Single Piece Frame for Transformer Core Coil Assembly
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Solution Overview
Problem
Conventional core/coil assemblies for single-phase distribution transformers require multiple frame parts, bolts, and banding straps for mounting, increasing assembly time and cost, and posing safety risks due to structural integrity issues during lifting.
Innovation Solution
A single-piece metal frame with integral walls and notches is used to enclose the core/coil assembly, allowing for secure mounting without additional brackets or banding straps, facilitating quicker assembly and improved safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple frame parts, bolts, and banding straps are used for mounting the core/coil assembly, then the structural integrity is improved, but the assembly time and cost increase
Solution Approach 1:
The patent combines multiple separate frame parts (U-shaped channel, top frames, angular brackets) into a single integrated frame structure. This unified frame maintains the necessary structural integrity while eliminating the need for multiple bolts and separate mounting components, thereby reducing assembly time and complexity.
Solution Approach 2:
The single frame structure serves multiple functions simultaneously: it provides structural support, enables mounting to the tank, and secures the core/coil assembly. This multi-functional design replaces the conventional multi-component system that required separate elements for each function, reducing both assembly steps and cost.
2Stability of the object's composition
If multiple frame parts and bolted hardware are used for mounting, then the structural stability is improved, but the device complexity increases
Solution Approach 1:
The patent integrates multiple frame components into one continuous frame structure that surrounds the core/coil assembly. This single frame maintains structural stability through its integrated design while reducing the total number of parts from multiple separate components to just one piece, thereby simplifying the overall device complexity.
3Strength
If banding straps are used to secure the assembly, then the structural integrity is improved, but safety issues arise during lifting
Solution Approach 1:
The patent replaces the banding strap system with an integrated frame structure that is inherently part of the assembly. This unified frame provides consistent structural integrity and creates reliable lifting points, eliminating the safety concerns associated with banding straps that can slip or fail under load during lifting operations.
Data Source
AI summary
A one-piece frame is provided for a core/coil assembly of a transformer. The frame includes a first wall, a second wall integral with the first wall, a third wall integral with the second wall and in opposing relation to the first wall, and a fourth wall integral with the third wall and in opposing relation to the second wall. Mounting structure secures the fourth wall to the first wall. The walls define a generally rectangular enclosure having open sides communicating with an interior space. The interior space is constructed and arranged to house at least a portion of a core/coil assembly of a transformer.