Laminated Wound Core Joint Layout for Transformer Noise Reduction
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Solution Overview
Problem
Existing wound cores suffer from excessive noise, particularly in transformer and reactor applications, despite efforts to reduce iron loss.
Innovation Solution
A wound core design featuring laminated bent bodies made from grain-oriented electrical steel sheets with specific curvature radii and joint portion arrangements, including imaginary lines and average distances between joint portions, to minimize noise and strain.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional wound core designs are used, then iron loss reduction is achieved, but noise suppression is insufficient
Solution Approach 1:
The patent applies local quality by differentiating the treatment of different regions of the bent body. Corner portions have different curvature radius requirements (5.0mm or less) compared to side portions, and joint portions are specifically positioned in flat regions rather than distributed uniformly. This localized differentiation optimizes both iron loss reduction and noise suppression by addressing the specific characteristics of each region.
Solution Approach 2:
The patent employs parameter changes by specifying precise curvature radius values (5.0mm or less for bent regions) and controlling the positioning parameters of joint portions relative to imaginary lines. These quantitative parameter specifications transform the qualitative goal of noise suppression into measurable and controllable design criteria, enabling systematic optimization of both iron loss and noise characteristics.
2Object-affected harmful factors
If bent regions with small curvature radii are introduced, then noise is suppressed, but manufacturing complexity increases
Solution Approach 1:
The patent applies preliminary action by pre-defining the positions of joint portions in flat regions before the bending process. The imaginary lines and positioning criteria are established in advance, allowing joint portions to be created during the bending operation itself rather than requiring subsequent complex assembly operations. This reduces manufacturing complexity while achieving the desired small curvature radius for noise suppression.
3Object-affected harmful factors
If joint portions are positioned in flat regions with specific arrangements, then noise and strain are reduced, but design complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the bent body into distinct functional regions: flat regions for joint portions and bent regions for curvature. The imaginary lines create additional segmentation that defines specific zones for joint portion placement. This segmentation simplifies the design process by providing clear guidelines for where joint portions should be positioned, reducing overall design complexity while effectively reducing noise and strain.
Data Source
AI summary
In this wound core, the average distance of first-group joint portions and the average distance of second-group joint portions determined under predetermined conditions satisfy predetermined conditions.