Stereo Wound-Core Amorphous Alloy Transformer Design
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Solution Overview
Problem
Conventional oil immersed amorphous alloy transformers experience performance degradation due to external forces during production, leading to higher no-load losses and inefficient production processes.
Innovation Solution
An oil immersed stereo wound-core amorphous alloy transformer with a triangular prism iron core made of wound amorphous alloy strips, featuring semi-circular or semi-polygonal cross-sections, and a quasi-triangular tank design, which reduces processing steps and minimizes external disturbances, along with a clamp system and oil ducts for improved winding arrangement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional separate manufacturing and assembly of iron core and windings is used, then production flexibility is maintained, but external forces during assembly degrade iron core performance and increase no-load loss
Solution Approach 1:
The patent merges the iron core and windings into a single integrated unit by winding the amorphous alloy strip directly with the winding embedded within it, eliminating the need for separate assembly and avoiding external forces that would otherwise degrade the iron core performance
Solution Approach 2:
The winding is preliminarily embedded within the amorphous alloy strip during the winding process itself, before the iron core is fully assembled. This preliminary integration ensures the winding and iron core move together as one unit, preventing subsequent assembly forces from damaging the iron core
2Productivity
If conventional three-leg or four-frame five-leg structure with rectangular tank is used, then traditional manufacturing processes are maintained, but production efficiency is reduced and material usage is inefficient
Solution Approach 1:
The iron core is segmented into three identical single-phase units, each formed by winding amorphous alloy strips into rectangular frames. This segmentation allows for standardized, repeatable manufacturing of each phase while maintaining overall system performance
Solution Approach 2:
The patent transitions from conventional rectangular or five-leg structures to a three-frame stereo structure where each frame is a complete rectangular loop. This dimensional reconfiguration simplifies the manufacturing process while improving material efficiency and production speed
3Loss of substance
If conventional rectangular tank structure is used, then traditional design is maintained, but material usage is inefficient and cooling performance is suboptimal
Solution Approach 1:
The patent adopts an asymmetric triangular cross-section tank design that precisely accommodates the three rectangular frame iron core units. This asymmetric geometry optimizes space utilization, reduces material usage compared to conventional rectangular tanks, and creates optimal pathways for cooling oil circulation
Solution Approach 2:
The tank design incorporates oil ducts and channels that create a porous-like flow path for cooling oil, allowing efficient heat dissipation through multiple circulation routes while minimizing the tank volume and material required
Data Source
AI summary
An oil immersed stereo wound-core amorphous alloy transformer, comprising an iron core, a high-low voltage winding, leads and a tank. The core comprises three single frames made of amorphous alloy strips by winding and are identical in structure, and the single frames have a rectangular shape; the vertical sides of every two adjacent frames fit together fixedly to form a core pillar, and the horizontal sides of the single frame form iron yokes; the cross sections of the core pillars have an approximately circular or polygonal shape; the transformer further comprises a clamp, comprising a quasi-triangular upper and lower clamp, and posts, the lower clamp is provide with three food pads; the iron yokes in the lower portion of the iron core are located on the foot pads, and the high-low voltage winding is wound on the core pillars.