Суханов Владимир Николаевич
New construction of three-phase transformer without copper windings

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1. New construction of three-phase transformer without copper windings

2. Technology of assemblage of transformer without copper winding

3.

  

1. New construction of three-phase transformer without copper windings

   In 1984, the inventor obtained author's certificate of the USSR N 1089639, ICI: H01F33/00 by name three-phase transformer, in which the role of copper windings are replaced by a steel magnetic circuit. This transformer preserves all parameters of the traditional one, but does not use expensive copper. The economic advantage of this transformer is not requiring the use of copper.
   The conductors of magnetic flux and the current-conducting windings which mutually encircle each other under the 60o angle are one and the same. Such mutual encirclement is necessary for closing the magnetic fluxes around the electric currents which themselves have been created by the magnetic fluxes. This ensures that Faraday's law of induction (M. Faraday, 1831) with apply to the transformer. According to that action, the magnetic circuit must intersect the electrical winding conductors at an angle of 90o. The Faraday Effect will be most effectively used and this characteristic will be greatest under the described condition. However, in the newly designed transformer, we must examine any short-comings since the angle is set at 60o.
   The suggested new layout of the transformer without copper windings, is one in which the electrically conducting windings (magnetic circuit) intersect under an angle of 90o. The winding (magnetic circuit) in each transformer is in form of concentric system which encircles two other analogous systems, and all they are located relative to each to other under an angle 90o (see Fig.1)

Transformer [Владимир Суханов]

Fig. 1

   where 1, 2 and 3 are (primary and second) windings of all three phases.

   The transformer, on author's certificate N 1089639, has other deficiencies. It inherited the proposed transformer (see Fig.1). The fact is that assembling of such transformers is difficult.
   A new type transformer of construction of this transformer is now propelled to improve its technological effectiveness. Coiling of all three concentric systems of this transformer is produced simultaneously and as a result it presents the united three-dimensional concentric system (see Fig. 2),

Transformer 2 [Владимир Суханов]

Fig. 2

   where 1, 2 and 3 are windings of three phases.

   Fig. 3 shows a method by which coiling of the new transformer could take place.

Transformer 3 [Владимир Суханов]
Fig. 3

   where 1, 2 and 3 are steel tapes covered with isolation and wound into cylinders 4, 5 and 6 respectively. Each cylinder revolves on the axis with rods 7, 8 and 9 respectively. Each rod is attached to shafts 10, 11 and 12 respectively. The axes 13, 14 and 15 of each shaft 10, 11 and 12 are respectively directed toward the middle of plane 16, of 17 and 18 of the central technological cubes respectively. The cube is fixed at base 19 by means of rod 20, whose axis penetrates the complete diagonal of the cube. Shafts 10, 11 and 12 revolve synchronously. This ensures simultaneous windings of the transformer coil. Windings of the phases are connected by a known method. The technological cube is prepared from the magnetic soft material.
   A proposed constructive solution can now be found for the development and production of weak transformers. For developing of transformers of average power, further developments must be referred to the author.
   Description of the new three-phase transformer was registered as intellectual product in the All-Russian scientific and technical centre (VNTIC) of the ministry of industry, science and technologies of the Russian Federation on 25 December of 2000 years under number 72200000050. Text of the description is stored in the information fund VNTIC.
   The article was published in the book "Inventive Creation" ISBN: 5-94990-002-2 in Russian language in 2003.
   Vladimir Sukhanov 2000-2003
  
  

2. Technology of assemblage of transformer without copper winding

   Assemblage of weak power transformer. Materials and design features.
   About 150 years passed from time of transformer invention by M. Faraday. For that time in the world about million different inventions also constructive offers for improvement of the transformer were made. In all those case the construction of transformer, technology of its assembly, repair, cooling, and diagnostics, fastening and much other were developed and improved.
   Transformer without copper winding is concerning young. This construction is new. Calculations and production of the new construction transformer require of new approaches and new procedures. Therefore inventors still need work on its improvement and ensure its fitness for work in all modes of its operation under varied conditions of our diverse life.
   This article is beginning in the prolonged and tedious process of generation and propagation of the new transformer.
   Prototype of suggested three-phase transformer without copper winding is transformer registered in VNTIC, 25 December of 2000 years under N 72200000050.
   The best material for preparing of the new transformer is thin wires of soft-iron steel with good electrical conduction and with the smallest coercive force. To all these requirements corresponds chemically pure iron. Also can be used iron refined by electrolysis.
   Special steels for the new transformer are not yet developed. Traditional electro-technical (transformer) steels for preparing the new transformer are unfit.
   If you do not have necessary iron for preparing the transformer then using unalloyed steels with the smallest carbon content or even nail steel is permissible, but in this case you must know that all advantages of the new transformer that you can get.
   Iron wires must be thin, non-brittle and with varnish isolation. The bundles of the necessary thickness are formed from the thin wires. Each bundle can be placed into insulation. Isolation varnish is brushed off at the ends of the bundles in thin wires and then the cleaned surfaces of the wires are tinned and soldered.
   In the new transformer of wire of primary and secondary windings as a rule, are multiple-wires. All wires are insulated between themselves. This is basic difference from the construction of traditional windings. This is necessary for suppression of eddy currents.
   It is necessary framework for preparing of the transformer. On that framework is made coiling of windings from the multiple-wires bundles on technology of production of traditional toroidal transformer with using of a shuttle.
   Framework of the new transformer can be prepared from strong insulation material (plastic). This framework consists of three identical sections; each of them is for independent phase of the transformer (see Fig. 1). Only difference from its prototype is in this transformer, namely, this is presence of clearances between the sections for passing of coil shuttle.

Transformer 4 [Владимир Суханов]

Fig. 1

   where - 1, 2 and 3 are three sections of framework for coiling of windings by bundle wire,
   - 4 is space between the sections for passage of coil shuttle.
   Construction of one-phase transformer without copper winding is possible. For that the primary and secondary windings in form of united concentric system, wound from iron varnished wire, must be tied into "monkey assembly" (see Fig. 2). This construction can be prepared, plotting winding wires along transformer framework which looks as "monkey assembly". Winding wire before the coil of transformer is winding on shuttle for convenience.
   The concentric system of windings of transformer, tied on form "monkey assembly", has the following special feature: each section of the winding is perpendicular with respect to its other sections. That let us to direct electric current and magnetic flux along one ferromagnetic electrically conducting concentric system of windings. In this case direction of electric current always intersects magnetic flux under angle 90 o, and this is condition for work of the transformer.

Transformer 5 [Владимир Суханов]

Figure 2

   It follows to note that the "monkey assembly" was known from the immemorial times. It is surprised 'How ancient people can know this construction?'
   Author - Vladimir Sukhanov
   It was registered in VNTIC, 19 April of 2002 years under number 72200200011.
It was published in the bulletin VNTIC "Ideas. Hypothesises. Solutions" N 2, 2002 years.
   The article was published in the book "Inventive Creation" ISBN: 5-94990-002-2 in Russian language in 2003.
   Copyright - Vladimir Sukhanov 2000-2003
  
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