Magnetic core power loss test method

Abstract

The invention discloses a magnetic core power loss test method, and relates to the technical field of magnetic core preparation, and the method comprises the following steps: S1, sample preparation; s2, setting a test environment; s3, measuring equipment connection: connecting the magnetic core sample to a test circuit; s4, power loss measurement: starting a magnetic field generator, measuring the input power and the output power of the magnetic core through a power meter under a set test condition, and monitoring the temperature change of the magnetic core by using a temperature sensor; and S5, data analysis. According to the power loss testing method of the magnetic core, the control pressing plate is pressed downwards, the two insulating plates are controlled to move back to back, after the control pressing plate is loosened, the insulating plates are driven to move in the middle through resilience of the self-adaptive springs, the magnetic core is rapidly fixed in cooperation with the clamping assembly, and the clamping assembly can conduct self-adaptive adjustment according to the shape of the magnetic core. Meanwhile, after the magnetic core is clamped by the clamp, the magnetic core can be directly connected to a test circuit, so that the circuit connection operation is further simplified.

Description

Technical Field

[0001] This invention relates to the field of magnetic core manufacturing technology, specifically to a method for testing the power loss of magnetic cores. Background Technology

[0002] Magnetic core is a term specific to electrical engineering, referring to a magnetically conductive material placed in the magnetic circuit of an inductor coil to increase the magnetic flux density of an electromagnet. Magnetic cores are materials with high magnetic permeability and low electrical resistance, widely used in electrical, electronic, and communication fields, playing a crucial role, particularly in electronic devices such as transformers, inductors, and switching power supplies. There are many types of magnetic core materials, including ferrite, silicon steel sheets, and iron powder, each with different magnetic properties.

[0003] In the magnetic core manufacturing process, core power loss testing is crucial to ensure the efficiency and performance of the core in practical applications. Through testing, the selection and design of core materials can be optimized to reduce losses and improve the overall performance of the equipment. Core power loss testing primarily evaluates the energy loss of the core at different frequencies and magnetic flux densities. Losses include hysteresis loss, eddy current loss, and residual loss, and are key to evaluating core efficiency.

[0004] However, existing testing methods typically only focus on the energy loss of the magnetic core at different frequencies and magnetic flux densities, resulting in incomplete and inaccurate test results. Furthermore, the testing process requires first fixing the magnetic core with a clamp before connecting it to the test circuit for instrument detection. In practice, the tester not only needs to fix the magnetic core with the clamp but also connect the fixed core to the circuit, making the operation cumbersome, inefficient, and unsuitable for efficient batch testing of magnetic cores. Summary of the Invention

[0005] The purpose of this invention is to provide a method for testing the power loss of a magnetic core, so as to solve the problems mentioned in the background art.

[0006] To achieve the above objectives, the present invention provides the following technical solution: a method for testing the power loss of a magnetic core, comprising the following steps:

[0007] S1. Sample preparation: Randomly select magnetic core samples, ensure that their surfaces are clean and undamaged, and meet the test requirements, and use test fixtures to fix the magnetic cores.

[0008] S2. Test Environment Setup: Determine the test temperature range, magnetic field strength, frequency, and other conditions, and set up the corresponding test environment.

[0009] S3. Measurement equipment connection: Connect the magnetic core sample to the test circuit, which includes a power source, a magnetic field generator, a power meter, and a temperature sensor, etc.

[0010] S4. Power Loss Measurement: Start the magnetic field generator and, under the set test conditions, measure the input power and output power of the magnetic core using a power meter for subsequent power loss calculation. At the same time, use a temperature sensor to monitor the temperature change of the magnetic core to assess the impact of temperature on power loss.

[0011] S5. Data Analysis: Process and analyze the measurement data, calculate the power loss value of the magnetic core under different conditions, compare the power loss of different samples or under different conditions, and evaluate the performance and applicability of the magnetic core.

[0012] Furthermore, in step S4, the magnetic field generator gradually increases the excitation current, with the step size ≤ 5% of the rated value.

[0013] Furthermore, the test fixture, used to fix the magnetic core, includes a base and an insulating plate. A positive terminal bolt and a negative terminal bolt are provided on the top of the base. A fixing frame is fixedly connected to the top of the base, and a connecting assembly is installed on the inner side of the fixing frame. The insulating plate is movably installed on the top of the base, and is located inside the fixing frame. Square sliders are fixedly connected to both sides of the insulating plate, and a conductive element is fixedly installed on the front of the insulating plate. A circuit wire is fixedly connected to the end of the conductive element, and a U-shaped connector is fixedly connected to one end of the circuit wire. A clamping assembly is provided on the front of the insulating plate, and a T-shaped slider is welded to the bottom of the insulating plate. Two control pressure plates are movably connected to the top of the insulating plate via hinges.

[0014] Furthermore, the base includes a base plate, counterweight pads, a central support beam, and a guide groove. The four bottom corners of the base plate are fixedly connected to counterweight pads, and the center of the bottom of the base plate is fixedly connected to the central support beam. The top of the base plate is provided with a guide groove.

[0015] Furthermore, the insulating plate forms a sliding structure with the base plate through a T-shaped slider and a guide groove, and the T-shaped slider slides along the inner wall of the guide groove, while the outer wall of the T-shaped slider is in contact with the inner wall of the guide groove.

[0016] Furthermore, the fixing frame includes a guide frame, a support column, and a second guide groove. The bottom of the guide frame is fixedly connected to the support column, and the bottom of the support column is fixedly connected to the top of the base. The second guide groove is provided on the inner side of the guide frame.

[0017] Furthermore, the insulating plate forms a sliding structure with the guide frame through a square slider and a second guide groove, and the square slider slides along the inner wall of the second guide groove, and the shape and size of the square slider are completely matched with the shape and size of the second guide groove.

[0018] Furthermore, the connecting assembly includes a fixing block, a connecting spring, an insulating rod, and a limiting plate. The fixing block is fixed to the outer surface of the support column, and a connecting spring is fixedly connected to the side of the fixing block near the insulating plate. One end of the connecting spring is fixedly connected to the back of the insulating plate. One end of the insulating rod is fixedly connected to the back of the insulating plate, and the other end of the insulating rod is fixedly connected to the limiting plate.

[0019] Furthermore, the connecting spring is wound around the outside of the insulating rod, and the insulating rod and the fixing block form a through structure.

[0020] Furthermore, the clamping assembly includes an adaptive spring, a rubber arc-shaped disk, a guide rod, and a limiting component. One end of the adaptive spring is fixedly connected to the front side of the insulating plate, and the other end of the adaptive spring is fixedly connected to the rubber arc-shaped disk. The guide rod is fixedly connected to the side of the rubber arc-shaped disk near the insulating plate, and one end of the guide rod passes through the insulating plate and is welded with a limiting component.

[0021] This invention provides a method for testing the power loss of a magnetic core, which has the following advantages:

[0022] 1. This invention achieves the testing of magnetic core power loss by using a power source, magnetic field generator, power meter and temperature sensor in combination. The entire testing process is simple and easy to operate. In particular, compared with traditional testing methods, it no longer only focuses on the energy loss of the magnetic core at different frequencies and magnetic flux densities, but also considers the influence of temperature on power loss, making the test results more comprehensive and accurate.

[0023] 2. This invention controls the movement of two insulating plates in opposite directions by pressing down on the control plate. Upon release, the self-adaptive spring moves the insulating plates to the center, working in conjunction with the clamping assembly to quickly fix the magnetic core. The clamping assembly can adaptively adjust to the shape of the magnetic core, improving clamping effectiveness and enhancing adaptability. Furthermore, the inclusion of conductive elements, circuit lines, U-connectors, and positive and negative terminals allows the magnetic core to be directly connected to the test circuit after being clamped, further simplifying the circuit connection process. This invention optimizes the test fixture used to fix the magnetic core during testing, effectively simplifying the operation process and improving testing efficiency. Attached Figure Description

[0024] Figure 1 This is a schematic flowchart of the power loss testing method for a magnetic core according to the present invention.

[0025] Figure 2 This is a schematic diagram of the overall test fixture for a power loss testing method for a magnetic core according to the present invention;

[0026] Figure 3 This invention provides a method for testing the power loss of a magnetic core. Figure 2 Enlarged schematic diagram of the structure at point A in the middle;

[0027] Figure 4 This is a bottom view schematic diagram of the test fixture structure for a power loss testing method for a magnetic core according to the present invention;

[0028] Figure 5 This is a schematic diagram of the connection between the fixing frame and the insulating plate structure of the test fixture for the power loss testing method of a magnetic core according to the present invention.

[0029] Figure 6 This is a schematic diagram showing the disassembled structure of the fixing frame-insulating plate of the test fixture for the power loss testing method of a magnetic core according to the present invention.

[0030] In the diagram: 1. Base; 101. Base plate; 102. Counterweight pad; 103. Central support beam; 104. Guide groove one; 2. Positive terminal plug; 3. Negative terminal plug; 4. Fixing frame; 401. Guide frame; 402. Support column; 403. Guide groove two; 5. Connecting assembly; 501. Fixing block; 502. Connecting spring; 503. Insulating rod; 504. Limiting plate; 6. Insulating plate; 7. Square slider; 8. Conductor; 9. Circuit wire; 10. U-shaped connector; 11. Clamping assembly; 1101. Adaptive spring; 1102. Rubber arc-shaped plate; 1103. Guide rod; 1104. Limiting component; 12. T-shaped slider; 13. Control pressure plate. Detailed Implementation

[0031] The embodiments of the present invention will be described in further detail below with reference to the accompanying drawings and examples. The following examples are for illustrative purposes only and should not be construed as limiting the scope of the invention.

[0032] like Figure 1 As shown, a method for testing the power loss of a magnetic core includes the following steps:

[0033] S1. Sample preparation: Randomly select magnetic core samples, ensure that their surfaces are clean and undamaged, and meet the test requirements, and use test fixtures to fix the magnetic cores.

[0034] S2. Test Environment Setup: Determine the test temperature range, magnetic field strength, frequency, and other conditions, and set up the corresponding test environment.

[0035] S3. Measurement Equipment Connection: Connect the magnetic core sample to the test circuit, which includes a power source (providing stable power input to drive the magnetic field generator to generate the required magnetic field), a magnetic field generator (generating a controllable magnetic field to magnetize or excite the magnetic core, including electromagnets, permanent magnets, or Helmholtz coils), a power meter (measuring the input and output power of the magnetic core and calculating power loss), and a temperature sensor (monitoring the temperature change of the magnetic core, including thermocouples, thermistors, or infrared thermometers).

[0036] S4. Power Loss Measurement: Start the magnetic field generator and, under the set test conditions, measure the input power and output power of the magnetic core using a power meter for subsequent power loss calculation. At the same time, use a temperature sensor to monitor the temperature change of the magnetic core to assess the impact of temperature on power loss. In this embodiment, the magnetic field generator adopts a method of gradually increasing the excitation current, with a step size ≤ 5% of the rated value.

[0037] S5. Data Analysis: Process and analyze the measurement data, calculate the power loss value of the magnetic core under different conditions, compare the power loss of different samples or under different conditions, and evaluate the performance and applicability of the magnetic core.

[0038] like Figures 2-6As shown, the test fixture for fixing the magnetic core includes a base 1 and an insulating plate 6. The base 1 includes a base plate 101, counterweight feet 102, a central support beam 103, and a guide groove 104. Counterweight feet 102 are fixedly connected to the four corners of the bottom of the base plate 101, and the central support beam 103 is fixedly connected to the center of the bottom of the base plate 101. The guide groove 104 is provided on the top of the base plate 101. A positive terminal bolt 2 and a negative terminal bolt 3 are provided on the top of the base 1. A fixing frame 4 is fixedly connected to the top of the base 1. The fixing frame 4 includes a guide frame 401, a support column 402, and a guide groove 403. The support column 402 is fixedly connected to the bottom of the guide frame 401, and the bottom of the support column 402 is fixedly connected to the top of the base 1. Furthermore, a guide groove 403 is provided on the inner side of the guide frame 401, and a connecting assembly 5 is installed on the inner side of the fixing frame 4. The connecting assembly 5 includes a fixing block 501, a connecting spring 502, an insulating rod 503, and a limiting plate 504. The fixing block 501 is fixed to the outer surface of the support column 402, and the connecting spring 502 is fixedly connected to the side of the fixing block 501 near the insulating plate 6. One end of the connecting spring 502 is fixedly connected to the back of the insulating plate 6. One end of the insulating rod 503 is fixedly connected to the back of the insulating plate 6, and the other end of the insulating rod 503 is fixedly connected to the limiting plate 504. The connecting spring 502 is wound around the outside of the insulating rod 503, and the insulating rod 503 and the fixing block 501 form a through structure. The insulating plate 6 is movably installed on the base 1. At the top, the insulating plate 6 is located inside the fixing frame 4. Square sliders 7 are fixedly connected to both sides of the insulating plate 6. The insulating plate 6 forms a sliding structure with the guide frame 401 through the square sliders 7 and the guide groove 403. The square sliders 7 slide along the inner wall of the guide groove 403, and the shape and size of the square sliders 7 are completely matched with the shape and size of the guide groove 403. A conductor 8 is fixedly installed on the front of the insulating plate 6. A circuit wire 9 is fixedly connected to the end of the conductor 8, and a U-shaped connector 10 is fixedly connected to one end of the circuit wire 9. A clamping assembly 11 is provided on the front of the insulating plate 6. The clamping assembly 11 includes an adaptive spring 1101, a rubber arc-shaped disk 1102, a guide rod 1103, and a limiting member 1104. One end of the adaptive spring 1101 is connected to the insulating plate 6. The front of the plate 6 is fixedly connected, and the other end of the adaptive spring 1101 is fixedly connected to a rubber arc-shaped disk 1102. A guide rod 1103 is fixedly connected to the side of the rubber arc-shaped disk 1102 near the insulating plate 6. One end of the guide rod 1103 passes through the insulating plate 6 and is welded with a limit piece 1104. A T-shaped slider 12 is welded to the bottom of the insulating plate 6. The insulating plate 6 forms a sliding structure with the bottom plate 101 through the T-shaped slider 12 and the guide groove 104. The T-shaped slider 12 slides along the inner wall of the guide groove 104, and the outer wall of the T-shaped slider 12 fits against the inner wall of the guide groove 104. The top of the insulating plate 6 is movably connected to a control pressure plate 13 through a hinge. There are two control pressure plates 13, and the two control pressure plates 13 are movably connected through a hinge.

[0039] The specific operation is as follows: Prepare the test circuit in advance, and connect the wires to the positive terminal plug 2 and the negative terminal plug 3 according to the current flow direction of the circuit, thereby connecting the test fixture in series into the test circuit. During the test, the tester presses down on the control plate 13 with one hand, which, together with the guide groove 104 restricting the movement trajectory of the T-shaped slider 12 and the guide groove 403 restricting the square slider 7, allows the two insulating plates 6 to move in opposite directions under the downward pressure of the control plate 13. Then, the tester places the magnetic core to be tested between the two insulating plates 6 with the other hand. After releasing the pressure, the two insulating plates 6 will move in the center under the rebound action of the connecting spring 502. During this process, the fixing block 501 and the insulating rod 503 can restrict the movement of the insulating plates 6, allowing the insulating plates 6 to move... More stable, and as the insulating plate 6 moves, the rubber arc-shaped disk 1102 of part of the clamping assembly 11 abuts against the surface of the magnetic core, and the corresponding adaptive spring 1101 is compressed by force, and the guide rod 1103 extends to the back of the insulating plate 6. The design of multiple clamping assemblies 11 allows the clamp to adaptively adjust according to the shape of the magnetic core until the magnetic core is completely fixed. At this time, the conductor 8 just abuts against the left and right sides of the magnetic core, and the other end of the conductor 8 is connected to the positive terminal plug 2 and the negative terminal plug 3 through the circuit line 9 and the U-shaped connector 10. The magnetic core is directly connected to the test circuit.

[0040] The embodiments of the present invention are given for illustrative and descriptive purposes only, and are not intended to be exhaustive or to limit the invention to the forms disclosed. Many modifications and variations will be apparent to those skilled in the art. The embodiments were chosen and described in order to better illustrate the principles and practical application of the invention, and to enable those skilled in the art to understand the invention and to design various embodiments with various modifications suitable for a particular purpose.

Claims

1. A method for testing the power loss of a magnetic core, characterized in that, Includes the following steps: S1. Sample preparation: Randomly select magnetic core samples and fix the magnetic cores using test fixtures; S2. Test Environment Setup: Determine the test temperature range, magnetic field strength, frequency, and other conditions, and set up the corresponding test environment. S3. Measurement equipment connection: Connect the magnetic core sample to the test circuit, which includes a power source, a magnetic field generator, a power meter, and a temperature sensor; S4. Power loss measurement: Start the magnetic field generator and, under the set test conditions, measure the input power and output power of the magnetic core using a power meter, while simultaneously using a temperature sensor to monitor the temperature change of the magnetic core. S5. Data Analysis: Process and analyze the measurement data, calculate the power loss value of the magnetic core under different conditions, compare the power loss of different samples or under different conditions, and evaluate the performance and applicability of the magnetic core.

2. The method for testing the power loss of a magnetic core according to claim 1, characterized in that, In step S4, the magnetic field generator gradually increases the excitation current, with the step size ≤ 5% of the rated value.

3. The method for testing the power loss of a magnetic core according to claim 1, characterized in that, The power loss test method for the magnetic core uses a test fixture, which includes a base (1) and an insulating plate (6). A positive terminal bolt (2) is provided on the top of the base (1), and a negative terminal bolt (3) is provided on the top of the base (1). A fixing frame (4) is fixedly connected to the top of the base (1), and a connecting component (5) is installed on the inner side of the fixing frame (4). The insulating plate (6) is movably installed on the top of the base (1), and the insulating plate (6) is located inside the fixing frame (4). Square sliding blocks are fixedly connected to both sides of the insulating plate (6). Block (7), and a conductive component (8) is fixedly installed on the front side of the insulating plate (6). A circuit wire (9) is fixedly connected to the end of the conductive component (8), and a U-shaped connector (10) is fixedly connected to one end of the circuit wire (9). A clamping assembly (11) is provided on the front side of the insulating plate (6), and a T-shaped slider (12) is welded to the bottom of the insulating plate (6). A control pressure plate (13) is movably connected to the top of the insulating plate (6) through a hinge. There are two control pressure plates (13), and the two control pressure plates (13) are movably connected through a hinge.

4. The method for testing the power loss of a magnetic core according to claim 3, characterized in that, The base (1) includes a base plate (101), counterweight pads (102), a central support beam (103), and a guide groove (104). The base plate (101) has counterweight pads (102) fixedly connected to the four corners of its bottom, and a central support beam (103) fixedly connected to the center of its bottom. The base plate (101) also has a guide groove (104) on its top.

5. The power loss testing method for a magnetic core according to claim 4, characterized in that, The insulating plate (6) forms a sliding structure with the base plate (101) through the T-shaped slider (12) and the guide groove (104), and the T-shaped slider (12) slides along the inner wall of the guide groove (104), and the outer wall of the T-shaped slider (12) is in contact with the inner wall of the guide groove (104).

6. The method for testing the power loss of a magnetic core according to claim 3, characterized in that, The fixing frame (4) includes a guide frame (401), a support column (402) and a second guide groove (403). The bottom of the guide frame (401) is fixedly connected to the support column (402), and the bottom of the support column (402) is fixedly connected to the top of the base (1). The second guide groove (403) is provided on the inner side of the guide frame (401).

7. The power loss testing method for a magnetic core according to claim 6, characterized in that, The insulating plate (6) forms a sliding structure with the guide frame (401) through the square slider (7) and the second guide groove (403), and the square slider (7) slides along the inner wall of the second guide groove (403), and the shape and size of the square slider (7) are completely matched with the shape and size of the second guide groove (403).

8. The power loss testing method for a magnetic core according to claim 3, characterized in that, The connecting assembly (5) includes a fixing block (501), a connecting spring (502), an insulating rod (503), and a limiting plate (504). The fixing block (501) is fixed to the outer surface of the support column (402), and the connecting spring (502) is fixedly connected to the side of the fixing block (501) near the insulating plate (6). One end of the connecting spring (502) is fixedly connected to the back of the insulating plate (6). One end of the insulating rod (503) is fixedly connected to the back of the insulating plate (6), and the other end of the insulating rod (503) is fixedly connected to the limiting plate (504).

9. The method for testing the power loss of a magnetic core according to claim 8, characterized in that, The connecting spring (502) is wound around the outside of the insulating rod (503), and the insulating rod (503) and the fixing block (501) form a through structure.

10. The method for testing the power loss of a magnetic core according to claim 3, characterized in that, The clamping assembly (11) includes an adaptive spring (1101), a rubber arc-shaped disk (1102), a guide rod (1103), and a limiting member (1104). One end of the adaptive spring (1101) is fixedly connected to the front of the insulating plate (6), and the other end of the adaptive spring (1101) is fixedly connected to the rubber arc-shaped disk (1102). The rubber arc-shaped disk (1102) is fixedly connected to the guide rod (1103) on the side near the insulating plate (6), and one end of the guide rod (1103) passes through the insulating plate (6) and is welded with the limiting member (1104).

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