Modular Breakaway Transformer Base for Variable Pole Bolt Circles

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Solution Overview

Problem

Existing breakaway transformer bases for lighting poles require multiple tooling sizes and a large inventory due to variations in anchor bolt and pole bolt circle diameters, and they often lack easy access to the interior for maintenance.

Innovation Solution

A modular transformer base design using identical corner members and interchangeable side sheets of varying sizes, made from lightweight sheet metal, which reduces tooling requirements and allows for easier assembly and access by the end user.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple sizes of transformer base are offered to cover dimensional variations in anchor bolt and pole bolt circle diameters, then adaptability to different installations is improved, but tooling requirements and inventory maintenance increase

Engineering Contradiction:

Improveadaptability to different anchor bolt and pole bolt circle diametersVSAvoidtooling requirements and inventory maintenance

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The transformer base is divided into multiple standardized pieces (first piece, second piece, third piece, fourth piece) that can be selectively assembled. Each piece has standardized bolt holes positioned at specific locations, allowing different combinations to accommodate various anchor bolt and pole bolt circle diameter requirements without needing completely different base designs.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The standardized pieces are designed to be universally applicable across different installation configurations. The same set of pieces can be assembled in different configurations to meet various dimensional requirements, making the system multi-functional and adaptable without requiring separate tooling for each application.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Strength

If traditional welded construction is used for transformer base, then structural strength is improved, but manufacturing complexity and field assembly difficulty increase

Engineering Contradiction:

Improvestructural strength of transformer baseVSAvoidmanufacturing complexity and field assembly difficulty

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The base is constructed from multiple separate pieces that are assembled together using bolts rather than welded. This segmentation allows each piece to be manufactured independently with standardized bolt holes, simplifying production and enabling easy field assembly by simply bolting the pieces together in the appropriate configuration.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Bolts serve as intermediary elements that connect the standardized pieces together to form the complete transformer base. This intermediary connection method replaces complex welding operations with simple mechanical fastening, reducing manufacturing complexity while maintaining structural integrity.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS7690613B2Transformer base for lighting poles

Publication Date: 2010.04.06 KEARNEY NAT INC

AI summary

A breakaway transformer base for a lighting pole includes four upstanding corner members (preferably formed of aluminum castings), and four side sheets. Each side sheet is attached to two of the corner members, e.g., by welds or fasteners, thereby interconnecting the corner members. Each corner member forms bolt holes for enabling the base to be bolted to a lighting standard and to an anchored foundation.