Transformer Division Windings for Voltage Adaptability
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Solution Overview
Problem
Transformer designs struggle to easily accommodate various input voltage specifications, requiring complex redesigns and increased production management due to changes in input current and heat generation, leading to inefficiencies and higher production costs.
Innovation Solution
A transformer design where the primary-side and secondary-side windings are divided into multiple division windings with extending members, allowing for series or parallel connections to be switched, enabling the number of turns to be adjusted without altering the core or winding configurations, thus accommodating different voltage specifications and improving productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the number of turns of the transformer is changed to cope with various input voltage specifications, then the transformer can adapt to different voltages, but it requires redesigning the number of layers, number of turns, line width, and connection points, increasing device complexity and manufacturing difficulty
Solution Approach 1:
The primary-side winding is divided into multiple layers, with each layer having independent connection points. This segmentation allows selective connection between layers to achieve different effective turn ratios without redesigning the entire winding structure. The extending members from each layer can be independently connected to create various winding configurations.
Solution Approach 2:
The transformer winding structure is designed to be dynamically reconfigurable through selective connection of extending members between layers. By changing which extending members are connected, the effective number of turns can be adjusted to match different input voltage specifications, making the transformer adaptable without physical redesign.
2Adaptability or versatility
If the transformer is redesigned for each input voltage specification, then it can operate efficiently at different voltages, but it complicates production management and inventory management
Solution Approach 1:
A single transformer design with multi-layer windings and selectable connecting points serves multiple input voltage specifications. The same physical transformer can be configured for different voltages by changing the connection pattern of extending members, eliminating the need to manufacture and manage multiple specialized transformer variants.
3Power
If thermal design is performed for increased input current, then the transformer can handle higher currents, but it requires additional redesign of winding parameters
Solution Approach 1:
Dividing the winding into multiple layers with independent connection points allows flexible configuration to handle different current levels. When higher input current is expected, the transformer can be configured with fewer effective turns, and the segmented structure allows this reconfiguration without compromising thermal performance through optimized current distribution.
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 allows for efficient handling of various input voltage specifications without the need for extensive redesign, simplifying production management and reducing costs by using common materials and configurations, while maintaining operational efficiency.
Implementation Method 1
a core portion for forming a magnetic circuit; and a primary-side winding and a secondary-side winding wound at the core portion
Data Source
AI summary
A transformer that can easily cope with various input voltage specifications and that, has improved productivity is obtained. A transformer includes: a core portion for forming a magnetic circuit; and a primary-side winding and a secondary-side winding wound at the core portion. One or both of the primary-side winding and the secondary-side winding are divided into a plurality of division windings, and each of the plurality of the division windings of the at least one divided winding has a wound part wound at the core portion, and two extending members extending from both ends of the wound part. The extending members of the plurality of the division windings of the at least one divided winding are mutually connected, and a number of turns in the transformer of the at least one divided winding is set.