Transformer Core Oblique Lamination Self-Centering
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Solution Overview
Problem
Conventional transformer core manufacturing methods result in air gaps between U- and I-shaped plate parts, reducing the effective diameter for flux saturation and increasing manufacturing complexity and cost.
Innovation Solution
The transformer core is constructed using obliquely divided core laminations with contraform sub-parts that self-center and have oblique contact faces, allowing for a larger effective diameter and easier assembly, reducing air gaps and manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional stacking of U-shaped and I-shaped plate parts is used, then the transformer core can be manufactured, but air gaps arise between the parts reducing the effective diameter for flux saturation
Solution Approach 1:
The contact faces are oriented obliquely rather than perpendicularly to the centerline, creating an asymmetric configuration that enables self-centering during assembly. This oblique orientation (at angles between 30° and 60°) allows the core parts to automatically align, eliminating air gaps and maximizing the effective diameter for flux saturation.
2Ease of manufacture
If U-shaped and I-shaped plate parts are stacked alternately, then assembly is simplified, but the parts are never perfectly joined together creating air gaps
Solution Approach 1:
The oblique contact faces enable the core parts to self-center automatically during assembly without requiring external alignment tools or complex positioning mechanisms. The geometry of the contact faces itself provides the centering function, making the assembly process both simple and precise.
3Ease of manufacture
If conventional perpendicular division of core laminations is used, then manufacturing is straightforward, but only half the diameter is effectively available for flux conduction
Solution Approach 1:
By dividing the core laminations obliquely instead of perpendicularly, the effective diameter for flux conduction is increased by approximately a factor of √2. This asymmetric division angle optimizes the magnetic path while remaining compatible with standard manufacturing processes like stamping or laser cutting.
4Manufacturing precision
If core parts are joined with fastening means after grinding contact faces, then joining precision is improved, but manufacturing becomes more labor-intensive and expensive
Solution Approach 1:
The oblique contact faces inherently provide self-centering functionality during assembly, eliminating the need for separate grinding and fastening operations. The geometric design itself performs the alignment function that would otherwise require additional manufacturing steps and equipment.
Data Source
Figure 1a~3
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Figure 7a~8
AI summary
Transformer core comprising a stack of a plurality of planar core plates of a magnetically permeable material, which plates each consist of a first and a second sub-part that together enclose at least one opening. The sub-parts can be fitted together by means of contact faces that are located on either side of the opening and that extend obliquely with respect to the centerline of the core plate. The invention also relates to the use of the described transformer core in a Coriolis flowmeter with the Coriolis tube extending through the opening so as to induce a current in the tube.