Amorphous Alloy Transformer Core Laser Dotted Line Traces
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Solution Overview
Problem
Transformers using Fe-based amorphous alloy ribbons for their iron cores face challenges in achieving minimum iron loss, as existing methods like laser scribing do not fully meet the efficiency standards, leading to suboptimal energy savings and increased CO2 emissions due to higher no-load losses.
Innovation Solution
The use of Fe-based amorphous alloy ribbons with dotted line laser radiation traces arranged in a specific pattern, optimizing the line and spot spaces, and number density to reduce iron loss and inhibit exciting power increases, achieving lower no-load losses and improved energy efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional laser scribing is applied to Fe-based amorphous alloy ribbon, then iron loss is reduced, but the reduction is insufficient to meet stringent efficiency standards
Solution Approach 1:
The laser radiation pattern is segmented into dotted line traces rather than continuous lines, with specific spacing between dots. This segmentation creates optimized magnetic domain structures that reduce iron loss more effectively than conventional continuous laser scribing, addressing the insufficiency of existing methods to meet efficiency standards.
Solution Approach 2:
The invention changes the laser radiation parameters by specifying precise spot spaces (0.05mm to 0.50mm) and number densities (0.05 to 0.50 marks/mm²), transforming the conventional continuous laser pattern into a dotted line pattern. This parameter change optimizes the magnetic properties of the amorphous alloy ribbon, achieving greater iron loss reduction.
2Loss of energy
If laser scribing is applied to reduce iron loss, then energy efficiency improves, but exciting power may increase
Solution Approach 1:
By optimizing the spot space and number density of the dotted line laser radiation marks, the invention achieves a balance where iron loss is reduced while exciting power increase is inhibited. The specific parameter ranges (spot space: 0.05mm to 0.50mm, number density: 0.05 to 0.50 marks/mm²) are determined to simultaneously address both concerns.
Solution Approach 2:
The dotted line laser radiation creates localized modifications in the amorphous alloy ribbon with specific spacing, creating optimal local magnetic properties that reduce iron loss without causing excessive overall exciting power increase. The local quality of the laser marks is precisely controlled to achieve this balance.
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 approach results in transformers with significantly reduced no-load losses, enhancing energy consumption efficiency and reducing CO2 emissions by minimizing iron loss and maintaining magnetic flux density, thereby meeting stringent efficiency standards.
Implementation Method 1
dotted line laser radiation traces on at least a first surface of the Fe-based amorphous alloy ribbon
Implementation Method 2
an insulation thin film is formed on a surface of the amorphous alloy ribbon, which can help inhibit an increase in an eddy current loss
Implementation Method 3
A constant amount of the no-load loss is produced at the iron core at all times
Implementation Method 4
An iron loss of the Fe-based amorphous alloy ribbon in a single sheet is 0.150 W/kg or less
Data Source
AI summary
A transformer includes an iron core formed by using an Fe-based amorphous alloy ribbon and a winding wound around the iron core. The ribbon includes dotted line laser radiation traces arranged on at least a first surface in a casting direction. Each of the dotted line laser radiation traces is formed by arranging laser radiation marks on the first surface along a width direction. A spot space is from 0.10 mm to 0.50 mm. In a case in which a line space is d1 (mm), and the spot space is d2 (mm), a number density D of the laser radiation marks (D=(1/d1)×(1/d2)) is from 0.05 marks/mm2 to 0.50 marks/mm2. An iron loss of the ribbon in a single sheet is 0.150 W/kg or less at a frequency of 60 Hz and a magnetic flux density of 1.45 T.