Adjustable Primary Voltage Coil for Dry-Type Transformers
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Solution Overview
Problem
The production of high voltage/low voltage transformers is cumbersome and expensive due to the need for custom manufacturing of windings based on specific voltage and power requirements, leading to high costs and complex processes.
Innovation Solution
The use of stacked power wafers with multiple outputs, where the connection and orientation of the wafers allow for adjustable input voltage and power, enabling standardized and modular transformer design with interchangeable coils.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If custom manufacturing of windings is performed for each specific voltage and power requirement, then the transformer can be precisely adapted to customer specifications, but the production process becomes cumbersome and expensive
Solution Approach 1:
The winding is divided into multiple standardized pancakes, each with identical terminals. By stacking different numbers of pancakes and using different connection configurations (series, parallel, or combinations), a wide range of voltages and powers can be achieved without custom manufacturing each winding from scratch.
Solution Approach 2:
The standardized pancakes are designed to be universally applicable across different transformer models. The same pancake design can be used for various voltages and powers by changing only the number of pancakes and connection method, making the manufacturing process simpler and more versatile.
2Adaptability or versatility
If custom windings are manufactured for each transformer model, then precise voltage and power specifications are met, but delivery time increases due to lengthy manufacturing processes
Solution Approach 1:
The pancakes are pre-manufactured with standardized terminals and connection points. This preliminary preparation allows for rapid assembly when a transformer is needed - simply stack the required number of pancakes and connect them according to the desired voltage and power specification, dramatically reducing delivery time.
Solution Approach 2:
The system allows dynamic configuration of voltage and power by changing the number of pancakes and connection method. This flexibility enables the same standardized components to adapt to different customer requirements without retooling or custom manufacturing, speeding up production.
3Ease of manufacture
If standardized pancakes with multiple outputs are used, then production cost and complexity are reduced, but the connection and orientation requirements become more complex
Solution Approach 1:
Each pancake is designed with specific terminal orientations (e.g., 120 degrees apart for three-phase applications). This local structural quality simplifies the overall connection process because the terminals are pre-positioned for optimal connectivity, reducing the complexity of assembly despite the multi-output capability.
Solution Approach 2:
The standardized terminals act as intermediaries that simplify connections between pancakes. By providing uniform connection points with consistent geometry and spacing, the terminals mediate the connection process, making it simpler despite the complexity of achieving various voltage and power configurations.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach simplifies the manufacturing process, reduces costs, and allows for quick adaptation to various voltage and power needs, enabling efficient production of multiple transformer models with reduced delivery and maintenance times.
Implementation Method 1
a high voltage coil for an HV/LV transformer, made by superimposing power wafers comprising several outputs
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
The wafer (10-1-10-4) has outlets of 6 to 7 kilovolts spaced at 120 degrees with an inlet at 0 Volts of a rolling bearing. The inlets and outlets are accessible from exterior of a resin ring. One of the outlets corresponding to different voltage of the other outlet is accessible from exterior of the ring. The ring has lateral protrusions (12-0-12-2), where each inlet and outlet are connected to different protrusions and opens on both sides of the protrusion.