Integrated Transformer Winding Structure for UPS Size Reduction
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Solution Overview
Problem
Conventional uninterruptible power supplies (UPS) with isolation transformers require fully insulated and isolated windings, leading to increased size and cost due to the need for mutual insulation and isolation between primary and secondary windings, which limits the reduction of winding turns.
Innovation Solution
The UPS incorporates an integrated transformer with directly coupled windings that share a common winding, eliminating the need for mutual insulation and isolation, thereby reducing the number of winding turns and the overall size and cost of the transformer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If isolation transformer with fully insulated primary and secondary windings is used, then electrical isolation is ensured, but transformer size and cost increase due to required insulation distance and cannot be reduced
Solution Approach 1:
The patent merges the primary and secondary windings into a single integrated winding structure where the winding serves dual functions. The first and second windings are formed by different sections of the same continuous winding, eliminating the need for separate insulated windings and the insulation distance between them, thus reducing transformer size while maintaining isolation through the winding structure itself
Solution Approach 2:
The integrated winding structure performs multiple functions simultaneously: it provides both the primary and secondary windings for voltage transformation, and inherently provides the isolation function through its continuous structure. The single winding serves as both the high-voltage side and low-voltage side, eliminating redundant components
2Reliability
If isolation transformer with fully insulated primary and secondary windings is used, then electrical isolation is ensured, but winding turns cannot be reduced and cost increases
Solution Approach 1:
The patent combines multiple winding functions into a single integrated winding, reducing the total number of winding turns required. By forming both primary and secondary windings from one continuous winding structure, the manufacturing process is simplified and material costs are reduced while maintaining the necessary electrical isolation properties
3Reliability
If primary and secondary windings are spaced with safe distance for insulation, then electrical isolation is ensured, but transformer size increases
Solution Approach 1:
The patent eliminates the need for insulation distance between separate windings by merging them into a single continuous winding structure. The isolation is achieved through the winding configuration itself rather than through physical separation, thereby compacting the transformer dimensions without compromising electrical safety
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 allows for a reduction in the number of winding turns, resulting in a smaller and more cost-effective transformer while maintaining the necessary insulation and isolation, effectively addressing the size and cost constraints of conventional UPS transformers.
Implementation Method 1
The transformer T has a primary winding and a secondary winding... convert the DC power from the battery set 83 into AC power in collaboration with the transformer T
Data Source
AI summary
An interruptible power supply (UPS) has a surge cancellation and electromagnetic interference (EMI) prevention device, a charger, a battery set and a power converter. The power converter has multiple power switches, an integrated transformer and a controller. An input terminal of the surge cancellation and EMI prevention device is connected with the AC mains, and an output terminal is connected with the integrated transformer. The charger is connected with the battery set. The battery set is connected with the power switches. The integrated transformer has a primary side having a first winding and a second winding serially connected. The first and second windings respectively have multiple sub-windings. The first winding is connected with the power switches. The second winding is connected with a power output terminal and shares a part of the first winding, thereby decreasing turns of the windings and reducing the size and cost of the UPS.