Welding Transformer Bobbin with Vents for Cooling
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Solution Overview
Problem
Welding power supply transformers face challenges in cooling efficiency, particularly for inner windings, and adding size to improve cooling increases cost, weight, and complexity.
Innovation Solution
The design incorporates a bobbin with air vents and a winding separator to enhance airflow between windings, allowing for improved cooling while maintaining a compact form and reducing the number of transformers needed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the transformer size is increased to improve cooling efficiency, then cooling effectiveness is improved, but cost, weight, and size of the welding power supply increase
Solution Approach 1:
The transformer windings are segmented into inner and outer windings with a winding separator between them. This segmentation creates channels for air flow through the bobbin structure, allowing cooling air to reach the previously inaccessible inner windings without increasing the overall transformer size.
Solution Approach 2:
A winding separator is introduced as an intermediary component between the primary and secondary windings. This separator not only provides electrical insulation but also serves as a structural element that facilitates air flow channels, enabling effective cooling of inner windings while maintaining compact dimensions.
2Temperature
If the transformer size is increased to improve cooling efficiency, then cooling effectiveness is improved, but the welding power supply becomes more complex
Solution Approach 1:
The winding separator performs multiple functions simultaneously: it provides electrical insulation between windings, structurally supports the winding arrangement, and creates air flow channels for cooling. This multi-functionality eliminates the need for separate cooling structures, reducing overall device complexity.
Solution Approach 2:
The bobbin is designed with integrated air flow channels and vents that utilize thin structural elements to guide cooling air through the transformer. This approach provides effective cooling pathways without adding bulky external cooling components.
3Ease of manufacture
If standard off-the-shelf magnetic cores with square or rectangular cross-sections are used, then manufacturing is simplified, but magnetic coupling efficiency is reduced due to poor coil-to-core contact
Solution Approach 1:
The bobbin features rounded portions at its ends that conform to the curved surfaces of circular magnetic cores. This curvature design ensures optimal contact between the coil windings and the magnetic core, maximizing magnetic coupling efficiency while maintaining ease of manufacture through the simple rounded geometry.
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 solution effectively cools the transformer windings, reducing the need for larger, heavier units and minimizing costs, while maintaining efficient magnetic coupling and electrical insulation.
Implementation Method 1
The bobbin includes vents to allow air flow into the bobbin
Data Source
AI summary
A method and apparatus for providing welding type power supply includes a power circuit and a control circuit. The power circuit receives input power and provides welding type power to a welding output. The power circuit includes a transformer having a primary winding and a secondary winding. The secondary winding is in electrical communication with the welding output. The control circuit is connected to control the power circuit. The transformer includes a bobbin with the primary winding and the secondary winding wound thereon. The bobbin can includes vents to allow air flow into the bobbin. A winding separator can be disposed between the primary and secondary windings.