Stereo Wound-Core Amorphous Alloy Transformer Noise Reduction
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Solution Overview
Problem
Conventional amorphous alloy dry-type transformers suffer from high noise levels and low short-circuit withstanding ability due to their sensitive mechanical stress and magnetostriction performance, as well as inefficient core structure.
Innovation Solution
A non-encapsulated-winding stereo wound-core dry-type amorphous alloy transformer design featuring a core with semi-circular cross-section single frames, tightly wound amorphous alloy sheets, and evenly distributed circumferential forces on circular-shaped windings, which reduces noise and enhances short-circuit resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional rectangular core structure is used, then manufacturing is simple, but noise level is high and short-circuit withstanding ability is low
Solution Approach 1:
The patent applies spheroidality by changing the core pillar cross-section from rectangular to circular shape. This curvature allows the amorphous alloy sheets to be wound in a stereo pattern around the circular core, creating tight winding with uniform distribution of circumferential forces during short-circuit conditions. The circular geometry eliminates the rectangular stress concentration points that cause noise and weak spots in conventional designs.
Solution Approach 2:
The patent uses stereo winding where multiple layers of amorphous alloy sheets are wound in a copying pattern around the circular core pillars. This creates a tightly bound structure where each layer supports the others, distributing mechanical stresses uniformly and eliminating the weak spots present in conventional single-layer rectangular wound cores.
2Object-affected harmful factors
If amorphous alloy sheets are tightly wound, then noise is reduced, but manufacturing complexity increases
Solution Approach 1:
The circular core pillar geometry simplifies the winding process by providing a constant radius surface, allowing amorphous alloy sheets to be wrapped uniformly around the core. This curvature-based approach is more suitable for stereo winding than rectangular geometries, as it naturally guides the sheets into tight, uniform layers without requiring complex positioning mechanisms.
3Ease of manufacture
If conventional rectangular core structure is used, then material usage is straightforward, but no-load loss and weight are higher
Solution Approach 1:
The circular core structure allows for more efficient packing of amorphous alloy sheets in a stereo winding pattern, reducing air gaps and improving magnetic path continuity. This reduces magnetic flux leakage and minimizes no-load losses compared to rectangular structures where sheets cannot be as tightly packed.
Solution Approach 2:
The patent combines multiple layers of amorphous alloy sheets in a stereo winding configuration around circular core pillars, creating a composite magnetic structure. This multi-layer composite approach improves magnetic path efficiency and reduces losses while maintaining mechanical integrity.
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 solution effectively reduces noise and improves the transformer's ability to withstand short circuits while conserving amorphous alloy materials, reducing weight and no-load losses.
Implementation Method 1
the magnetic conduction direction of the amorphous alloy is completely in line with the magnetic circuit direction of the core
Implementation Method 2
have vary sensitive magnetostriction performance
Data Source
AI summary
A non-encapsulated-winding stereo wound-core dry-type amorphous alloy transformer. The core of the transformer has a stereo structure. Three lower yokes are placed on a base of a lower clamp, and an upper clamp and the lower clamp are connected with each other by several press screws. Low-voltage windings include a foil-wound or wire-wound cylindrical structure, while its high-voltage windings are wound with oxygen-free copper wires wrapped in an insulate paper and processed through vacuum pressure impregnation. Upper and lower padding blocks support and compress the high-voltage and low-voltage windings, so that the product is formed in a rigid stereo frame structure.