Toroid-Shaped Shield High Voltage Transformer Design
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Solution Overview
Problem
High-frequency and high-voltage transformers for compact equipment are costly and prone to failures, with existing solutions facing challenges in reducing electromagnetic interference and parasitic currents, and sharp edges in shields leading to partial discharges and increased electric field intensity.
Innovation Solution
A transformer design featuring a core with central and outer arms, with primary and secondary windings shielded by toroid-shaped shields to minimize electromagnetic interference and parasitic currents, and a DC-to-AC converter connected to the primary winding with a bias power supply, along with an AC-to-DC converter connected to the secondary winding, where the secondary bias power supply receives power from the secondary winding shield to power sensors and control mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If shields are added to reduce electromagnetic interference and parasitic currents, then electromagnetic compatibility is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent employs toroid-shaped shields with curved surfaces instead of flat or angular shields. This curvature smooths the electric field distribution, eliminates sharp edges that cause partial discharges, and reduces electromagnetic interference while maintaining a relatively simple single-piece shield structure that can be manufactured as a complete toroidal component.
Solution Approach 2:
The patent converts the potentially harmful electric fields near sharp edges into beneficial effects by using curved toroid surfaces that naturally smooth field distribution. The curvature transforms what would be field-concentrating sharp edges into field-distributing smooth surfaces, eliminating partial discharges while the shields themselves provide the beneficial electromagnetic shielding effect.
2Power
If high voltage and high frequency operation is implemented, then power delivery capability is improved, but corona inception and partial discharges increase
Solution Approach 1:
The toroid-shaped shields with continuously curved surfaces eliminate sharp edges and corners that would concentrate electric fields. This curvature ensures uniform electric field distribution across the shield surfaces, preventing field intensification that leads to corona inception and partial discharges, thereby enabling safe high-voltage high-frequency operation.
Solution Approach 2:
The patent changes the geometric parameters of the shields from flat or angular configurations to toroidal shapes with specific curvature radii. This parameter change in the shield geometry fundamentally alters the electric field distribution, smoothing out field concentrations and preventing corona inception while maintaining the shields' electromagnetic shielding functionality.
3Volume of moving object
If compact transformer design is used, then equipment size is reduced, but manufacturing precision and reliability requirements increase
Solution Approach 1:
The patent segments the transformer into distinct functional modules: the core structure, the toroid shields, and the windings. Each component can be manufactured and assembled separately, with the toroid shields serving as structural elements that define spatial relationships. This segmentation allows for standardized manufacturing of each component while maintaining compact overall dimensions.
Solution Approach 2:
The toroid-shaped shields provide a geometrically stable and structurally robust framework that maintains precise spatial relationships between components. The curved toroidal geometry inherently provides mechanical stability and defines clear mounting positions for windings and other components, reducing alignment complexity despite the compact size.
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 reduces the likelihood of corona inception and parasitic currents, enhances safety, and provides a more efficient and cost-effective power delivery system by using toroid-shaped shields to smooth the electric field and power the control mechanisms from the shields, thereby improving the reliability and efficiency of high-frequency transformers.
Implementation Method 1
using toroid-shaped shields to smooth the electric field and power the control mechanisms from the shields
Implementation Method 2
An alternating current provided at the input (e.g., primary) windings causes a varying magnetic flux in the transformer core
Implementation Method 3
This flux leads to a time varying magnetic field that includes a voltage in the output (e.g., secondary) windings of the transformer
Data Source
AI summary
A transformer includes: a core having a central arm and first and second outer arms on opposite sides of the of the central arm; a primary winding surrounding the central arm; a secondary winding surrounding the central arm; a primary winding shield surrounding the primary winding including a center tap connection connected to an output power connection; and a secondary winding shield surrounding the secondary winding including a center tap connection connected to an output power connection is disclosed. The transformer also includes a DC-to-AC converter connected to the primary winding that includes a primary bias power supply, a primary conversion element and a primary controller, an AC-to-DC converter connected to the secondary winding, a sensor connected to an output of the AC-to-DC converter and a secondary bias power supply that receives power from the secondary winding shield.