Isolation Transformer Winding Layers for High-Frequency Loss Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The challenge is to reduce winding loss and increase efficiency in isolation transformers to enable a reduction in size, while minimizing temperature rise and resistance values, which are exacerbated by increasing switching frequency.
Innovation Solution
The isolation transformer design features multiple winding layers with varying numbers of turns, where layers with the greatest number of turns are positioned internally, and windings are alternately stacked to minimize magnetic interference and proximity effects, using a shell-type configuration with a magnetic core and windings made of aluminum to reduce resistance and size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of stationary object
If switching frequency is increased to reduce transformer core size, then transformer core loss is reduced and core size is reduced, but winding resistance increases and winding loss increases
Solution Approach 1:
The winding is divided into multiple layers with different numbers of turns. By segmenting the winding structure into layers (first winding layer, second winding layer, etc.) with varying turn counts, the patent optimizes current distribution and reduces proximity effect losses at high switching frequencies, thereby reducing overall winding loss while maintaining reduced core size
Solution Approach 2:
Different winding layers are assigned different numbers of turns based on their position and function. The first winding layer has a different number of turns than the second winding layer, creating local variations in winding density and impedance that optimize performance at high frequencies and reduce localized heating and losses
2Productivity
If switching frequency is increased to reduce isolation transformer size, then efficiency is improved, but winding temperature rises due to increased winding loss
Solution Approach 1:
The winding is segmented into multiple layers with different turn counts to distribute current more evenly and reduce concentration of heat-generating losses in any single layer, thereby maintaining efficiency while reducing temperature rise
Solution Approach 2:
The patent transitions from a single-layer winding to a multi-layer winding structure, adding the dimensional aspect of layering to the winding design. This three-dimensional arrangement allows for better heat dissipation and reduced proximity effects, enabling high-frequency operation with controlled temperature rise
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 effectively reduces winding loss, increases efficiency, and restricts temperature rise, allowing for a smaller size of the isolation transformer while maintaining high-frequency operation, thus enhancing the power conversion device's performance.
Implementation Method 1
a core portion that forms a magnetic circuit
Implementation Method 2
an isolation transformer including a core portion that forms a magnetic circuit, and at least two kinds of winding, on a high voltage side and a low voltage side, wound around the core portion
Implementation Method 3
a primary winding and a secondary winding wound around the transformer core, wherein a number of turns in accordance with a target transformation ratio is set for the primary winding and the secondary winding
Data Source
AI summary
The isolation transformer includes two kinds of winding, a high voltage side winding and a low voltage side winding, and the high voltage side winding and the low voltage side winding are formed in winding layers, wherein the high voltage side winding includes windings formed in multiple winding layers, a winding layer having a different number of turns exists in one or more kinds of the two kinds of winding among the windings formed in the multiple winding layers, winding layers wherein current flows in the same direction are stacked in such a way as not to be neighboring, and at least one of winding layers having the greatest number of turns is disposed as a layer other than an outermost layer.