Modular Toroidal Transformer Core Segmentation
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Solution Overview
Problem
Existing 3-phase power transformers with ring-shaped cores require significant effort to replace winding segments as the entire core must be temporarily disassembled, making maintenance and replacement cumbersome.
Innovation Solution
A toroidal core with modular, interlocking sheet metal layers allows for the selective detachment and reassembly of core section modules, enabling easy replacement of winding modules without disturbing other segments, and includes electrical isolation and insulating materials to reduce mechanical stress and production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a ring-shaped core with multiple winding segments is used to achieve compact arrangement, then the transformer becomes more space-efficient, but replacement of winding segments requires temporary removal of other segments increasing maintenance complexity
Solution Approach 1:
The ring core is divided into multiple separable core section modules that can be detached from one another. Each core section module can be independently removed and reattached, allowing winding segments to be replaced without permanently disassembling the entire core structure. This segmentation enables selective access to individual winding segments while maintaining the compact ring configuration.
2Ease of repair
If a modular core structure with detachable sections is implemented to ease maintenance, then winding replacement becomes simpler, but the core structure becomes more complex
Solution Approach 1:
The core section modules are designed with interlocking features where smaller components are nested within or between larger structural elements. The sheet metal layers are arranged in nested configurations that allow easy attachment and detachment while maintaining structural integrity. This nesting approach enables modular functionality without proportionally increasing overall structural complexity.
3Ease of repair
If sheet metal layers are interlocked to provide detachable connection, then core module separation becomes possible, but magnetic flux guidance in transition regions may be compromised
Solution Approach 1:
Different regions of the core structure have different properties optimized for their specific functions. The sheet metal layers in transition regions are specifically configured with interlocking features that maintain magnetic flux continuity, while other regions prioritize ease of assembly and disassembly. This local differentiation ensures magnetic reliability at critical interfaces without compromising overall modular functionality.
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 modular design significantly reduces maintenance effort, allows for efficient replacement of defective winding modules, and maintains magnetic flux guidance, enhancing the operational efficiency and cost-effectiveness of power transformers.
Implementation Method 1
The connection of the core section modules is provided by means of interlocking of individual sheet metal layers or sheet metal layer areas
Implementation Method 2
Adequate guidance of a magnetic flux in the transition region of adjacent core sections is thus ensured
Data Source
Figure 1~2
Figure 3
AI summary
The invention relates to a ring-shaped core for a power transformer (18), wherein the ring-shaped core extends about an imaginary center axis (70) in the form of a closed toroidal structure and is constituted of a plurality of adjacent layers of sheet metal. The ring-shaped core, along the length of the toroidal structure, is constituted of at least three core section modules (11) that can be connected to and detached from each other, the core section modules being interconnected by an overlap of individual sheet layers and/or sheet layer sections. The invention also relates to the arrangement of ring-shaped cores having winding modules (100). The latter can be arranged in a common connecting structure and every ring core having winding modules (101-103, 111-113, 121 -123) arranged therein can be separately introduced into the connecting structure and removed therefrom in a non-destructive manner.