Welding Transformer Winding With Integral Cooling Channel Sealing
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Solution Overview
Problem
The existing methods for producing windings for welding transformers are time-consuming, expensive, and prone to leaks due to the use of multiple copper components and brazing, which can lead to corrosion and machine failure when using aggressive cooling water.
Innovation Solution
A method involving a one-piece profile to create a t-cross-section winding module with milling, eliminating the need for water-jet-cutting and brazing, and using inserts for sealing cooling channels to prevent leaks and corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple copper components are used and brazed together to form the winding, then the cooling channels can be formed, but the production process becomes time-consuming and expensive
Solution Approach 1:
The patent merges multiple separate copper components into a single integral copper casting that forms the entire winding with embedded cooling channels. This eliminates the need for water-jet cutting, machining, and brazing operations, significantly reducing production time and cost while maintaining cooling channel integrity through the continuous copper material structure.
Solution Approach 2:
The cooling channels are pre-formed as integral parts of the copper winding during the casting process, rather than being created afterward through machining or assembly. This preliminary formation of cooling channels eliminates subsequent production steps and ensures their integrity from the outset.
2Shape
If multiple copper components are brazed together to form the winding, then the complex geometry can be achieved, but the production cost increases
Solution Approach 1:
The patent combines the entire winding structure with integrated cooling channels into a single copper casting. This approach achieves the required complex geometry through the casting process itself, eliminating the need for multiple components, machining operations, and costly brazing processes while maintaining manufacturing simplicity.
3Ease of manufacture
If brazing is used to connect copper plates, then the components can be assembled, but aggressive cooling water causes corrosion and leaks
Solution Approach 1:
The patent creates a monolithic copper structure where the winding and cooling channels are formed as one integral piece through casting. This eliminates all brazed joints that would be vulnerable to corrosion from aggressive cooling water, ensuring long-term sealing reliability while the copper material itself provides the necessary assembly capability through its inherent structural integrity.
4Manufacturing precision
If water-jet cutting and machining are used to prepare copper plates, then the cooling channels can be formed, but energy consumption increases
Solution Approach 1:
The cooling channels are formed directly during the copper casting process through the use of insert molds, eliminating the need for subsequent water-jet cutting and machining operations. This preliminary formation maintains manufacturing precision while dramatically reducing energy consumption by avoiding high-energy post-processing operations.
Data Source
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AI summary
There is provided a method for producing a winding (35) for a welding transformer (30) and a winding (35) for a welding transformer (30). In particular, the winding is (35) a secondary winding for the welding transformer (30). In the method, handling a one-piece profile (350; 3500) is performed for forming a one-piece winding module (35A; 35B) which comprises a first winding element (351), a second winding element (352) and a base element (353; 353B), wherein each one of the first and second winding elements (351; 352) protrudes from the base element (353; 353B) and wherein the first and second winding elements (351; 352) are positioned spaced to each other at the base element (353; 353B) so that the one-piece profile (350; 3500) and the winding module (35A; 35B) have a t-cross-section. The method further comprises the steps of milling at least one window (3511; 3512) into the first winding element (351) so that the first winding element (351) frames the at least one window (3511; 3512) for accommodating a part of a core (37) of the welding transformer (30), milling at least one window (3521; 3522) into the second winding element (352) so that the second winding element (352) frames the at least one window (3521; 3522) for accommodating a part of the core (37) of the welding transformer (30), and milling grooves (3534, 3535) into the base element (353; 353B) to separate the base element (353; 353B) into sections (3531, 3532, 3533), wherein the grooves (3534, 3535) are milled such that at least one of the sections (3531, 3532, 3533) is connected to the first and second winding elements (351; 352) and such that at least one of the sections (3531, 3532, 3533) is connected to only one of the first and second winding elements (351; 352).