Low-Voltage High-Current Transformer Layout for Low Leakage Cooling
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Solution Overview
Problem
Existing low voltage high current high frequency transformers suffer from large leakage inductance, leading to increased heat dissipation, complex structure, heavy weight, and reduced efficiency, which complicates design, operation, and safety in robotic welding devices.
Innovation Solution
A transformer design with tightly wound primary and secondary coils filled with thermal conductive insulation paste, symmetrically arranged terminals, and a dual heat dissipation system with water-cooled panels, integrated with an inverter and rectifier assembly, reduces leakage inductance and enhances heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If water-cooled winding methods are used for medium frequency resistance welding transformers, then heat dissipation is improved, but leakage inductance increases
Solution Approach 1:
The patent introduces a water-cooled channel as an intermediary heat dissipation path that runs through the magnetic core, allowing heat to be removed efficiently without requiring loose winding structures. This mediator enables tight winding (low leakage inductance) while still achieving effective cooling through the dedicated water channel.
Solution Approach 2:
The patent merges the heat dissipation function directly into the magnetic core structure by integrating water-cooled channels within the core itself. This combination allows the magnetic core to serve dual purposes: magnetic flux conduction and active heat dissipation, eliminating the need for separate cooling mechanisms that would increase leakage inductance.
2Adaptability or versatility
If transformers are detachably connected with invertors, then installation flexibility is improved, but leakage inductance increases due to larger clearance
Solution Approach 1:
The patent introduces a clamping mechanism as an intermediary structure that maintains tight coupling between the transformer and inverter while allowing detachable connection. This clamping structure eliminates the large clearance problem by providing a mechanical interface that holds components in close proximity, thereby maintaining low leakage inductance while preserving installation flexibility.
3Loss of energy
If inverters are installed close to the transformer to reduce leakage inductance, then leakage inductance is reduced, but loading weight of the robot is increased
Solution Approach 1:
The patent segments the heavy transformer-inverter assembly into lighter modular components that can be distributed along the robotic arm. By dividing the system into separate but tightly-coupled modules connected through low-inductance interfaces, the overall weight is reduced while maintaining low leakage inductance through careful spatial arrangement and clamping connections.
4Ease of manufacture
If medium frequency resistance welding transformers are designed with traditional structures, then manufacturing is simplified, but volume and weight are increased
Solution Approach 1:
The patent nests the water-cooled channels within the magnetic core structure, and integrates the inverter and transformer components in a nested arrangement where the inverter is positioned within the transformer housing. This nesting approach achieves compact volume while maintaining manufacturing simplicity through standardized modular components that fit together efficiently.
Solution Approach 2:
The patent utilizes the vertical dimension by positioning the water-cooled channels vertically through the magnetic core and arranging components in stacked layers. This dimensional approach reduces the horizontal footprint and overall volume while maintaining ease of manufacture through straightforward vertical 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
The design achieves efficient high current output with reduced leakage inductance, smaller volume, and improved heat dissipation, allowing reliable operation at high frequencies with reduced switch stress and increased efficiency.
Implementation Method 1
a thermal conductive insulation paste is filled in between the primary coil and the at least one secondary coil
Implementation Method 2
a heat dissipation unit, comprises a first heat dissipation panel and a second heat dissipation panel... the inverter assembly is provided on the first heat dissipation panel... the rectifier assembly is provided symmetrically at both sides of the second heat dissipation panel
Implementation Method 3
when an AC current is energized in a primary coil, AC magnetic flux is generated in the iron core or the magnetic core, and voltage or current will be induced in a secondary coil
Data Source
AI summary
A low voltage high current power supply device includes at least one transformer body, a primary coil and at least one secondary coil. Central leading out terminals and secondary leading out terminals of strip shapes are provided at different positions of the at least one secondary coil, central leading out terminals and the secondary leading out terminals are provided symmetrically at both sides of the magnetic core. A heat dissipation unit includes a first heat dissipation panel and a second heat dissipation panel. The first heat dissipation panel is provided at a top portion of the at least one transformer body. The second heat dissipation panel is provided at a bottom portion of the at least one transformer body. The central leading out terminals and secondary leading out terminals are connected symmetrically at both sides of the first heat dissipation panel and the second heat dissipation panel.