3D Electrical Routing in Power Transformers
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Solution Overview
Problem
The design of power transformers and other power network components faces challenges in determining three-dimensional layouts of internal electrical connections, which are complex due to varying boundary conditions and constraints, requiring iterative and error-prone human-based processes that are not efficiently automated.
Innovation Solution
A method and system that automatically determine three-dimensional layouts of electrical connections without requiring user-specified support framework geometry, using path optimization routines and conflict management to generate conflict-free routes, considering thermal, mechanical, and electrical constraints, and allowing for joint routing of connections to reduce costs and manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional iterative design process is used for determining three-dimensional layout of electrical connections, then the design can be completed with manual adjustments, but the process is time-consuming and error-prone
Solution Approach 1:
The patent replaces the manual iterative design process with an automated computer-based system that uses algorithms to determine optimal three-dimensional routing of electrical connections. The system automatically processes boundary conditions and constraints to generate routing layouts without requiring manual trial-and-error adjustments, thereby eliminating time loss while maintaining or improving layout accuracy.
2Device complexity
If the routing is constrained to two-dimensional planes, then the design process is simpler, but it cannot achieve optimal three-dimensional routing paths
Solution Approach 1:
The patent explicitly enables three-dimensional routing by allowing electrical connections to traverse through the vertical dimension (z-axis) in addition to horizontal planes. The system models the transformer interior as a three-dimensional space with multiple levels and allows routing paths to move between these levels, achieving optimal routing efficiency that cannot be obtained with two-dimensional constraints alone.
3Ease of operation
If support framework geometry is predetermined, then the routing process is more constrained, but it simplifies the overall design process
Solution Approach 1:
The system performs preliminary identification and processing of boundary conditions and constraints before determining the routing layout. By pre-processing the design space, defining accessible regions, and identifying obstacles in advance, the system maintains routing flexibility while simplifying the actual routing determination process. This preliminary action allows the system to adapt to different framework geometries without requiring manual reconfiguration.
4Manufacturing precision
If individual routing of each electrical connection is performed, then each connection can be optimized independently, but the overall layout complexity increases
Solution Approach 1:
The patent merges the routing determination for multiple electrical connections into a single integrated optimization process. The system simultaneously considers all connections, their respective boundary conditions, and spatial constraints to generate a coordinated three-dimensional layout. This combined approach optimizes each connection's route while maintaining overall layout coherence, reducing complexity compared to separate individual optimizations.
Data Source
AI summary
To determine a three-dimensional layout of electrical connections of an electric component, a processor executes a path optimization routine to determine three-dimensional routes for a plurality of electrical connections of the electric component. A conflict management is performed to generate conflict-free three-dimensional routes for the plurality of electrical connections.