Transformer Coil Coupling for Thermal Expansion and Vibration

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Solution Overview

Problem

Existing coil arrangements in electrical transformers face issues with mechanical stability, vibration resistance, and dimensional changes due to thermal expansion, leading to reduced lifetime and increased manufacturing costs.

Innovation Solution

A coil arrangement featuring a resin cast coil, a support base, a coil block, and a coupling device with a sliding member and elastic member that provides a form fit and absorbs energy from vibrations, compensating for thermal expansion and deformation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a rigid support structure is used to maintain mechanical stability, then the structural strength is improved, but the ability to absorb thermal expansion and vibration increases

Engineering Contradiction:

Improvemechanical stabilityVSAvoidresistance to thermal expansion and vibration

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The coupling device changes its physical state between rigid (when engaged) and flexible (when absorbing expansion), allowing it to provide mechanical stability while accommodating thermal expansion through state transformation

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The coupling device transitions from a static rigid connection to a dynamic system that can move and absorb vibrations, enabling the structure to adapt to changing conditions while maintaining overall stability

Inventive Principle:

Principle #15Dynamics

2Reliability

If multiple components are used to ensure mechanical stability and vibration resistance, then the reliability is improved, but the device complexity increases

Engineering Contradiction:

Improvemechanical stability and vibration resistanceVSAvoidnumber of components

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The coupling device merges multiple functions (mechanical connection, vibration absorption, thermal expansion compensation) into a single integrated component, reducing the total number of parts while maintaining reliability

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The coupling device is designed as a multi-functional element that simultaneously provides structural support, vibration damping, and thermal expansion accommodation, eliminating the need for separate components for each function

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Manufacturing precision

If a complex assembly process is used to achieve optimal stress distribution, then the manufacturing precision is improved, but the ease of manufacture decreases

Engineering Contradiction:

Improvestress distributionVSAvoidassembly process

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The coupling device is pre-configured with engagement features and geometric constraints that automatically ensure proper stress distribution during assembly, eliminating the need for complex alignment procedures or precision adjustments

Inventive Principle:

Principle #10Preliminary action

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

Enhances mechanical stability, reduces assembly complexity, and extends the lifetime of the coil arrangement while maintaining optimal stress distribution, particularly in high-vibration and high-heat environments.

Implementation Method 1

the coupling device comprises an elastic member providing a force along the sliding direction pushing the sliding member away from support base and/or towards the recess and/or towards the coil block

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

deformations may occur due to thermal expansion of the coil, wherein the expansion may be compensated by the coupling device without risking functionality of the arrangement

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Data Source

PatentEP4687162A1Coil arrangement and transformer

Publication Date: 2026.02.04 HITACHI ENERGY LTD

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Figure 3A~3B

AI summary

The invention relates to a coil arrangement (10) for an electrical transformer (1) and comprising a coil (20) made from cast resin, a support base (40) for supporting the coil (20), a coil block (30) arranged between the support base (40) and the coil (20), and a coupling device (50) configured for provision of a form fit between the support base (40) and the coil block (30) and extending into a recess (32) of the coil block (30), wherein the coupling device (50) comprises a sliding member (52) extending into the recess (32) and configured for sliding relative to the support base (40) along a sliding direction (54), and the coupling device (50) comprises an elastic member (56) providing a force along the sliding direction (54) and pushing the sliding member (52) away from support base (40) and/or towards the coil block (30).