Vacuum Heating Device Balanced Three-Phase Power Distribution
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Solution Overview
Problem
Conventional vacuum heat treatment methods using heating lamps in a vacuum environment face inefficiencies due to unbalanced current supply from three-phase AC power sources when the number of loads is not a multiple of three, leading to degraded service efficiency and increased transformer capacity requirements.
Innovation Solution
The use of a three-phase transformer configuration with Δ-connection or Y-connection primary windings and Scott transformers, along with bidirectional switches, allows for balanced current flow and efficient power distribution to heating lamps, eliminating unloaded secondary windings and reducing primary winding burden, while phase and cycle control manage heat generation and minimize inrush currents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a three-phase transformer is used to supply power to heating lamps, then power distribution is efficient, but when the number of loads is not a multiple of three, unbalanced current flows causing degraded service efficiency and requiring larger transformer capacity
Solution Approach 1:
The patent divides the three-phase transformer into three separate single-phase transformers. Each single-phase transformer has its own primary and secondary windings that are magnetically coupled. This segmentation allows each transformer to independently supply power to loads without requiring balanced three-phase loading, thereby eliminating the unbalanced current problem while maintaining efficient power distribution.
2Temperature
If heating lamps are used in vacuum environment, then radiation heating is effective, but high electric current is required leading to potential discharge in the vacuum chamber
Solution Approach 1:
The patent introduces a vacuum feedthrough as an intermediary component that allows electrical connection to heating lamps inside the vacuum chamber while maintaining vacuum integrity. The feedthrough includes a seal structure that prevents vacuum leakage and a shielding structure that reduces electromagnetic interference and prevents discharge. This intermediary enables effective radiation heating while eliminating the harmful discharge effect in the vacuum environment.
3Device complexity
If multiple heating lamps are connected to a single secondary winding, then power distribution is simplified, but when the number of loads is not a multiple of three, unloaded secondary windings occur reducing service efficiency
Solution Approach 1:
The patent segments the power distribution system into multiple independent single-phase transformers, each with its own secondary winding. This allows flexible configuration where each secondary winding can supply power to any number of heating lamps independently. The segmentation eliminates the constraint of requiring loads to be in multiples of three, thereby maintaining high service efficiency while keeping the power distribution structure relatively simple.
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 configuration ensures balanced current flow, reduces transformer capacity needs, prevents discharge in the vacuum chamber, and effectively controls heating lamp temperature for efficient vacuum heat treatment, maintaining processing temperatures without noise or coil burnout risks.
Implementation Method 1
a three-phase transformer including three primary windings 51 to 53 which connects in a Y-connection shape or a Δ-connection shape to which a three-phase AC voltage is applied; and three secondary windings 61 to 63 magnetically coupled to the respective primary windings 51 to 53
Implementation Method 2
heating lamps that allow object to be processed which is located apart from the heating lamps
Implementation Method 3
The heating lamp, which heats an object to be processed mostly by radiation in a vacuum of a low thermal conductivity
Data Source
AI summary
A uniform voltage is applied to loads even to other than a multiple of three loads made of heating lamps connected in parallel to each other, without causing any burden on a primary side. The number of loads is divided into a multiple of three and a multiple of two. A three-phase AC voltage is applied to three primary windings, which are connected as a Y-connection or a Δ-connection. Secondary windings, which are each magnetically coupled to a primary winding of a plurality of three-phase transformers and have the same number of turns, are connected with the multiple of three loads.