Amorphous Alloy Ribbon Slip Friction Control
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Solution Overview
Problem
The use of amorphous alloy ribbons in transformer iron cores results in higher material and production costs due to small saturation magnetization force, leading to reduced design magnetic flux density and increased Watt loss and noise, as existing solutions focus on surface roughness rather than slip property and lamination factor.
Innovation Solution
An amorphous alloy ribbon produced by the single roll method with a specific slip friction coefficient range of 0.1≦F=P/M≦1.0, achieved by adjusting cooling roll roughness, air pocket formation, ejection pressure, and casting speed, to enhance magnetic characteristics and lamination factor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If amorphous alloy ribbon is used for transformer iron core, then magnetic characteristics are improved, but material cost and production cost increase due to smaller saturation magnetization force
Solution Approach 1:
The invention changes the surface physical parameters of the amorphous alloy ribbon by controlling the slip friction coefficient to be between 0.05 and 0.15, which improves the lamination factor and allows for more efficient magnetic flux density utilization, thereby reducing the required material quantity for achieving the same transformer performance
2Manufacturing precision
If surface roughness is reduced to improve magnetic characteristics, then local physical characteristics improve, but slip property and lamination factor are not optimized
Solution Approach 1:
The invention shifts the focus from controlling surface roughness alone to controlling the slip friction coefficient, a new parameter that directly characterizes the slip property. By optimizing the slip friction coefficient to 0.05-0.15, the invention simultaneously achieves good magnetic characteristics and improved lamination factor without compromising slip property
3Force
If cross-sectional area of iron core is increased to compensate for reduced magnetic flux density, then design magnetic flux density is maintained, but core size and material cost increase
Solution Approach 1:
The invention optimizes the slip friction coefficient to improve the lamination factor, which reduces air gap losses and improves the effective utilization of magnetic flux density. This allows for more efficient use of the available magnetic flux density without requiring increased core cross-sectional area
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
The solution effectively improves magnetic flux density, reduces Watt loss, and maintains a high lamination factor, preventing core enlargement and noise, while simplifying surface property evaluation through slip friction coefficient measurement.
Implementation Method 1
ejecting a molten alloy onto the surface of a rotating cooling roll from a rectangular orifice for rapid cooling and solidification
Data Source
AI summary
The present invention provides an amorphous alloy ribbon superior in magnetic characteristics and lamination factor by defining the slip property of the amorphous alloy ribbon surface in a specific range, that is, an amorphous alloy ribbon superior in magnetic characteristics and lamination factor produced by the single roll method, characterized in that the slip property of the ribbon surface satisfies the following equation:0.1≦F=P/M≦1.0where, F is the slip friction coefficient, P is the force pulling the intermediate part of the amorphous ribbon when applying weight from above to three amorphous ribbons stacked together, and M is the load applied from the top of the amorphous ribbon (5 kg).