Concentric Winding Transformer for Electric Vehicle
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Solution Overview
Problem
Existing transformers for electrically driven vehicles face inefficiencies in energy transfer and increased energy losses due to magnetic leakage flux, particularly in the conversion of high voltage to traction and auxiliary voltages, leading to higher manufacturing costs and thermal loads.
Innovation Solution
A transformer design with a traction secondary winding arranged concentrically around a magnetically conductive core, a high-voltage primary winding in an outer layer, and an auxiliary secondary winding with two coils encasing the primary winding, optimizing inductive coupling and reducing magnetic leakage flux, thereby enhancing energy transfer efficiency and reducing losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional winding arrangements (disc or tubular) are used, then the transformer structure is simpler, but energy transfer efficiency is reduced due to magnetic leakage flux
Solution Approach 1:
The patent applies nesting by arranging the high-voltage primary winding, traction secondary winding, and auxiliary secondary winding in concentric layers around the core. The traction secondary winding is placed in an inner layer, the high-voltage primary winding in a middle layer, and the auxiliary secondary winding in an outer layer, with each winding nested within the electromagnetic field of the others to maximize flux utilization and minimize leakage.
Solution Approach 2:
The patent transitions from planar disc winding arrangements to a three-dimensional concentric cylindrical arrangement. This dimensional change allows the windings to be positioned in radial layers around the core, creating overlapping magnetic flux paths that reduce leakage flux and improve coupling between windings.
2Temperature
If magnetic leakage flux is not optimized, then the transformer construction is simpler, but thermal load increases
Solution Approach 1:
The concentric nesting of windings ensures that magnetic flux generated by the high-voltage primary winding passes through both the traction secondary and auxiliary secondary windings in sequence. This nested arrangement minimizes flux leakage and reduces unwanted eddy currents in the tank and structural components, thereby reducing thermal load.
3Use of energy by moving object
If conventional winding arrangements are used, then manufacturing costs are lower, but energy transfer efficiency is reduced
Solution Approach 1:
The patent employs a three-dimensional concentric winding arrangement where windings are positioned in radial layers around the core rather than in planar discs. This dimensional reconfiguration optimizes magnetic flux linkage and reduces leakage, significantly improving energy transfer efficiency despite the increased manufacturing complexity.
4Use of energy by moving object
If windings are arranged to maximize coupling, then energy transfer efficiency improves, but the transformer occupies more space
Solution Approach 1:
The concentric nesting of windings allows maximum magnetic coupling between the high-voltage primary, traction secondary, and auxiliary secondary windings within a compact cylindrical volume. Each winding is positioned in a radial layer, creating efficient flux paths that maximize energy transfer while minimizing the overall transformer dimensions.
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 design achieves a high efficiency in energy transfer to the traction secondary voltage while minimizing energy losses and thermal loads, allowing for a more cost-effective and space-saving transformer construction.
Implementation Method 1
an upper voltage primary winding fed with the upper voltage is inductively coupled to a traction secondary winding and to an auxiliary operating secondary winding
Implementation Method 2
a magnetically conductive core
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The transformer has a traction secondary winding (2) that is arranged in an inner layer (6) concentrically around a core limb (4). A high-tension primary winding (1) and an auxiliary operation secondary winding (3) are arranged in an outer layer (7) concentrically around core limb and traction secondary winding. The auxiliary operation secondary winding is composed of two electrically connected coils (3.1,3.2) which enclose the high-tension primary winding in axial direction (A).