Rotating Power Transformer Segmented Ferrite Core Design
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Solution Overview
Problem
Existing rotating power transformers for high-power applications, such as CT scanners, face challenges in simplifying mechanical design, increasing robustness, withstanding centrifugal forces, and reducing weight while maintaining reliability.
Innovation Solution
The design incorporates ring-shaped or disk-shaped transformer segments with standard ferrite or iron soft magnetic cores and windings, using wedge-shaped spacers for alignment and casting for enhanced stability and isolation, along with a termination module for secure electrical connections, allowing for dual or multiple power transmission channels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If heavy iron or ferrite cores are used for guiding magnetic fields, then magnetic field guidance is improved, but weight and mechanical support structure requirements increase
Solution Approach 1:
The rotating transformer is divided into multiple independent transformer segments, each with its own soft magnetic core. These segments are distributed around the circumference of the rotating part, allowing the magnetic field guidance function to be distributed rather than concentrated in a single massive core structure.
Solution Approach 2:
The patent changes the material parameter from heavy iron or ferrite to lightweight soft magnetic materials that still provide adequate magnetic permeability. This parameter change allows maintaining magnetic field guidance while reducing weight.
2Volume of moving object
If large inner diameter is provided for free bore, then CT scanner application requirements are met, but mechanical support structure size and weight increase
Solution Approach 1:
The transformer is segmented into multiple small units arranged around the free bore, allowing the large inner diameter requirement to be met without requiring a single large continuous support structure. Each segment provides localized magnetic field guidance.
3Ease of manufacture
If standard ferrite cores with rectangular cross-section are used, then manufacturing ease is improved, but assembly complexity increases
Solution Approach 1:
The transformer is divided into multiple identical segments, each containing a standard ferrite core. This segmentation allows using off-the-shelf standard cores while the modular segment design simplifies assembly by making all segments interchangeable and pre-assembled.
Solution Approach 2:
Each transformer segment is designed as a universal module that can be identically assembled around the rotating circumference, allowing the same standardized components to serve multiple positions and functions in the overall transformer assembly.
4Stability of the object's composition
If transformer segments are used with casting for stability, then mechanical stability is improved, but manufacturing complexity increases
Solution Approach 1:
The transformer segment merges multiple components (soft magnetic core, winding, housing, and casting material) into a single integrated modular unit. The casting process combines these elements into one stable assembly that maintains mechanical integrity while simplifying overall manufacturing through modularity.
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 simplifies assembly, enhances mechanical stability and electrical isolation, reduces weight, and improves reliability by providing a robust and efficient means for high-power transmission, effectively addressing the challenges of centrifugal forces and magnetic stray fields.
Implementation Method 1
rectangular cross sectioned soft magnetic cores (110) within the transformer segments
Implementation Method 2
at least one winding (141, 142, 143, 144) in the soft magnetic cores
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A rotating power transformer has a stationary and a rotating part. At least one of these parts comprises a plurality of transformer segments which are preferably of plastic material. Rectangular shaped soft magnetic cores are held with within the transformer segments together with at least one winding located in the soft magnetic cores. This allows for a simple and efficient assembly of the rotating power transformer.