Concentric Multi-Helical Transformer Windings for Cooling and Compactness
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Solution Overview
Problem
The configuration of windings in transformers can negatively impact dimensions and performance, including size, rated power, permissible current and voltage, and internal temperatures.
Innovation Solution
The use of helical windings configured concentrically around a transformer core, with at least one winding conductively connected in series to an adjacent winding and having a different inner radial distance, and groups of windings connected in parallel or series with axial and radial separations to optimize magnetic flux and cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If conventional winding configurations are used, then the transformer can maintain adequate cooling and structural stability, but the transformer size and mass increase
Solution Approach 1:
The winding is divided into multiple discrete helical windings arranged concentrically around the core, with each winding separated by insulating barriers. This segmentation allows for optimized current distribution and improved cooling pathways while reducing the overall winding volume and transformer mass.
Solution Approach 2:
The patent transitions from traditional planar or layered winding arrangements to a three-dimensional concentric helical configuration around the core. This dimensional change enables more efficient use of space, reduced mass, while maintaining effective cooling surfaces and thermal management.
2Power
If conventional winding configurations are used, then the transformer can maintain structural integrity, but the rated power and permissible current are limited
Solution Approach 1:
The winding system is segmented into multiple independent helical windings that can be connected in series or parallel configurations. This allows the rated power and current capacity to be scaled independently while each individual winding maintains adequate mechanical strength and structural integrity.
Solution Approach 2:
The patent employs composite construction with conductive winding materials combined with insulating barriers and structural support elements. This composite approach enables higher current carrying capacity and rated power while maintaining the necessary mechanical strength and structural integrity of the overall winding assembly.
3Temperature
If conventional winding configurations are used, then the transformer can achieve adequate cooling, but the internal temperatures rise due to heat accumulation
Solution Approach 1:
The concentric helical windings are separated by insulating barriers that create channels for coolant flow. This segmentation enables efficient heat removal from each winding individually, maintaining lower internal temperatures while reducing energy losses through improved thermal management and reduced thermal resistance.
Solution Approach 2:
The patent incorporates fluid cooling systems where coolant flows through channels created by the segmented concentric winding structure. This hydraulic cooling approach efficiently removes heat from the windings, maintaining lower operating temperatures and reducing energy losses associated with thermal effects.
4Productivity
If helical windings with different radial distances are used, then the magnetic flux is optimized and current circulation increases, but the device complexity increases
Solution Approach 1:
The winding system is segmented into multiple standardized helical windings with defined radial positions. While the configuration is more complex than traditional windings, the modular segmented structure allows for systematic design, manufacturing, and assembly, making the complexity manageable while achieving superior current circulation and magnetic flux optimization.
Solution Approach 2:
The patent optimizes performance by varying parameters such as the radial distance of each helical winding from the core, the number of windings, and their helical pitch. These controlled parameter changes enable optimized magnetic flux and current circulation while the systematic approach to parameter selection keeps the overall device complexity manageable.
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 configuration reduces the transformer's size and mass while maintaining core area and rated power, allows higher current circulation, reduces axial forces, and enhances cooling, leading to a more compact and efficient transformer design.
Implementation Method 1
A varying current through a primary one of the two windings induces magnetic flux in the core, which in turn, induces a varying electromotive force in the secondary winding
Data Source
AI summary
Multi-helical windings in a transformer are disclosed. A group of helical windings (100) that are connected in series (e.g., a single, continuous cable wound around a cylinder) may be concentrically arranged around a longitudinal axis to induce magnetic flux in the same direction along the longitudinal axis. A plurality of such groups (100) may be connected in series and arranged radially around the longitudinal axis. Additionally or alternatively, a pair of groups may be connected in parallel and arranged at the same radial distance around the longitudinal axis with an axial separation between the pair. In addition, spaces (DI) may be formed radially between the turns (112A-N) of the helical windings (110A-D) and axially on radial ends of the group for cooling. The disclosed configurations may be used as the LV or HV winding in any type of transformer, including single-phase and three-phase distribution, dry, and power transformers.