Abstract: A versatile distribution transformer having an electromagnetic transformer and a power electronic module is provided. A pocket having connectors electrically connected to at least one winding structure of the electromagnetic transformer is mounted above the electromagnetic transformer. The power electronic module is removably mounted in a cavity of the pocket. The power electronic module includes a plurality of semiconductor switching devices and a plurality of connectors adapted to slidably engage the connectors of the pocket. The power electronic module is movable between a removed position, wherein the power electronic module is located outside the pocket, and an installed position, wherein the power electronic module is disposed in the cavity of the pocket and the connectors of the power electronic module engage the connectors of the pocket so as to electrically connect the power electronic module to the at least one winding structure.

Abstract: A versatile distribution transformer having an electromagnetic transformer and a power electronic module is provided. A pocket having connectors electrically connected to at least one winding structure of the electromagnetic transformer is mounted above the electromagnetic transformer. The power electronic module is removably mounted in a cavity of the pocket. The power electronic module includes a plurality of semiconductor switching devices and a plurality of connectors adapted to slidably engage the connectors of the pocket. The power electronic module is movable between a removed position, wherein the power electronic module is located outside the pocket, and an installed position, wherein the power electronic module is disposed in the cavity of the pocket and the connectors of the power electronic module engage the connectors of the pocket so as to electrically connect the power electronic module to the at least one winding structure.

Abstract: A method and apparatus for describing and managing properties of a transformer coil. A metadata text file is generated which contains metadata describing objects of the transformer coil. The objects are arranged hierarchically and have one or more related properties attached therewith. One or more properties of one object refer to one or more other properties of the same object or of other objects by means of paths defined in the metadata text file. The generated metadata text file is then stored.

Abstract: A method and tool for creating documentation for a transformer design uses design files created during the transformer design process to generate drawings and other information necessary to populate documentation. The design files contain information relating to the physical layout of all of the components of the coil as well as the electrical connectivity of the windings. The method and tool retrieve the design information, construct the associated drawings, format the drawings to the appropriate sizes, and display any associated text.

Abstract: A method and product are described for creating a model of a physical layout and/or a circuit layout of an electrical device. The layouts are defined in a user interface. A text file having metadata elements in a hierarchical format is produced that can be used by other programs.

Abstract: A method of manufacturing a dry-type, resin-encapsulated transformer coil that includes forming a plurality of conductive layers and positioning a plurality of pre-formed plastic cooling ducts so as to be disposed between the conductive layers.

Abstract: A method and system are described for creating a metadata text file corresponding to a geometry of a physical layout and/or a circuit layout of an electrical device. The layouts are defined in a user interface. A text file having metadata elements in a hierarchical format is produced that can be used by other programs.

Abstract: A method of fabricating electrical core sheet assemblies such as transformer limbs, transformer yokes, and transformer cores, includes the steps of first cutting electrical core sheets, whose main surfaces have been provided with an anti-corrosion layer, into a desired shape. The side surfaces of the cut core sheets are first provided with an anti-corrosion layer, before the cut core sheets are assembled into the desired core sheet assembly.

Abstract: A winding for a transformer or a coil having a ribbon electrical conductor and an insulating material layer composed of ribbon insulation material wound jointly to form turns around a winding core. The individual turns of the winding have a predetermined winding angle with respect to a winding axis of the winding core and are disposed such that they partially overlap one another. An insulating layer is inserted between two radially adjacent layers of the turns. Furthermore, a thickness of the insulating layer is locally matched to the voltage difference determined there. In addition, the thickness of the insulating layer is locally matched, the thickness being interchanged in sequence of the method A+B determined there, to the voltage difference between the two relevant radially adjacent layers at the relevant axial point.

Abstract: A dry-type, resin-encapsulated transformer coil that includes multiple layers formed from a length of conductive material, and multiple cooling ducts that are formed of thermoplastic material and spaced between the layers of conductive material. The thermoplastic material forming the cooling ducts and the resin that encapsulates the multiple layers of conductive material are thermally and electrically compatible.

Abstract: A presently-preferred process for manufacturing a magnetic-induction device comprises stacking a plurality of laminae to form a winding leg, a first yoke, and a second yoke, and fixedly coupling a first end of the winding leg to the first yoke. The presently-preferred process also comprises winding a length of insulated conductive cabling on the winding leg to form a phase winding after fixedly coupling the winding leg to the first yoke, and fixedly coupling a second end of the winding leg to the second yoke after forming the phase winding. Alternatively, the length of insulated conductive cabling may be wound on the winding leg after the second end of the winding leg has been fixedly coupled to the second yoke.

Abstract: An internal heating method for drying, gelling and final curing of epoxy resin insulation systems used for encapsulating dry type cast distribution transformer coils is disclosed. The internal method uses a Direct-Current (DC) power source to control and supply DC current to resistively heat the transformer coil encapsulated with a liquid resin under vacuum in a mold. DC current is applied to a given coil based on its conductor cross-sectional area and its epoxy resin quantity to achieve a specified temperature for drying, gelling and final curing. The temperature, controlled by DC resistive heating is maintained for a given period for each step.

Abstract: A winding for a transformer or a coil having a ribbon electrical conductor and an insulating material layer composed of ribbon insulation material wound jointly to form turns around a winding core. The individual turns of the winding have a predetermined winding angle with respect to a winding axis of the winding core and are disposed such that they partially overlap one another. An insulating layer is inserted between two radially adjacent layers of the turns. Furthermore, a thickness of the insulating layer is locally matched to the voltage difference determined there. In addition, the thickness of the insulating layer is locally matched, the thickness being interchanged in sequence of the method A+B determined there, to the voltage difference between the two relevant radially adjacent layers at the relevant axial point.

Abstract: An internal heating method for drying, gelling and final curing of epoxy resin insulation systems used for encapsulating dry type cast distribution transformer coils is disclosed. The internal method uses a Direct-Current (DC) power source to control and supply DC current to resistively heat the transformer coil encapsulated with a liquid resin under vacuum in a mold. DC current is applied to a given coil based on its conductor cross-sectional area and its epoxy resin quantity to achieve a specified temperature for drying, gelling and final curing. The temperature, controlled by DC resistive heating is maintained for a given period for each step.

Abstract: Electrical core sheet assemblies such as transformer limbs, transformer yokes, and transformer cores, are produced by first cutting electrical core sheets, whose main surfaces have been provided with an anti-corrosion layer, into a desired shape. The side surfaces of the cut core sheets are first provided with an anti-corrosion layer, before the cut core sheets are assembled into the desired core sheet assembly.

Abstract: A presently-preferred process for manufacturing a magnetic-induction device comprises stacking a plurality of laminae to form a winding leg, a first yoke, and a second yoke, and fixedly coupling a first end of the winding leg to the first yoke. The presently-preferred process also comprises winding a length of insulated conductive cabling on the winding leg to form a phase winding after fixedly coupling the winding leg to the first yoke, and fixedly coupling a second end of the winding leg to the second yoke after forming the phase winding. Alternatively, the length of insulated conductive cabling may be wound on the winding leg after the second end of the winding leg has been fixedly coupled to the second yoke.

Abstract: A method of manufacturing an electrical-power transformer comprises forming a first and a second plurality of laminae from one or more pieces of magnetic material, and applying a corrosion-protection measure to edges of the laminae. The first plurality of laminae are stacked to form a winding leg and a first yoke after the corrosion-protection measure is applied to the edges thereof, and a phase winding is installed on the winding leg. The second plurality of laminae are stacked to form a second yoke after the corrosion-protection measure is applied to the edges thereof, and the second yoke is fixedly coupled to the winding leg.

Abstract: A method of manufacturing a transformer coil encapsulated in casting resin utilizing a disposable casting mold where the disposable mold acts both as a winding mandrel and as an inner mold shell for resin encapsulation. The disposable casting mold may be oval shaped or circular shaped depending upon the desired shape of the coils to be encapsulated. The inner and outer mold shells are made from thin sheet metal and thus may be adjusted for the manufacture of a wide variety of sizes of oval shaped or circular shaped epoxy encapsulated coils.

Abstract: A method of manufacturing transformer windings embedded in casting resin is disclosed which utilizes an integrated winding mandrel for producing a non-standard oval shaped epoxy encapsulated low voltage coil for dry type distribution transformers. The method includes a process of winding a low voltage oval coil over a disposable mold which acts as both a winding mandrel and as an inner mold shell for epoxy encapsulation. Both the inner and outer molds are made of low cost sheet metal utilizing a “wrap and band” process The complete winding and molding processes can all be conducted on a standard winding machine.

Abstract: A method of making various insulated conductor sizes during a transformer coil winding process by slitting and bonding insulating sheet materials and foil sheet conductor into a composite foil conductor/insulation. The method includes folding the composite into a substantially U-shaped length having a central portion between two leg portions with each leg portion having a free end. The method also includes folding the leg portions of the "U" inwardly to a position substantially parallel to the central portion of the "U" to bring the free ends of the leg portions into opposing relation to provide a folded insulated foil conductor having a two-conductor thickness surrounded by insulation. Provision is also made for increasing the cross-sectional area of the conductor.