Pulling Plate Structure for 3D Wound Transformer Core

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Solution Overview

Problem

Traditional transformer designs with three-dimensional wound cores face challenges in compression forces and insulation requirements, leading to increased size, manufacturing complexity, and costs due to the use of pulling screws and mixed structures.

Innovation Solution

A novel pulling plate structure for three-dimensional wound cores, comprising spliced rectangular frames with an upper and lower iron yoke, a pulling plate connected via a connecting shaft, and chamfered triangular frames, simplifies the design and manufacturing process while reducing the overall transformer size and cost.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Force

If a pulling screw or mixed structure is used in a three-dimensional wound core, then the compression force is relatively small, but the insulation requirements increase the size and manufacturing difficulty of the transformer oil tank

Engineering Contradiction:

Improvecompression forceVSAvoidinsulation requirements

Core Design Contradiction:

ForceVSDevice complexity

Solution Approach 1:

The patent removes the pulling screw component from the structure, replacing it with a simplified pulling plate that integrates directly into the core assembly. This extraction of the problematic pulling screw eliminates the insulation complexity while maintaining compression functionality through the pulling plate's direct connection to the core legs.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The pulling plate is merged with the core structure through direct connection to the core legs, creating an integrated assembly. This merging eliminates the need for separate insulation components between the pulling mechanism and windings, reducing overall complexity while providing sufficient compression force.

Inventive Principle:

Principle #5Merging (Combining)

2Force

If a pulling screw is used with insulation requirements, then compression force is achieved, but the manufacturing cost increases

Engineering Contradiction:

Improvecompression forceVSAvoidmanufacturing cost

Core Design Contradiction:

ForceVSEase of manufacture

Solution Approach 1:

The patent extracts the pulling screw and its associated insulation requirements from the design, replacing them with a pulling plate that requires no additional insulation. This reduces manufacturing steps and material costs while maintaining the necessary compression force on the windings.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The pulling plate is designed as a simple, inexpensive metal component that replaces the more complex and costly pulling screw assembly. The simplified structure requires fewer manufacturing steps and materials, directly reducing production costs while achieving the same functional outcome.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Reliability

If insulation between windings and leads is required, then electrical safety is maintained, but the overall size of the transformer increases

Engineering Contradiction:

Improveelectrical safetyVSAvoidoverall size

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The patent removes the insulation layer between the pulling mechanism and windings by eliminating the pulling screw and replacing it with a pulling plate that integrates directly into the core structure. This extraction reduces the overall transformer size while maintaining electrical safety through proper structural design and spacing.

Inventive Principle:

Principle #2Taking out (Extraction)

4Ease of operation

If a traditional pulling screw structure is used, then the transformer can be assembled, but the manufacturing process becomes more difficult

Engineering Contradiction:

Improveassembly capabilityVSAvoidmanufacturing process difficulty

Core Design Contradiction:

Ease of operationVSEase of manufacture

Solution Approach 1:

The patent extracts the complex pulling screw assembly and replaces it with a simple pulling plate that connects directly to the core legs. This simplification maintains assembly capability while dramatically reducing manufacturing process difficulty, as the pulling plate requires no threading, tapping, or complex fastening operations.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

Instead of using a pulling screw that threads into the core structure, the patent inverts the approach by using a pulling plate that is directly attached to the core legs. This inversion simplifies the manufacturing process by eliminating complex fastening operations while maintaining assembly capability.

Inventive Principle:

Principle #13The other way round (Inversion)

Data Source

PatentUS11295889B2Pulling plate structure for a three-dimensional wound core of transformer

Publication Date: 2022.04.05 HAIHONG ELECTRIC CO LTD

AI summary

A novel pulling plate structure for a three-dimensional wound core of a transformer, including a three-dimensional wound core spliced by three rectangular single frames, the three-dimensional wound core includes three core legs, an upper iron yoke and a lower iron yoke, an upper frame surrounding the upper iron yoke is installed in a top of the three-dimensional wound core, a lower frame surrounding the upper iron yoke is installed at a bottom of the three-dimensional wound core, the core leg has a longitudinal cross-section opposite and parallel to inside faces of the upper frame and the lower frame, a pulling plate is installed in a plane of the longitudinal cross-section, the pulling plate is connected with the upper frame and the lower frame.