Modular Reconfigurable Polyphase Transformer Core
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Solution Overview
Problem
Existing AC transformers require complex and costly internal winding structures and large quantities of conductive wire for multiple phase conversions, necessitating multiple dedicated transformer units for different applications, including those powering variable frequency drives.
Innovation Solution
A modular, reconfigurable transformer core and winding structure with a cylindrical nested design that allows for single or polyphase inputs and outputs, reducing the need for multiple transformer units and simplifying winding processes by using pre-fabricated cores and a compact winding pattern that minimizes wire usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple dedicated transformer units are used for different phase conversion applications, then reliability and application-specific performance are improved, but device complexity and inventory requirements increase
Solution Approach 1:
The transformer core structure is designed with multiple ladder rungs that can be configured to support different phase conversion applications (single-phase to single-phase, single-phase to multi-phase, poly-phase to poly-phase) using the same physical hardware, eliminating the need for multiple dedicated transformer units
2Manufacturing precision
If ladder core structures are specifically configured for particular phase conversion applications, then manufacturing precision for dedicated applications is improved, but ease of manufacture across multiple applications deteriorates
Solution Approach 1:
The transformer core is divided into multiple modular ladder rungs that can be selectively activated or deactivated depending on the required phase conversion application, allowing a single manufactured core to serve multiple purposes without requiring precision configuration for each specific application
3Stability of the object's composition
If primary windings are wrapped around the ferromagnetic core before secondary windings, then winding structure integrity is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The primary windings are pre-installed on selected ladder rungs before the secondary windings are wrapped around the entire core assembly, allowing the primary winding configuration to be established once during manufacturing while maintaining the ability to configure different secondary winding arrangements for various applications
4Power
If complex internal winding structures are used in primary/secondary cores, then power conversion capability is improved, but ease of operation and installation footprint increase
Solution Approach 1:
The transformer windings are arranged in a nested configuration where secondary windings are wrapped around the primary windings that are already positioned on the ladder rungs, creating a compact integrated structure that maintains high power conversion capability while minimizing the overall installation footprint
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
The modular transformer design simplifies manufacturing, reduces wire consumption, and allows for versatile applications, replacing multiple dedicated transformers with a single unit while maintaining a compact footprint, thereby reducing inventory and installation complexity.
Implementation Method 1
A primary winding within the primary slots, coupled to a phase of electrical input power
Implementation Method 2
A secondary winding within the secondary slots, inductively coupled to the primary winding, for generating separate phases of electrical output power
Data Source
AI summary
An AC transformer having a cylindrical core configurable for single or polyphase power input and/or output transformer applications. The transformer core structure is capable of being configured to provide for single or polyphase inputs or outputs by varying the transformer primary and secondary winding configurations. A polyphase input configuration can be utilized in polyphase output transformers, such as for variable frequency drive (VFD) applications. Additional methods for winding transformer cores minimize the quantity of core winding wire necessary for transformer manufacture.