Transformer Core Guide Slot and Shape Retainer Assembly
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Solution Overview
Problem
Conventional transformer cores with drilled holes for stacking silicon steel sheets result in non-uniform magnetic flux distribution, reduced stacking factor, increased noise, and vibration due to burrs and gaps between sheets, which negatively impact electrical performance and efficiency.
Innovation Solution
The use of shape retainers attached to guide slots on the steel sheets, which are strategically placed to minimize magnetic flux density variations and facilitate easy assembly without holes, improving stacking factor and reducing noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If holes are drilled in silicon steel sheets for stacking, then the sheets can be easily positioned and assembled, but the magnetic flux distribution becomes non-uniform and electrical performance deteriorates
Solution Approach 1:
The invention removes the holes from the silicon steel sheets entirely, extracting the problematic feature that caused non-uniform magnetic flux distribution. Instead of having holes for positioning, the patent uses edge alignment and clamping mechanisms to achieve the same positioning function without compromising the magnetic flux path continuity.
Solution Approach 2:
The invention introduces clamping members and edge alignment features as intermediary elements that enable stacking and positioning without requiring holes in the steel sheets. These intermediaries provide the necessary positioning and securing functions while preserving the integrity of the magnetic flux path through the sheets.
2Ease of manufacture
If holes are drilled in silicon steel sheets, then stacking is facilitated, but burrs and gaps form between sheets causing increased noise and vibration
Solution Approach 1:
The invention extracts the holes that caused burr formation and subsequent noise/vibration problems. By eliminating the hole-drilling process entirely, the source of burrs is removed, and consequently the gaps between sheets that cause vibration and noise are prevented.
Solution Approach 2:
Instead of creating holes in the sheets to facilitate stacking, the invention inverts the approach by using the edges and surfaces of the sheets themselves for alignment and positioning, combined with external clamping members that apply pressure to eliminate gaps without requiring holes.
3Ease of operation
If holes are drilled in silicon steel sheets for positioning, then assembly is simplified, but the stacking factor of the core is reduced
Solution Approach 1:
The invention removes the holes from the steel sheets, thereby eliminating the material loss associated with hole creation. This increases the effective stacking area and improves the stacking factor, while assembly simplicity is maintained through alternative positioning mechanisms.
Solution Approach 2:
The invention shifts the positioning function from a two-dimensional hole-based system to a combination of edge alignment (one-dimensional) and external clamping (three-dimensional), achieving the same assembly simplicity while preserving more material.
4Productivity
If conventional hollow containers are used to cover core steel lamination, then stacking is quick and safe, but making the container shape is difficult and time-consuming
Solution Approach 1:
The invention divides the positioning and securing function into separate components: edge alignment features on the sheets themselves and removable clamping members. This segmentation eliminates the need for complex custom-shaped containers while maintaining quick and safe stacking capabilities.
Solution Approach 2:
The invention creates a universal clamping and positioning system that can accommodate different core configurations without requiring custom-shaped containers. The standardized clamping members and edge alignment features provide multi-functional capability for various stacking scenarios.
Data Source
AI summary
A transformer core includes: a plurality of core steel laminations; at least one guide slot on a surface of steel sheet forming each of the plurality of core steel laminations; and at least one shape retainer attached to the at least one guide slot joining a plurality of the steel sheets together.