Railway Transformer Tank Decoupling for Weight Reduction
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Solution Overview
Problem
Existing railway transformers have a disadvantageous design where the active part is connected to the fastening means across the entire tank, necessitating a mechanically stable material like steel, which increases the dead weight, making it unsuitable for compact and lightweight applications.
Innovation Solution
The active part is mechanically connected to the tank only at the end casings, with the central part made from a lightweight material, avoiding mechanical stress and allowing the use of materials with lower density than steel, such as aluminum or glass-fiber-reinforced plastics, and using a support frame with steel profile supports for secure fastening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the active part is connected to the fastening means across the entire tank, then mechanical stability is improved, but the dead weight increases due to requiring steel material
Solution Approach 1:
The patent divides the tank into three distinct segments: a central part made from lightweight material and two end casings made from mechanically stable material. The active part is mechanically connected only at the end casings to the fastening means, while the central part remains mechanically decoupled. This segmentation allows different materials to be used in different regions, achieving both weight reduction and mechanical stability.
Solution Approach 2:
The patent applies different material qualities to different parts of the tank based on local requirements. The end casings, which require mechanical stability for fastening, are made from steel or other mechanically stable materials. The central part, which does not require mechanical fastening, is made from lightweight materials such as aluminum, plastics, or fiber-reinforced plastics. This local differentiation of material properties optimizes both weight and stability.
2Strength
If the entire tank is made from steel, then mechanical strength is improved, but the dead weight increases
Solution Approach 1:
The tank is segmented into regions requiring different strength levels. The end casings, which bear mechanical loads from fastening, are made from steel. The central part, which is mechanically decoupled and does not bear fastening loads, is made from lightweight materials. This segmentation allows strength to be applied only where necessary.
Solution Approach 2:
Different material strengths are applied locally based on functional requirements. The end casings use high-strength steel material to handle mechanical fastening loads. The central part uses lower-strength but lighter materials such as aluminum or fiber-reinforced plastics, since these regions do not require mechanical fastening capability.
3Weight of stationary object
If the central part is made from lightweight material, then dead weight is reduced, but mechanical stress resistance deteriorates
Solution Approach 1:
The patent extracts the mechanical fastening function from the central part of the tank and relocates it to the end casings. By taking out the mechanical connection requirement from the central region, lightweight materials can be used without compromising overall structural integrity, as the mechanical stress resistance function is fulfilled by the end casings and support frame.
Solution Approach 2:
The end casings act as intermediary elements that transfer mechanical loads from the active part to the fastening means. This intermediary structure allows the central part to be made from lightweight materials while still providing mechanical stress resistance through the end casings and support frame system.
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 reduces the dead weight of the electrical appliance by distributing the weight of the active part through the end casings and support frame, enabling a more compact and lightweight construction suitable for railway applications without compromising mechanical stability.
Implementation Method 1
at least two winding assemblies which enclose in each case one core portion of the core and have windings that are inductively coupled to one another
Implementation Method 2
an active part which comprises a magnetizable core and at least two winding assemblies
Data Source
AI summary
An electrical appliance for connecting to a high voltage includes an active part, which is provided with a magnetizable core and at least one winding assembly, surrounding a respective core section of the core and having windings that are inductively coupled to one another. A tank, which can be filled with an insulating fluid, encases the active part. The tank has two end casings and a central part arranged between the end casings. The electrical appliance is compact and has a low tare weight. The active part is mechanically connected to the boiler only at the end casings and the end casings are supported on fasteners. The central part is produced from a light material.