Inductor, simulation method, computer system, computer program product

Abstract

The invention relates to an inductor (ID0) having at least one core (CRE), the core (CRE) having an at least partially recessed shape at least partially enclosing a spatial volume (CVT), and the inductor having a power connection (TRM). In order to increase the power density, according to the invention, at least some of the power connections (TRM) are arranged at least partially in the volume of space (CVT).

Description

Technical Field

[0001] The invention relates to an inductor having at least one core, wherein the core having an at least partially concave shape at least partially encloses a spatial volume, wherein the inductor has a power connection. Background Art

[0002] The present invention understands an inductor as an electrical or electronic component with a fixed or adjustable inductance value. The term inductance refers not only to a physical quantity in Henry, but also to inductive electrical and electronic components. In power electronics, inductors are designed as passive components to limit the current in power lines, buffer energy in the form of a magnetic field and adjust impedance or for filtering. These components, which are called inductors, include in particular coils, converters, baluns, chokes and transformers. In the following, the terms inductor, coil and choke are used as synonyms.

[0003] As with all other building blocks in power electronics, ever higher power densities are also required in inductors in order to develop more compact filter elements or integrated filter converters. Summary of the invention

[0004] An object of the present invention is to increase the power density of an inductor.

[0005] In the development of inductors, optimization has been carried out in two areas so far. One area is the area of ​​the choke core and the choke winding. The other area is the connection technology. Depending on the power and the current, conventional connection technology can take up up to 25% of the total volume of the choke.

[0006] The invention achieves the object of increasing the power density of an inductor of the type defined in the introduction according to the features indicated in claim 1. The invention enables a higher integration of all inductor components.

[0007] In particular, it is envisaged that at least some of the power connections are at least partially arranged in a spatial volume which is at least partially surrounded by the inductor. Firstly, it follows that the connection technology device is relocated in the previous dead space of the component and that the volume of the connection technology device is also reduced due to the shortening of the connection path. The invention relates not only to the inductor itself, but also to an arrangement which has this inductor according to the invention - also according to the advantageous developments of the invention. In particular, a corresponding arrangement with an inductor according to the invention can in particular be a filter component or a transformer, each comprising an inductor according to the invention.

[0008] According to the invention, the core provided with the inductor is designed as a partial ring or a closed ring. Here, the ring or partial ring can have any shape, in particular different from a circle, for example, an ellipse, an egg, a rectangle or a polygon.

[0009] According to the invention, an elongated power connection is provided, in particular in the form of a screw or current screw, for electrical contacting of, for example, a printed circuit board. The power connection has two ends and is electrically conductively connected to a winding of an inductor in the region of a first end and is prepared or arranged at a second end for connection to an adjacent element.

[0010] A further particularly advantageous development provides that the inductor consists of at least two individual inductors, a core having an at least partially recessed shape at least partially enclosing a spatial volume in each individual inductor, the cores being arranged adjacently so that the individual spatial volumes are arranged adjacently to one another, so that a common spatial volume is formed by the adjacent spatial volumes of the individual inductors, wherein the power connections of the individual inductors are arranged in the common spatial volume. In this way, a multi-current conducting connection, such as a current bolt, with two or more inductors can be implemented in a space-saving manner in the common spatial volume by two ring-core chokes. This thus enables internal wiring of the two inductors and the volume of the device is not increased unnecessarily.

[0011] In order to hold the power connector in a specific spatial position, it is particularly advantageous if at least one holding element attached to the inductor is arranged in the spatial volume, the holding element being mechanically connected to at least some of the power connectors to improve the mechanical integration. It is particularly convenient to produce the holding element by injection molding or to produce the holding element as an insulating glass fiber reinforced plate (GFK). In addition, the current bolt can be injection molded in the molding process so that all current bolts and holding elements can be formed into a mechanical unit. It is convenient here if the holding element is made of a non-conductive material or is attached to at least some of the power connectors to be held in an electrically insulating manner.

[0012] Alternatively, the holding element can be connected to at least some of the power connections in an electrically conductive manner as a conductor element equipped with components or as a printed circuit board equipped with components. This embodiment not only saves space above the inductor, but also reduces the impedance of the connection line, because the connection of the components (e.g. capacitors) can be very short.

[0013] A particularly preferred application of the invention is obtained when the inductor according to the invention is installed in a filter device or a filter-integrated frequency converter by means of one or more individual inductors.

[0014] The invention and the developments result in a compact system with decisive advantages:

[0015] 1) Compared with the conventional power connector placed outside the inductor, the use of power connectors with internal guidance enables more compact connection technology devices

[0016] 2) Two or more inductors can be stacked on top of each other and connected to one another in a space-saving manner with, for example, internally guided power connections or current bolts;

[0017] 3) Connecting components or inductors in this novel way enables adjacent components (such as filter capacitors) to be directly connected in a short distance without parasitic inductor components

[0018] 4) The manufacture of the inductor according to the present invention can be produced in a semi-automatic assembly or fully automatic assembly manner to achieve an ideal alignment between power connectors or current bolts;

[0019] 5) Using holding elements to isolate the power connections from each other internally and to keep the windings of the inductor at a defined distance from the core;

[0020] 6) According to the design of the invention, other components, such as a filter capacitor, can be connected to the choke in the intermediate space.

[0021] An advantageous development provides a computer-implemented method for simulating a machine according to the invention or one of the developments of the invention. For this purpose, a computer system comprising at least one computer is preferably designed and prepared for simulating according to the method. Advantageously, the computer or computer system can be prepared for the purpose of executing the method according to the invention or one of the developments of the invention by means of a corresponding computer program product.

[0022] Preferably, the core is a magnetic core.

[0023] Preferably, ferromagnetic metal alloys, for example in the form of sheets or films (electrical steel sheets, metallic glass) or bonded powders (powder cores), or oxide ceramic ferrimagnetic materials (ferrites) are used as material for the core.

[0024] Preferably, the core is designed as a closed core at least in the operating state. For this reason, the core can also be designed as modular, so that the closed form only exists in a ready-to-use assembly (for example from two individual inductors).

[0025] Preferably, the core has an annular shape. To this end, the spatial volume enclosed by the concave shape is determined by the annular shape of the core in the radially inner region of the annular shape, so that at least some of the power connections of the inductor are at least partially arranged in the radial inner region of the annular shape.

[0026] Preferably, the electrical winding is wound around a preferably closed core or a toroidal core and the winding is connected in an electrically conductive manner to a power supply, preferably using a power connection. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Hereinafter, the present invention will be described in more detail with the aid of specific embodiments. They show:

[0028] Figure 1 shows a schematic, simplified three-dimensional illustration of a first variant of an inductor according to the invention,

[0029] Figure 2 shows a schematic, simplified three-dimensional partial cross-sectional view of an inductor according to the invention, which consists of two individual inductors arranged one above the other,

[0030] Figure 3 Shown according to Figure 2 The inductor has additional components attached thereto.

[0031] Figure 4 shows a schematic, simplified three-dimensional partial cross-sectional illustration of an inductor according to the invention, which consists of two individual inductors arranged one above the other, the individual inductors having components integrated in an enclosed volume,

[0032] Figure 5 A schematic diagram showing a simulation of the operation of an inductor of a computer program product according to the present invention running on a computer. DETAILED DESCRIPTION

[0033] Figures 1 to 4 A schematic, simplified three-dimensional variant of an inductor according to the invention is shown in each case. Figure 2 , Figure 3 and Figure 4 It is shown here in a partially cut-away manner to provide a view of the interior (enclosed spatial volume) of the inductor ID0 according to the present invention. Figure 1 The inductor ID0 has an annular core CRE which surrounds a spatial volume CVT with a concave contour or shape. The inductor has a power connection TRM. The power connection TRM is arranged in the spatial volume CVT, but can also partially protrude from the spatial volume CVT in a manner not shown, or be arranged completely in the spatial volume CVT. The inductor ID0 uses the spatial volume CVT, which is always present in, for example, annular core chokes / elliptical core chokes and rectangular core chokes, and the conductive three-phase connection technology or the power connection TRM is integrated into this intermediate space. In accordance with Figure 4In the arrangement, other components, such as filter capacitors, are integrated in the spatial volume CVT, CVC.

[0034] Figure 2 An inductor ID0 according to the invention is shown, wherein the inductor ID0 consists of two individual inductors ID1, ID2. The two individual inductors ID1, ID2 are arranged adjacent to each other so that the spatial volume CVC is arranged adjacent to each other. In this way, a common spatial volume CVC is formed by the adjacent spatial volumes CVT of the individual inductors ID1, ID2. The power connections TRM of the individual inductors ID1, ID2 are arranged in the common spatial volume CVC.

[0035] exist Figure 2 As can be clearly seen from the cross-sectional view, a holding element CRR attached to the inductor ID0 is arranged in the spatial volume CVT. The holding element CRR is mechanically connected to the power connector TRM so that the power connector TRM is held in a specific spatial position. Figure 2 In the embodiment of the present invention, a holding element CRR made of a non-conductive material or an electrically insulating material is attached to the power connection TRM to be held. The holding element CRR ensures that the winding, the core CRE and the power connection TRM or the current bolt are held in place. The holding element CRR can be made, for example, of an injection molded or insulating glass fiber reinforced (GFK) plate. Furthermore, the current bolt can be overmolded in a molding process so that all current bolts and insulating brackets can form a single unit.

[0036] exist Figure 3 It is shown in Figure 2 1 and 2. An exemplary combination of an inductor ID0 and an adjacent element NEE in FIG. 1. This connection situation is space-saving. Some power connections TRM directly contact the printed circuit board PCB and other power connections are connected to a single conductor metal CMT.

[0037] Figure 4An embodiment or device ARR with an inductor according to the invention is shown, in which the holding element CRR is conductively connected as a printed circuit board PCB equipped with components to at least some of the power connections TRM. This connection technology enables the connection of the filter capacitor FCD to a short distance, for example to the center point of two chokes. This situation is very useful so that no parasitic inductances appear on the filter capacitor. For example, the filter capacitor FCD can be soldered to a printed circuit board, for example, whereby the assembly of the entire system can be completed much faster. However, the filter capacitor can also be connected without a printed circuit board, for example, by means of the wire leads of the filter capacitor directly to the current bolt or the inductor. For example, the connection of the other choke components (input and output of the filter device) is carried out via a three-phase busbar or a flexible or rigid power line CDC.

[0038] Alternatively, the filter capacitor FCD can be integrated in the intermediate space so that the filter capacitor is directly connected to the center point of the inductor with a short line. These arrangements not only save space above the inductor ID0, but also reduce the impedance of the connecting cables because the connection between adjacent components is very short.

[0039] Figure 5 A schematic diagram of a simulation SIM of an inductor ID0 according to the invention is shown, the simulation being run on a computer CMP (here on a plurality of computers CMP of a network WWB including a cloud CLD). The software installed on the computer CMP is a computer program product CPP which, when executed on at least one computer CMP, enables a user to exert influence or configuration by means of an interface (e.g. by means of a screen and a keyboard) and to acquire knowledge based on the executed simulation SIM, so that decisions, in particular regarding the technical design, can be supported and verified by means of the simulation.

[0040] Although the present invention has been illustrated and described in more detail by preferred exemplary embodiments, the present invention is not limited to the disclosed examples. A person skilled in the art will be able to derive variations therefrom without departing from the scope of protection of the present invention, such as that defined by the following claims.

Claims

1. An inductor (ID0) having at least one core (CRE), wherein: The core (CRE) having an at least partially concave shape at least partially encloses a spatial volume (CVT), wherein the inductor has a power connection member (TRM), characterized in that At least some of the power connections (TRM) are at least partially arranged in the spatial volume (CVT).

2. The inductor (ID0) according to claim 1, wherein: The core of the inductor (ID0) is designed as a closed loop.

3. The inductor (ID0) according to claim 1 or 2, wherein: The power connector (TRM) has two ends, and at a first end the power connector is electrically conductively connected to the winding of the inductor (ID0) and at a second end the power connector is provided for connection to an adjacent element.

4. An inductor (ID0) according to any one of the preceding claims, wherein The inductor (ID0) is composed of at least two individual inductors (ID1, ID2), the core (CRE) having a shape that is at least partially concave in each of the individual inductors at least partially encloses a spatial volume (CVT), the individual inductors are arranged adjacently so that the spatial volumes (CVT) of the two individual inductors (ID1, ID2) are arranged adjacently to each other, so that a common spatial volume (CVC) is formed by the adjacent spatial volumes (CVT) of the individual inductors (ID1, ID2), Therein, the power connections (TRM) of the individual inductors (ID1, ID2) are arranged in the common spatial volume (CVC).

5. An inductor (ID0) according to any one of the preceding claims, wherein In order to hold the power connectors (TRM) in a specific spatial position, at least one holding element (CRR) is arranged in the spatial volume (CVT), which holding element is fixed to the inductor (ID0) and is mechanically connected to at least some of the power connectors (TRM).

6. An inductor (ID0) according to claim 5, wherein The holding element (CRR) consists of a non-conductive material or is attached in an electrically insulating manner to at least some of the power connections (TRM) to be held.

7. A computer-implemented simulation method (SIM) of the operation of an inductor (ID0) according to at least one of the preceding claims.

8. A computer system (CPS) comprising at least one computer (CMP) designed and prepared for carrying out simulations according to the method according to claim 7.

9. A computer program product for executing the method according to claim 7 by means of a computer system (CPS) according to claim 8.

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