Multi-phase Transformer Winding Topology for Shipboard Voltage Step-up
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Solution Overview
Problem
In shipboard and aircraft applications, increasing the voltage output of motor controllers without adding weight or encountering issues like corona, high voltage spikes, and component breakdown is challenging, as existing methods either require higher input AC voltage or additional heavy magnetic components.
Innovation Solution
A multi-phase transformer design with specific winding configurations, including primary, secondary, and third windings, that receive and magnetically couple multi-phase input voltage to achieve higher output voltage efficiently, avoiding the need for additional heavy components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a step-up autotransformer is added before or after the motor controller to increase voltage output, then the rectified output DC voltage increases, but the weight of the electrical subsystem increases significantly
Solution Approach 1:
The patent combines the autotransformer and rectifier unit into a single integrated device, eliminating the need for separate heavy magnetic components. The transformer windings are directly coupled to the rectifier circuitry, merging two previously separate components into one unified structure that reduces overall weight while maintaining voltage transformation capability.
Solution Approach 2:
The integrated autotransformer rectifier unit performs multiple functions simultaneously: it transforms voltage levels through the autotransformer windings while also performing rectification of AC to DC conversion in the same device. This multi-functionality eliminates the need for additional separate components, reducing the weight of the electrical subsystem.
2Power
If the input AC voltage is increased to increase the output voltage of motor controllers, then the rectified DC voltage increases, but the insulation level requirements and risk of electrical breakdown increase
Solution Approach 1:
The patent changes the voltage transformation approach by using an autotransformer configuration that provides voltage step-up while maintaining better insulation characteristics. The specific winding arrangement and tap points are designed to achieve the required voltage output without subjecting the system to excessively high input voltage stress, thereby reducing the risk of corona discharge and component breakdown.
3Power
If additional heavy magnetic components are added to the power generation system to increase voltage, then the output voltage increases, but the overall system weight increases
Solution Approach 1:
The patent merges the transformer and rectifier into a single integrated unit, eliminating the need for additional separate heavy magnetic components. The autotransformer windings are directly coupled to the rectifier circuitry, creating a compact design that reduces overall system weight while achieving the required voltage transformation.
Solution Approach 2:
The integrated design nests the rectifier circuitry within the transformer structure, with the rectifier components positioned within or adjacent to the transformer core and windings. This nesting approach minimizes the overall volume and weight of the power generation system by eliminating air gaps and structural requirements for separate components.
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 multi-phase transformer design effectively increases the output voltage while minimizing weight and reducing the risk of electrical issues, providing a more efficient and lightweight solution for power generation in these applications.
Implementation Method 1
Each secondary winding is magnetically coupled to a primary winding. Each third winding is magnetically coupled to a primary winding
Data Source
AI summary
Various embodiments of multi-phase transformers are disclosed. Exemplary transformer includes primary windings, secondary windings and third windings. Primary windings, secondary windings and third windings may include sub windings coupled to form functions. Primary windings are coupled at ends to form a delta configurations. Secondary windings are coupled to primary windings. Third windings are coupled to primary windings and secondary windings. Secondary windings and the third windings are magnetically coupled to primary windings. The outputs at second ends of third windings are greater than the outputs at the second ends of secondary windings. In some embodiments, the outputs at adjacent second ends of the third windings are substantially equal. In some embodiments, the phase angle difference of outputs at adjacent second ends of third windings are substantially equal. In some embodiments, the phase angle difference of outputs at adjacent second ends of secondary windings are substantial equal.