Transformer Core Frame Slot-and-Tab Interlocking Design

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Solution Overview

Problem

The production of conventional transformer core frames is costly and labor-intensive due to the need for bolting, welding, or dowel pinning for mechanical interlocking.

Innovation Solution

A slot-and-tab interlocking core frame design that replaces traditional assembly methods with a simpler mechanism using clamps and side supports, allowing for easier assembly and reduced production time, and incorporates locking plates, cams, and main plates for added strength in heavier transformers.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional bolting, welding, or dowel pinning methods are used for mechanical interlocking of core frame components, then the structural strength and reliability are improved, but the production cost and labor intensity increase significantly

Engineering Contradiction:

Improvestructural strengthVSAvoidproduction cost and labor intensity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The core frame is divided into modular components (side supports, clamps, plates) that can be independently manufactured and then quickly assembled together using the slot-and-tab interlocking mechanism, reducing manufacturing complexity and labor requirements while maintaining structural integrity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The slot and tab features are integrated directly into the core frame components during forming, combining the connection mechanism with the structural elements themselves, eliminating the need for separate fasteners, welds, or bolts, thereby reducing production cost and labor intensity

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If conventional bolting, welding, or dowel pinning methods are used for mechanical interlocking, then the structural strength is improved, but the assembly time and production efficiency decrease

Engineering Contradiction:

Improvestructural strengthVSAvoidassembly time and production efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The slot and tab features are pre-formed as integral parts of the core frame components during the manufacturing process, so that when assembly is required, the components can be quickly interconnected without requiring additional fastening operations, welding procedures, or dowel pinning steps, significantly reducing assembly time and improving production efficiency

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Instead of using separate fastening elements (bolts, welds, dowels) to connect components, the invention inverts the approach by making the components themselves interlock through integrated slot-and-tab features, reversing the traditional fastening paradigm and enabling rapid assembly while maintaining structural strength

Inventive Principle:

Principle #13The other way round (Inversion)

Data Source

PatentUS8970338B2Transformer having a core frame with interlocking members

Publication Date: 2015.03.03 HITACHI ENERGY LTD

AI summary

A distribution transformer having a slot-and-tab core frame assembly. The core frame (17) encloses a transformer core (11) having at least one phase and provides compression on the core yokes and end members of the transformer to bind the assembly together. First and second clamps (10, 24) of the core frame contain receiving slots (34) for the tabbed (18, 28), longitudinal side supports (20), creating an interlock when connected. For larger transformers, the tabbed side supports may be alternatively comprised of a subassembly of end plates, cams, and tabbed locking plates, encompassing a sturdy locking mechanism.