Transformer Winding Assembly With Gap-Bonded Radial Securing
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Solution Overview
Problem
Existing transformer clamping devices are bulky, consume excessive space, and require high-temperature resistant materials, making them expensive and labor-intensive to mount, while also needing additional adapters to conform to winding geometry, which exacerbates their drawbacks.
Innovation Solution
A winding assembly with a securing device that uses a material-bond between windings to secure them radially, occupying the gap between windings and providing a compact, sturdy connection that can replace or reduce the need for traditional clamping devices, utilizing adhesives or welding to create a monolithic construction that withstands forces and maintains insulation integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional clamping devices are used to secure windings, then the windings are restrained from movement during short circuits, but the devices consume excessive space and increase device complexity
Solution Approach 1:
The patent combines the securing function with the existing gap structure between windings. The securing device is integrated into the radial gap, merging the clamping function with the insulating gap structure, thereby eliminating the need for separate bulky clamping devices while maintaining winding stability during short circuits
Solution Approach 2:
The securing device is nested within the radial gap between adjacent windings. By placing the securing element inside the existing gap space, the patent utilizes otherwise wasted space for a dual-purpose function: maintaining electrical insulation and providing mechanical securing, thus reducing overall device volume
2Reliability
If traditional clamping devices are used to secure windings, then the windings are restrained from movement during short circuits, but the devices require high-temperature resistant materials making them expensive
Solution Approach 1:
The patent changes the material parameter requirements by using standard insulating materials with adequate temperature resistance rather than specialized high-temperature materials. The securing device operates at temperatures below the breakdown point of common insulating materials, allowing use of cost-effective materials while maintaining reliability
Solution Approach 2:
The securing device uses inexpensive insulating materials that provide sufficient service life for transformer operation. Rather than investing in expensive high-temperature resistant materials, the patent employs cost-effective insulating materials that meet the operational requirements, reducing manufacturing costs
3Reliability
If traditional clamping devices are used to secure windings, then the windings are restrained from movement, but mounting the devices is time-consuming and labor-intensive
Solution Approach 1:
The securing function is incorporated into the winding assembly structure itself, with securing devices already positioned in the radial gaps during winding fabrication. This preliminary integration eliminates the need for separate mounting operations, reducing assembly time and labor requirements while ensuring proper positioning
4Reliability
If traditional clamping devices are used to secure windings, then the windings are restrained from movement, but additional adapters are required to conform to winding geometry
Solution Approach 1:
The securing device designed according to this patent serves multiple functions simultaneously: it provides mechanical securing to prevent winding movement, maintains electrical insulation between adjacent windings, and adapts to the cylindrical geometry of the windings. This multi-functionality eliminates the need for separate adapters and reduces overall device complexity
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 reduces movement between windings, provides a compact design that minimizes space usage, and maintains insulation impregnation and dielectric properties, while withstanding forces such as those from short circuits, offering a cost-effective and efficient alternative to traditional clamping methods.
Implementation Method 1
The at least one securing device may be connected to the at least one first winding and the at least one second winding by a material-bond
Implementation Method 2
utilizing adhesives or welding to create a monolithic construction
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
The present disclosure relates to a winding assembly (110) for a transformer (10) including at least one first winding (112) configured to be wound about a core (14) of the transformer (10), at least one second winding (118) configured to be wound around the first winding (112), the first winding (112) and the second winding (118) being spaced apart from each other in a radial direction (R) by at least one gap (122), and at least one securing device (126) connected to the first winding (112) and the second winding (118) by a material-bond (128) to secure the first winding (112) to the second winding (118) to reduce movement of the first winding (112) and the second winding (118) relative to each other, the securing device (126) being arranged in the gap (122) to partially occupy the gap (122). The present disclosure also relates to a method for manufacturing a winding assembly (110).