mining transformer

Product Details of Mine-Specific Special Transformer

1. Core Performance Parameters (Precisely Adapt to Mine Power Distribution Needs)(Customizable)

Rated Voltage and Capacity

The mainstream high-voltage input is 6kV and 10kV (adapting to mine high-voltage power distribution systems), and special voltage levels such as 3kV and 110kV can be customized; the low-voltage output covers 380V, 660V, 1140V and 127V, among which 660V and 1140V are suitable for underground large-scale equipment (fans, water pumps, conveyors), and 127V is suitable for underground lighting and small control equipment; the rated capacity ranges from 50kVA to 2000kVA, fully covering various mine power distribution scenarios from small-scale lighting power distribution to large-scale equipment power supply, and can be flexibly selected according to actual load requirements.

Insulation Class and Insulation Performance

The mainstream adopts Class F (maximum allowable temperature 155℃) and Class H (maximum allowable temperature 180℃) insulation design, which can be upgraded to Class C according to underground high-temperature and high-humidity scenarios. The core insulation materials are high-quality moisture-resistant and anti-aging insulation oil (oil-immersed), epoxy resin (dry-type) and DuPont NOMEX® insulation paper, with high insulation strength and breakdown voltage. In the underground environment with relative humidity ≥95% and condensed water, the insulation performance does not degrade, effectively avoiding potential safety hazards such as leakage and short circuit, and ensuring the safety of personnel and equipment.

Overload and Impact Resistance

Aiming at the large inrush current generated during the start-up of mine equipment such as fans, water pumps and crushers, the electromagnetic design and winding structure are optimized. It can withstand short-term overload of 1.5 times the rated load for 6 hours, 1.75 times the rated load for 3 hours, and 2.0 times the rated load for 1 hour. It can stably cope with load fluctuations, avoid power supply interruption caused by equipment start-up impact or short-term high load, and ensure the continuity of mine production.

Cooling Mode and Temperature Rise Control

Oil-immersed products mainly adopt natural cooling (ONAN), and can be optionally equipped with forced air cooling (ONAF), equipped with corrugated oil tanks and finned radiators with large heat dissipation area, which can quickly dissipate heat generated during overload; dry-type products adopt air natural cooling (AN), and can be optionally equipped with forced air cooling (AF), equipped with low-noise temperature-controlled fans, which can automatically start and stop according to the winding temperature, strictly controlling the winding temperature rise within the allowable insulation range, avoiding insulation aging caused by high temperature, and adapting to underground scenarios with poor ventilation and high ambient temperature.

Protection Level and Safety Design

Strictly following the requirements of general mine-type protection, the shell adopts a fully enclosed metal structure. The outdoor model has a protection level of IP54, and the underground model is upgraded with dust-proof, moisture-proof and drip-proof structures, which can effectively prevent mine dust, coal cinder and condensed water from entering the equipment, protecting conductive components and insulation structures; the conductive parts are completely enclosed with no exposed contacts, avoiding the risk of electric shock caused by accidental contact of personnel, and adapting to the complex mine environment with dust, high humidity and falling objects.

Noise and Anti-Interference Performance

By optimizing the iron core lamination process and winding technology, the electromagnetic noise is reduced. The noise of dry-type transformers is ≤55dB, and the noise of oil-immersed transformers is ≤60dB, which is far lower than the mine noise control standard, avoiding impact on the hearing of underground operators; the anti-harmonic and anti-unbalanced load capabilities are strengthened, which can adapt to harmonic interference generated by mine frequency converters, large motors and other equipment, reduce voltage fluctuations, ensure power supply quality, and avoid equipment damage due to unstable voltage.

2. Structural Design and Core Materials (Lay a Solid Foundation for Durability in Harsh Mine Working Conditions)

2.1 Core Structural Design (Adapting to Mine Transportation, Installation and Operation Conditions)

Iron Core Structure

Low-loss oriented silicon steel sheets are adopted, processed by stepped lamination and three-dimensional wound iron core technology, with uniform magnetic circuit and less magnetic leakage, which not only reduces no-load loss and noise, but also improves the mechanical strength of the iron core; buffer and shock absorption pads are installed between the iron core and the shell to reduce vibration transmission during operation, adapting to the continuous vibration environment generated by mine equipment operation and vehicle traffic.

Winding Structure

High-conductivity oxygen-free copper conductors are selected, and multi-layer segmented winding and transposition winding processes are adopted to reduce winding circulating current and stray loss, and improve heat dissipation efficiency and short-circuit resistance; the winding surface is wrapped with multiple layers of high-quality insulation materials, and insulation spacers are set between the winding and the iron core, and between the winding and the shell to ensure insulation distance, avoid partial discharge, and strengthen winding fixation, which can withstand mechanical impact during mine transportation and operation, preventing winding deformation and displacement.

Shell/Oil Tank Design

Oil-immersed products adopt fully sealed corrugated oil tanks with excellent sealing performance, using oil-resistant and anti-aging rubber seals, which can effectively prevent insulation oil leakage and aging, avoid insulation performance degradation caused by oil pollution, and no need for frequent oil replenishment; the corrugated sheets can expand and contract with the change of oil temperature to enhance heat dissipation effect, and the shell is treated with anti-corrosion coating to resist the erosion of corrosive gases and moisture in underground mines. Dry-type products adopt flame-retardant cold-rolled steel sheet shell, which is electrostatically sprayed on the surface, dust-proof, moisture-proof and corrosion-resistant, equipped with ventilation shutters and dust filters, which not only ensures air channel circulation, but also blocks dust entry, adapting to the dusty underground environment.

Fixing and Shock Absorption Structure

The whole adopts a reinforced fixing design, the iron core, winding and shell are firmly connected, equipped with shock absorption pads and reinforcing bolts to improve the shock resistance and impact resistance of the equipment, which can withstand bumps during mine transportation, impact during hoisting, and continuous vibration generated by underground equipment operation, with no loosening or damage during long-term operation; the bottom of the equipment is equipped with skids or lifting lugs, skids are suitable for underground track transportation, and lifting lugs are convenient for hoisting operations, adapting to the transportation and installation needs of narrow mine spaces and underground roadways.

Electrical Protection and Accessory Configuration

Standard multiple electrical protection devices are equipped, with built-in short-circuit, overload, overvoltage and undervoltage protection components, which quickly cut off the power supply in case of failure, prevent accident expansion, and ensure the safety of personnel and equipment; oil-immersed products are additionally equipped with oil temperature gauge, oil level gauge and pressure relief valve to real-time monitor oil status, avoiding equipment failure caused by excessive oil temperature and low oil level; dry-type products are equipped with winding temperature controller to real-time monitor winding temperature, automatically alarm and start cooling fan when overheating. Optional oil chromatogram online monitoring, winding temperature online monitoring and remote monitoring modules can be installed to realize real-time monitoring of equipment operation status and fault early warning, facilitating remote management by operation and maintenance personnel and reducing underground on-site inspection workload.

2.2 Core Material Selection (Controllable Quality, Adapting to Harsh Mine Environment)

• Iron Core Material: Low-loss oriented silicon steel sheets from well-known domestic brands are selected, with high magnetic permeability, low loss and strong anti-aging ability, which can withstand the underground high-temperature and high-humidity environment for a long time, and is not prone to iron core rust and magnetic loss increase.

• Winding Material: Oxygen-free copper conductors, with high conductivity, low resistance and high mechanical strength, heat-resistant and wear-resistant, avoiding conductor deformation and burnout caused by overload heating and vibration friction, ensuring long-term stable operation of the winding.

• Insulation Material: Oil-immersed products adopt high-quality special mineral insulation oil for mines, which is moisture-resistant, low-temperature resistant and high in insulation strength, and can work stably in the environment of -20℃～+40℃; natural ester insulation oil (environmental protection type, non-toxic and degradable) can be optionally installed; dry-type products adopt epoxy resin casting, flame-retardant, fire-proof and oil-free pollution, adapting to underground scenarios with high fire protection requirements; insulation paper is DuPont NOMEX®, which is temperature-resistant, moisture-resistant and has excellent anti-aging performance.

• Shell/Oil Tank Material: Cold-rolled steel sheet, stainless steel (optional), surface treated with anti-corrosion and anti-rust, which can resist the erosion of corrosive gases, moisture and dust in underground mines, extending the service life of the equipment; seals are made of oil-resistant and anti-aging rubber to ensure the sealing performance of oil-immersed products and prevent oil leakage.

3. Core Product Advantages (Precisely Solving Mine Power Distribution Pain Points)

Safe and Compliant, Adapting to High-Risk Mine Scenarios

Strictly designed in accordance with general mine-type standards, passed KY/KA mine product safety certification, fully in line with mine safety production specifications, and can be directly used in underground methane-free coal dust areas and ground auxiliary facilities. The fully enclosed structure avoids exposure of conductive parts, and multiple electrical protections (short circuit, overload, overvoltage, etc.) respond quickly to faults, effectively avoiding potential safety hazards such as leakage and fire; insulation materials are moisture-resistant and anti-aging, adapting to the harsh underground environment with high humidity, dust and corrosive gases, ensuring the safety of personnel and equipment.

Strong Environmental Adaptability, Resistant to Harsh Working Conditions

Optimized design for core mine pain points, wide temperature operation range (-20℃～+40℃), can operate stably in northern cold mines and southern high-temperature and high-humidity mines, insulation oil does not solidify in low-temperature environment, and heat dissipation is stable in high-temperature environment; outstanding shock resistance and impact resistance, can withstand bumps during mine transportation, vibration of equipment operation, and falling rock impact underground, with no loosening or failure during long-term operation; insulation performance does not degrade in high-humidity environment, can work continuously in underground scenarios with relative humidity ≥95% and condensed water, without additional moisture-proof treatment.

Good Load Adaptability, Ensuring Continuous Production

It has excellent short-term overload and impact resistance, can easily cope with the instantaneous large current during the start-up of mine equipment such as fans, water pumps, conveyors and crushers, as well as load fluctuations during production, avoiding power supply interruption caused by overload, and ensuring the continuity of mine production; the voltage and capacity specifications are complete, which can be flexibly selected according to different underground and ground load requirements, adapting to various power distribution scenarios from small-scale lighting to large-scale equipment power.

Efficient and Energy-Saving, Reducing Mine Operation Costs

Adopting low-loss oriented silicon steel sheet iron core and optimized winding technology, the no-load loss is 15%~25% lower than that of conventional transformers, and the load loss is 10%~20% lower, fully meeting the national Level 1 energy efficiency standard, and some products reach super Level 1 energy efficiency. In the scenario of 24-hour continuous operation of mines, a large amount of electricity costs can be saved; materials are corrosion-resistant and anti-aging, the normal service life can reach more than 30 years, the failure rate is low, reducing maintenance frequency, maintenance costs and shutdown losses, and the long-term comprehensive use cost is greatly reduced.

Convenient Installation and Transportation, Adapting to Narrow Mine Spaces

Compact structure, small size and light weight. Compared with conventional industrial transformers, the weight is reduced by 15%~20%. The bottom is equipped with skids (suitable for underground track transportation) and the top is equipped with lifting lugs (suitable for hoisting operations), which is convenient for transportation and installation in underground roadways and narrow spaces, without large hoisting equipment, reducing installation and transportation costs; the wiring method is flexible, and the wiring direction can be adjusted according to the on-site power distribution layout, adapting to the complex installation environment of mines.

Convenient Maintenance, Adapting to Mine Operation and Maintenance Scenarios

Oil-immersed products adopt fully sealed corrugated oil tanks, no leakage and no oil replenishment, reducing oil maintenance workload; dry-type products have no oil pollution, flame-retardant and fire-proof, no oil-related maintenance, only regular dust cleaning is needed. Optional intelligent monitoring and remote monitoring modules are available, operation and maintenance personnel can remotely view equipment operation parameters (temperature, current, voltage, etc.) through computers and mobile phones, realize fault early warning and data statistics, without 24-hour on-site duty, greatly reducing underground inspection workload and labor intensity of operation and maintenance personnel.

Compliant and Durable, Quality Assured

Core materials are all selected from well-known domestic brands, the production process strictly follows national and industry standards, and undergoes multiple processes such as raw material inspection, semi-finished product inspection and finished product inspection. Before leaving the factory, no-load test, load test, overload test, insulation test, etc. are carried out to ensure that product performance meets the standards; the product has strong consistency, passed mine safety certification, can be directly connected to the mine power distribution system without additional transformation, adapting to mine safety production requirements.

4. Typical Application Scenarios (Precisely Matching Various Mine Power Distribution Needs)

4.1 Power Distribution in Underground Non-Explosive Hazard Areas

Adapting to underground areas without methane coal dust and flammable and explosive gases, such as auxiliary power distribution in transportation roadways, return air roadways, excavation working faces, underground lighting power distribution, power supply for small control equipment, as well as power distribution for underground fan rooms, pump rooms and power substations. It can withstand the underground high-humidity, dusty and strong vibration environment, ensuring stable power supply for underground production equipment and lighting systems.

4.2 Power Distribution for Mine Ground Auxiliary Facilities

Suitable for mine ground power substations, fan rooms, pump rooms, crushing workshops, screening workshops, coal preparation plants and other auxiliary facilities, providing stable power supply for ground large-scale equipment (such as crushers, conveyors, coal preparation equipment), office areas and lighting systems. The low-noise and low-loss design adapts to ground environmental protection and noise control requirements.

4.3 Power Distribution in Similar Harsh Environments

In addition to mine scenarios, it can also be adapted to harsh environments with dust, high humidity, strong vibration and large load fluctuations such as tunnel projects (subway tunnels, highway tunnels), metallurgy and chemical industry, as a special power distribution equipment to ensure stable operation of various equipment.

5. Specifications, Models and Customization Services (Adapt on Demand, Meet Personalized Mine Needs)

5.1 Conventional Specifications

• Voltage Level: High voltage 6kV, 10kV (mainstream), special voltage levels such as 3kV and 110kV can be customized; low voltage 380V, 660V, 1140V, 127V, which can be adjusted as needed.

• Capacity Range: 50kVA～2000kVA, which can be flexibly selected according to actual load requirements, covering various mine power distribution scenarios.

• Product Type: Oil-immersed (KS series), dry-type (KSG series). Oil-immersed is suitable for ground and underground areas with good ventilation, and dry-type is suitable for underground areas with high fire protection requirements and no oil pollution requirements.

• Connection Group Label: Dyn11, Yyn0 (mainstream), supporting on-load tap changing (OLTC) and off-load tap changing, and the tap changing range can be customized according to the voltage fluctuation of the mine power grid.

• Protection Level: Outdoor model IP54, underground model is upgraded with dust-proof and moisture-proof structure, which can be upgraded to IP65 according to the installation environment.

• Cooling Mode: Oil-immersed (ONAN, ONAF), dry-type (AN, AF), which can be selected according to ambient temperature and load conditions.

5.2 Customization Services

Combined with the personalized needs of different mine scenarios, comprehensive customization services are provided to precisely adapt to actual power distribution pain points:

• Load Customization: According to the start-up impact intensity of mine equipment and the duration of short-term high load, customize different levels of overload capacity from 1.2 to 2.2 times, adapting to fluctuating loads such as fans and water pumps.

• Structure Customization: Customize equipment volume and weight to adapt to special spaces such as narrow underground roadways and high-altitude installation; strengthen shock absorption structure to adapt to mine strong vibration scenarios; customize shell anti-corrosion level to adapt to the highly corrosive underground environment.

• Voltage and Capacity Customization: Customize special voltage levels (such as 3kV, 110kV) and non-standard capacity to adapt to special mine power distribution systems; adjust connection groups and voltage regulation ranges to adapt to mine power grid voltage fluctuations.

• Accessory Customization: Configure accessories such as oil chromatogram online monitoring, remote monitoring, lightning protection and grounding, and explosion-proof junction boxes as needed to realize intelligent operation and maintenance; customize integrated power distribution schemes to integrate transformers, switches and protection devices, reducing on-site installation workload.

• Environmental Protection Customization: Oil-immersed products can be upgraded to natural ester insulation oil (non-toxic and degradable), and dry-type products can strengthen flame-retardant performance, adapting to mine environmental protection and fire protection requirements.