Air Choke Coil Compensation Block for Settlement Gap Prevention
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Solution Overview
Problem
Air throttle coils experience gap formation due to thermal and mechanical operating loads, leading to system shutdowns during operation, as existing solutions require laborious filling of gaps with suitable materials.
Innovation Solution
A compensation block with a sandwich structure comprising an upper insulating block, a lower insulating block, and an elastomer block is inserted between the winding ends and the star arms of the air throttle coil, fixed using a comb connection and clamping device to prevent slipping and settlement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional air choke coils are used without compensation blocks, then the structure is simpler and assembly is easier, but gap formation occurs due to settlement under thermal and mechanical loads
Solution Approach 1:
The compensation block is divided into three distinct segments: an upper insulating block, a lower insulating block, and an elastomer block in between. This segmentation allows each component to perform its specific function - the insulating blocks provide electrical isolation while the elastomer block absorbs settlement movements, collectively preventing gap formation without overly complicating the overall structure
Solution Approach 2:
The elastomer block acts as an intermediary element between the upper and lower insulating blocks. This intermediary component absorbs the settlement movements caused by thermal and mechanical loads, preventing direct contact and potential damage between the rigid insulating blocks while maintaining structural integrity and preventing gap formation
2Reliability
If gap filling material is used to address settlement gaps, then gap formation is compensated, but system shutdowns are required during operation
Solution Approach 1:
The compensation block is installed during the initial assembly of the air choke coil, before the device enters operation. The elastomer block is pre-positioned to absorb future settlement movements, eliminating the need for subsequent gap filling operations that would require system shutdowns. This preliminary action ensures continuous operation and maintains high productivity
3Quantity of substance
If multiple star-shaped blades are used instead of a single-piece star support, then material usage is reduced, but assembly complexity increases
Solution Approach 1:
The star support is segmented into multiple individual star-shaped blades positioned above and below the winding layers, rather than using a single-piece construction. This segmentation reduces material usage and allows for easier manufacturing of individual components, while the standardized design of these segments maintains assembly simplicity through consistent positioning and connection methods
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
The compensation block reduces gap formation, minimizing the need for gap filling and associated system shutdowns by maintaining the structural integrity and stability of the air throttle coils under operational loads.
Implementation Method 1
a compensation block (3) is inserted between one winding end and an upper star arm (2) of the air throttle coil... an elastomer block (5) in between
Data Source
Figure 1~2
Figure 3~4
AI summary
The invention relates to a compensating block for air-core inductors and transformers, wherein the compensating block comprises a sandwich structure with an upper insulating block, a lower insulating block, and an intermediate elastomeric block. The compensating block according to the invention can reduce gap formation caused by settling.