DESC:Technical Field of the Invention

[0001] The present invention relates to manufacturing of a three phase transformer. More particularly, the present invention relates to a method of manufacturing a three phase transformer comprising three frames forming a core with a step lap joint arranged in a manner to form a Y or a star configuration.

Background of the Invention

[0002] In these days transformers play an important role for power transmission in various places such as power grids, industries, commercial and residential buildings etc. Generally, Y shaped transformers are known for low material consumption with no significant difference in the performance when compared. This is achieved if both low voltage and high voltage winding coils are wound directly on the core along with insulation between each turn. The amount of material consumed in case of wound core transformers and considerable have lower losses when compared with the stacked core transformer. However, the losses in a Y transformer is more less when compared to a wound core transformer

[0003] The performance of the transformer core depends on plurality of parameters and also on various factors includes a peak magnetic flux density in the core, the applied frequency, and the irregularities in the magnetic flux path. The wound core or stacked core transformers generally have physical joints at the frames of the core which creates physical gaps between the joints. Though the gap is minimized in design frequently by exerting a force to minimize the gap, they still influence the losses of a transformer. Current winding procedures facing difficulties while assembling the coil to the core of a transformer.

[0004] Therefore, there is a need to develop a method to reduce the physical gap at the magnetic flux path and number of joints by introducing a unique core configuration of a three phase transformer that reduces the winding material and losses.

Brief Summary of the Invention

[0005] The present invention recognizes the limitations of the prior art and the need for systems and methods that are able to provide assistance to users in a manner that overcomes these limitations.

[0006] A principal object of the present invention is to provide a unique configuration of a core formed from a plurality of sheets laminated together made from steel such as Cold Rolled Grain Oriented (CRGO) or any other suitable material.

[0007] According to a first aspect of the present invention, a three phase transformer with a unique core configuration for reducing a physical gap at the magnetic flux path is disclosed. The three phase transformer comprises of three distinct frames each having two portions made from a plurality of sheets laminated together arranged in a form a unique core configuration.

[0008] In accordance with a first aspect of the present invention, further the transformer also comprises of a unique core configuration comprising a plurality of windings wound on the frames for creating magnetic flux in the core and a means for providing insulation between each winding turn of each frame.

[0009] In accordance with a first aspect of the present invention, further the three phase transformer with unique core configuration comprising a plurality of clamping plates with at least three slots and also provided with a means to hold the said frames and windings assembly in the slots of the clamping plates to form a three phased transformer.

[0010] In accordance with a first aspect of the present invention, further the transformer comprises C shaped frames provided with uneven ends capable of coupling with one another configured in a zig-zag pattern.

[0011] In accordance with a first aspect of the present invention, further the transformer also has a core laminated with sheets made from steel or Ferro magnetic material for reducing the losses.

[0012] In accordance with a first aspect of the present invention, the windings of the transformer comprises a plurality of high voltage (HV) windings and a plurality of low voltage windings (LV) windings wound on the frames of the core for reducing the winding losses.

[0013] In accordance with a first aspect of the present invention, the clamping plates of the transformer are metallic or non-metallic having various configurations for holding core coil assembly through a plurality of fastening elements includes at least two inner clamping plates and at least two outer clamping plates.

[0014] According to a second aspect of the present invention, a method of assembling a three phase transformer with a unique core configuration that reduces a physical gap at the magnetic flux path is disclosed. The method comprises steps of fixing of at least one frame in one slot of the inner clamping plate of a three phase transformer and fixing of another frame adjacent to the said frame such that end portions of the C frame abuts with other frame sections in a linear combination.

[0015] In accordance with a second aspect of the present invention, further step of the method is affixing an outer clamping plate at the bottom of the assembly of inner clamp, winding high voltage and low voltage winding turns on each frame and providing insulation between each winding turn.

[0016] In accordance with a second aspect of the present invention, further the method also comprises step of affixing an inner clamping plate on the top of the winding assembly and affixing an outer clamping plate on top of the frame assembly.

[0017] In accordance with a second aspect of the present invention, wherein the step is to arrange the ‘C’ frames in a manner to form a Y or star configured three phase transformer.

[0018] In accordance with a second aspect of the present invention, wherein the method eliminates the physical joints at the frames of the core thereby eliminating the gaps between the joints.

Brief Description of the Drawings

[0019] Other objects and advantages of the present invention will become apparent to those skilled in the art upon reading the following detailed description of the preferred embodiments, in conjunction with the accompanying drawings, wherein like reference numerals have been used to designate like elements, and wherein

[0020] FIGS. 1-3illustratea perspective view of arranging C shaped frames one-by-one during the assembly of a three phase transformer according to the present invention.

[0021] FIG. 4 illustrates a perspective view of arrangement clamping plates on the transformer according to the present invention.

[0022] FIGS. 5-7illustrate a perspective view of winding high voltage and low voltage coils on each frame of a transformer according to the present invention.

[0023] FIG. 8 illustrates a perspective view of arranging clamping plates on a transformer according to the present invention.

[0024] FIGS. 9-10 illustrate a schematic view of inner clamping plate and outer clamping plate of a transformer according to the present invention.

[0025] FIG. 11 illustrates a schematic view of a C shaped frame of a star or Y configured transformer according to the present invention.

[0026] FIG. 12 illustrates a schematic view of winding coil of a star or Y configured transformer according to the present invention.

Detailed Description of the Invention

[0027] The present invention is directed towards manufacturing of a star configured three phase transformer comprising three frames forming a core with step lap joint arranged in a manner to form a Y or a star configuration. Referring to the drawings, wherein like reference numerals designate identical or corresponding systems, preferred embodiments of the present invention are described.

[0028] The use of “including”, “comprising” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. The terms “a” and “an” herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item. Further, the use of terms “first”, “second”, and “third”, and the like, herein do not denote any order, quantity, or importance, but rather are used to distinguish one element from another.

[0029] Now referring to drawings, illustrates various embodiments of arrangement of a three phase transformer depicting the process of arrangement according to the present invention.

[0030] FIGS. 1-3illustratea perspective view of arranging C shaped frames of a transformer assembly 100according to the present invention. Initially, consider an inner clamping plate 106 provided with three grooves and a plurality of holes for fastening as shown in the FIG. 9. A first ‘C’ shaped frame 102 of a core comprising two end portions104 with uneven surface such as zig-zag pattern made from a plurality of sheets laminated together to form a ‘C’ structure made from steel such as Cold Rolled Grain Oriented (CRGO) or any other suitable material. Affixing the first frame 102 in one of the groove of the inner clamping plate 106to form a three phase transformer.

[0031] A second frame 208 is arranged on another groove of the inner clamping plate 206 as shown in the FIG. 2 of a three phase transformer 200.The frame 208 is placed adjacent to first frame 202 such that an end portion 204 of the first C frame 202 abuts with other. A third frame 310 is arranged in the third groove of the inner clamping plate 306 as shown in the FIG. 3 forming a three phase star configured transformer 300. The three frames of the core 302, 308 and 310 abuts with each other at their ends with their corresponding end frames in a linear combination way. The inner clamping plate 306 is affixing to bottom of the transformer core is fixing of core frames in the slots. The physical joints at the frames of the core eliminate the gap between the joints for reducing magnetic flux losses in the transformer.

[0032] FIG. 4 illustrates a perspective view of a three phase transformer 400 with three ‘C’ shaped frames of a core according to the present invention. The arrangement depicts a three phase transformer 400 comprising three frames a first frame 402, a second frame 408 and a third frame 410 connected each other in a linear combination way at uneven ends forming a delta or Y configuration on an inner clamping plate 406 and an outer clamping plate 412is mounted at the bottom of the three frames with three slots for affixing to the transformer to hold the frames of a transformer 400.

[0033] FIGS. 5-7 illustrates a perspective view of winding a high voltage and low voltage coils on each frame of a three phase transformer 500 according to the present invention. The transformer 500comprises three core frames a first frame 502, a second frame 508 and a third frame 510 are connected each other in a way to form a star or Y transformer. A plurality of windings 514 are wound on the said frames for creating magnetic flux in the transformer core. The winding 514 comprises a plurality of high voltage (HV) and a plurality of low voltage (LV). An insulation layer is also provided between each winding turn of each frame to reduce the winding losses in the transformer core. The inner clamping 506 and outer clamping 512 are arranged with three slots are affixed to the transformer 500 for holding the core and windings.

[0034] FIG. 6 illustrates perspective view of winding high voltage and low voltage coils according to the present invention. A plurality of windings 614 are wound on the second frames 608 for creating magnetic flux in the transformer core. The winding 614 comprises a plurality of high voltage (HV) and a plurality of low voltage (LV). Insulation is provided between each winding turn of said each frame for reducing the winding losses in the transformer core. The inner clamping 606 and outer clamping 612 are arranged with at least three slots are affixed to the transformer for holding the core and windings of a transformer.

[0035] Also, high voltage and low voltage winding turns 714 are also wounded on the third frame 710 as shown in the FIG. 7 depicting a three phase transformer 700 with three frames 702, 708, 710 and two inner clamping plates 706 and an outer clamping plate 712.The transformer comprises the inner clamping plates 706 are arranged at top and bottom of the transformer. The outer clamping plates 712 are arranged at the bottom of the transformer.

[0036] FIG. 8 illustrates the arrangement of outer clamping plate 812 on the top of the starconfigured transformer 800 with three frames and windings 814 on each frame along with inner clamping plates 806 of the transformer.

[0037] FIG. 9 illustrates a perspective view 900 of the inner clamping plate 906 provided with three grooves for accommodating three frames and plurality of holes for fastening with the transformer structure arranged at the top and bottom of the transformer for holding the assembly of core and windings.FIG. 10 illustrates a perspective view 1000 outer clamping plate1012 of a star or Y configuration transformer with a plurality of holes for fastening it to the transformer and arranged at the top and bottom for holding the frame and winding assembly. The clamping plates are made from metallic or non-metallic materials.

[0038] FIG. 11 illustrates a schematic view 1100 of ‘C’ shaped frame 1102 provided with uneven ends 1104 capable of coupling with the other frames of similar shape. FIG. 12 illustrates a schematic view 1200 of a winding coil wounded on three frames of a three phase star or Y configured transformer for creating magnetic flux in the transformer core. A layer of insulation is provided between each turn of the winding coil for reducing the losses in the transformer. The number of joints of the three phase transformer is less when compared with the stacked core transformer which is generally two joints at appropriate places.

[0039] From the foregoing description of the present invention thus described, variations and modifications will occur to those skilled in the art, and all such variations and modifications embodying the teachings in this disclosure, are considered to be within the scope of the invention.

[0040] The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.
,CLAIMS:Claims
I/We claim

1. A three phase transformer with a unique core configuration for reducing a physical gap at the magnetic flux path, wherein the three phase transformer comprises of:
three distinct frames each having two portions made from a plurality of sheets laminated together arranged in a manner to form a unique core configuration;
a plurality of windings wound on the said frames for creating magnetic flux in the transformer core;
a means for providing insulation between each winding turn of each frame;
a plurality of clamping plates with at least three slots; and
the said clamping plates, provided with a means to hold said frames and winding assembly in the slots of the clamping plates to form a three phased transformer.

2. The transformer according to claim 1, characterized to have C shaped frames provided with uneven ends capable of coupling with one another configured in a zig-zag pattern.

3. The transformer according to claim 1, characterized to have a laminated core with sheets made from steel or Ferro magnetic material.

4. The windings according to claim 1, characterized to have a plurality of high voltage (HV) windings and a plurality of low voltage (LV) windings.

5. The clamping plates according to claim 1, characterized to be metallic or non-metallic having various configurations for holding core coil assembly through a plurality of fastening elements, includes:
at least two inner clamping plates; and
at least two outer clamping plates.

6. A method of assembling a three phase transformer with a unique core configuration that reduces a physical gap at the magnetic flux path, wherein the method comprises steps of:
fixing at least one frame in one slot of the inner clamping plate of a three phased transformer;
fixing of a frame adjacent to the said frame such that end portions of the C frames abuts with other frame sections in a linear combination;
affixing an outer clamping plate at the bottom of the assembly of inner clamp;
winding high voltage and low voltage winding turns on each frame;
providing insulation between each winging turn;
affixing an inner clamping plate on the top of the winding assembly; and
affixing an outer clamping plate on top of the frame assembly.

7. The method according to claim 6, wherein the ‘C’ frames are arranged in a manner to form a Y or a star configured three phase transformer.

8. The method according to claim 6, characterized to eliminate the physical joints at the frames of the core thereby eliminating the gaps between the joints.

9. The method according to claim 6, characterized for using a machine for developing laminations for cutting and bending the sheets of the core.