Transformer Low-Voltage Coil Core Leg Mounting
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Solution Overview
Problem
Existing transformer designs require alignment and support of low-voltage coils relative to high-voltage coils, which complicates assembly and can lead to misalignment and increased complexity.
Innovation Solution
The low-voltage coil is directly attached to the transformer core leg using fixing bolts, eliminating the need for support profiles and allowing independent positioning, with spacer elements ensuring proper alignment and wedge elements preventing detachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the low-voltage coil is held on support profiles with blocks and aligned relative to the high-voltage coil, then the coil assembly is stable, but the assembly process becomes complex and time-consuming
Solution Approach 1:
The invention extracts and eliminates the support profiles and blocks from the assembly structure. The low-voltage coil is now held directly by the core leg through fixing bolts, removing the intermediate support elements and simplifying the overall structure while maintaining stability.
Solution Approach 2:
The invention merges the holding function directly into the core leg structure. The core leg now directly holds the low-voltage coil through integrated fixing bolts, combining what were previously separate components (support profiles, blocks, and core leg) into a more unified structure.
2Manufacturing precision
If the low-voltage coil is aligned relative to the high-voltage coil using support blocks, then proper positioning is achieved, but the alignment process requires additional adjustment steps
Solution Approach 1:
The invention incorporates preliminary alignment features directly into the core leg structure, including positioning protrusions and corresponding recesses. This preliminary action ensures proper alignment is built-in during manufacturing, eliminating the need for field adjustment while maintaining precision.
Solution Approach 2:
The core leg structure with integrated fixing bolts and positioning features serves itself to align and hold the low-voltage coil. The structure automatically ensures proper positioning without requiring external alignment tools or multiple adjustment steps, making the assembly process simpler.
3Reliability
If multiple support blocks and alignment features are used, then the coil positioning is secure, but the number of parts and assembly steps increases
Solution Approach 1:
The invention removes the support blocks and intermediate alignment features from the assembly. The core leg directly secures the low-voltage coil through fixing bolts, reducing the total part count and assembly steps while maintaining secure positioning.
Solution Approach 2:
The core leg is given multiple functions: it provides structural support, positioning, and direct attachment of the low-voltage coil through integrated fixing bolts. This multi-functionality eliminates the need for separate support blocks and alignment features, speeding up assembly while maintaining reliability.
Data Source
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AI summary
The invention relates, inter alia, to a transformer comprising a transformer core (20) having transformer core laminations, at least one high-voltage coil and at least one low-voltage coil (100), wherein a core limb (120) of the transformer core passes through the low-voltage coil. According to the invention, the low-voltage coil is held by the core limb with at least one fixing pin (200, 210).