Modular Support Structure for Amorphous Transformer Cores
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Amorphous transformer cores face manufacturing complexity and high scrap rates due to the sensitivity of thin band-like sheets and the need for stabilizing arrangements, which are not adequately supported, especially in the upper yoke section, leading to instability and increased weight-bearing issues.
Innovation Solution
A modular plate-like support structure with plug-in connections allows for step-wise assembly and stabilization of the transformer core, using barbed nozzles, milled holes, and U-shaped modules to provide stability and ease of assembly, while maintaining the ability to open the core for coil mounting and reducing material waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a stabilizing arrangement (E-plate) is mounted on the transformer core, then the mechanical stability is improved, but the manufacturing complexity and scrap rate increase
Solution Approach 1:
The support structure is divided into multiple modular segments (first support segment, second support segment, third support segment) that can be independently manufactured and then assembled together. Each segment corresponds to different parts of the transformer core (lower yoke, limb sections, upper yoke), allowing for simplified manufacturing of individual components while achieving overall structural stability when assembled.
Solution Approach 2:
The support segments are pre-assembled into a complete support structure before being mounted onto the transformer core. This preliminary assembly allows for quality control and adjustment to be performed on the support structure itself, separate from the core assembly process, thereby reducing overall manufacturing complexity and scrap rate.
2Strength
If a complete E-plate is used to stabilize the core, then the weight-bearing capacity is improved, but the material waste increases
Solution Approach 1:
Instead of using a single complete E-plate, the support structure is segmented into multiple smaller support segments that are distributed at specific locations on the core (lower yoke section, limb sections, upper yoke section). This segmentation reduces the total amount of material required while maintaining adequate weight-bearing capacity at critical locations.
Solution Approach 2:
Support segments are strategically placed at specific locations where mechanical support is most needed (lower yoke, limb sections, upper yoke) rather than providing uniform support across the entire core. This localized approach optimizes material usage by concentrating support where required while reducing material waste in areas where less support is needed.
3Stability of the object's composition
If the core is stabilized with a rigid support structure, then the mechanical stability is improved, but the ease of assembly for coil mounting deteriorates
Solution Approach 1:
The support structure is divided into separate modular segments that can be independently positioned and assembled. This modularity allows for flexible assembly sequences where coils can be mounted on limb sections while support segments are being installed, and the upper yoke support segment can be installed last after coil assembly, thus maintaining ease of assembly while achieving mechanical stability.
4Ease of manufacture
If the support structure is made as a single piece, then the manufacturing process is simplified, but the adaptability to different core configurations decreases
Solution Approach 1:
The support structure is segmented into multiple standardized modules that can be independently manufactured using simple processes and then assembled in different configurations. This segmentation maintains manufacturing simplicity for each individual component while providing adaptability through modular assembly to accommodate different transformer core sizes and configurations.
Solution Approach 2:
The support segments are designed with universal features (such as standardized mounting interfaces and dimensions) that allow the same basic module to be used across different transformer core configurations. This universality maintains ease of manufacture through standardized components while providing adaptability to various core sizes and designs.
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention is related to a wound transformer core (10, 66, 82) with at least one core loop (12, 14) made of magnetic material, comprising multiple thin amorphous band-like iron sheets (16) which are concentrically stacked around at least one center axis (18, 20). A lower yoke section (24), an upper yoke section (22) and at least two limb sections (26, 28, 30) are developed, comprising a modular plate-like support structure (40, 74, 76) which is glued upright to the center axis (18, 20) on both face sides (70, 72) of the lower yoke section (24) and on both face sides (70, 72) of each limb section (26, 28, 30) in that way, that neighboured iron sheets are glued together at their outer edge. The modular plate-like support structure (40, 74, 76) comprises for each face side (70, 72) of the belonging core sections (24, 26, 28, 30) at least two plate-like modules (42, 44, 46, 48, 50, 86, 88, 90), which are connected each to each other by a first (100) or second (110) plug-in connection..