Transformer Core Polygonal Adapter Plates Mechanical Stability
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Solution Overview
Problem
Transformer cores with a polygonal layout, especially those made from amorphous wound band-like material, suffer from reduced mechanical stability and fragility, limiting their rated power to 10MVA and requiring careful handling due to sensitivity to mechanical stress and temperature constraints.
Innovation Solution
Incorporating polygonal adapter plates with slanted edges in the upper and lower yoke areas, which apply pressure forces to increase mechanical stability, and using connected flat plates or bent plates to enhance stiffness and cooling, while potentially using elastic materials for vibration damping and improved thermal resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a transformer core is constructed with a polygonal layout using wound band-like amorphous material, then core losses are reduced and compactness is improved, but mechanical stability is significantly reduced and the structure becomes extremely fragile
Solution Approach 1:
The patent introduces adapter plates as intermediary elements between the core parts. These plates have a triangular configuration that matches the polygonal layout and provide a stable interface for connecting the fragile wound amorphous material core parts, thereby mediating between the compact polygonal structure and mechanical stability requirements
Solution Approach 2:
The patent combines different materials and structures: wound band-like amorphous material for the core parts (providing low core losses) combined with adapter plates (providing mechanical stability). This composite approach allows each component to fulfill its specific function while together they resolve the contradiction between energy efficiency and mechanical strength
2Loss of energy
If amorphous band-like material is used to reduce core losses, then energy efficiency is improved, but the material becomes extremely sensitive to mechanical stress and temperature constraints
Solution Approach 1:
The adapter plates are designed to apply pre-compression forces to the wound amorphous material core parts before the transformer enters service. This pre-compression cushions the fragile material against subsequent mechanical stresses during operation, transport, and assembly, preventing damage while maintaining the energy-efficient amorphous material structure
3Ease of manufacture
If the transformer core is designed with slanted areas for polygonal connection, then ease of manufacture is improved, but the connection between adjacent core parts becomes mechanically unstable
Solution Approach 1:
The adapter plates serve as mediators between the slanted areas of adjacent core parts. The plates have corresponding slanted surfaces that match the core parts, providing a large contact area for stable connection while distributing mechanical loads evenly across the joint, thereby maintaining both ease of assembly and connection strength
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 solution significantly enhances the mechanical stability and efficiency of the transformer core, allowing for higher rated power and improved handling and cooling, while maintaining reduced core losses and compactness.
Implementation Method 1
a plug is formed therewith within each yoke area, so that a pressure force is applicable on both yoke area. This pressure force additionally increases the mechanical stability of the transformer core
Implementation Method 2
the edges of the adapter plates comprise an elastic material such as a thermal suitable rubber material... any vibrations of the wound layers are damped therewith
Implementation Method 3
using connected flat plates or bent plates to enhance stiffness and cooling
Implementation Method 4
transformer cores made from an amorphous material provides reduced core-losses in comparison to a standard transformer core... the effect of reduced core losses is only gained in a temperature range of lower than 140°
Data Source
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AI summary
The invention is related to a transformer core (30, 50, 80, 100, 110), comprising at least three hollow-cylindrical rectangular shaped core-discs (10, 42, 44, 46, 52, 54, 56, 82, 84, 102, 104, 112) wound from a magnetic band-like material (12, 14, 16), wherein two opposed limb areas (20, 22) and an upper (24) and lower (26) yoke area are formed along a circumferential path (18a, 18b, 18c, 18d). The core-discs (10, 42, 44, 46, 52, 54, 56, 82, 84, 102, 104, 112) comprise one first (60, 64, 90, 94) and at least one second (58, 62, 86) slanted area parallel to the circumferential path (18a, 18b, 18c, 18d) in the belonging limb (20, 22) area. The at least three core-discs (10, 42, 44, 46, 52, 54, 56, 82, 84, 102, 104, 112) are connected according to a polygonal layout (48) at their belonging first slanted areas (60, 64, 90, 94), which are arranged adjacently face to face. Conical shaped polygonal adapter plates (118, 120) fitted to the polygonal layout (48) are foreseen within the upper (114) and lower (116) yoke areas, which are clamped together each to each other.