Transformer Eddy Losses Reducer for Axial Flux Management
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Solution Overview
Problem
Transformers in power systems experience issues with radial flux causing vibrations, noise, losses, and hotspots due to axial forces, which are not effectively addressed by existing technologies.
Innovation Solution
The integration of an eddy losses reducer at the axial ends of the winding, comprising a non-ferromagnetic main body surrounded by a ferromagnetic layer, reduces eddy losses and axial forces by collecting magnetic flux, thereby minimizing vibrations and hotspots.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If radial flux is allowed to flow freely at the axial end of the winding, then the magnetic circuit is simple, but eddy losses and axial forces increase causing vibrations and noise
Solution Approach 1:
A ferromagnetic layer is introduced as an intermediary component at the axial end of the winding. This layer serves as a mediator to redirect radial magnetic flux, collecting it and guiding it into the core, thereby reducing eddy losses in the winding conductors without fundamentally redesigning the entire magnetic circuit structure
Solution Approach 2:
The ferromagnetic layer is divided into multiple segments or zones along the axial direction. Each segment can be independently optimized for flux collection, and the segmented structure allows for flexible installation and adjustment while achieving effective flux redirection to reduce eddy losses
2Object-affected harmful factors
If radial flux flows freely at the axial end, then the winding structure is simple, but axial forces cause vibrations and noise
Solution Approach 1:
The ferromagnetic layer acts as a mediator between the winding and the core, intercepting radial magnetic flux before it can freely flow at the axial end. By collecting and redirecting this flux, the layer reduces the axial forces that cause vibrations and noise, while maintaining a relatively simple overall winding structure
Solution Approach 2:
The radial flux that previously caused harmful axial forces and vibrations is converted into a useful component by the ferromagnetic layer. The layer redirects this flux into the core, transforming what was a harmful effect into a contribution to the overall magnetic circuit, thereby reducing vibrations and noise
3Reliability
If radial flux is not restricted at the axial end, then the transformer structure is simple, but hotspots are generated reducing reliability
Solution Approach 1:
The ferromagnetic layer is positioned as an intermediary between the winding and the core at the axial end. It serves as a flux collection point that redirects radial magnetic flux into the core, preventing the formation of hotspots in the winding conductors and improving transformer reliability with minimal structural addition
Solution Approach 2:
The ferromagnetic layer is installed at the axial end before the transformer begins operation. This preliminary structure is designed to preemptively collect and redirect radial flux, preventing hotspot formation before it can occur, thereby ensuring reliable operation from the start
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 eddy losses reducer effectively reduces eddy losses and axial forces, improving transformer efficiency and reliability while reducing material requirements and noise emissions.
Implementation Method 1
the eddy losses reducer can an integral part of an equipotential ring which is arranged at the axial end of the winding... the ferromagnetic layer is provided which surrounds the non-ferromagnetic main body... the eddy losses reducer is arranged to reduce losses, hotspots and thus also forces. Due to the eddy losses reducer, the magnetic flux generated by the winding generates less eddy losses in conductors of the winding
Implementation Method 2
the eddy losses reducer is arranged to reduce losses, hotspots and thus also forces. Due to the eddy losses reducer, the magnetic flux generated by the winding generates less eddy losses in conductors of the winding
Data Source
Figure 1
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AI summary
A transformer comprises: - a core (101), - a winding (102, 103) wound around a winding axis (105) extending along the core (101), - an eddy losses reducer (200), the eddy losses reducer (100) being arranged at an axial end (106) of the winding (102, 103) and comprising a non-ferromagnetic main body (201) and a ferro-magnetic layer (202) surrounding the main body (201).