Leakage Reactance Plate for Power Transformer Design
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Solution Overview
Problem
Existing power transformer designs face challenges in decoupling leakage reactance from coil and core design, leading to increased design and construction times, and custom manufacturing requirements, which hinder grid reliability and resilience due to unique application-specific power requirements.
Innovation Solution
Incorporating a leakage reactance plate with a relative permeability greater than 1 and less than 75, made of a polymeric composite with ferromagnetic fillers, into the air gap between windings to adjust leakage reactance without modifying the coil or core design, allowing for a range of leakage reactance values without the need for auxiliary windings or power electronics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If custom coil and core design is made to satisfy leakage reactance requirements, then leakage reactance parameter is optimized, but design time and manufacturing lead time increase to as much as two years
Solution Approach 1:
The invention separates the leakage reactance control function from the coil and core design by introducing an independent adjustable element (leakage reactance plate or auxiliary winding) that can be modified without changing the main transformer components. This segmentation allows the leakage reactance parameter to be adjusted independently, reducing design time while maintaining manufacturing precision.
Solution Approach 2:
The invention enables adjustment of leakage reactance by changing parameters of the adjustable element (plate position, plate dimensions, or auxiliary winding turns) rather than redesigning the entire coil and core. This parameter change approach allows rapid adaptation to different leakage reactance requirements without extending design and manufacturing lead times.
2Adaptability or versatility
If custom design and manufacturing is performed for each application, then specific power requirements are met, but construction time increases significantly
Solution Approach 1:
By segmenting the transformer into fixed components (coil and core) and an adjustable component (leakage reactance plate or auxiliary winding), the invention enables a standardized base design to be adapted to different applications through simple adjustments, thereby maintaining versatility while significantly improving construction speed.
Solution Approach 2:
The invention creates a universal coil and core design that can serve multiple applications with different power requirements by adding or adjusting the leakage reactance element. This multi-functionality approach allows a single standardized design to be adapted across various applications, enhancing both versatility and productivity.
3Manufacturing precision
If leakage reactance is controlled through coil and core design modifications, then leakage flux is optimized, but design complexity and manufacturing complexity increase
Solution Approach 1:
The invention extracts the leakage reactance control function from the complex coil and core design and places it in a separate, simpler adjustable element (leakage reactance plate or auxiliary winding). This extraction reduces the complexity of the main coil and core design while maintaining precise control over leakage reactance through the isolated adjustable component.
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 approach enables the use of the same coil and core design for a wide range of applications by varying the dimensions and permeability of the plate, reducing design and construction time, and enhancing grid reliability by allowing for quicker adaptation to different power requirements.
Implementation Method 1
a plate having a relative permeability greater than 1 and less than 75 and inserted into the air gap
Data Source
AI summary
Unique systems, methods, techniques and apparatuses of a power transformer are disclosed. One exemplary embodiment is a transformer comprising a core; a first winding wound around the core; a second winding coaxially wound around the first winding so as to surround the first winding and forming an air gap between the first winding and second winding; and a plate having a relative permeability greater than 1 and less than 25 structured to be inserted into the air gap.