperature gradient (winding-to-air)
System Advantages:
- Fans activate only when ΔT > 40℃, minimizing idle energy
- 30° angled fans createhelical turbulence(+18% h-value vs. direct airflow)
- Real-time humidity-based speed adjustment prevents insulation moisture
Validation: 50℃ Lab Test Data
Simulating Saudi PV plant conditions:
Cooling Mode | Winding Temp Rise (℃) | Noise dB(A) | Fan Energy (kWh/yr) |
Conventional Continuous | 78 | 52 | 2100 |
Smart Control System | 82 | 45 | 680 |
Despite 4℃ higher winding temperature, noise drops 13% with 68% fan energy savings, aligning with IEC 60076-11 “human-friendly transformer” standards.
Engineering Impact: Redefining Dry-Type Transformer Lifespan
Smart thermal control enables amorphous core transformers in tropical zones to achieve:
- Core service life up to 300,000 hours (2.4x conventional dry-types)
- Maintenance cost reduction by 60% (less fan wear & dust cleaning)
