Amorphous Alloy Transformer Core with 3D Triangular Structure
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Solution Overview
Problem
Traditional amorphous alloy transformers with planar cores face issues such as larger size, heavier weight, longer processing times, inflexible design, higher costs, asymmetrical three-phase power distribution, high energy consumption due to seams, and reduced ability to withstand short-circuits.
Innovation Solution
A triangular amorphous alloy 3D core is manufactured using three identical rectangle frames with approximate semicircular cross sections, where trapezoid strips are wound layer by layer to form a semicircular cross section, eliminating seams and allowing direct coil winding, and annealing is used to improve performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If planar rectangular core structure is used, then manufacturing is simple, but weight and size are larger
Solution Approach 1:
The patent transitions from traditional planar (2D) core structure to a three-dimensional triangular core structure. The core limbs are arranged in a triangular configuration with specific spatial relationships, allowing magnetic flux to travel through multiple paths including diagonal yokes. This dimensional change reduces the overall material required while maintaining magnetic circuit functionality, directly addressing the weight reduction goal.
2Ease of manufacture
If planar core with seams is used, then assembly is easier, but energy loss increases due to air gaps
Solution Approach 1:
The three-dimensional triangular core structure eliminates the need for traditional yoke seams by providing continuous magnetic paths through the spatial arrangement of core limbs. The diagonal yokes connect the limbs in three-dimensional space, creating seamless magnetic circuits that avoid air gaps and associated energy losses.
3Device complexity
If rectangular core is used, then design is standardized, but adaptability to different power requirements is limited
Solution Approach 1:
The patent employs asymmetric triangular core configuration where the three phases are arranged in a triangular pattern with diagonal yokes connecting the limbs. This asymmetric spatial arrangement provides greater design flexibility compared to symmetric rectangular cores, allowing optimization for different power requirements while maintaining manufacturing efficiency through standardized triangular module production.
4Device complexity
If traditional planar core is used, then magnetic circuit is simpler, but three-phase power distribution becomes asymmetrical
Solution Approach 1:
The three-dimensional triangular core structure with diagonally arranged yokes creates symmetric magnetic paths for all three phases. Each phase has equivalent magnetic circuit length and impedance due to the geometric symmetry of the triangular configuration, ensuring balanced three-phase power distribution despite the increased spatial complexity.
5Ease of manufacture
If rectangular core structure is used, then coil winding is traditional, but short-circuit resistance is weak
Solution Approach 1:
The three-dimensional triangular core structure with its spatial arrangement of limbs and diagonal yokes provides inherently stronger mechanical support for the coils. The triangular geometry distributes mechanical stresses more effectively during short-circuit conditions compared to planar rectangular cores, enhancing the overall structural strength and short-circuit resistance while maintaining practical coil winding processes.
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 triangular 3D core is significantly lighter, reducing alloy consumption, minimizing noise and energy losses, achieving symmetrical power distribution, enhancing short-circuit resistance, and optimizing magnetic conductibility.
Implementation Method 1
The annealing of the assembled triangular 3D core is finished in annealing oven in order to relieve the internal stress, recover the magnetism, and further improve the performance of core
Data Source
AI summary
An amorphous alloy transformer iron core of a three-dimensional triangle structure belongs to the technical field of electrical devices. The amorphous alloy transformer iron core of the three-dimensional triangle structure is formed by piecing three identical rectangular single frames whose sections are approximately semicircular. A manufacturing method thereof comprises steps of cutting, winding, assembling, annealing and molding. The amorphous alloy transformer iron core of the three-dimensional triangle structure has the advantages of saving materials, reducing loss and noise, balancing three phases, enabling coils not to be sleeved, and being stable in performance and strong in anti-short circuit capacity.