Transformer Iron Core Gaps Reduce Fringing Flux
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Solution Overview
Problem
Transformers face inefficiencies and losses due to fringing flux effects and errors in iron core gaps, which are not effectively addressed by existing technologies.
Innovation Solution
A transformer design featuring stacked iron cores with fixed iron core gaps and a winding structure around them, where the positions of the gaps correspond to and are staggered from the coils, reducing fringing flux losses and copper losses by precise positioning of the gaps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If iron cores are stacked closely together, then the transformer structure is compact, but fringing flux losses increase
Solution Approach 1:
The patent introduces iron core gaps that segment the continuous iron core structure into discrete sections. These gaps are strategically positioned to interrupt fringing flux paths while maintaining compact overall dimensions. The segmentation allows the transformer to achieve both compactness and reduced fringing flux losses by breaking up the magnetic flux distribution pattern.
2Ease of manufacture
If iron core gaps are not precisely positioned, then manufacturing is simpler, but error between actual and theoretical gaps increases
Solution Approach 1:
The patent incorporates positioning structures that are pre-formed during the manufacturing process, such as positioning protrusions on iron cores that fit into corresponding positioning grooves in the winding frame. This preliminary positioning action ensures that iron core gaps are accurately positioned relative to coils before final assembly, reducing manufacturing errors while maintaining ease of assembly.
3Ease of operation
If iron core gaps are not aligned with coils, then assembly is easier, but copper losses increase
Solution Approach 1:
The patent implements localized alignment features at specific positions where iron core gaps intersect with coil windings. The positioning structures create localized geometric constraints that ensure precise alignment between gaps and coils at critical locations, while allowing flexibility in other areas. This local quality approach reduces copper losses at key interfaces without complicating overall assembly procedures.
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 effectively reduces losses caused by fringing flux and improves transformer performance by fixing the relative positions of the iron core gaps, aligning them with the coils, and using a winding frame to maintain precise gap heights, thereby minimizing errors and enhancing efficiency.
Implementation Method 1
losses caused by fringing flux effects
Implementation Method 2
a plurality of coils, a position of at least one of the iron core gaps corresponds to a position of at least one of the coils
Data Source
AI summary
A transformer includes iron cores and a winding structure. The iron cores are stacked on each other at intervals, and iron core gaps are formed between the iron cores, wherein relative positions between the iron core gaps are fixed. The winding structure is disposed around the iron cores and includes a plurality of coils. A position of at least one of the iron core gaps corresponds to a position of at least one of coils.