Split Core Transformer Winding Method
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Solution Overview
Problem
Conventional power distribution transformer manufacturing processes involve separate core and coil production, leading to suboptimal configurations and increased costs due to standardization, which hinders flexibility and competitiveness.
Innovation Solution
A method of forming a transformer core by cutting and bending laminations into C-shaped members, stacking them to create core portions with main and end legs, and arranging them in a back-to-back manner, allowing direct winding of primary and secondary windings around the core leg, enabling flexible core configurations similar to existing wound core technology.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate core and coil production with standardization is used, then manufacturing simplicity and tooling reduction are improved, but configuration flexibility and optimization capability deteriorate
Solution Approach 1:
The patent merges the core manufacturing process with the coil winding process by integrating the coil former directly onto the core structure. This allows the core and coils to be produced as a single integrated unit rather than separate components, enabling full configuration flexibility while maintaining manufacturing efficiency through a unified production line.
Solution Approach 2:
The invention introduces dynamic adaptability by allowing the core configuration to be adjusted and optimized for specific coil requirements during the same manufacturing process. The core structure can be dynamically modified to accommodate different winding patterns, turn ratios, and electrical specifications without requiring separate tooling sets.
2Adaptability or versatility
If separate core and coil production is used, then process standardization is improved, but full optimization of both core and coil configurations deteriorates
Solution Approach 1:
By combining core formation and coil winding into a single integrated process, the patent eliminates the need for separate production lines and assembly operations. This unified approach enables simultaneous optimization of both core geometry and coil configuration while actually reducing overall process complexity through process integration rather than multiplication.
3Ease of manufacture
If standardization of core and coil sizes is implemented, then manufacturing cost reduction is improved, but competitiveness and performance optimization deteriorate
Solution Approach 1:
The patent enables continuous parameter optimization by allowing core dimensions, laminations, and coil specifications to be adjusted within the same manufacturing process. This eliminates the need for standardized size constraints, permitting precise tailoring of transformer performance parameters such as impedance, voltage ratio, and loss characteristics while maintaining cost-effectiveness through efficient resource utilization.
Data Source
AI summary
A method provides a portion of a transformer by forming a core by providing transformer core material, cutting individual laminations and bending them into generally C-shaped members, stacking some members to define a first core portion having a main leg and two opposing end legs, stacking other members to define a second core portion having a main leg and two opposing end legs, arranging the main legs in a back-to-back manner to define the core having a core leg defined by the two main legs, and opposing core yokes, defined by the end legs. Conductive material is wound directly around the core leg to form a primary winding and secondary winding in any order of arrangement, thus providing a first transformer portion. The transformer portion may be part of a single transformer or, when second and third transformer portions are provided, as part of a three-phase transformer.