Horizontal Vehicle Transformer Limb Axis Design
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing vehicle transformers face challenges in compact design and weight reduction due to limited space and mechanical strength issues, particularly when arranged underfloor or on the roof of vehicles, where vertical orientation and lack of rigidity exacerbate flexural burdens.
Innovation Solution
A vehicle transformer with a horizontal oriented limb axis, supported by yokes with hollow cylindrical coils rigidly connected to the limbs, utilizing fiber composite materials and glue for enhanced mechanical stability and reduced height, eliminating the need for additional stabilization components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the transformer is arranged in limited vehicle space (underfloor or roof area), then space utilization is improved, but the height requirement increases and mechanical strength decreases due to flexural burdens
Solution Approach 1:
The patent changes the orientation of the limb axis from vertical to horizontal, transforming the transformer from a vertically-oriented structure to a horizontally-oriented one. This dimensional change allows the transformer to fit within the limited height constraints of vehicle underfloor or roof spaces while distributing mechanical loads differently to maintain strength
Solution Approach 2:
The patent employs composite materials in the construction of the transformer core and support structures, combining materials with different properties to achieve both reduced weight and maintained or improved mechanical strength, thereby resolving the contradiction between space constraints and structural integrity
2Device complexity
If the limb axis is oriented vertically as in conventional transformers, then structural simplicity is maintained, but the height increases and flexural resistance decreases under vehicle operating conditions
Solution Approach 1:
The patent rotates the transformer core structure by 90 degrees, changing the limb axis orientation from vertical to horizontal. This reorientation reduces the height dimension from approximately 1.5-2 meters to a much smaller dimension, allowing the transformer to fit within vehicle space constraints while maintaining structural integrity through the horizontal support structures
3Strength
If additional stabilization components are added to improve flexural resistance, then mechanical strength is improved, but device complexity and weight increase
Solution Approach 1:
The patent integrates the support structures directly into the transformer core design, merging the functional elements (core limbs and support structures) into a unified horizontal configuration. This integration provides necessary flexural resistance without requiring separate stabilization components, thereby avoiding increased complexity and weight
Solution Approach 2:
The use of composite materials in the core and support structures provides high strength-to-weight ratio, achieving improved flexural resistance without the need for additional stabilization components that would increase complexity and weight
4Ease of manufacture
If the transformer uses conventional vertical orientation, then manufacturing simplicity is maintained, but weight increases and space efficiency decreases
Solution Approach 1:
The horizontal reorientation of the transformer core changes the load distribution and structural configuration, enabling the use of lighter materials and more efficient structural forms that reduce overall weight while maintaining manufacturing feasibility through standardized horizontal assembly processes
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 solution provides a compact, lightweight, and robust transformer design that reduces height requirements, optimizes space usage, and enhances mechanical strength, allowing for efficient placement in constrained vehicle spaces while minimizing weight and environmental impact.
Implementation Method 1
a hollow cylindrical coil with at least one respective electrical winding is arranged around each of the limbs
Implementation Method 2
the hollow cylindrical coil is rigidly connected with the limb so that a flexural resistance of a rigid combination of both is improved therewith
Data Source
AI summary
A vehicle transformer has a transformer core with two opposed yokes and at least two limbs extending in between them along a parallel limb axis, wherein a support structure is provided at each of the yokes for carrying the vehicle transformer with horizontal oriented limb axis, wherein a hollow cylindrical coil with at least one respective electrical winding is arranged around at least one of the limbs. The coil may be rigidly connected with the limb so that the flexural resistance of the rigid combination of both is improved therewith compared to a combination of both without rigid connection.