Transformer Winding Stability via Spacer Protrusion Guide
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Solution Overview
Problem
The existing transformer winding structures face issues with inconsistent winding stability and leakage inductance differences between wire groups due to varying distances between the primary and secondary windings, affecting transformer performance and accuracy.
Innovation Solution
A transformer winding structure with a wire frame featuring a spacer portion and protrusions that guide the second and third wire groups to approach the spacer, ensuring consistent winding densities and minimizing leakage inductance differences by forming specific winding areas and using electrodes for precise winding and electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the second wire group and third wire group are separately wound on the wire frame, then the winding process can be completed, but the winding stabilities are inconsistent causing apparent difference between distances from first wire group
Solution Approach 1:
The patent introduces a guide structure as an intermediary component between the wire frame and the second/third wire groups. This guide structure standardizes the winding path and positioning, ensuring that both wire groups maintain consistent distances from the first wire group. The guide structure acts as a mediator that transforms the separate winding process into a controlled, consistent operation without requiring simultaneous winding of both groups.
2Device complexity
If the second wire group and third wire group are wound with different distances from the first wire group, then the winding structure is formed, but leakage inductance difference is generated affecting transformer characteristics
Solution Approach 1:
The patent implements preliminary action by providing a pre-formed guide structure on the wire frame before winding the second and third wire groups. This guide structure预先 establishes the correct positioning and spacing, ensuring that when the wire groups are wound, they automatically achieve the required distance consistency from the first wire group. This preliminary preparation prevents leakage inductance differences from occurring in the first place.
Solution Approach 2:
The patent applies parameter changes by modifying the physical geometry of the wire frame through the addition of the guide structure. This structural modification changes the spatial parameters (distances and positions) during the winding process, ensuring that the second and third wire groups are positioned at standardized distances from the first wire group, thereby controlling the leakage inductance parameters of the transformer.
Data Source
AI summary
A transformer winding structure for enhancing winding stability includes a wire frame having a first winding area and a second winding area, a first wire group wound in the first winding area, a second wire group wound in the second winding area, and a third wire group wound in the second winding area and wound in an overlaying manner on the second wire group. The wire frame forms the first winding area and the second winding area by a first plate, a second plate, and a winding column connected to the first plate and the second plate and having a spacer portion. The second plate comprises at least one protrusion protruding from the second plate toward the first plate. The second wire group and the third wire group approach the spacer portion when passing through the position of the protrusion.