Amorphous Silicon Steel Composite Transformer Core
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Solution Overview
Problem
Amorphous thin magnetic strips used in transformer cores lack mechanical strength and rigidity, making it difficult to maintain shape and increasing magnetic losses when scaled up, while silicon steel sheets are easier to process but increase stray losses with holding members.
Innovation Solution
A composite core structure using an amorphous thin magnetic strip inner core and silicon steel sheet outer core, supported by a wear plate and amorphous core frame, with a nonmagnetic support frame to prevent direct clamping and stress-induced magnetic loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If amorphous thin magnetic strips are used to form the core, then magnetic loss is reduced, but mechanical strength and rigidity are insufficient
Solution Approach 1:
The patent employs a composite core structure where an amorphous thin magnetic strip inner core is combined with a silicon steel sheet outer core. The amorphous strips provide low magnetic loss characteristics while the silicon steel sheets provide mechanical strength and rigidity. This composite approach allows the core to simultaneously achieve low energy loss and sufficient structural integrity.
2Loss of energy
If amorphous thin magnetic strips are used to form the core, then magnetic loss is reduced, but rigidity is insufficient making it difficult to maintain shape
Solution Approach 1:
The composite structure combines amorphous thin magnetic strips (for low magnetic loss) with silicon steel sheets (for rigidity and shape stability). The silicon steel outer core acts as a rigid framework that maintains the overall shape and dimensional stability of the transformer core, while the amorphous inner core provides the low-loss magnetic path.
Solution Approach 2:
The core is segmented into an inner core region (amorphous thin magnetic strips) and an outer core region (silicon steel sheets). This segmentation allows each material to be placed where it provides the most benefit: amorphous material in the inner magnetic path for low loss, and silicon steel in the outer structural regions for rigidity and shape maintenance.
3Strength
If holding members are added to support the core, then mechanical strength is improved, but stray losses increase
Solution Approach 1:
The composite core structure itself acts as the primary load-bearing element, eliminating the need for separate holding members. The silicon steel sheet outer core provides the necessary mechanical strength and rigidity to support the core structure without requiring additional metal fasteners or support components that would generate stray losses.
4Strength
If direct clamping is used to hold the core, then mechanical strength is improved, but magnetic loss increases due to stress
Solution Approach 1:
The silicon steel sheet outer core acts as an intermediary between the clamping/holding structure and the amorphous thin magnetic strip inner core. This intermediary layer protects the amorphous strips from direct contact with stress-inducing components, preventing stress-induced magnetic loss while still providing the necessary mechanical support and clamping force through the outer silicon steel structure.
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 provides a core with enhanced mechanical strength and reduced magnetic losses, allowing for even clamping and protection of the core without direct pressure on the amorphous strips, improving the core's stability and efficiency.
Implementation Method 1
the iron-based amorphous alloy has a higher electric resistivity and a smaller eddy current loss because it has a sheet thickness as thin as 1/10
Implementation Method 2
the iron-based amorphous alloy has characteristics of an easy domain wall displacement because it is amorphous and a small hysteresis loss
Implementation Method 3
a wear plate arranged on the outermost peripheral surface of the silicon steel sheet core
Implementation Method 4
a support frame which supports and fixes the amorphous core and the silicon steel sheet core via the wear plate
Data Source
AI summary
The invention provides a core for a stationary induction apparatus including an amorphous core formed of an amorphous thin magnetic strip arranged inside the core, a silicon steel sheet core formed of a silicon steel sheet arranged on a side surface of the amorphous core, a wear plate arranged on the outermost peripheral surface of the silicon steel sheet core, an amorphous core frame arranged around the amorphous core including a space between the amorphous core and the silicon steel sheet core, and a support frame which supports and fixes the amorphous core and the silicon steel sheet core via the wear plate.