Abstract:
A preferred method for manufacturing a transformer winding includes winding an electrical conductor into a first plurality of turns, placing an electrically insulating material having adhesive thereon over the first plurality of turns, and winding the electrical conductor into a second plurality of turns over the electrically insulating material. The preferred method also includes melting and curing the adhesive by energizing the electrical conductor so that a current greater than a rated current of the transformer winding flows through the electrical conductor.
Abstract:
A preferred method for forming a transformer winding (10a, 10b, l0c, 11a, 11b, 11c) includes providing a length of copper wire (16) having a substantially circular cross section, flattening the length of copper wire (16) in two dimensions on a substantially simultaneous basis, and winding the length of copper wire (16) into a first layer of adjacent turns (20).
Abstract:
A preferred method for forming a transformer winding (10a, 10b, l0c, 11a, 11b, 11c) includes providing a length of copper wire (16) having a substantially circular cross section, flattening the length of copper wire (16) in two dimensions on a substantially simultaneous basis, and winding the length of copper wire (16) into a first layer of adjacent turns (20).
Abstract:
A preferred embodiment of a three-phase transformer (100) includes a first (104), a second (106), and a third winding leg (108), and a first, a second, and a third winding positioned around the respective first, second, and third winding legs. The first, second, and third windings (10) each includes an electrical conductor (16) wound into a plurality of overlapping layers each formed by a plurality of adjacent turns of the electrical conductor, and an insulating material (18) without end fill positioned between each of the overlapping layers. The electrical conductor has a transition portion formed therein between a first and a second of the overlapping layers. The transition portion is at least one of bent to form an offset in the electrical conductor, and secured to at least one of the plurality of adjacent turns.
Abstract:
A preferred embodiment of a three-phase transformer includes a first, a second, and a third winding leg, and a first, a second, and a third winding positioned around the respective first, second, and third winding legs. The first, second, and third windings each includes an electrical conductor wound into a plurality of overlapping layers each formed by a plurality of adjacent turns of the electrical conductor, and an insulating material without end fill positioned between each of the overlapping layers. The electrical conductor has a transition portion formed therein between a first and a second of the overlapping layers. The transition portion is at least one of bent to form an offset in the electrical conductor, and secured to at least one of the plurality of adjacent turns.
Abstract:
Method for manufacturing a transformer winding includes winding an electrical conductor (16) into a first plurality of turns, placing an electrically insulating material (18) having adhesive thereon over the first plurality of turns (20), and winding the electrical conductor into a second plurality of turns (22) over the electrically insulating material (18), melting and curing the adhesive (18b) by energizing the electrical conductor.