Pre-wired AC Input Connector for Power Transformer Installation
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Solution Overview
Problem
Existing power conversion systems in power grids face inefficiencies and heat-related issues due to high-frequency operation, leading to power loss and increased costs, especially in distributed systems like remote lighting, data centers, and communication systems, where heat management becomes a significant challenge.
Innovation Solution
The introduction of a pre-wired connector for power transformers that allows for series or parallel input winding configurations, simplifying installation and reducing the need for manual wiring, coupled with a low-frequency transformer design that improves efficiency and reduces heat loss, thereby eliminating the need for additional cooling systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If high-frequency operation is used in power conversion systems, then space is conserved, but efficiency decreases and heat loss increases
Solution Approach 1:
The patent changes the operating frequency parameter from high-frequency to low-frequency operation. This parameter change resolves the contradiction by allowing the system to operate at lower frequencies where transformer efficiency is higher and heat loss is reduced, while still achieving compact design through proper magnetic core selection and winding configuration optimized for low-frequency operation
2Adaptability or versatility
If manual wiring of thick wires is performed during installation, then flexibility is achieved, but installation complexity increases
Solution Approach 1:
The patent applies preliminary action by pre-configuring the connector with internal jumpers and wiring arrangements before installation. The connector is manufactured with predetermined wiring patterns that correspond to different voltage configurations (120V, 240V, 208V, 480V). During installation, the installer simply selects and connects the appropriate connector type without needing to manually wire thick wires, thereby maintaining flexibility while dramatically simplifying installation
Solution Approach 2:
The patent introduces a pre-wired connector as an intermediary component between the power source and the transformer. This connector serves as a mediator that encapsulates the complex wiring logic internally, presenting a simple connection interface to the installer while handling the complexity of thick wire manipulation and configuration internally through its pre-established jumper arrangements
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 solution enhances the overall efficiency of power conversion to over 98%, reduces waste heat, and simplifies the installation process by minimizing the manipulation of thick wires, while also reducing the size and cost of the power conversion system.
Implementation Method 1
a transformer for providing isolation between the external power grid and a power distribution line
Implementation Method 2
a rectifier coupled to the transformer output port
Data Source
AI summary
Systems and methods for an alternating current (AC) input selection for a power transformer are disclosed. In particular, a connector is provided that is pre-wired to utilize internal wiring in the power transformer to provide a desired connection. A first option allows two transformers' input winding to be in series while a second option allows the two transformers' input winding to be in parallel. By moving the wiring into the connector, installation is simplified as the wiring has already been done. The installer need only attach the correct plug based on the desired voltage and couple the plug to the transformer. Further, the manipulation of thick wires is also avoided by the installer, further simplifying the installation process.