Efficiency Increase in Railway Technology Transformers
Litz Wire Solutions for Railway Power Supplies
PACK LitzWire, together with a railway technology manufacturer, developed an optimized litz wire winding for transformers that reliably conducts high currents, avoids thermal hotspots, and simultaneously reduces component volume.
The Application
For a project in railway technology, PACK LitzWire supported a manufacturer in the development of transformers that had to handle extremely high currents while meeting the strict safety requirements of the railway.
The Challenge
The challenge was to efficiently handle large current cross-sections without creating local overload points or hotspots that could compromise the safety systems. At the same time, the insulation had to withstand high thermal and mechanical stresses – reliability was mission-critical.
The optimized litz wire winding enables uniform current distribution at very high currents and forms the basis for compact, efficient transformers in safety-critical railway power applications.
The reinforced insulation and fixation concept with HF litz wire and aramid materials is designed for the high thermal, mechanical, and normative requirements of railway technology and supports long-term reliable operation.
Solution Strategy
PACK LitzWire proposed the use of a high-frequency litz wire system. The many fine individual wires distributed the current almost evenly over the entire winding, thereby avoiding local overloads and thermal peaks. In addition, aramid adhesive tapes were integrated to increase the mechanical strength of the winding and absorb vibrations or shocks.
Result
Through these measures, the customer was able to realize a transformer that was not only more compact than conventional solutions but also showed significantly lower power losses. The optimized litz wire winding made it possible to comply with the strict railway standards while improving energy efficiency and reducing component volume – a decisive advantage for the reliable operation of high-current applications in trains.
RUPALIT® Safety Profil
The VDE-certified safety of a triple-insulated structure meets the extreme packing density of a profiled geometry. Due to the sealed film insulation, every millimeter of winding space is used efficiently, while the highest dielectric strength remains guaranteed.
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