Welding Transformer Winding Cooling Channel Sealing Without Solder
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Solution Overview
Problem
Welding transformers face challenges in maintaining reliable cooling due to corrosion and leakage issues with existing sealing methods, particularly when using aggressive cooling media, which can damage the device and affect the quality of welded products.
Innovation Solution
A method for producing a winding with a solid-state welding joint using a plug made of the same material as the cooling channel, eliminating the need for soldered or glued connections, and utilizing ultrasonic, rotation friction, or friction welding to create a secure seal that withstands high pressures without additional materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soldering or brazing is used to seal cooling channel holes, then sealing is achieved, but the process is time-consuming and requires skilled personnel
Solution Approach 1:
The patent replaces thermal joining methods (soldering/brazing) with mechanical insertion of plugs into the cooling channel holes. This mechanical substitution eliminates the need for heat-based processes, skilled personnel, and extensive processing time while achieving reliable sealing through precise plug fit and positioning.
2Reliability
If soldering is used to seal cooling channel holes, then sealing is achieved, but corrosion occurs due to contact between cooling media and soldered connections
Solution Approach 1:
The patent extracts the problematic soldered/brazed connections from the cooling channel system and replaces them with plugs made of corrosion-resistant materials. This removal of harmful elements (solder, brazing material) that are susceptible to corrosion from cooling media eliminates the corrosion issue while maintaining sealing functionality.
Solution Approach 2:
The patent uses plugs made of the same material as the cooling channel (copper or copper alloy), creating homogeneous material composition throughout the cooling channel system. This homogeneity eliminates galvanic corrosion between dissimilar materials and ensures uniform corrosion resistance throughout the entire cooling channel structure.
3Temperature
If aggressive cooling media are used, then cooling efficiency is improved, but corrosion and leakage increase
Solution Approach 1:
The patent ensures all components in contact with the cooling media (cooling channel, plugs, sealing surfaces) are made of the same corrosion-resistant copper or copper alloy material. This homogeneous material selection allows the system to withstand aggressive cooling media without corrosion, enabling the use of such media for improved cooling efficiency.
4Reliability
If multiple materials (copper, brass, silver solder) are used in cooling channel connections, then sealing is achieved, but corrosion increases due to material incompatibility
Solution Approach 1:
The patent eliminates multi-material construction in the cooling channel system by using plugs and sealing components made of the same copper or copper alloy material as the cooling channel itself. This homogeneous material approach removes galvanic corrosion risks between dissimilar materials (copper, brass, silver solder) while maintaining effective sealing.
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 method ensures stable and reliable cooling of welding transformers, reducing maintenance costs and extending the lifespan of the device while preventing corrosion and leakage, even with aggressive cooling media, thus ensuring high-quality welding processes.
Implementation Method 1
sealing a plug into a first hole of a cooling channel, which first hole is open to the outside of one of the elements, by controlling a movement of the plug relative to the first hole so that a solid-state welding joint is produced by material of the plug and material of the winding module
Implementation Method 2
utilizing ultrasonic, rotation friction, or friction welding to create a secure seal
Implementation Method 3
utilizing ultrasonic, rotation friction, or friction welding to create a secure seal
Data Source
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AI summary
There is provided a method for producing a cooling channel in a winding (35) for a welding transformer (30) and a winding (35) for a welding transformer (30). In particular, the winding is (35) a secondary winding for the welding transformer (30). In the method, a holder (70) holds a winding module (35A; 35B) which comprises a first winding element (351), a second winding element (352) and a base element (353; 353B), wherein each one of the first and second winding elements (351; 352) protrudes from the base element (353; 353B) and wherein the first and second winding elements (351; 352) are positioned spaced to each other at the base element (353; 353B) so that the winding module (35A; 35B) has a t-cross-section, wherein the first winding element (351) comprises at least one window (3511; 3512) for accommodating a part of a core (37) of the welding transformer (30), wherein the second winding element (352) comprises at least one window (3521; 3522) for accommodating a part of a core (37) of the welding transformer (30), and wherein the base element (353; 353B) comprises grooves (3534, 3535) separating the base element (353; 353B) into sections (3531, 3532, 3533) such that at least one of the sections (3531, 3532, 3533) is connected to the first and second winding elements (351; 352) and such that at least one of the sections (3531, 3532, 3533) is connected to only one of the first and second winding elements (351; 352), and a plug (60; 60A, 60B, 60C) is sealed into a first hole (355) of a cooling channel (45), which first hole (355) is open to the outside of one of the elements (351, 352, 353), by controlling a movement of the plug (60; 60A, 60B, 60C) relative to the first hole (355) so that a solid-state welding joint (600; 601; 602) is produced by material of the plug (60; 60A, 60B, 60C) and material of the winding module (35A; 35B), in which the first hole (355) is positioned, wherein the holder (70) holds the winding module (35A; 35B) such that a movement between the winding module (35A; 35B) and the holder (70) is prevented while the step of sealing is performed.