Split-Core Transformer Cooling for Leakage Inductance Control
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Solution Overview
Problem
Transformers in existing electric power converting devices face issues such as core cracking due to temperature variations and difficulties in manufacturing transformers with desired leakage inductance due to manufacturing dispersion.
Innovation Solution
A transformer device is designed with a primary and secondary coil inserted into a first and second core, where the first core is divided into parts facing each other through a gap, and both cores are cooled by a cooling device, allowing for adjustment of leakage inductance and reducing stress from temperature variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the transformer uses a conventional solid core structure, then the manufacturing is simple, but core cracking occurs due to temperature variation
Solution Approach 1:
The first core is divided into a first core part and a second core part that are disposed to face each other through a gap. This segmentation allows the core to expand and contract independently during temperature variations, preventing the buildup of thermal stress that causes cracking in solid core structures, while still maintaining manufacturing simplicity through modular assembly.
2Reliability
If the first core is divided into parts with a gap, then core cracking is prevented, but the manufacturing precision becomes more difficult to control
Solution Approach 1:
The gap between the first core part and second core part serves as a controllable parameter to adjust leakage inductance. By precisely controlling the gap distance, the leakage inductance can be tuned to desired values. Additionally, the cooling device temperature control parameter is used to maintain consistent thermal conditions during manufacturing, reducing variability in core dimensions and improving overall manufacturing precision.
3Power
If the transformer operates at high power, then the energy conversion efficiency is high, but temperature variation causes core cracking
Solution Approach 1:
The segmented core structure with a gap between the first core part and second core part allows for thermal expansion and contraction during high-power operation, preventing the buildup of thermal stress that would cause cracking in solid core structures.
Solution Approach 2:
The cooling device acts as an intermediary between the transformer core and the thermal environment. It actively removes heat from the core during high-power operation, maintaining temperature within safe operating limits and preventing thermal stress-induced cracking while allowing the transformer to operate at high power levels.
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
The transformer device achieves a desired leakage inductance while preventing core cracking, enhancing reliability by managing temperature variations and manufacturing dispersion.
Implementation Method 1
a cooling device that cools the transformer
Implementation Method 2
cooling device that cools the transformer
Implementation Method 3
a primary coil, a secondary coil, and a first core and a second core, into which the primary and secondary coils are respectively inserted
Data Source
AI summary
A transformer device according to the disclosure includes a transformer and a cooling device that cools the transformer. The transformer includes a primary coil, a secondary coil, and a first core and a second core, into which the primary and secondary coils are respectively inserted. The first and second cores are disposed to face each other. The first core includes a first core part and a second core part, each of the first and second core parts formed by dividing the first core in a predetermined division plane. The first and second core parts of the first core are disposed to face each other through a gap, and in which the first core and the cooling device are disposed to face each other.