Amorphous Transformer Core Winding via Inversion
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Solution Overview
Problem
Current methods for manufacturing transformers with ferromagnetic cores made of amorphous metal are inefficient and economically suboptimal, particularly due to the complexity of winding conductors around the core and the use of excessive ferromagnetic material, leading to high costs and energy consumption.
Innovation Solution
A mechanized process for manufacturing transformers using strip-shaped ferromagnetic material, where electrically conductive windings and ferromagnetic cores are formed separately, allowing for the use of a closed path to wind the ferromagnetic material efficiently around the windings, reducing material usage and enhancing compactness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conductors are wound around a pre-formed amorphous metal core, then the core provides magnetic coupling, but the winding process becomes extremely complex and technologically restricted due to insufficient traction
Solution Approach 1:
The patent inverts the traditional manufacturing sequence by forming the ferromagnetic core around the conductors rather than winding conductors around a pre-formed core. This is achieved by positioning conductors in a mold cavity and then depositing ferromagnetic material around them, eliminating the traction problem associated with winding thin amorphous metal strips around complex core geometries.
Solution Approach 2:
The conductors are positioned in the mold cavity before the ferromagnetic core is formed. This preliminary placement allows the core to be built around the conductors in a single casting or deposition operation, avoiding subsequent complex winding operations and ensuring precise positioning.
2Loss of energy
If traditional lamination stacking methods are used, then electrical insulation between laminations is achieved, but the assembly process becomes highly time-consuming due to the large number of laminations required
Solution Approach 1:
The patent replaces the mechanical stacking and assembly of numerous individual laminations with a single-step ferromagnetic material deposition process. The ferromagnetic material is deposited directly around the conductors in a mold, forming the complete core structure without requiring manual or automated stacking of thin sheets, thereby dramatically reducing assembly time while maintaining electrical insulation properties.
3Ease of manufacture
If circular cross-section cores are used, then the structure is simple to form, but excessive ferromagnetic material is required creating empty spaces around the windings
Solution Approach 1:
The patent employs a mold cavity with a specific geometry that matches the desired core shape, allowing the ferromagnetic material to be deposited only where needed around the conductors. This localized formation eliminates empty spaces and ensures optimal material utilization, creating a core with irregular cross-section that closely fits the winding geometry rather than using a simple circular shape.
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 method results in a more compact, economical, and efficient transformer production process, reducing overall costs and energy consumption by minimizing material usage and optimizing the winding process.
Implementation Method 1
a first ferromagnetic core linked to the first electrically conductive winding and to the second electrically conductive winding
Data Source
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AI summary
A device for the production of a transformer is disclosed, comprised of at least two electrically conductive windings (A, B, C) adjacent to one another, and a ferromagnetic core (1l; N2; N3) linked to the two electrically conductive windings, formed by wound strip-shaped ferromagnetic material. The device comprises guide members (9) configured and arranged so as to define a closed path linked to the two electrically conductive windings, along which one or more strip-shaped ferromagnetic materials can be wound from at least one coil (R; R1-R18).