Composite Wheel Support for Electric Transformers

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Solution Overview

Problem

Existing wheels for electric transformers face challenges with resistance to corrosion, humidity, and temperature, while being heavy and difficult to manufacture and transport, and they fail to effectively handle high vertical and lateral dynamic loads.

Innovation Solution

A wheel support and roller system made from composite materials, specifically polyamide reinforced with glass fibers, featuring a fork with vertical portions and ribs for load distribution, and an orientable rotable connection for easy assembly and resistance to corrosion and temperature extremes, allowing for efficient handling of heavy loads.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If cast iron rollers are used, then resistance to compression and hardness are improved, but weight increases and corrosion resistance deteriorates

Engineering Contradiction:

Improveresistance to compressionVSAvoidcorrosion resistance

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent applies composite materials by combining polyamide (providing corrosion resistance) with glass fibers (providing mechanical strength and rigidity). This composite structure resolves the contradiction by achieving both corrosion resistance and compression strength without using metal materials that are prone to rust.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent changes the material parameters by selecting polyamide with specific glass fiber reinforcement (30-60% by weight) to optimize the balance between mechanical properties and corrosion resistance. This parameter optimization allows the roller to withstand transformer weights while remaining corrosion-resistant.

Inventive Principle:

Principle #35Parameter changes

2Strength

If cast iron rollers are used, then hardness is improved, but weight increases and manufacturing complexity increases

Engineering Contradiction:

ImprovehardnessVSAvoidweight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The composite material of polyamide reinforced with glass fibers provides hardness comparable to or exceeding cast iron while significantly reducing weight. The glass fibers contribute to the mechanical strength and rigidity needed to support heavy transformers without the weight penalty of metal.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent adopts a design where the roller can be replaced if damaged, leveraging the advantage of composite materials that can be manufactured cost-effectively through injection molding. This approach is economically viable given the low cost of the composite material and simplified manufacturing process.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Strength

If cast iron rollers are used, then resistance to compression is improved, but ease of manufacture deteriorates

Engineering Contradiction:

Improveresistance to compressionVSAvoidease of manufacture

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The composite material system allows for injection molding of complex roller geometries in a single manufacturing step, eliminating the need for casting, machining, and assembly operations required for metal rollers. This dramatically simplifies manufacturing while maintaining compression resistance through proper material selection and fiber orientation.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent merges the roller body and hub into a single monolithic composite component, eliminating the need for separate metal shafts and fasteners. This integration simplifies manufacturing and assembly while the glass fiber reinforcement ensures the combined structure maintains adequate mechanical strength.

Inventive Principle:

Principle #5Merging (Combining)

4Strength

If metal supports are used, then strength is improved, but corrosion resistance deteriorates

Engineering Contradiction:

ImprovestrengthVSAvoidcorrosion resistance

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent replaces metal supports with composite materials (polyamide with glass fibers) that inherently resist corrosion. The composite support structure maintains adequate strength for supporting the transformer while eliminating the corrosion and rust problems associated with metal components in outdoor environments.

Inventive Principle:

Principle #40Composite materials

Data Source

PatentEP3535136B1Wheel support and wheel for electric transformer

Publication Date: 2020.09.16 CDR ITAL SRL

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AI summary

Wheel support (S) for distribution electric transformer comprising: a fork (2) made of a composite material comprising a upper portion (3) connective to an electric transformer; two vertical portions (4) monolithically connected to the upper portion (3), each one comprising a portion configured to receive and turnably support a roller (R) and in particular a pivot of the roller (R); said support further comprising a couple of blocking elements (10) each one of them being configured to be connected to one of the two vertical portions (4) of the support (S) to contain said roller (R) and in particular its pivot (14); wherein said vertical portions (4) comprise a plurality of ribs (5) bottom-up oriented. Wheel (1) for electric transformer comprising a support (S) and a roller (R) entirely made of a composite material comprising a pivot (14) turnably connected to the support (5).