U.S. patent number 3,629,759 [Application Number 05/038,966] was granted by the patent office on 1971-12-21 for coupling transformer assembly.
This patent grant is currently assigned to The Rucker Company. Invention is credited to Ellwood S. Douglas, Wallace W. Wahlgren.
United States Patent |
3,629,759 |
Douglas , et al. |
December 21, 1971 |
COUPLING TRANSFORMER ASSEMBLY
Abstract
Transformer assembly having an electrically conductive casing
and spindle member forming a one-turn winding linking a plurality
of toroidal cores within the casing.
Inventors: |
Douglas; Ellwood S. (Orinda,
CA), Wahlgren; Wallace W. (Oakland, CA) |
Assignee: |
The Rucker Company (Oakland,
CA)
|
Family
ID: |
21902939 |
Appl.
No.: |
05/038,966 |
Filed: |
May 20, 1970 |
Current U.S.
Class: |
336/82; 336/174;
336/212; 336/175; 336/229; 137/494 |
Current CPC
Class: |
H01H
83/144 (20130101); H01F 38/30 (20130101); H02H
3/33 (20130101); Y10T 137/7781 (20150401) |
Current International
Class: |
H01F
38/28 (20060101); H02H 3/33 (20060101); H02H
3/32 (20060101); H01F 38/30 (20060101); H01f
015/02 () |
Field of
Search: |
;336/82,174,175,212,229,73 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Kozma; Thomas J.
Claims
What is claimed is:
1. In a coupling transformer assembly, a first toroidal core
fabricated of a material having a high magnetic permeability, a
winding comprising a plurality of turns wound on said first
toroidal core, a second toroidal core of substantially smaller size
than said first toroidal core coaxially disposed within the opening
of said first core at the central plane thereof, said second core
being fabricated of a material of high magnetic permeability and
having no windings wound thereon, an electrically conductive
spindle member extending coaxially through said second toroidal
core and through at least a portion of said first toroidal core,
and an electrically conductive casing enclosing said first and
second toroidal cores and connected to the ends of said spindle
member to form with said spindle member a single-turn winding
linking both of said cores.
2. A coupling transformer assembly as in claim 1 together with at
least one additional winding wound on said first toroidal core.
3. A coupling transformer assembly as in claim 1 wherein said
casing comprises a generally toroidal shell formed of two parts
joined together at the central plane of said first toroidal core,
each of said parts being formed to include a central web portion to
which the ends of said spindle member are connected.
4. A coupling transformer assembly as in claim 1 wherein said
second toroidal core comprises a plurality of annular inductor core
members coaxially stacked in intimate contact with each other.
5. In a coupling transformer assembly, a first toroidal core
fabricated of a material having a high magnetic permeability,
second and third toroidal cores spaced apart from each other and
disposed coaxially of said first toroidal core, a winding
comprising a plurality of turns wound on said first core, an
electrically conductive spindle member extending axially through
said toroidal cores, an electrically conductive casing enclosing
said first and second toroidal cores and connected to the ends of
said spindle member to form with said spindle member a single-turn
winding linking said cores, and an additional single-turn winding
on said first toroidal core, said additional winding having a
center tap connected to said spindle member intermediate its ends,
and a common conductor connected to said casing proximate the ends
of said spindle member.
6. In a coupling transformer assembly a first toroidal core
fabricated of a material having a high magnetic permeability,
second and third toroidal cores spaced apart from each other and
disposed coaxially of said first toroidal core, a winding
comprising a plurality of turns wound on said first core, an
electrically conductive spindle member extending axially through
said toroidal cores, and an electrically conductive casing
enclosing said first and second toroidal cores and connected to the
ends of said spindle member to form with said spindle member a
single-turn winding linking said cores, said spindle member
including a cylindrical central portion, a pair of cylindrical end
portions of smaller diameter than said central portion, and an
annular recess formed in each end of said central portion adjacent
said end portions, said first toroidal core being disposed over
said central portion and said second and third toroidal cores being
disposed over said end portions and in said annular recesses.
7. In a transformer assembly, a first toroidal core fabricated of a
material having a high magnetic permeability, a second toroidal
core of smaller size than said first toroidal core disposed
coaxially of said first core, a winding comprising a plurality of
turns wound on said first core, an electrically conductive spindle
member extending axially through the cores, said spindle member
including a cylindrical central portion and a cylindrical end
portion of smaller diameter than said central portion, said first
toroidal core being disposed over said central portion and said
second toroidal core being disposed over said end portion, and an
electrically conductive casing enclosing said first and second
toroidal cores, said casing being connected to the ends of said
spindle member to form with said spindle member a single-turn
winding linking said cores.
8. A transformer assembly as in claim 7 wherein the central portion
of said spindle member is formed to include an annular recess
adjacent to the end portion of said spindle member, said second
toroidal core being disposed in said recess.
Description
BACKGROUND OF THE INVENTION
This invention pertains generally to electrical transformers and
inductors and more particularly to a transformer having a plurality
of coupled toroidal cores.
In ground fault detectors and current interrupters of the type
disclosed in U.S. Pat. application Ser. No. 18,158, filed Mar. 10,
1970 and assigned to the assignee of the present invention, ground
fault signals are stored magnetically in inductor cores coupled to
the secondary winding of a differential transformer. As is pointed
out in the aforementioned application, it is desirable to make this
coupling through a coupling transformer having a multiple-turn
primary winding connected to the secondary winding of the
differential transformer. The coupling transformer is coupled to
the inductor cores by a single-turn coupling link. Additional
windings can be provided on either the differential transformer or
the coupling transformer for reading the stored flux signals out of
the inductor cores. Alternatively, the coupling transformer primary
winding can serve as a readout winding.
The inductor cores used in such ground fault detectors and current
interrupters are typically very small in size, and it is therefore
difficult to provide proper coupling between them and the coupling
transformer. Conventional coupling links have a resistance and
stray inductance which severely limit the signals which can be
coupled between the coupling transformer and inductor cores.
There is therefore, need for a new and improved coupling
transformer assembly which overcomes the foregoing and other
problems encountered with coupling transformers and coupling links
of the type heretofore provided.
SUMMARY AND OBJECTS OF THE INVENTION
The coupling transformer assembly of the present invention includes
a toroidal core having a winding comprising a plurality of turns
wound thereon. One or more inductor cores is disposed coaxially of
the toroidal core, and an electrically conductive spindle member
extends axially through at least a portion of these cores. An
electrically conductive casing encloses the cores and is connected
to the ends of the spindle member to form a single-turn winding
linking all of the cores. The casing also serves to protect the
toroidal core and inductor core against mechanical damage. An
additional winding is provided on the toroidal core for reading
stored flux signals out of the inductor cores. While intended
primarily to provide coupling between the secondary winding of a
differential transformer and one or more toroidal inductor cores in
ground fault detector, the coupling transformer assembly of the
present invention can also be utilized in other situations in which
it is desirable to provide coupling between two or more toroidal
cores.
It is in general an object of the present invention to provide a
new and improved coupling transformer assembly.
Another object of the invention is to provide a coupling
transformer assembly of the above character which is particularly
adapted for driving a plurality of toroidal inductor cores.
Another object of the invention is to provide a coupling
transformer assembly of the above character which is usable over a
wide range of frequencies.
Another object of the invention is to provide a coupling
transformer assembly of the above character which includes a
coupling transformer core and at least one toroidal inductor core
in an integral package.
Another object is to provide a coupling transformer assembly of the
above character which includes single-turn coupling between the
coupling transformer core and at least one toroidal inductor
core.
Another object is to provide a coupling transformer assembly of the
above character in which the resistance and stray inductance of the
coupling link are very small.
Additional objects and features of the invention will be apparent
from the following description in which the presently preferred
embodiment are set forth in detail in conjunction with the
accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top plan view of one embodiment of a coupling
transformer assembly incorporating the present invention.
FIG. 2 is a cross-sectional view taken along line 2--2 in FIG.
1.
FIG. 3 is an enlarged sectional view illustrating the construction
of the inductor core in the embodiment shown in FIGS. 1 and 2.
FIG. 4 is a front elevational view of the embodiment shown in FIG.
1.
FIG. 5 is a front elevational view, partially sectioned, of another
embodiment of a coupling transformer assembly incorporating the
present invention.
FIG. 6 is an enlarged sectional view of one end of the spindle
assembly of the embodiment illustrated in FIG. 5.
FIG. 7 is an exploded perspective view of the embodiment
illustrated in FIG. 5.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The embodiment illustrated in FIGS. 1-4 includes a toroidal
transformer core 10, and inductor core 11, a spindle 12, and a
casing 13.
The cores 10 and 11 are fabricated of a material having a high
magnetic permeability. The core 10 is substantially larger than the
core 11, and the core 11 is disposed coaxially of the core 10 and
within the opening of that core. In one presently preferred
embodiment, the core 10 has an inside diameter on the order of
0.375 inch, and the core 11 has an outside diameter on the order of
0.030 inch. The core 11 is formed of a plurality of individual
toroidal core members 16 stacked between a pair of insulative
washers 17. The inductance of the inductor core 11 can be varied by
changing the number of core members 16 in the stack. While the
toroidal core 10 is shown as comprising a single core member, this
core can also be formed of a plurality of stacked core laminations
if desired.
The spindle 12 lies on the axis 18 of the toroidal core 10 and
passes axially through the opening in the inductor core 11. This
spindle is fabricated of an electrically conductive material such
as copper. The casing 13 is likewise fabricated of an electrically
conductive material. This casing is formed in two sections 13a, 13b
which are joined together at 19 in the central plane 21 of the
toroidal core 10. The casing 13 is generally toroidal in shape, and
each of the sections 13a, 13b includes a central web portion 22.
These web portions are formed to include axially disposed openings
23 through which the spindle 12 passes. The web portions of the
casing sections are connected to the ends of the spindle by
conventional means such as soldering, as indicated at 24. The joint
at 19 between the two casing sections is likewise formed by
conventional means such as soldering.
It is to be noted that the casing 13 and the spindle 12 together
form a single-turn winding which links both the toroidal core 10
and the inductor core 11. The casing also protects the cores 10 and
11 from mechanical damage.
A plurality of windings, designated generally by the reference
numeral 26, are provided on the toroidal core 10. At least one of
these windings is formed of a plurality of turns wound on the core
10 and is thereby adapted for connection to the multiple-turn
winding such as the secondary winding of a differential
transformer. Each of the windings 26 is provided with a pair of
leads 27 which extend through an opening 28 formed in the casing
13.
Operation and use of the coupling transformer assembly shown in
FIGS. 1-4 can now be described briefly. Let it be assumed that one
of the windings 26 on the toroidal core 10 has been connected to
the secondary winding of a differential transformer in a ground
fault detector. Let it further be assumed that a second of the
windings 26 has been connected to the output of a pulse generator
and that a third of these windings is utilized as an output winding
and is connected to suitable means such as a silicon controlled
rectifier. The occurrence of a ground fault produces a current in
the secondary winding of the differential transformer and the first
of the windings 26. This current produces a magnetic flux in the
toroidal core 10. The flux in the core 10 produces a current in the
single-turn coupling link formed by the spindle 12 and casing 13.
Since this link passes through the opening in the inductor core 11,
the current in the link causes a change in the state of flux in the
inductor core. This change in flux can be thought of as storing the
fault signal in the inductor core.
When a readout pulse of the proper polarity is applied to the
second of the windings 26, it is coupled to the inductor core 11
through the spindle and casing. The stored flux signal is read out
of the inductor core and delivered back to the toroidal core 10
through the spindle and casing. This readout flux signal produces
an output signal in the third of the windings 26. Alternatively,
the third winding on the toroidal core 10 can be eliminated in
which case the readout flux signal can be delivered by either the
primary or secondary winding.
The embodiment illustrated in FIGS. 5-7 includes a toroidal core
31, first inductor core 32, a second inductor core 33, a spindle
34, and a casing assembly 36.
The cores 31-33 are fabricated of magnetic materials and disposed
coaxially of each other. The toroidal core 31 is provided with a
winding 37 having a plurality of turns wound on the core. A pair of
leads 38 provides connections to the winding 37. Each of the
inductor cores 32, 33 is formed of a plurality of individual
toroidal core members 39, the number of which can be varied to
provide the desired inductance in the inductor cores.
The spindle 34 extends along the axis of the toroidal core 31 and
passes through the opening of this core. This spindle is formed to
include a cylindrical central portion 41 with cylindrical stems 42
extending axially from the ends thereof. An annular recess 43 is
formed at each end of the central portion 41 adjacent the stem 42.
The inductor cores 32, 33 are mounted on the stems 42 and disposed
in the recesses 43. They are retained in place by insulative
washers 44 mounted on the stems. The toroidal core 31 is disposed
over the central portion 41 of the spindle.
The casing assembly 36 includes a cylindrical sidewall 46, disposed
coaxially of the toroidal core 31, and a pair of circular end walls
47. The sidewall is joined to the end walls by conventional means
such as soldering. Each of the end walls is formed to include an
axially disposed central opening 48 through which the stems 42
extend. The stems are connected to the end walls by conventional
means such as soldering. The sidewall 46 is formed to include an
opening 49 through which the leads of the transformer pass.
The spindle 34 and casing assembly 36 are fabricated of an
electrically conductive material such as copper. Together they form
a single-turn winding which links the toroidal core 31 with the
inductor cores 32, 33.
An additional one-turn winding 51 is provided on the toroidal core
31. This winding includes a center tap 52 which is connected to the
central portion 41 of the spindle. Leads 53, 54 provide means for
making connections to the winding 51. Conductors 56, 57 are
provided for making additional connections to the end walls 47 of
the casing assembly. One end of each of these conductors passes
through an opening 58 in the end wall and is soldered thereto. The
other ends of these conductors are joined together at 59 to form a
common conductor. The conductors 56, 57 are formed of insulated
wire and are wrapped around the conductors 53, 54.
Operation and use of the embodiment illustrated in FIG. 5-7 can now
be described briefly. Let it be assumed that the winding 37 on the
toroidal core 31 has been connected to the secondary winding of a
differential transformer in a ground fault detector. Further, let
it be assumed that the leads 53, 54 and the common conductor 59
have been connected to a source of pulses. A ground fault signal is
coupled to the toroidal core 31 through the winding 37, and from
there it is coupled to the inductor cores 32, 33 through the
single-turn winding comprising the spindle 34 and casing assembly
36. As before, the fault signal is stored in the inductor cores in
the form of a magnetic flux signal. When a readout pulse of either
polarity is applied to the inductor cores through the leads 53, 54
and the common conductor 59, a stored flux signal is coupled back
to the toroidal core 31 through the spindle and casing. From the
toroidal core it is coupled back to the differential transformer
secondary.
While the transformer assembly of the present invention has been
described with specific reference to ground fault detectors and
current interrupters, its use is not limited thereto. The
principles disclosed herein can be utilized in coupling toroidal
cores in many other applications, including amplitude, frequency,
and phase modulators. The magnetic properties of the toroidal and
inductor cores can be chosen in accordance with the requirements of
the particular application.
When combined with a differential transformer of the type commonly
used in ground fault interrupters, the coupling transformer of the
present invention provides an efficient means of coupling the
one-turn primary windings of the differential transformer to a
small toroidal inductor core having a single-turn winding of very
low impedance. At the same time, this coupling transformer assembly
permits multiple-turn windings to be used for delivering readout
pulses to the inductor core and for delivering output signals
therefrom. With this transformer assembly and load currents on the
order of 15 amperes to hundreds of amperes flowing in the primary
windings of the differential transformer, fault currents as small
as a few milliamperes produce usable signals in the inductor
cores.
The use of a multiple-turn secondary winding on the differential
transformer and a multiple-turn primary winding on the coupling
transformer provides a close coupling with very little leakage
inductance. In the preferred embodiment, these windings include a
full layer of turns on each of the cores. This construction has
been found to provide optimum coupling between the one-turn primary
windings of the differential transformer and the one-turn winding
of the inductor core. The differential transformer secondary and
coupling transformer primary windings are connected together to
form a transmission line loop having impedance values of more
convenient proportions than the one-turn windings would permit. The
size of the toroidal core in the coupling transformer can be chosen
to accommodate any additional windings that may be desirable for
purposes such as modulation, biasing, and readin or readout.
It is apparent from the foregoing that a new and improved coupling
transformer assembly has been provided. This assembly permits the
coupling of two or more toroidal cores with a minimum of resistance
and stray inductance. In addition, it provides protection for the
cores against mechanical damage. While only the presently preferred
embodiments have been described herein, as will be apparent to
those familiar with the art, certain changes and modifications can
be made without departing from the scope of the invention as
defined by the following claims.
* * * * *