AC/DC Converter Windings Vibration Decoupling
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Solution Overview
Problem
AC/DC converters with transformers generate significant acoustic noise due to magnetic circuit saturation, causing vibrations that lead to high levels of noise, and existing solutions like decoupling with damping pads or acoustic covering are costly and bulky.
Innovation Solution
The use of a supple material with A-scale Shore hardness lower than or equal to 50, such as an adhesive, to hold windings away from the magnetic circuit at every point, providing a vibrationally decoupling interface between the magnetic circuit and windings, reducing acoustic noise transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If damping pads and electrical braids are used to decouple the magnetic circuit from the rest of the converter, then acoustic noise is reduced, but cost and device complexity increase
Solution Approach 1:
The harmful vibration transmission path is extracted by removing the direct mechanical connection between the magnetic circuit and the windings. The supple material acts as an isolating layer that separates the vibration source (magnetic circuit) from the transmission path (windings), effectively taking out the harmful interaction while maintaining electrical connectivity.
Solution Approach 2:
A supple material with Shore hardness ≤50 is introduced as an intermediary element between the magnetic circuit and the windings. This intermediary material serves dual functions: it provides electrical insulation while simultaneously dampening mechanical vibrations and preventing noise transmission, thus resolving the contradiction between noise reduction and device simplicity.
2Object-affected harmful factors
If acoustic covering methods are used to reduce common-mode self-induction noise, then acoustic noise is reduced, but volume and weight increase
Solution Approach 1:
Instead of adding external acoustic covering layers that increase volume, the solution extracts the noise reduction function directly into the bonding interface between the magnetic circuit and windings. The supple material is integrated into the existing structure, providing noise reduction without increasing the overall converter volume or weight.
Solution Approach 2:
The Shore hardness parameter of the bonding material is specifically controlled to be ≤50 to optimize its vibration-damping properties. By changing the material parameter (hardness) rather than adding structural elements, the solution achieves noise reduction without increasing volume, directly resolving the contradiction between noise reduction and compactness.
3Power
If the magnetic circuit operates at high saturation levels, then power density is improved, but acoustic noise increases due to magnetostriction vibrations
Solution Approach 1:
The supple material serves as a mediator that allows the magnetic circuit to operate at high saturation levels for improved power density while simultaneously isolating the resulting magnetostriction vibrations from the windings and external structure, thus enabling high power operation without proportionally increasing acoustic noise.
Solution Approach 2:
The harmful vibration effects are extracted and isolated from the main power conversion path. By separating the vibration source (magnetic circuit operating at high saturation) from the transmission path (windings and housing), the system can maintain high power density while minimizing the propagation of acoustic noise to external components.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution effectively reduces acoustic noise levels by 5-15 dB, is compact, and avoids the need for additional bulk or weight, maintaining the converter's electrical operation and layout, while being cost-effective.
Implementation Method 1
providing a vibrationally decoupling interface between the magnetic circuit and windings, reducing acoustic noise transmission
Implementation Method 2
operation of the AC/DC converter results in a high level of saturation of the magnetic circuit. This level of saturation, via the magnetostriction effect, is responsible for high levels of vibration of the magnetic circuit
Data Source
AI summary
An AC/DC converter comprising a set of two rectifying bridges, each rectifying bridge comprising a first output connected to an output terminal of the AC/DC converter by an interphase inductor. The interphase inductor may comprise a magnetic circuit comprising two branches that are substantially parallel and two windings, each winding being wound about one branch selected from the two branches. Each winding may be held away from the magnetic circuit, at every point of the winding, by means of a set of at least one holding block made of a material having an A-scale Shore hardness lower than or equal to 50 and being distant at every point from the branches.