Compact Triangular Core Transformer Radial Lamination Design
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Solution Overview
Problem
Oil-immersed distribution transformers have high no-load losses and material costs, and require compact designs to reduce total ownership cost, while maintaining efficient operation and minimizing material usage.
Innovation Solution
A three-phase stacked triangular transformer core with three legs and six yoke parts, where the legs are composed of stacked laminations oriented radially, allowing for a compact design with reduced yoke material and core loss, and enabling efficient coil winding and reduced oil usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional transformer core designs are used, then structural stability is maintained, but the transformer size and material usage increase
Solution Approach 1:
The patent employs curved yoke parts with a radius of curvature R that connects adjacent leg stacks. This curvature allows the magnetic flux path to follow a natural arc, reducing the overall transformer volume while maintaining structural integrity. The curved design enables more compact arrangement of core components compared to traditional straight-line configurations.
Solution Approach 2:
The transformer core is divided into multiple leg stacks (at least three) with alternating polarities, where each leg stack is a separate stacked lamination assembly. This segmentation allows for modular construction and compact arrangement, reducing the overall volume while maintaining the necessary magnetic circuit stability through precise geometric relationships between segments.
2Strength
If more yoke material is used to maintain structural integrity, then core strength increases, but material cost and weight increase
Solution Approach 1:
The patent specifies precise geometric parameters for the yoke parts, including a radius of curvature R and width W that satisfy specific mathematical relationships. By optimizing these parameters, the design achieves the minimum necessary material quantity while maintaining sufficient mechanical strength and magnetic flux conduction capability. The parameter optimization reduces material usage without compromising core strength.
Solution Approach 2:
The core utilizes stacked laminations made of electrically insulated metal sheets, forming a composite structure that provides both mechanical strength and magnetic properties. This composite approach allows the use of thinner, lighter materials while maintaining the necessary structural integrity and electrical insulation, reducing overall material quantity compared to solid core designs.
3Loss of energy
If leg cross-section is enlarged to reduce core loss, then core loss decreases, but the distance between neighboring legs increases, reducing compactness
Solution Approach 1:
The curved yoke parts with optimized radius of curvature allow the magnetic flux path to efficiently connect enlarged leg cross-sections without requiring increased linear dimensions. The curvature enables the flux to follow a compact arc path, maintaining small transformer volume even with larger leg cross-sections that reduce core loss through reduced flux density.
4Loss of energy
If stacked laminations are oriented radially, then core loss is reduced and manufacturing is simplified, but manufacturing precision requirements increase
Solution Approach 1:
The radial orientation of stacked laminations in each leg stack aligns with the curved geometry of the yoke parts. This radial arrangement naturally follows the circular flux path, reducing eddy current losses and simplifying the lamination stacking process. The curved template or jig used in manufacturing ensures consistent radial orientation while accommodating the natural curvature of the flux path.
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
The design achieves a compact and lightweight transformer with reduced core loss, lower material requirements, and simplified production processes, leading to cost-effective and efficient operation.
Implementation Method 1
said stacked laminations are oriented in substantially radial direction
Data Source
AI summary
A three-phase stacked triangular transformer core is provided. The transformer has three legs and six yoke parts therebetween, wherein the legs include stacked laminations. In a cross-sectional plane perpendicular to a central transformer core axis, the stacked laminations are oriented in substantially radial direction, and each leg has two leg halves, wherein each leg half has a plurality of outer corners facing a corresponding leg half of a neighboring leg. For each of the leg halves the plurality of outer corners lie on a respective straight line within a lateral tolerance, and for each leg half the straight line defined by this leg half and the straight line defined by the corresponding leg half of the neighboring leg are parallel.