Horizontal Transformer with Air Gaps for Cooling
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Solution Overview
Problem
Conventional multi-level power converters are cumbersome, bulky, and expensive due to large DC link capacitors and complex customized isolation systems, making them inefficient for varying voltage and power requirements, and lack modularity in transformer and control components.
Innovation Solution
A modular drive system design featuring a horizontally configured transformer with air gaps for cooling and a modular cabinet structure that separates power cells into fixed and moveable portions, allowing for easier access and scalability, and a power service bus for connecting components, enabling efficient power conversion across a wide range of voltages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional multi-level power converters use large DC link capacitors and complex customized isolation systems to achieve high voltage capability, then voltage and power requirements are met, but the equipment becomes cumbersome, bulky, and expensive
Solution Approach 1:
The transformer is divided into multiple modular columns, each handling a specific phase or voltage level. This segmentation allows the system to achieve high voltage capability through series connection of modular units rather than requiring a single large transformer, thereby reducing overall weight and bulk while maintaining the required power capability.
Solution Approach 2:
Secondary windings are concentrically adapted about the primary winding columns, creating a nested configuration. This nesting approach optimizes space utilization within the transformer structure, reducing the overall footprint and weight while maintaining the necessary voltage transformation capability for high power applications.
2Adaptability or versatility
If power cells are designed as fixed enclosed modules for specific voltage and power levels, then customization for particular applications is achieved, but the design becomes costly and complex with increased footprint and weight
Solution Approach 1:
The transformer design uses standardized modular columns that can be universally applied across different voltage and power configurations. By using the same basic column design that can be replicated and combined in different quantities, the system achieves adaptability for various applications without requiring custom-designed power cells, thereby reducing footprint and weight.
Solution Approach 2:
The modular column configuration allows the transformer to be dynamically adapted to different power requirements by adding or removing columns rather than redesigning the entire system. This dynamic scalability enables the same basic design to serve multiple applications with varying power levels, reducing the need for heavy customizations.
3Reliability
If medium voltage drives exclude transformers and control components from modular approach, then optimization for specific voltage and power ratings is achieved, but these components are not easily transferable to other drive ratings
Solution Approach 1:
The transformer is segmented into independent modular columns that can be individually optimized for specific voltage and power ratings while maintaining a standardized interface. This segmentation allows each column to be optimized for reliability at its specific rating while the modular architecture enables easy reconfiguration and transferability to different drive ratings by simply changing the number and arrangement of columns.
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 modular design reduces size, weight, and cost while improving airflow for cooling and enabling flexible power and voltage configurations, enhancing the efficiency and adaptability of power conversion systems.
Implementation Method 1
an air gap is present between adjacent ones of the primary winding and the secondary windings... configured within the housing to prevent air flow at a periphery of the coils and to direct air flow through the air gaps of the coils
Data Source
AI summary
In one embodiment, a transformer is provided for coupling between a utility connection and a plurality of power cells of a drive system. The transformer may be of a horizontal arrangement and include a housing and a core configured within the housing and having multiple columns each adapted along a horizontal axis. Each column corresponds to a phase, and each phase includes a coil having primary winding and multiple secondary windings concentrically adapted about the column horizontal axis to provide an air gap between adjacent ones of the primary and secondary windings. In addition, the transformer may include a baffler adapted about the core and configured within the housing to prevent air flow at a periphery of the coils and to direct air flow through the air gaps of the coils.