Plug Lead-Through Winding Arrangement for High Voltage Transformers
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Solution Overview
Problem
Existing winding arrangements for transformers and chokes lack sufficient dielectric strength for operating voltages above 40 kV and have complex connection designs that complicate high-voltage connections.
Innovation Solution
A plug-in bushing is embedded in solid insulation, featuring a flange section connected to a receiving section on the outer surface, with recesses or grooves for enhanced surface area, allowing secure and standardized connections using commercially available cable connectors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a winding arrangement is provided for a motor vehicle seat adjustment device, then the electrical connections between control unit and actuator are established, but the assembly requires complex routing through the foam core with multiple channels and cavities
Solution Approach 1:
The foam core is divided into multiple channels and cavities that guide different conductors along predetermined paths. The winding arrangement is segmented into multiple sections (first, second, third sections) that can be independently routed through different foam channels, allowing complex electrical connections to be achieved through modular segmentation of the routing paths.
Solution Approach 2:
The conductor is routed through nested structures within the foam core, passing through channels that are themselves nested within the larger foam body. The winding arrangement nests conductors within foam channels, and the foam core nests within the outer shell, creating a hierarchical nested structure that organizes complex electrical connections.
2Ease of manufacture
If the foam core is divided into multiple channels for routing conductors, then conductor routing is organized and protected, but the manufacturing process becomes more complex
Solution Approach 1:
The foam core is pre-formed with integrated channels and cavities before the winding process. Conductors are pre-assembled into sections and pre-positioned within the foam channels. The outer shell is also pre-formed with recesses that accommodate the winding arrangement. These preliminary preparations simplify the final assembly process despite the complex foam structure.
Solution Approach 2:
The foam core acts as an intermediary structure that mediates between the conductors and the outer shell. It provides a structured pathway system that guides conductors from the control unit to the actuator while protecting them during the winding process. The foam channels serve as intermediate routing paths that simplify conductor management.
3Manufacturing precision
If conductors are routed through the foam core channels, then electrical connections are established, but the winding process requires precise positioning and increases processing time
Solution Approach 1:
Conductors are pre-assembled into sections and pre-positioned within the foam channels before the winding process begins. The foam core with integrated channels is prepared in advance, providing predetermined pathways that guide conductor placement. This preliminary preparation ensures precise positioning during winding while reducing actual processing time.
Solution Approach 2:
The routing problem is solved by adding the vertical dimension through the foam core's thickness. Instead of routing conductors only in the horizontal plane, the foam channels extend through the thickness of the foam, allowing conductors to be routed in three dimensions. This dimensional approach enables precise positioning while simplifying the winding process.
Data Source
Figure 1~2
Figure 3~4
AI summary
The invention relates to a winding arrangement (1) for a transformer or an inductor, comprising a winding formed by a winding conductor, a solid insulation surrounding the winding and a connecting unit embedded in the solid insulation. The aim of the invention is to obtain such a winding arrangement which provides the required dielectric strength even at higher operating voltages. In order to achieve said aim, it is proposed that the connecting unit is a plug lead-through (5) and is designed to allow the connection of a cable connector.