Rotating Transformer Spring Retainer Assembly Without Adhesives
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Solution Overview
Problem
Existing rotating transformers in electric machines face challenges such as increased manufacturing complexity and cost due to the use of adhesives, limited temperature capabilities, and difficulty in recycling components, particularly those using rare-earth magnets.
Innovation Solution
A rotating transformer design that utilizes spring retainers to couple copper coil windings to a ferrite core, eliminating the need for adhesives by using compression and elongation of springs to secure the windings during assembly, allowing full temperature utilization and easier recycling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesives are used to bond the coil to the ferrite core, then the coil is securely fixed, but the manufacturing complexity and expenditure increase, and the temperature capabilities are limited
Solution Approach 1:
The patent removes the adhesive bonding process entirely from the manufacturing system. Instead of applying adhesive to bond the coil to the ferrite core, the invention uses a spring retainer mechanism that mechanically secures the coil through compression forces, completely extracting the problematic adhesive step from the manufacturing process.
Solution Approach 2:
The patent replaces the chemical bonding mechanism (adhesive) with a mechanical bonding mechanism (spring retainer). The spring retainer applies continuous mechanical compression force to hold the coil against the ferrite core, substituting the chemical adhesion process with a purely mechanical system that avoids the limitations of adhesive materials.
2Strength
If adhesives are used to bond the coil, then the coil is secured, but the ability to recycle components is reduced
Solution Approach 1:
The patent segments the bonding function from the coil and ferrite core components themselves. By introducing a separate spring retainer as the bonding mechanism, the coil and ferrite core remain as distinct, separable components that can be easily recycled. The bonding function is performed by the removable spring retainer rather than being integrated into the components through adhesive.
Solution Approach 2:
The spring retainer is designed to be easily removed and replaced, allowing the coil and ferrite core to be separated for recycling and recovery. The spring retainer itself can be recovered and reused, creating a circular economy approach where components are discarded and recovered without the permanent bonding constraints of adhesives.
3Strength
If adhesives are used, then the coil is fixed in position, but the maximum allowable temperature is limited to 252°C
Solution Approach 1:
The patent replaces the temperature-limited adhesive material with a temperature-resistant mechanical spring retainer system. The spring retainer, typically made of metal, can operate at temperatures far exceeding 252°C, removing the thermal constraint imposed by adhesive materials while maintaining the necessary bonding function through mechanical compression.
4Strength
If adhesives are used in the manufacturing process, then the coil is secured, but the manufacturing process requires wet manufacturing which increases complexity
Solution Approach 1:
The patent extracts the wet manufacturing process step entirely from the production line. By using a mechanical spring retainer system, the invention eliminates the need for adhesive application, curing, and associated wet processing steps, dramatically simplifying the manufacturing process and removing all associated complexity.
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 design enhances manufacturing efficiency, reduces costs, and improves sustainability by enabling higher temperature operation and easier recycling, while maintaining mechanical integrity and reducing electrical faults.
Implementation Method 1
the spring retainer may be configured to affix coil windings of the rotating transformer to a ferrite core... by compressing the spring, the radius of the spring may increase and the spring may be shifted over the foil winding... by elongating the spring, the radius of the spring will decrease
Data Source
AI summary
Systems and methods of manufacture for a rotating transformer are herein provided. In one example, a rotating transformer comprises a rotating part and a static part, wherein the rotating part comprises a rotor core coupled to a first winding via a first spring retainer and the static part comprises a stator core coupled to a second winding via a second spring retainer.