Continuously Transposed Conductor Adhesive Bonding
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Solution Overview
Problem
Current twisted conductor manufacturing processes face limitations in twisting factor, leading to inefficiencies in transformer windings due to eddy current losses, hotspot temperatures, and complex production steps, making it difficult to produce stable and efficient twisted conductors for large, powerful transformers.
Innovation Solution
A method involving the frictional connection of adjacent individual conductors using glue at their contact surfaces before twisting, allowing for a continuous twisted conductor that prevents conductor shifting during winding and improves fill factor and voltage distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the number of individual conductors is increased to reduce eddy current losses, then the efficiency is improved, but the twisting factor becomes difficult to maintain due to manufacturing limitations
Solution Approach 1:
The patent divides the conductor bundle into groups where individual conductors are arranged one above another and connected at contact surfaces, rather than twisting all conductors together uniformly. This segmentation allows maintaining the twisting factor while using a higher number of individual conductors, thus reducing eddy current losses without exceeding manufacturing capabilities.
Solution Approach 2:
The patent transitions from a traditional planar arrangement of conductors to a three-dimensional stacked arrangement where conductors are positioned one above another. This dimensional change enables better utilization of space and maintains the twisting factor while accommodating a larger number of conductors, thereby reducing eddy current losses.
2Ease of manufacture
If conventional twisting methods are used, then the production process is simple, but conductor shifting occurs during winding leading to poor stability
Solution Approach 1:
The patent applies preliminary action by connecting adjacent individual conductors at their contact surfaces before the twisting and winding processes. This pre-connection ensures that conductors remain in their designated positions throughout subsequent processing, preventing conductor shifting while maintaining production simplicity.
Solution Approach 2:
The patent introduces an intermediary connection at the contact surfaces between adjacent conductors. This intermediary connection acts as a stabilizing element that prevents conductor shifting during winding, while not significantly complicating the overall production process.
3Loss of energy
If more individual conductors are used, then eddy current losses are reduced, but the fill factor becomes difficult to optimize due to geometric constraints
Solution Approach 1:
The patent segments the conductor arrangement into stacked groups, allowing optimal packing of individual conductors in a three-dimensional configuration. This segmentation enables better space utilization and maintains a high fill factor while accommodating a larger number of conductors for reduced eddy current losses.
Solution Approach 2:
By transitioning to a three-dimensional stacked arrangement, the patent optimizes the use of available space. This dimensional change allows the conductor bundle to achieve a higher fill factor while containing more individual conductors, thereby reducing eddy current losses without compromising compactness.
4Stability of the object's composition
If manual twisting of short-length bars is used, then conductor stability is maintained, but production efficiency and automation are poor
Solution Approach 1:
The patent applies preliminary connection at contact surfaces, which can be implemented through automated processes rather than manual twisting. This preliminary action ensures conductor stability while enabling continuous, automated production, thereby significantly improving productivity compared to manual methods.
Solution Approach 2:
The patent replaces the manual mechanical twisting process with an automated connection method at contact surfaces. This substitution maintains conductor stability while enabling continuous automated production, thereby improving productivity and reducing labor requirements.
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 method enhances the stability and processability of twisted conductors, reducing eddy current losses, hotspot temperatures, and improving the fill factor and voltage distribution, making them more suitable for large transformers.
Implementation Method 1
Each of the individual conductors (11) is provided with an adhesive layer (15) in order to provide adhesion between adjacent individual conductors (11)
Implementation Method 2
Friction between adjacent individual conductors at contact surfaces prevents shifting during the twisting process
Data Source
Figure 1
Figure 2~4
AI summary
In order to be able to industrially manufacture a transposed conductor that has jointly transposed, superimposed partial conductors and then be able to form a winding from such a transposed conductor, according to the invention, two adjoining, superimposed individual conductors (11) are non-positively connected, preferably glued, to one another at their contact surface (16).