Transformer With Segmented Windings For Voltage Adaptability
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Solution Overview
Problem
Current transformer designs struggle to easily accommodate various input voltage specifications in electric vehicles, requiring complex redesigns and increased production management due to changes in input voltage, which complicates manufacturing and inventory management.
Innovation Solution
A transformer design featuring a core portion with primary and secondary windings that can be divided into multiple layers with extending members, allowing for adjustable connections via a first connection portion, enabling series and parallel connections to be switched without altering the core or winding configurations, thus accommodating different input voltage specifications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the transformer structure is redesigned to accommodate various input voltage specifications, then the adaptability to different voltage requirements is improved, but the device complexity and production management complexity increase
Solution Approach 1:
The primary winding is divided into multiple layers (first layer, second layer, third layer, etc.), with each layer having independent connection terminals. This segmentation allows flexible combination of layers to achieve different total turn numbers for different input voltage specifications, while maintaining a standardized multi-layer structure that simplifies production management.
Solution Approach 2:
The transformer adopts a universal multi-layer winding structure where the same basic structure can serve multiple input voltage specifications. By selectively connecting different layers in series or parallel, the transformer can accommodate various input voltages without requiring completely different designs, thus reducing production management complexity while maintaining high adaptability.
2Adaptability or versatility
If the number of turns and connection configuration are changed to cope with various input voltage specifications, then the adaptability is improved, but the manufacturing precision requirements and production complexity increase
Solution Approach 1:
The transformer is manufactured with all layers pre-wound and pre-positioned in their final locations during a single manufacturing process. The connection configuration (which layers are connected in series or parallel) is determined after manufacturing, allowing the physical structure to be standardized while the electrical configuration is adjusted later to meet different voltage requirements.
Solution Approach 2:
The transformer employs dynamic reconfigurability where the connection topology between layers can be changed after manufacturing to adapt to different input voltage specifications. This allows the same physical transformer structure to be dynamically reconfigured for different applications, reducing both manufacturing precision requirements and production complexity.
3Reliability
If different transformers are manufactured for each input voltage specification, then the reliability for specific applications is improved, but the productivity and inventory management efficiency decrease
Solution Approach 1:
A single standardized transformer design with multi-layer windings can serve multiple input voltage specifications through different connection configurations. This universal design enables one transformer type to replace multiple specification-specific models, significantly improving productivity by eliminating the need to manufacture and manage multiple different transformer variants.
Solution Approach 2:
Instead of manufacturing different transformers for different specifications, the invention recovers the value of a single transformer design by enabling it to serve multiple purposes through reconfigurable connections. The same physical transformer can be adapted to different input voltage requirements, effectively recovering production resources and improving overall manufacturing efficiency.
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 allows for efficient adaptation to various input voltage specifications without the need for extensive redesign, simplifying production and inventory management by using the same materials and configurations, thereby improving productivity.
Implementation Method 1
A transformer has a core for forming a magnetic circuit, a primary winding, and a secondary winding
Data Source
AI summary
To obtain a transformer that can easily cope with various input voltage specifications and that has improved productivity. A transformer includes: a core portion for forming a magnetic circuit; a primary winding and a secondary winding wound at the core portion; and a first connection portion having a plurality of first conductive parts arranged with an insulation interval therebetween. One or both of the primary winding and the secondary winding are divided into a plurality of division windings, and each of the plurality of division windings of the at least one divided winding has a wound part wound at the core portion, and two extending members extending from both ends of the wound part. The first connection portion is connected to one of the two extending members of each of the plurality of division windings of the at least one divided winding.