Underfloor Transformer with Suspended Core and Tensile Securing
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Solution Overview
Problem
Underfloor transformers in mobile applications face space constraints and mechanical challenges due to their limited height and the need to avoid oil, which complicates their arrangement and cooling, especially when oriented horizontally, and existing dry transformers struggle with compressive loading and weight transmission.
Innovation Solution
A dry underfloor transformer with a layered core and securing devices at axial ends, allowing for a horizontally oriented limb axis, featuring bonded lamination layers, stabilizer plates, resin-impregnated fibre windings, and damping elements to manage weight and mechanical stress, enabling a suspended arrangement that optimizes space usage and mechanical stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the transformer is arranged in a lying position to utilize underfloor space, then space utilization is improved, but mechanical stability deteriorates due to compressive loading of the winding
Solution Approach 1:
Instead of arranging the transformer in a conventional lying position with the core parallel to the floor, the patent inverts the arrangement by orienting the core vertically (perpendicular to the floor) while still maintaining a compact underfloor footprint. This inversion allows the winding to support tensile loads from the core weight rather than compressive loads, resolving the mechanical stability issue while preserving space utilization benefits.
2Temperature
If oil is used as coolant and insulating medium, then cooling efficiency is improved, but safety deteriorates due to combustible properties of oil
Solution Approach 1:
The patent extracts and eliminates the oil from the transformer system, replacing it with a dry, solid insulating and cooling medium. This removal of the combustible oil addresses the safety concern while the patent compensates for cooling efficiency through alternative means such as enhanced thermal conduction paths and optimized heat dissipation structures using non-combustible materials.
Solution Approach 2:
The patent employs composite materials that combine insulating and cooling functions in a single non-combustible structure. These composite materials provide both the necessary electrical insulation and thermal management capabilities previously provided by oil, thereby maintaining cooling efficiency while eliminating fire hazards.
3Strength
If the transformer core is suspended to eliminate compressive loading, then mechanical stability is improved, but device complexity increases due to additional securing devices
Solution Approach 1:
The patent merges the securing devices with the transformer core structure itself, integrating the suspension function into the core design. Rather than adding separate, complex suspension mechanisms, the core is designed with built-in features that allow direct attachment to the vehicle floor, thereby achieving mechanical stability through tensile loading while minimizing additional structural complexity.
Data Source
AI summary
An underfloor transformer includes a layered transformer core and at least one electrical winding through which the transformer core extends along a limb axis. In each of two axial end regions of the transformer core, a securing device, which interacts with the transformer core mechanically, is provided. The securing devices are configured for such tensile force stressing. The underfloor transformer can be carried suspended therefrom.