Transformer Winding Layout With Embedded Magnetic Path for Leakage Impedance
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Solution Overview
Problem
Commercial transformers exhibit significant variability in leakage impedance due to differences in winding structure, requiring additional components to adjust, which complicates manufacturing and increases bulkiness.
Innovation Solution
A winding configuration with multiple layers and a second magnetic circuit embedded between layers to control and increase leakage impedance, reducing variations and allowing for precise setting of total leakage impedance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If additional discrete inductive or capacitive components are added to adjust leakage impedance, then the leakage impedance can be increased or adjusted, but the device becomes bulky and manufacturing complexity increases
Solution Approach 1:
The patent merges the leakage impedance adjustment function directly into the transformer winding structure by introducing a second magnetic circuit that couples with the primary and secondary windings. This integration eliminates the need for separate discrete inductive or capacitive components, thereby reducing device complexity while maintaining precise leakage impedance control.
Solution Approach 2:
The second magnetic circuit acts as an intermediary element that mediates between the primary and secondary windings to control the leakage impedance. By introducing this intermediate magnetic path with adjustable turns ratio, the patent achieves precise impedance control without requiring additional discrete components outside the transformer structure.
2Manufacturing precision
If additional discrete inductive or capacitive components are added to adjust leakage impedance, then the leakage impedance can be increased or otherwise adjusted, but the circuit becomes bulky
Solution Approach 1:
The patent combines the leakage impedance adjustment functionality within the existing transformer volume by introducing a second magnetic circuit that shares the same core structure. This integration allows precise impedance setting without adding external bulky components, thereby maintaining a compact transformer design.
Solution Approach 2:
The second magnetic circuit is nested within the existing transformer structure, utilizing the same core and winding space. This nested configuration allows the leakage impedance control mechanism to be embedded within the transformer itself, avoiding additional external components and maintaining a compact overall size.
3Loss of energy
If conventional winding configuration is used with loss reduction constraints, then efficiency is improved, but leakage impedance may not be sufficient
Solution Approach 1:
The patent introduces a dynamically adjustable second magnetic circuit with variable turns ratio that can independently control the leakage impedance without affecting the efficient winding configuration. This dynamic adjustment capability allows the system to maintain low power loss from optimized winding placement while simultaneously achieving the required leakage impedance values through magnetic circuit adjustment.
Solution Approach 2:
The patent changes the magnetic circuit parameters by introducing a second magnetic circuit with adjustable turns ratio, which independently controls the leakage impedance. This parameter change allows the system to maintain the efficient winding configuration for low loss while achieving sufficient leakage impedance through magnetic circuit parameter adjustment rather than compromising the winding structure.
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 results in a compact transformer with controlled leakage impedance, reducing manufacturing complexity and bulkiness, while achieving high efficiency and low impedance tolerance.
Implementation Method 1
When an electric potential V1 is applied between the terminals of the primary winding 12 of the ideal transformer 11, the electric potential generated between the terminals of the secondary winding 14 is given by: (n2/n1)×V1
Implementation Method 2
The losses resistance RS represents the power lost in the form of heat, by Joule effect, in the conductors
Data Source
AI summary
An electric transformer comprising a first magnetic circuit coupling a primary coil and a secondary coil, the first magnetic circuit comprising a first limb extending along a vertical axis, the primary coil comprising inner and outer primary coils connected in series, the inner primary coil, the secondary coil, and the outer primary coil being cylindrical and arranged concentrically around the first limb, wherein the inner primary coil, the secondary coil and the outer primary coil are mounted in a manner to maintain a predefined inner gap between the inner primary coil and the secondary coil and a predefined outer gap between the secondary coil and the outer primary coil, the inner and outer gaps being evaluated along a radial direction relative to the vertical axis, the inner and outer gaps increasing a leakage of a magnetic flux between the first coil and the secondary coil. The electric transformer comprising an additional second magnetic circuit having selected limb(s) that pass through predefined gap(s) between coils thereby providing preferred increase in leakage magnetic flux between the first coil and the secondary coil.