Welding Transformer Secondary Winding Rectifier Integration
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Solution Overview
Problem
High Joule losses and complex structures in resistance spot welding systems due to long connections between secondary windings and rectifier means, leading to inefficiency and increased cooling requirements.
Innovation Solution
Integration of rectifier means directly into the secondary winding elements, using power diodes or MOSFET transistors, which reduces connection lengths and simplifies cooling, allowing operation at higher frequencies with reduced losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If rectifier means are connected to secondary winding exits with long massive connections, then sufficient high output dc welding current can be obtained, but high Joule losses occur and intensive cooling is required
Solution Approach 1:
The patent merges the rectifier means directly with the secondary winding elements by integrating them into a common cooling structure. This eliminates the need for separate massive connections between the secondary winding exits and rectifier means, reducing connection length and Joule losses while maintaining sufficient high output dc welding current.
Solution Approach 2:
The patent transitions from a conventional separate arrangement to an integrated three-dimensional structure where rectifier means are embedded within or adjacent to secondary winding elements. This spatial reorganization reduces connection paths and enables direct thermal coupling for cooling, simultaneously addressing electrical and thermal management requirements.
2Power
If rectifier means are connected with long massive connections, then sufficient high output dc welding current can be obtained, but complex structure and intensive cooling requirements arise
Solution Approach 1:
The patent combines multiple functional components (secondary winding elements, rectifier means, and cooling structures) into an integrated assembly. This merging reduces the number of separate parts and connections, simplifying the overall structure while maintaining the capability to deliver sufficient high output dc welding current.
Solution Approach 2:
The integrated structure serves multiple functions simultaneously: the common cooling structure provides thermal management for both secondary winding elements and rectifier means, while the integrated arrangement also reduces electrical connection length and simplifies mechanical assembly, demonstrating multi-functionality that reduces device complexity.
3Weight of stationary object
If frequency of PWM supply voltage is increased, then cross-sectional area of iron core and transformer size can be reduced, but dc welding current at output decreases
Solution Approach 1:
The patent divides the secondary winding into multiple elements (first and second secondary winding elements) with integrated rectifier means. This segmentation allows the transformer to operate at higher PWM frequencies with reduced core size while maintaining high output dc welding current through the combined contribution of multiple parallel secondary elements.
Solution Approach 2:
The patent changes the operational parameters by integrating rectifier means directly with secondary winding elements, enabling the transformer to efficiently operate at higher PWM supply frequencies. This parameter change allows reduction of iron core cross-sectional area and transformer size while compensating for the decrease in individual winding current through the combined output of multiple secondary elements.
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
Significant reduction in Joule losses and increased power density, along with simplified cooling and reduced complexity, enabling efficient operation at higher frequencies without the need for parallelizing secondary windings.
Implementation Method 1
a welding transformer with a primary and secondary winding, which is divided into two equal parts with the so-called central tapping
Implementation Method 2
an output rectifier, wherein the two power diodes of an output rectifier are connected with both parts of the secondary winding
Implementation Method 3
the need for reduction of intensive cooling of these connections due to high losses
Implementation Method 4
which reduces the efficiency of the entire system
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The invention solves the technical problem of the too long connections between the output from the secondary winding and an output rectifier also reducing the need for intensive cooling of rectifier means by integrating the rectifier means in the form of power diodes or MOSFET transistors into the parts of the secondary winding, where the arrangement is not more complex compared to the conventional solutions, however, it enables substantially shorter output connections. The proposed modified structure changes the electrical parameters of the welding system in such a way that, despite the required unchanged maximum value of the welding current and the use of rectifier means in the form of power diodes or MOSFET transistors, it is possible to further reduce electrical losses in secondary connections that become shorter, while simplifying also the cooling of rectifier means in the form of power diode or MOSFET transistors, which, with the proposed integration of secondary windings with output rectifier means in the form of power diode or MOSFET transistors, is cooled indirectly simultaneously with the cooling of the secondary winding. The proposed embodiment allows a significant increase in the power density of the welding transformer with an output rectifier. Because of the change in the electrical properties of the secondary part of the system, it is also possible to operate at slightly higher frequencies than 1 kHz, without parallelizing the secondary winding.