Transformer With Distributed Air Gaps Reducing Eddy Current Losses
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Solution Overview
Problem
Transformers with traditional E-shaped magnetic cores suffer from low excitation inductance, leading to high excitation currents and additional eddy current losses in the secondary winding, which reduces transformer efficiency and cannot be improved by increasing copper foil thickness.
Innovation Solution
The transformer design incorporates an E-shaped magnetic core with two I-shaped magnetic cores and strategically placed air gaps, allowing for a distributed air gap configuration that reduces leakage magnetic flux and optimizes copper foil thickness based on excitation and load currents, thereby minimizing winding losses and enhancing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the air gap width is increased to adjust excitation inductance, then the excitation inductance increases, but the excitation current decreases and additional eddy current loss in the secondary winding increases
Solution Approach 1:
The patent divides the single air gap into multiple distributed air gaps across different magnetic core legs. This segmentation allows the excitation current to be distributed across multiple paths, reducing the peak current through any single winding while maintaining the required excitation inductance, thereby reducing eddy current losses in the secondary winding.
Solution Approach 2:
The patent applies different air gap configurations to different parts of the magnetic core structure. By strategically placing air gaps in specific locations (side legs, bottom legs, or middle legs), the magnetic flux distribution is optimized locally, reducing leakage flux and minimizing eddy current losses in the secondary winding while maintaining overall transformer performance.
2Reliability
If the transformer winding is wound on the middle leg with air gap, then the excitation inductance can be adjusted, but the excitation current generates magnetomotive force that induces additional eddy current loss in the secondary winding
Solution Approach 1:
The patent segments the air gap from the middle leg to multiple distributed locations across the magnetic core. This segmentation redistributes the magnetomotive force generation across multiple windings, preventing concentrated excitation current from inducing excessive eddy currents in the secondary winding while maintaining adjustable excitation inductance.
Solution Approach 2:
The patent introduces distributed air gaps as intermediary elements that mediate between the primary and secondary windings. These air gaps control the magnetic coupling and flux distribution, reducing the direct induction of eddy currents in the secondary winding while maintaining the necessary excitation inductance control.
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 reduces transformer winding losses and improves efficiency by minimizing eddy current losses and allowing for optimal copper foil thickness selection, resulting in a more efficient energy transfer.
Implementation Method 1
A transformer is means for changing an alternating voltage utilizing the principle of electromagnetic induction
Implementation Method 2
The middle leg 111 of the E shaped magnetic core is of an air gap. The size of the excitation inductance of the transformer can be adjusted by adjusting the width of the air gap
Implementation Method 3
The magnetomotive force generated by the excitation current spans the secondary winding, and induces to generate additional eddy current loss in the secondary winding
Data Source
AI summary
There is provided a transformer including an E shaped and two I shaped magnetic cores and a first, second and third windings, wherein: one I shaped magnetic core is located between one side and a middle legs of the E shaped magnetic core, another is located between another side and the middle legs; there is an air gap on each of the two I shaped magnetic cores or two side or bottom legs of the E shaped magnetic core, the first winding is wound on a part of the magnetic cores where the air gap exists; the second and third windings are wound on the middle leg; and the first winding is connected in parallel with the second winding to constitute a primary winding; the third winding is a secondary winding. With the transformer provided by the disclosure, transformer winding loss can be reduced, and transformer efficiency can be improved.