Transformer Tank with Winding-Complementary Shape
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Solution Overview
Problem
Existing railway transformers have a bulky and heavy design due to their box-shaped tanks, which occupy significant space and increase weight, making them unsuitable for compact and lightweight applications.
Innovation Solution
The transformer design features a tank with a shape complementary to the windings, reducing the internal volume and insulating fluid requirement, allowing for a more compact and lightweight structure with beveled core corners and a distribution device arrangement that supports a more efficient use of space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a box-shaped tank is used to enclose the active part, then the structural integrity and ease of manufacture are improved, but the volume and weight of the device increase
Solution Approach 1:
The tank is designed with a curved inner wall that is complementary to the outer contour of the windings, replacing the traditional box-shaped structure. This curved design allows the tank to closely follow the shape of the active part, minimizing the internal volume while maintaining structural integrity and ease of manufacture.
2Strength
If a box-shaped tank is used to enclose the active part, then the structural integrity is improved, but the weight of the device increases
Solution Approach 1:
The curved inner wall design of the tank reduces the overall volume of the device while maintaining structural integrity. By eliminating unnecessary corners and edges of a box-shaped structure, the amount of material required for the tank is reduced, thereby decreasing the weight while preserving strength.
3Volume of moving object
If the tank shape is adapted to the outer contour of the windings, then the volume and weight are reduced, but the manufacturing complexity increases
Solution Approach 1:
The curved inner wall of the tank is designed to be complementary to the outer contour of the windings. This design allows the tank to be manufactured as a single piece with a smooth curved surface, which can be achieved using standard forming techniques. The curvature follows the natural shape of the windings, simplifying the manufacturing process while minimizing volume.
4Volume of moving object
If the tank shape is adapted to the outer contour of the windings, then the volume and weight are reduced, but the manufacturing cost increases
Solution Approach 1:
The curved tank design reduces the volume of the device, which in turn reduces the amount of insulating fluid required and the overall material usage. Although the manufacturing process for a curved tank may be slightly more complex than a box-shaped tank, the reduction in material costs and fluid costs offsets the increased manufacturing complexity, resulting in a cost-effective solution.
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 results in a cost-effective, lightweight, and compact electrical device with improved dielectric strength, reducing the need for additional internal volume and simplifying assembly, while maintaining the necessary insulation and structural integrity for railway applications.
Implementation Method 1
at least one winding configured to generate a magnetic flux in the core
Implementation Method 2
the tank maintains a sufficient distance from the windings to ensure the desired dielectric strength of the electrical device
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
The aim of the invention is to provide an electrical appliance (21) for connecting to a high voltage, comprising an active part (22) comprising a magnetisable core (23) and at least one winding (25, 26) designed to produce a magnetic flow in the core (23), and a boiler (10) that can be filled with an insulating fluid and in which the active part (22) is arranged, said electrical appliance being compact and lightweight. To this end, the boiler (10) has an inner wall of a shape that is complementary to the outer contour of the winding or the windings (25, 26).