Patent Publication Number: US-10319510-B2

Title: Transformers with alternately radially disposed first and second conductors

Description:
The present disclosure relates to transformers comprising a winding wrapped around a magnetic core. 
     BACKGROUND 
     The basic purpose of a transformer is to convert electricity at one voltage to electricity at another voltage, either of higher or lower value. In order to achieve this voltage conversion, conductors are wrapped on a core which provides a path for the magnetic flux. The conductors of the transformer may be wrapped using a plurality of techniques such a helical winding, layer winding, disc winding, foil winding, foil-disk winding, etc. 
     A transformer winding can include only one big and thick conductor wrapped on a core of the transformer. A problem of this solution may be that the width of the conductor in the radial direction may lead to undesired axial eddy losses in the transformer. 
     These eddy currents are induced by the magnetic flux generated by the current flowing through the winding, and they depend mainly on the module and direction of the magnetic flux. 
     In order to reduce the axial eddy losses, a conductor of the power transformer winding can include several parallel flat conductors along the radial axis of the winding instead of one big and thick conductor. These conductors may be parallel and radially adjacent with respect to each other along the total length of the winding. 
     A problem of this solution may be that recirculating currents may appear, which may cause extra losses and consequently an overheating which could degrade prematurely the insulations and consequently lead to an electrical failure. 
     The present invention aims to provide a transformer which solves at least partly the above drawbacks, by improving the performance of transformers with several parallel and radially adjacent conductors. 
     SUMMARY 
     In a first aspect, a transformer comprising a winding wrapped around a magnetic core is provided. The winding having at least one winding portion extending between the magnetic core and the exterior of the winding in radial direction. The winding comprising at least a first conductor and at least a second conductor, arranged radially adjacent to each other in each winding portion with the interposition of an insulating layer, wherein the first conductor is arranged radially inwardly with respect to the second conductor for part of each winding portion length, and radially outwardly with respect to the second conductor for another part of each winding portion length. 
     In a winding comprising at least a first conductor and at least a second conductor, arranged radially adjacent to each other in each winding portion with the interposition of an insulating layer, the axial losses of the transformer dependent on the width in the radial direction of the conductor may be reduced. 
     The configuration of the first conductor being arranged radially inwardly with respect to the second conductor for part of of each winding portion length, and radially outwardly with respect to the second conductor for another part of each winding portion length leads to the transposition of the first conductor and the second conductor along the length of each winding portion. This improves the performance of the transformer, because the recirculating currents may be reduced, thus the extra losses generated in the conductors may be avoided or at least reduced as well. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Non-limiting examples of the present disclosure will be described in the following, with reference to the appended drawings, in which: 
         FIG. 1  schematically shows a winding of a transformer according to an implementation; 
         FIGS. 2 a -2 c    schematically show the transposition between a first and a second conductor according to examples; 
         FIG. 3  schematically shows the transposition between a first and a second conductor according to another example; 
         FIGS. 4 a -4 b    schematically show a foil winding configuration according to examples; 
         FIGS. 5 a -5 b    schematically show a foil-disc winding configuration according to examples. 
     
    
    
     DETAILED DESCRIPTION OF EXAMPLES 
       FIG. 1  shows schematically a winding of a transformer according to an implementation. The transformer may be of any known type e.g. a dry type transformer. The transformer may comprise a winding  1 . The winding  1  may comprise at least one winding portion e.g. winding portion  20  extending between the magnetic core  150  and the exterior of the winding in radial direction. Furthermore, the winding  1  may be wrapped around a magnetic core. 
     The winding  1  may be made of a conducting material e.g. copper or aluminium. The winding  1  may comprise a plurality of electrically insulated conductors. 
     The winding  1  may have a foil-disc winding configuration. In this configuration, each winding portion may be a disc. The required conductors e.g. two strips may be wound in a plurality of these discs spaced apart along the axial length of the winding. The conductors may be rectangular in cross-section and the conductors may be wound in a radial direction parallel to each other, one on top of the other until the required number of turns per disc has been wound. 
     In some other examples, the winding  1  may have a foil winding configuration. In this configuration, one winding portion may be a foil. The required number of conductor foils e.g. two conductor foils may be wound. The conductor foils may be rectangular in cross-section and the conductor foils may be wound in a radial direction parallel to each other, one on top of the other, until the required number of turns has been wound. 
     In examples, the winding  1  may comprise a first conductor  3  e.g. a first conductor foil or a first strip and a second conductor  4  e.g. a second conductor foil or a second strip. The first conductor  3  and the second conductor  4  may be arranged radially adjacent to each other in the winding with the interposition of an insulating layer (not shown). With this arrangement, the undesired axial eddy losses in the transformer related to the radial width of the conductor may be reduced. 
     The first conductor  3  and the second conductor  4  may be transpositioned; the transposition of the conductors refers to the exchanging of position of the first  3  and the second  4  conductor along the winding portion  20  in such a manner that the first part  3   a  of the first conductor  3  may be located radially inwardly with respect to second conductor  4  and the second part  3   b  of the first conductor  3  may be located radially outwardly with respect to the second conductor  4 . With this transposition of the conductors along the winding portion  20  the recirculating current and, consequently, the extra losses and the overheating of the winding, may be reduced. 
     At least one of the conductors, for example the first conductor  3 , may be discontinuous along the length of the winding portion  20 . More particularly, the first conductor  3  may comprise a first part  3   a  in which the first conductor is arranged radially inwardly with respect to the second conductor  4  for part of the winding portion length and a second part  3   b  in which the first conductor is arranged radially outwardly with respect to the second conductor  4  for another part of the winding portion length. The first part  3   a  may comprise a first intermediate end  6  and the second part  3   b  may comprise a second intermediate end  7 , wherein the two ends  6 ,  7  are intended to be connected to each other to allow current flow in the first conductor. The second conductor  4  may be continuous along the length of the winding portion. 
     The first conductor  3  and the second conductor  4  may be made of e.g. aluminum or copper although some other conductor materials may be possible. 
       FIGS. 2 a -2 c    show examples of the transposition between the first conductor  3  and the second conductor  4 . In  FIG. 2 a   , as commented above, the first conductor  3  may be discontinuous along the length of the winding portion, and have a first intermediate end  6  and a second intermediate end  7 . The two separate parts or lengths of the first conductor  3 , each ending with one of the intermediate ends  6  and  7 , are arranged on different sides of the second conductor  4 , and their ends  6  and  7  are intended to be connected together. This structure allows the transposition between the two conductors  3  and  4 , that is, the change in their relative radial position, such that each conductor is arranged radially inwardly with respect to the other along a length of the winding portion, and is arranged radially outwardly with respect to the other along another length of the winding portion. 
     The first intermediate end  6  may comprise a first elongated lead-out  10 . The elongated lead-out  10  may comprise a plurality of fasteners  11 , such as bolts, pins, studs or the like. The second intermediate end  7  may comprise a second elongated lead-out  12 . The elongated lead-out  12  may comprise a plurality of holes (not visible) in which the fasteners  11  are to be fitted in order to assemble the first conductor with the second conductor. 
     An insulating layer element  13  may be provided so as to maintain two separate electric current paths in conductors  3  and  4 . The insulation layer  13  may be made of rubber-like polymers and/or plastics although some other insulation materials may be possible. 
     The first intermediate end  6  and the second intermediate end  7  may be aligned with, for example, a centering element (not shown), thus resulting in the fasteners  11  of the first conductor  3  being aligned with the openings of the second conductor  4 . This way, the first intermediate end  6  may be fastened into the plurality of openings of the second intermediate end  7 , thus the first part of the first conductor  3  may be connected to the second part of the first conductor  3 . In consequence, the first conductor  3  may pass from one side of the second conductor  4  to the other side. This structure allows the transposition between the two conductors  3  and  4 , that is, the change in their relative radial position, such that each conductor is arranged radially inwardly with respect to the other along a length of the winding portion, and is arranged radially outwardly with respect to the other along another length of the winding portion. 
     In  FIG. 2 b   , a first socket  20  and a second socket  24  may be provided. The first socket  20  may be connected e.g. welded to the first intermediate end of the first conductor. The second socket  24  may be connected e.g. welded to the second intermediate end of the first conductor. 
     The first socket  20  may comprise a first leg  21 , a second leg  22  and a first bight portion  23 . The first bight portion  23  may be configured to join the first leg  21  and the second leg  22 . The second socket  24  may comprise a first leg  25 , a second leg  26  and a second bight portion  27 . The second bight portion  27  may be configured to join the first leg  25  and the second leg  26  of the second socket  24 . 
     The second socket  24  may include a hole (not shown) in which the first leg  21  and the second leg  22  of the first socket  20  may be fit for making electrical contact with the second socket  24  when the first leg  21 , the second leg  22  (and thus the bight portion  23 ) are fit into the hole. Alternatively, the hole for making electrical contact may be situated in the first socket  23 . 
     In examples, a locking mechanism for connectors may be provided. The locking mechanism e.g. a clamp may prevent the connectors from being insufficiently engaged and it may allow the connectors to be engaged or disengaged with ease. 
     With this arrangement, the first intermediate end of the first conductor may be connected to the second intermediate end of the second conductor using the first socket  20  and the second socket  24 , thus the first conductor may pass from one side of the second conductor to the other side. This structure allows the transposition between the two conductors, that is, the change in their relative radial position, such that each conductor is arranged radially inwardly with respect to the other along a length of the winding portion, and is arranged radially outwardly with respect to the other along another length of the winding portion. With this transposition of the conductors along the winding portion the recirculating current and, consequently, the overheating of the winding, may be reduced. 
     The first and second socket  20 ,  24  may be made of aluminium or copper although some other conductor materials may be possible. 
     The structure and operation of the first conductor, the second conductor and the insulating layer may be the same as described in the  FIGS. 1 and 2   a.    
       FIG. 2 c   , the operation of the sockets may be the same as described in the  FIG. 2 b   . The structure of the sockets may also be the same with the inclusion of a second bight portion  29  at the first socket and the inclusion of a second bight portion  28  at the second socket. 
       FIG. 3  schematically shows the transposition between the first conductor  3  and the second conductor  4  according to another example. In this  FIG. 3 , the first conductor  3  may comprise a first guide channel  31  and the second conductor  4  may comprise a second guide channel  30 . The first guide channel  30  and the second guide channel  31  may comprise a groove cut below or above or in between the normal surface of the first conductor  3  and the second conductor  4 . In this particular example, the first guide channel  30  may comprise a groove cut above the normal surface and the second guide channel  31  may comprise a groove cut below the normal surface. 
     Furthermore, a first insulation layer  32  and a second insulation layer  33  may be provided. The first insulation layer  32  may be located between the first conductor  3  and the second conductor  4  along the first part of the winding portion, thus two separate electric current paths may be maintained in conductors  3  and  4  along this first part of the winding portion. In the same way, the second insulation layer  33  may be located between the first conductor  3  and the second conductor  4  along the second part of the winding portion, thus two separate electric current paths may be maintained in conductors  3  and  4  along this second part. 
     In this arrangement, the first guide channel  30  may be configured to fit with the second guide channel  31 , thus the first conductor  3  may pass at least in part through the second conductor  4 . This structure allows the transposition between the two conductors, that is, the change in their relative radial position, such that each conductor is arranged radially inwardly with respect to the other along a length of the winding portion, and is arranged radially outwardly with respect to the other along another length of the winding portion. With this transposition of the conductors along the winding portion the recirculating current and, consequently, the overheating of the winding, may be reduced 
     In this particular example, a first and a second guide channel have been depicted although in some other examples the transposition between the first conductor and the second conductor may be performed with three or more guide channels located at the first and the second conductor. 
     The first insulation layer  32  and a second insulation layer  33  may be made of rubber-like polymers and/or plastics although some other insulation materials may be possible. 
       FIGS. 4 a -4 b    schematically show a foil winding configuration according to examples. In this configuration, the transformer may comprise one winding portion which may be regarded as a foil. In  FIG. 4 a   , the first conductor  3  may be a first conductor foil and the second conductor may be a second conductor foil  4 . The first conductor foil and the second conductor foil may be spaced apart with respect to each other in the radial direction of the foil. With this arrangement, the first conductor foil may be arranged radially inwardly with respect to the second conductor foil for part of the foil length, and radially outwardly with respect to the second foil for another part of the foil length. 
     This structure allows the transposition between the two conductors foils, that is, the change in their relative radial position, such that each foil conductor is arranged radially inwardly with respect to the other along a length of the foil, and is arranged radially outwardly with respect to another length of the foil. With this transposition of the foil conductors along the foil the recirculating current and, consequently, the overheating of the winding, may be reduced. 
       FIG. 4 b    shows a cross-sectional view of the winding. A commented above, in this example, the transformer may comprise one winding portion  25  which may be regarded as a foil. The first conductor foil  3  and the second conductor foil  4  may be spaced apart with respect to each other in the radial direction of the winding. The first conductor foil  3  and the second conductor foil  4  may be rectangular in this cross-sectional view. 
       FIGS. 5 a -5 b    schematically show a foil-disc winding configuration according to examples. In this example, the transformer may comprise a plurality of winding portions. Each winding portion may be a disc. In  FIG. 5 a   , the first conductor  3  may be a first strip and the second conductor  4  may be a second strip. The strips may be wrapped spaced apart with respect to each other in the radial direction of the winding and in a plurality of discs spaced apart with respect to each other in the axial direction of the winding. For each disc, the first strip may be arranged radially inwardly with respect to the second strip for part of the disc length, and radially outwardly with respect to the second conductor for another part of the disc length. Furthermore, may be a space between each pair of discs. In some examples, the space may be filled with an insulating material e.g. resin. 
       FIG. 5 b    shows a cross-sectional view of the winding. In this configuration, each winding portion p.ej, the winding portion  30  is a disc. As commented above, the first conductor  3  may be a first strip and the second conductor  4  may be a second strip. The first strip may be arranged radially inwardly with respect to the second strip for part of the disc length, and radially outwardly with respect to the second strip for another part of the disc length. 
     Although only a number of examples have been disclosed herein, other alternatives, modifications, uses and/or equivalents thereof are possible. Furthermore, all possible combinations of the described examples are also covered. Thus, the scope of the present disclosure should not be limited by particular examples, but should be determined only by a fair reading of the claims that follow.