U.S. patent number 3,732,514 [Application Number 05/158,334] was granted by the patent office on 1973-05-08 for transformers.
Invention is credited to Ryoda Sato.
United States Patent |
3,732,514 |
Sato |
May 8, 1973 |
TRANSFORMERS
Abstract
Electric transformers, such as for spot welding machines and the
like, which have at least the secondary winding divided into
sections of less than one turn so as to obtain a large current at a
low voltage, such as one-half, one-third or one-fourth turns.
Inventors: |
Sato; Ryoda (Amagasaki,
JA) |
Family
ID: |
26408982 |
Appl.
No.: |
05/158,334 |
Filed: |
June 30, 1971 |
Foreign Application Priority Data
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|
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Jul 7, 1970 [JA] |
|
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45/67768 |
Oct 2, 1970 [JA] |
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45/86772 |
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Current U.S.
Class: |
336/172; 336/212;
336/232; 336/183; 336/223; 336/234 |
Current CPC
Class: |
H01F
27/25 (20130101); H01F 29/025 (20130101); H01F
27/2847 (20130101); H01F 30/10 (20130101) |
Current International
Class: |
H01F
30/06 (20060101); H01F 30/10 (20060101); H01F
29/02 (20060101); H01F 29/00 (20060101); H01F
27/28 (20060101); H01F 27/25 (20060101); H01f
027/28 () |
Field of
Search: |
;336/172,182,183,232,215,223,212,234 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Kozma; Thomas J.
Claims
What I claim Is :
1. A transformer comprising an iron core and thereon primary and
secondary coils constituted by electrically interconnected discrete
coil sections, said iron core being formed of laminates in the
shape of a framework, said coil sections being electrically divided
into mechanically continuous, seamless plural coil components which
successively cross said iron core, said components in the primary
coil section being at least one full turn while said components in
the secondary coil section are less than one turn in length,
thereby generating in said secondary coil section a large current
at a low voltage.
2. The transformer as defined in claim 1, wherein said coil
components are equally divided into portions of less than one turn,
each component being crossed by said iron core in an equal
arrangement.
3. The transformer as defined in claim 1, wherein said coil
components are made of electroconductive sheet material, and an
appropriate number of said components is successively piled
together in the direction of their thickness.
4. The transformer as defined in claim 1, wherein said iron core
includes seamless component sheets having substantially identical
central openings, piled together so that said openings overlap in
coincidence, each coil component being allotted to a respective
portion of said framework and inserted through said openings.
5. the transformer as defined in claim 1, further comprising
seamless component sheets having central openings of substantially
identical outline, said sheets being wound in shapes to constitute
said iron core, each coil component being allotted to a respective
portion of said framework and inserted through said openings.
6. The transformer as defined in claim 1, wherein said iron core
encloses said coil sections and is constructed of plural shapes of
blocks having different dimensions so as to fill an opening inside
said framework.
7. The transformer as defined in claim 1, wherein said framework
has a polygonal shape.
8. The transformer as defined in claim 1, wherein said framework
has a substantially circular shape.
Description
In the function of an electric welder such as a spot welding
machine, important is the current value but not the voltage. For
example, a large current is required to work on material of large
thickness.
It is evident in general that a definite electric power can serve
to obtain a large current when it is transformed to a low-voltage
condition.
In this type of conventional transformers, however, large
transformer dimensions are inevitable to obtain a great current for
welding because the minimum limit of the secondary winding is one
turn.
The present invention is designed to provide a constitution of a
transformer in which the secondary windings are divided into minute
components less than one turn to obtain a large current with a low
voltage.
DETAILED DESCRIPTION OF THE INVENTION
The present invention relates generally to electric apparatus, and
more particularly, transformers employable for electric welders
such as spot-welding machines and the like which are required to
furnish a large current with a low voltage for a great power
output.
This type of conventional transformers could not have the secondary
winding portion less than one turn because of the structural
constitution. If the number of turns of the primary coil is
diminished for a countermeasure, the secondary voltage or output
voltage rises and a very large input power is necessary to obtain a
great current. For example, when a transformer of a welding machine
for the input power 500 KVA is designed, the voltage of power
source 200 V requires eight turns of primary winding, and one turn
of secondary coil corresponds to 25 V.
Provided an instantaneous welding current of 50,000 amp. is
required, the necessary instantaneous input will be 1,250 KVA and
the primary current 6,250 amp. These data suggest a great uneconomy
with a transformer requiring a large current at a low voltage such
as an electric welder.
On the other hand, when the coil and the iron core of this type of
transformer are constructed, it is normal to wind the coils and
have oblong iron sheets cross them, the coils being connected in
series, so that these iron sheets may be overlapped to form a frame
work as a magnetic core. However, in order that the iron sheets
cross the coils, connected in series to construct a coil-pile, at
least one seam or junction had to be formed and, therefore, the
resulting magnetic resistance, produced by the jointing gap,
inevitably deteriorated the function of transformer. On the other
hand as regards the case of employing a spiral core, disadvantages
similar to those as above mentioned have been found because the
winding process was practised by cutting off the spiral core,
fitting the coil on the spiral core and joining the cut
sections.
One object of the present invention is to furnish an improved
transformer of the above mentioned structural type, applicable to a
wide field of utilization, and more particularly, in which the
combination of coil windings and iron cores is improved so that the
length of the turns in the secondary winding is reduced to less
than one turn, for example, one-half turn, one-third turn or
one-fourth turn, which has not yet been realized, thereby
increasing the output current produced from the same input
power.
Another object of the invention is to form coil sections from
plural winding components by dividing equally the secondary winding
of the mentioned type of transformer into quotients of one turn,
wherein the winding components are crossed in series by the core
blocks of the same shape, and the electric powers of equal voltage
corresponding to a winding component less than one turn are
supplied from the terminals of each winding component of the
secondary winding so that the output voltage may be optionally
selected by connecting these winding components appropriately in
series and in parallel.
Further object of the invention is to furnish a transformer of
which each winding component for the primary and secondary coils
can be formed by one stamping strike from a sheet material which is
a good electric conductor, piled alternatingly with isolating
sheets to be fastened into one assembly block, and connected in
respective adequate manner whereby the apparatus can be minified,
the magnetomotive force may not be large, the power factor can be
improved, and the leakage flux can diminish so as to provide an
apparatus of high efficiency.
Furthermore an object of the invention is to propose a transformer
of the mentioned type of which the iron core is composed of
seamless component sheets to make a closed magnetic circuit and
which can save exciting current.
Another object of the invention is to propose an apparatus of the
mentioned type which produces magnetic fluxes as many as possible
with a definite magnetomotive force to improve efficiency so that
the produced fluxes may cross the secondary windings in series
efficiently, thereby curtailing the mean magnetic circuit of the
iron core constituting magnetic circuit to reduce the magnetic
resistance.
Other objects, characteristics and advantages of the present
invention will be demonstrated in the following description, the
attached claims and enclosed drawings, in which:
FIG. 1 is a plan view of an exemplary embodiment of the transformer
of the invention;
FIG. 2 is a side elevation for the transformer of FIG. 1;
FIG. 3 (1) to (4) shows side elevations of iron core components for
the transformer of FIG. 1;
FIG. 4 and 5 are plan views of primary and secondary winding
components for the transformer of FIG. 1;
FIGS. 6 and 7 are plan views of other examples of respective
winding components;
FIG. 8 shows another example of the invention and is a side
elevation of a transformer constructed with a ring-type wound iron
core;
FIG. 9 shows another example of the invention and is a side
elevation of a transformer constructed with a rhombic wound iron
core; and
FIG. 10 shows a further example and is a side elevation of a
transformer constructed with a pyramidal wound iron core.
To illustrate with reference to the drawings, an exemplary
embodiment of the transformer of the invention is generally
represented with numeral 10. This apparatus is composed of a iron
core 12 of the iron enclosure type and a coil or winding section
14.
Iron core 12 is constructed of blocks 16, 18, 20 and 22, which are
formed by the combination of iron cores of different dimensions so
that every side of square coil sections 14 may be crossed in series
by said iron cores, and which are disposed abutting against each
other to build a cross structure.
As shown in FIG. 3 (1) - (4), respective iron cores for forming the
core blocks 16, 18, 20 and 22 are constructed in the manner that a
predetermined numbers of iron core components 24, 26, 28 and 30 of
the same dimensions among those components of different dimensions
are piled separately with respective openings punched in the
centers of seamless rectangular iron sheets.
On the other hand, the coil section 14 is constructed in the manner
that, when the iron core components 24, 26, 28 and 30 have been
piled separately, respective primary and secondary coil or winding
components 34, 36, composed of electroconductive sheet material
divided uniformly along each side of a square frame-shaped space
32a, which was formed by the penetration of punch hole 32, are
disposed in the shape of said frame-shaped space 32 (see FIG. 3)
and these components for the primary and secondary coils are
alternately piled with inserted insulating sheets. Terminal lugs 38
and 40 are provided respectively at both ends of the primary and
secondary coil components 34, 36. It should be noted from FIGS. 4
to 7 and others that all coil components are continuous or
seamless, the terminal lugs constituting the points of electrical
interconnection.
The mentioned iron core 12 and coil section 14 may be constructed
as follows: A predetermined number of either the primary or
secondary components 34 or 36 (herein the former components will be
considered) are piled together, are successively penetrated with
punch hole 32 for the iron core components 24, 26, 28 and 30 to
heap up to predetermined thicknesses and build iron cores, and the
resulting members are combined to form respective iron cores 16,
18, 20 and 22.
Then each secondary coil component 36 is inserted together with
insulating material layer such as glass fiber between adjacent
primary coil components 34, and the resulting structure is fastened
together with insulating rods or the like. Terminal lugs 38 and 40
are appropriately connected to constitute the primary coils and the
secondary coils.
After then these prepared members are disposed in a square shape to
complete the winding section 14. The iron core blocks 16, 18, 20
and 22 are abutted against one another to form a cross shape. They
are brought to close contact together to fill the square space
enclosed by the core frame of the winding section 14, thus building
iron core 12. In this construction, each core block 16, 18, 20 or
22, connected with iron core 12, crosses successively each side of
square winding section 14, i.e. each primary and secondary coil
component 34 or 36 in the same condition of arrangement so that the
primary and secondary coil components 34 and 36 are firmly enclosed
into the frame-shaped space 32a penetrated by the punch hole 32
whereby the average magnetic circuit is much shortened. Therefore
the characteristics of transformer are improved to obtain larger
output of the secondary coil with smaller magnetomotive force.
In addition to the improvements of the characteristics of the
transformer, the compact combination of iron core 12 with coil or
winding section 14 and the exclusion or surplus iron core sections
can assure a weight reduction of conventional transformers as
compared to the same capacity.
Furthermore, since iron core 12 is composed of the iron laminate
structure piled together with core components 24, 26, 28 and 30 of
which four sides are continued without seam, so the magnetic
circuit becomes a completely closed magnetic circuit so that the
exciting current may be reduced.
Now the function of the inventive transformer 10 will be explained:
Primary coil components 34 are connected together in series to
amount to the predetermined number of turns, and secondary coil
components 36 are connected appropriately in series or in parallel,
so that very low voltage corresponding to less than one coil turn
such as one-fourth, one-half or three-fourths turn may be obtained
from the secondary coil and also voltages corresponding to one,
five-fourths or three-halves turns may be taken out. Particularly,
in the former case the same primary input as that applicable to
conventional apparatus can produce a larger current with a lower
voltage.
For example, in a transformer of a welding machine for an input of
500 KVA, the power source of 200 V requires eight turns of primary
winding to yield 25 V per one turn of secondary winding, but
because one turn is divided into quarters one-fourth turn
corresponds to 6.25V. Therefore, if 50,000 amp. is obtained with
this voltage, 200,000 amp. can be taken out of the secondary coil.
Suppose that 50,000 amp. are sufficient for the welding current,
then primary current may be 1.562 amp. This fact will be
particularly desirable for power source equipments and control
apparatus etc.
The transformer of the above-described example is constituted in
the manner that each side of square winding section 14 is
divided.
However, as shown with another example in FIG. 6, both or one of
the primary and secondary coil components 34 and 36 may be disposed
to form a substantial rectangle together with a coil component 42
so that the two adjacent sides make an L-combination, or otherwise
as shown in FIG. 7 the rectangle may be composed of a U-shaped coil
component 44 with three consecutive sides and said component 34 or
36.
Furthermore, the primary coil component also may be electrically
interrupted only at one point but have four sides continued
together.
Hereinbefore the examples were described in the case that the
primary and secondary coils were arranged alternatively. In the
present invention, however, concentrated type or the type of the
primary and secondary coils being respectively collected are
practicable, too, and moreover the secondary coil may be composed
of the coil constructing components formed in an entirely
collective structure of secondary coil components.
Finally, iron core 12 may be constructed in the shape of a
ring-form wound or circular core 12a as shown in FIG. 8, in the
shape of a rhombic wound core 12b as shown in FIG. 9 and in the
shape of a L-form wound or triangular core 12c as shown in FIG. 10.
The two latter variants constitute polygonal arrangements.
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