Transformer Housing Mounting Interface for PCB Integration
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Solution Overview
Problem
Large transformers used in electrical systems, such as programmable logic controllers and variable frequency drives, cannot be directly mounted on printed circuit boards due to size constraints, necessitating a method to connect them effectively while maintaining compactness and assembly efficiency.
Innovation Solution
A transformer design featuring a magnetic core with primary and secondary windings electromagnetically coupled through a housing part, where a printed circuit board is mounted to the housing part, allowing for the use of compatible components and efficient assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If large transformers are used in electrical systems, then the transformer can handle higher power requirements, but the transformer cannot be directly mounted on printed circuit boards due to size constraints
Solution Approach 1:
The transformer assembly is segmented into distinct functional components: the electromagnetic core with windings, a separate housing structure, and a printed circuit board mounting interface. This segmentation allows the transformer to be adapted for PCB mounting by providing a standardized interface without changing the core power handling components.
Solution Approach 2:
A housing structure serves as an intermediary element between the large transformer and the printed circuit board. The housing provides a mounting interface that adapts the transformer's physical dimensions to compatible PCB footprints, enabling connection without direct mounting of the transformer itself.
2Reliability
If traditional mounting methods are used for large transformers, then the transformer can be securely mounted, but assembly labor increases and compactness is reduced
Solution Approach 1:
The mounting structure is merged with the housing of the transformer, combining the protective enclosure and mounting functions into a single integrated component. This eliminates separate mounting brackets or fastening mechanisms, reducing assembly steps and labor while maintaining secure mounting through the housing's integrated design.
3Ease of operation
If direct mounting of transformers on circuit boards is attempted, then connection is achieved, but electrical clearances cannot be properly maintained
Solution Approach 1:
The housing structure acts as an intermediary that maintains proper electrical clearances between the transformer windings and the printed circuit board. By providing a physical barrier and standardized mounting interface, the housing ensures that minimum clearance requirements are met without requiring precision adjustments during assembly.
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
Enables the use of printed circuit board-compatible components, reduces assembly time, and ensures minimal electrical clearances by leveraging the dimensional accuracy of printed circuit board assemblies, facilitating the integration of large transformers into electrical systems.
Implementation Method 1
a primary winding with a plurality of primary winding taps, a secondary winding with a plurality of secondary winding taps, and a magnetic core on which the primary winding and the secondary winding are mounted. The primary winding and the secondary winding are electromagnetically coupled through the core.
Data Source
AI summary
An electromagnetic assembly which has a base, at least one winding, and a magnetic core connected to the base, where at least one winding is mounted on the magnetic core. A housing part encloses at least part of at least one winding, and a printed circuit board is mounted to the housing part. The electromagnetic assembly can be a transformer or inductor, for example.