Welding Transformer Integrated Modules
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Solution Overview
Problem
Current welding transformers with separate secondary windings and rectifier units are complex, expensive, and require hard soldering, leading to stability and cooling challenges, which complicates assembly and increases costs.
Innovation Solution
A welding transformer design with integrated modules that eliminate the need for separate secondary windings and rectifier units, using a magnetic core with modules connected via fastening elements, reducing the number of components and eliminating hard soldering, and incorporating coolant channels for efficient cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the transformer and rectifier are made from a plurality of different parts to allow cooling and compact size, then the cooling efficiency and compactness are improved, but the assembly complexity and manufacturing cost increase
Solution Approach 1:
The patent combines the transformer and rectifier into a single integrated module where the rectifier is mounted directly on the transformer core. This merging reduces the number of separate parts from multiple discrete components to a unified structure, simplifying assembly while maintaining cooling channels for efficient heat dissipation.
2Strength
If hard-soldering is used to connect multiple parts, then the connection strength is improved, but the manufacturing complexity and oxidation problems increase
Solution Approach 1:
The patent replaces hard-soldering with a mechanical fastening system using fastening elements that engage with recesses in the transformer core. This substitution eliminates the need for complex soldering processes, oxidation prevention measures, and laborious cleaning operations while maintaining secure connections through the mechanical interlocking structure.
3Device complexity
If the number of components is reduced, then the assembly simplicity and manufacturing cost are improved, but the stability and security of operation may worsen
Solution Approach 1:
The patent segments the integrated module into distinct functional sections with dedicated fastening elements and recesses. The transformer core is divided into regions for winding arrangement, rectifier mounting, and cooling channels, each secured by specific fastening mechanisms. This segmentation maintains operational stability through structured mechanical connections while keeping the overall component count low.
4Stability of the object's composition
If multiple joints with fastening elements are used, then the structural stability is improved, but the current losses and manufacturing complexity increase
Solution Approach 1:
The patent designs fastening elements that serve multiple functions: mechanically securing components, providing electrical connections, and facilitating cooling channel formation. This multi-functionality reduces the number of separate joints needed compared to traditional designs where fastening and electrical connection are separate operations, thereby reducing current losses while maintaining structural stability.
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 simplifies assembly, enhances stability, reduces current losses, and lowers production costs by minimizing components and joints, while maintaining efficient cooling through integrated coolant channels.
Implementation Method 1
at least one secondary winding wound around the core such that the at least one secondary winding can transform the primary voltage into a secondary voltage used for supplying a welding current to the welding tool
Implementation Method 2
This requires cooling of the transformer-rectifier-unit, for example by water as a coolant
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
There is provided a welding transformer (30), a method for producing a module (34; 3401; 3402) for a welding transformer (30) and a method for producing a welding transformer (30). The welding transformer (30) comprises a magnetic core (33), at least one primary winding (31) wound around the core (33) such that the at least one primary winding (31) can be connected with a power supply (25) to supply a primary voltage to the at least one primary winding (31), and at least two modules (3401, 3402), wherein each module (3401, 3402) of the at least two modules (3401, 3402) is formed as one component which comprises at least one secondary winding (32; 341) wound around the core (33) such that the at least one secondary winding (32; 341) can transform the primary voltage into a secondary voltage (U21, U22) used for supplying a welding current (I2) to the welding tool (10), and a mounting unit (342) for mounting to the welding transformer (30) a rectifier (40) for rectifying the secondary voltage (U21, U22) to supply a direct current as the welding current (I2) to the welding tool (10).