Transformer Iron Core Coupling Design for Vibration Reduction
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Solution Overview
Problem
The existing construction of transformer iron cores, where steel sheets are stacked with alternating ends overlapping, leads to protrusions and gaps that cause displacement due to magnetostriction, resulting in significant vibration and noise.
Innovation Solution
The iron core design includes overlapping yoke and leg steel sheets with angled coupling ends and open ends forming a space, which is filled with a coupling material to secure the sheets and prevent protrusions, thereby minimizing vibration and noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If steel sheets are stacked with alternating ends overlapping at yoke-leg coupling portions, then the structural assembly is achieved, but protrusions are formed causing displacement and vibration
Solution Approach 1:
The protruding portion of the steel sheet is removed through cutting or shearing, eliminating the source of displacement and vibration. This extraction of the harmful protrusion prevents magnetostriction-induced vibration while maintaining the structural assembly capability of the stacked steel sheets.
Solution Approach 2:
The steel sheet is designed with an asymmetric configuration where one end has a protruding portion that is subsequently removed, creating a non-uniform shape that optimizes the coupling between yoke and leg portions. This asymmetric design allows for better fit and reduced gaps at the joint interfaces.
2Ease of manufacture
If steel sheets are stacked with alternating ends overlapping, then the coupling structure is formed, but gaps are generated between protruding sheets
Solution Approach 1:
The protruding portions that cause gaps are removed through cutting, eliminating the source of misalignment. This extraction ensures that the steel sheets fit closely together without gaps, improving the alignment precision of the stacked structure.
Solution Approach 2:
Instead of trying to make the steel sheets fit together with protruding ends, the design inverts the approach by removing the protruding portions entirely. This inversion simplifies the coupling structure and eliminates gaps between adjacent sheets.
3Productivity
If protrusions are formed at yoke-leg coupling portions, then the steel sheets can be stacked, but magnetostriction displacement occurs
Solution Approach 1:
The protruding portions are removed through cutting or shearing, eliminating the source of magnetostriction displacement. This extraction maintains stacking efficiency while ensuring magnetic stability by preventing displacement at the coupling portions.
Solution Approach 2:
The protruding portions are removed in advance during the manufacturing process, before the iron core is assembled and subjected to magnetic fields. This preliminary action prevents magnetostriction displacement from occurring in the first place, ensuring reliable magnetic performance.
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
This design ensures secure coupling of steel sheets, reduces vibration and noise, and enhances the durability of the transformer iron core by eliminating protrusions and gaps.
Implementation Method 1
displacement due to a magnetostriction phenomenon occurs at the protrusion 40
Data Source
AI summary
The present invention relates to a transformer iron core. The present invention comprises: an upper yoke (50); a lower yoke (51) extending in parallel with the upper yoke (50); and an end leg (60) which is installed between the upper yoke (50) and the lower yoke (51), which extends perpendicularly to the longitudinal direction of the upper yoke (50) and the lower yoke (51), and which is coupled to the upper yoke (50) and to the lower yoke (51). The upper yoke (50) and the lower yoke (51) are made by laminating multiple yoke steel plates (50′). The end leg (60) is also made by laminating multiple leg steel plates (60′). The upper yoke (50) and the lower yoke (51) have leg coupling portions (52) on both ends thereof. The end leg (60) has yoke coupling portions (62) coupled to the leg coupling portions (52).