Three-Phase Toroidal Transformer Layout for Lower Size and Weight
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Solution Overview
Problem
Existing voltage transformers, such as those using distributed gap cores, mitered cores, or stamped lamination cores, are often large and heavy, posing challenges in terms of size and weight.
Innovation Solution
A three-phase transformer design utilizing three toroidal transformers stacked vertically, each transforming one phase of a three-phase voltage, reducing overall size and weight while meeting Department of Energy and UL requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If traditional core constructions (distributed gap cores, mitered cores, stamped lamination cores) are used, then voltage transformation function is achieved, but the transformer becomes large and heavy
Solution Approach 1:
The three-phase transformer is divided into three separate single-phase toroidal transformers, each handling one phase. This segmentation allows each unit to be optimized independently using toroidal core geometry, achieving compact size and reduced weight while maintaining reliable voltage transformation for each phase
Solution Approach 2:
The patent employs toroidal (doughnut-shaped) core construction for each single-phase transformer. The curved toroidal geometry provides continuous magnetic flux paths with no air gaps, significantly improving magnetic efficiency and reducing the size and weight compared to traditional linear core constructions while maintaining transformation reliability
2Volume of moving object
If traditional core constructions are used, then voltage transformation is achieved, but the transformer size increases
Solution Approach 1:
By separating the three-phase transformation into three independent single-phase toroidal units, each transformer can be miniimized in volume while maintaining adequate cooling and magnetic flux paths. The segmented design allows optimized winding arrangements and core dimensions for each phase, reducing overall volume compared to a monolithic three-phase core
Solution Approach 2:
The toroidal core shape provides the most efficient magnetic flux path geometry, minimizing the magnetic path length and required core cross-sectional area for a given power rating. This curved geometry eliminates air gaps and provides uniform flux distribution, achieving compact volume while ensuring reliable transformation performance
3Weight of moving object
If traditional core constructions are used, then voltage transformation is achieved, but the transformer becomes heavy
Solution Approach 1:
The three-phase system is implemented as three separate single-phase toroidal transformers rather than one integrated three-phase unit. This segmentation simplifies the construction of each individual transformer, allowing standard single-phase winding techniques and core assembly procedures to be applied repeatedly, reducing overall manufacturing complexity despite having multiple units
Solution Approach 2:
The toroidal core construction uses standardized curved laminations that can be stacked and assembled using conventional techniques. The continuous curved geometry simplifies the magnetic circuit design compared to angular or linear core joints, reducing the need for complex gap management and alignment procedures, thereby simplifying construction while achieving weight reduction
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 design achieves a compact and lightweight transformer that meets regulatory standards, enabling wall or floor mounting and efficient voltage transformation.
Implementation Method 1
The first toroidal transformer is configured to transform a first phase of the three-phase voltage. The second toroidal transformer is electrically connected to the first toroidal transformer. The second toroidal transformer is configured to transform a second phase of the three-phase voltage.
Data Source
AI summary
A three-phase transformer configured to transform a three-phase voltage. The transformer includes first, second, and third toroidal transformers. The first toroidal transformer is configured to transform a first phase of the three-phase voltage. The second toroidal transformer is electrically connected to the first toroidal transformer. The second toroidal transformer is configured to transform a second phase of the three-phase voltage. The third toroidal transformer is electrically connected to the first toroidal transformer and the second toroidal transformer. The third toroidal transformer is configured to transform a third phase of the three-phase voltage.