Modular Annular Transformer Structure for High-Current Loss Reduction
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Solution Overview
Problem
Conventional DC transformers face issues with high material loss and wear due to high current and low voltage requirements, leading to low efficiency, large volume, and energy wastage, along with noise and pollution from cooling methods.
Innovation Solution
A modularized transformer design featuring an annular iron core and multiple copper modules that overlap to form multiple layers, allowing for continuous amplification of voltage or current and regulation to meet industry requirements, while minimizing volume and maximizing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional DC transformer uses iron core and copper windings to meet high current and low voltage requirements, then the transformer can deliver the required power, but the material loss and wear increase significantly
Solution Approach 1:
The patent divides the transformer into modular units, each containing an annular iron core with copper modules wrapped around it. These modules can be stacked in series or parallel configurations to achieve the desired high current output while maintaining efficiency. The segmentation allows optimization of each module's material usage rather than requiring excessive material in a single large transformer.
Solution Approach 2:
The patent employs a nested structure where copper modules are wrapped around annular iron cores, and multiple such units are nested within each other. The copper modules encircle the iron cores, and multiple modules are arranged concentrically, creating a compact nested arrangement that maximizes magnetic coupling while minimizing material waste.
2Power
If conventional DC transformer uses iron core and copper windings, then the transformer can transform electrical energy, but the volume becomes large
Solution Approach 1:
The nested arrangement of copper modules around annular iron cores allows multiple transformer units to be compactly arranged within a small volume. The concentric nesting of modules maximizes the use of space, enabling high power output in a compact footprint.
Solution Approach 2:
The patent transitions from traditional linear winding arrangements to a three-dimensional nested modular structure. By stacking modules in multiple layers and arranging them concentrically around annular cores, the design utilizes vertical and radial dimensions to achieve high power density without increasing horizontal footprint.
3Power
If conventional DC transformer operates at high current and low voltage, then the power output is sufficient, but the working efficiency decreases
Solution Approach 1:
Dividing the transformer into multiple modular units allows each module to operate at optimized current densities, maintaining high efficiency even when the overall system delivers high current. The modular architecture enables better heat dissipation and reduced eddy current losses in each individual module.
Solution Approach 2:
The patent uses composite construction with annular iron cores and copper modules, optimizing the magnetic circuit and electrical conductors separately. This composite approach allows independent optimization of magnetic flux paths and current distribution, reducing losses and improving efficiency at high current operation.
4Temperature
If conventional DC transformer uses forced fan cooling, then the high temperature is managed, but noise is produced
Solution Approach 1:
The modular design with annular iron cores and wrapped copper modules provides inherent heat dissipation surfaces that allow passive cooling. The large surface area of the annular structure and exposed copper modules enables natural convection and radiation of heat without requiring active fan cooling, thus eliminating noise while managing temperature.
5Temperature
If conventional DC transformer uses oil or water cooling, then the high temperature is managed, but pollution is produced
Solution Approach 1:
The transformer's modular annular design provides large surface area for natural heat dissipation through convection and radiation, eliminating the need for polluting liquid cooling systems. The structure serves its own cooling needs through passive thermal management.
Solution Approach 2:
The patent replaces mechanical liquid cooling systems (pumps, pipes, fluids) with passive thermal radiation and convection surfaces. The annular modular structure's geometry is optimized for heat dissipation without requiring mechanical cooling infrastructure, thereby eliminating pollution from coolant leakage or disposal.
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 modularized transformer achieves high efficiency with a smaller volume, reduces material loss, and effectively regulates voltage or current, addressing the limitations of conventional DC transformers.
Implementation Method 1
a modularized transformer comprising an annular iron core, a first module encircling the annular iron core, a second module encircling the first module, a third module encircling the second module, a fourth module encircling the third module, and a primary-side power supply line mounted on the fourth module and encircling the annular iron core
Data Source
AI summary
A modularized transformer includes an annular iron core, a first module encircling the annular iron core, a second module encircling the first module, a third module encircling the second module, a fourth module encircling the third module, and a primary-side power supply line mounted on the fourth module and encircling the annular iron core. Thus, the modularized transformer has a modularized structure and includes multiple modules that are extended and increased to amplify the voltage or current continuously and to regulate the voltage or current.