Interleaved Winding Transformers Reducing Stray Losses
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Solution Overview
Problem
Conventional transformers suffer from inefficiencies due to stray losses, particularly in transformers supplying voltage to non-linear loads, as they are not designed to minimize stray losses which result in overheating and failure.
Innovation Solution
The design includes a magnetic core with winding assemblies having substantially equal magnetic lengths, either through helical or concentric winding configurations, and an interleaved arrangement to reduce stray losses by minimizing leakage flux.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional transformer windings are used, then the transformer can supply voltage to non-linear loads, but stray losses increase significantly causing overheating and failure
Solution Approach 1:
The transformer windings are divided into multiple segments with different winding densities along the magnetic core. The first winding assembly has a first winding density in a first region and a second winding density in a second region, while the second winding assembly has corresponding segmented densities. This segmentation allows optimization of magnetic flux distribution to reduce stray losses while maintaining reliability.
Solution Approach 2:
Different regions of the transformer are given different local properties through variable winding densities. The winding assemblies have non-uniform density distributions tailored to specific regions along the magnetic core, creating local optimization of magnetic coupling and flux containment, thereby reducing stray losses in critical areas while maintaining overall transformer reliability.
2Loss of energy
If transformer design is optimized to reduce stray losses, then efficiency improves, but device complexity increases due to multiple winding assemblies with different densities
Solution Approach 1:
Multiple winding assemblies with different winding densities are combined around the same magnetic core, with each assembly serving a specific function in reducing stray losses. The first and second winding assemblies are positioned concentrically or adjacently, merging their effects to achieve superior loss reduction while sharing common magnetic path and structural support infrastructure.
Solution Approach 2:
The multiple winding assemblies serve multiple functions simultaneously: they provide voltage transformation, reduce stray losses through optimized magnetic coupling, and can be configured to handle different load types including non-linear loads. The same winding structure achieves both efficiency improvement and adaptability to various operating conditions.
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 configuration reduces stray losses, improves transformer efficiency, and allows for a lighter, more compact construction, effectively addressing overheating issues, especially in transformers supplying voltage to non-linear loads.
Implementation Method 1
The second winding assembly is inductively coupled to the first winding assembly
Implementation Method 2
The first winding assembly includes a first conductive conduit helically wound around the first winding leg
Data Source
AI summary
A transformer includes a magnetic core, a first winding assembly inductively coupled to the magnetic core, and a second winding assembly inductively coupled to the first winding assembly. The magnetic core includes a winding leg. The first winding assembly includes a plurality of first layers, and the second winding assembly includes a plurality of second layers. The first and second winding assemblies are concentrically wound around the winding leg in an interleaved configuration, where at least one of the plurality of second layers is disposed between two of the plurality of first layers, and at least one of the plurality of first layers is disposed between two of the plurality of second layers.