Segmented Amorphous Transformer Iron Cores
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Solution Overview
Problem
The existing power converter transformers face challenges in increasing capacity while restraining hysteresis loss due to the size limitations of iron cores made from amorphous materials, which are used as a magnetic path shared among multiple windings.
Innovation Solution
The transformer design incorporates a first and second iron core group with annular iron cores stacked alternately, allowing for the use of amorphous material with low hysteresis loss, and features winding portions wound across both groups to enhance capacity and minimize hysteresis loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If one iron core is used as a magnetic path shared among multiple windings to increase capacity, then the transformer capacity increases, but the iron core size increases leading to increased hysteresis loss
Solution Approach 1:
The patent divides the single iron core into multiple separate iron cores (first iron core and second iron core). Each winding is associated with specific iron core(s), eliminating the need for a large shared magnetic path. This segmentation allows the transformer to achieve high capacity through multiple smaller magnetic paths while restraining hysteresis loss in each individual iron core.
2Loss of energy
If amorphous material is used for the iron core to reduce hysteresis loss, then the hysteresis loss decreases, but the iron core size is limited by manufacturing constraints
Solution Approach 1:
The patent uses multiple smaller iron cores made from amorphous material instead of one large iron core. Each small iron core can be manufactured within the size limits of amorphous material production, while the collection of multiple iron cores provides sufficient total magnetic path area for high-capacity transformation.
Solution Approach 2:
The patent combines multiple small iron cores into a coordinated magnetic circuit system. The first and second iron cores work together with the windings to achieve the required transformation capacity, effectively merging the functionality of multiple small units to replace a single large unit.
3Loss of energy
If multiple iron core stacks are arranged adjacently in groups to use amorphous material, then hysteresis loss is restrained, but the structural complexity increases
Solution Approach 1:
The patent organizes iron cores into segmented groups (first iron core group and second iron core group) with defined spatial relationships. This structured segmentation provides clarity in the magnetic circuit paths and winding associations, making the complex arrangement more manageable and systematic rather than chaotic.
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 enables a higher capacity transformer with reduced hysteresis loss, utilizing amorphous material effectively within size constraints and improving reliability through insulation and cooling mechanisms.
Implementation Method 1
Each of the plurality of winding portions is wound across a corresponding one of the plurality of iron core stacks of the first iron core group and a corresponding one of the plurality of iron core stacks of the second iron core group
Implementation Method 2
As a loss in the iron core of a transformer, a hysteresis loss is known that is proportional to the frequency of an alternating-current (AC) voltage exciting the transformer. Also, an amorphous material is known as a material having a low hysteresis loss.
Data Source
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AI summary
A transformer (1) includes a first iron core group (20), a second iron core group (21), and winding portions (30). The first iron core group (20) includes iron core stacks (10) adjacent to each other. The second iron core group (21) is disposed to face the first iron core group (20) while being spaced from the first iron core group (20) and includes iron core stacks (11) each disposed to face a corresponding one of the iron core stacks (10) of the first iron core group (20). Each of the winding portions (30) is wound around its corresponding iron core stack (10) of the first iron core group (20) and its corresponding iron core stack (11) of the second iron core group (21), the corresponding one iron core stack (11) of the second iron core group (21) facing the corresponding one iron core stack (10) of the first iron core group (21). The iron core stacks (10) of the first iron core group (20) and the iron core stacks (11) of the second iron core group (21) each include annular iron cores (100) stacked alternately.