Current Transformer Primary Circuit Layout for Faster Assembly
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Solution Overview
Problem
Conventional current transformers have a primary circuit design that is time-consuming to assemble, prone to human errors, and limits the number of turns to four due to separate components like primary bars, terminals, and return bars.
Innovation Solution
A current transformer design with a head tank and head tank cover made of conductive materials, integrating primary and secondary windings within a cavity, allowing for multiple parallel primary bars and return conductors wound around the secondary winding, and using insulating materials to reduce assembly complexity and material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional separate primary bars, terminals, and return bars are used, then electrical functionality is achieved, but assembly time increases and human errors occur
Solution Approach 1:
The patent merges the primary bars, terminals, and return bars into a single integrated primary circuit structure. The primary bars are formed as continuous conductive elements with integrated terminal connections, eliminating the need for separate assembly steps and reducing the number of components that need to be assembled.
2Adaptability or versatility
If conventional separate components are used, then electrical connections can be made, but the number of turns is limited to four
Solution Approach 1:
The patent employs flexible primary bars that can be bent and shaped to create multiple turns around the core. The dynamic flexibility of the primary bars allows them to accommodate various winding configurations (more than four turns) while maintaining electrical continuity and proper mechanical alignment.
3Reliability
If conventional aluminum tube with resin filling is used, then insulation is provided, but additional oil tightness components are needed
Solution Approach 1:
The patent uses composite material structures where the aluminum tube is combined with resin filling to create an integrated insulation and sealing system. The resin impregnated into the aluminum tube structure provides both electrical insulation and oil tightness simultaneously, eliminating the need for separate O-ring and insulated bushing components.
4Ease of manufacture
If multiple separate components are assembled, then electrical connections are established, but material costs increase
Solution Approach 1:
The patent combines multiple separate components (primary bars, terminals, return bars, insulation, and sealing elements) into integrated structures. This merging reduces the total quantity of materials needed by eliminating redundant components and optimizing the use of each material for multiple functions simultaneously.
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
Enables faster assembly, reduced material costs, and flexibility to have more than four turns, with improved insulation and sealing to prevent oil leakage, resulting in a leaner, cheaper, and more efficient design.
Implementation Method 1
an upper flange of the head tank is configured for fluid tightly sealing against a cover flange of the head tank cover
Implementation Method 2
an electrically insulating ring is arranged between the cover flange and the upper flange
Implementation Method 3
a secondary winding wound around the at least one primary bar, the primary and secondary windings arranged within a cavity
Data Source
AI summary
A current transformer includes a head tank and a head tank cover, both of an electrically conductive material, a primary winding for conducting a current to be measured. The primary winding has a primary bar, and a secondary winding is wound around the primary bar. The primary and secondary windings are arranged within a cavity defined within the head tank and cover. An upper flange of the head tank is configured for fluid tightly sealing against a cover flange of the head tank cover. The head tank and cover respectively have a primary terminal for electrically contacting the primary winding. One or more connection points are within the head tank and cover, respectively, to electrically connect a respective end of the primary winding to the head tank or to the cover, wherein an electrically insulating ring is arranged between the cover flange and the upper flange.