HF Litz Wire for Power Transformers and Chokes for Railway Technology
Compact, Durable, and Vibration-Resistant
PACK LitzWire, together with a manufacturer of auxiliary power supply components, developed high-frequency optimized litz wire systems for power transformers and chokes that are compact, efficient, and extremely durable – even under high shock and vibration loads.
The Application
For a project in railway technology, PACK LitzWire supported a manufacturer in optimizing power transformers and chokes in the auxiliary power unit (APU). The goal was to reduce component volume and weight, increase energy efficiency, and at the same time meet the extreme requirements of the railway environment.
The Challenge
The challenge was to design the litz wire for windings in such a way that high currents are safely transmitted without creating hotspots or thermal overloads. At the same time, the insulation had to withstand shock and vibration loads and function reliably for over 300,000 operating hours or 30 years. A central aspect was the insulation concept: To mitigate partial discharge risks, the windings were carefully designed based on applicable standards and customer-specific specifications.
The power transformer shows the compact winding design with HF litz wire, specifically developed for high continuous currents, long service life, and use under shock and vibration loads typical for railways.
The detail illustrates the low-partial-discharge insulation concept of the winding with HF litz wire and additional mechanical fixation, designed for decades of operation in the auxiliary power supply of rail vehicles.
Solution Strategy
PACK LitzWire used HF litz wires with fine individual wires that conducted current evenly over the entire cross-section and minimized AC losses. Due to the high copper fill factor, the winding could be designed compactly, while mechanical stability was simultaneously increased through specialized wrapping and resin-bonding techniques, e.g., with aramid tapes. Simulation-based analyses helped to find the optimal balance between installation space, thermal load, and electrical efficiency.
Result
Thanks to this approach, the customer was able to realize power transformers and chokes that were more compact and lighter than conventional solutions, reliably transmitted the required currents, and functioned reliably even after decades of operation. The HF-optimized litz wire in combination with a robust, low-partial-discharge insulation concept thus enabled a durable, efficient, and vibration-resistant solution for auxiliary power supply in trains.
RUPALIT® Plus Profil
This solution combines precise outer insulation wrapping with a square or rectangular profile geometry for maximum space utilization. The reinforced insulation offers the highest dielectric strength and reliably protects against voltage breakdowns in the smallest installation spaces.
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