Medium-Frequency Transformer Winding Layout for Lower Proximity Loss
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Solution Overview
Problem
Medium-frequency transformers face challenges in efficient cooling, reducing winding losses due to the proximity effect, and locating high-voltage winding bushings, particularly in compact designs, which are exacerbated by high operating frequencies and insulation requirements.
Innovation Solution
A transformer design with interleaved windings, where the high-voltage winding is split and rearranged to reduce stray fields and proximity effects, and cast with insulation material to maintain mechanical stability and insulation distances, allowing for efficient cooling and compact placement of bushings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the high-voltage winding is arranged with full length along the core leg, then the insulation distance is sufficient, but the transformer size increases and cooling efficiency decreases
Solution Approach 1:
The high-voltage winding is segmented into two parts: a first high-voltage winding portion and a second high-voltage winding portion. These segments are arranged on opposite sides of the low-voltage winding, allowing the transformer to achieve sufficient insulation distances while reducing the overall transformer size and improving cooling efficiency through better heat dissipation paths.
2Ease of manufacture
If the windings are arranged in conventional non-interleaved configuration, then the manufacturing is simpler, but winding losses due to proximity effect increase significantly
Solution Approach 1:
The windings are segmented into high-voltage and low-voltage portions arranged in an interleaved configuration. The first high-voltage winding portion is arranged on one side of the low-voltage winding, while the second high-voltage winding portion is arranged on the opposite side, creating an alternating pattern that reduces proximity effect losses while remaining manufacturable.
Solution Approach 2:
The winding arrangement transitions from a conventional single-layer configuration to a multi-dimensional interleaved structure. By arranging high-voltage and low-voltage winding portions in alternating layers along the core leg, the design reduces the magnetic coupling between windings of the same voltage level, thereby reducing proximity effect losses.
3Ease of manufacture
If the transformer core uses conventional geometry, then the manufacturing is standard, but the stray fields and proximity effects are not sufficiently reduced
Solution Approach 1:
The transformer core is segmented into multiple core legs with windings arranged in specific patterns. The first and second high-voltage winding portions are wound around different core legs or arranged on opposite sides, which helps cancel out stray magnetic fields and reduces proximity effects while using standard core manufacturing 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
This design significantly reduces high-frequency winding losses and enables a compact, robust, and cost-effective transformer with improved insulation and cooling, suitable for high-voltage applications.
Implementation Method 1
reducing winding losses due to proximity effect
Implementation Method 2
transformer includes a transformer core having a first core leg having a first longitudinal axis and second core leg having a second longitudinal axis. Additionally, the transformer includes a first low voltage (LV) winding arranged around the first core leg
Data Source
AI summary
A transformer includes a transformer core having a first core leg having a first longitudinal axis and second core leg having a second longitudinal axis; a first low voltage (LV) winding arranged around the first core leg, a first high voltage (HV) winding arranged around the first LV winding; a second low voltage (LV) winding arranged around the second core leg; and a second high voltage winding arranged around the second LV winding, wherein the first HV winding is provided with a first HV connector and a second HV connector each extending substantially perpendicular away from the first longitudinal axis, and wherein the second HV winding is provided with a third HV connector and a fourth HV connector each extending substantially perpendicular away from the second longitudinal axis.