Current-Compensated Inductor Geometry for Higher Inductance
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Solution Overview
Problem
Current current-compensated inductors for high-voltage on-board power systems in motor vehicles have suboptimal utilization of magnetic core volume due to rectangular or circular busbar cross sections, leading to low inductance, increased material, space, and weight requirements.
Innovation Solution
The inductor features a toroidal magnetic core with busbars shaped to match the inner core's cross-sectional profile, creating an airgap for optimal volume utilization, allowing for high inductance with reduced material, space, and weight by aligning the busbar and core shapes for efficient interference signal damping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If busbars with rectangular or circular cross sections are used, then the inductor structure is simple and easy to manufacture, but the utilization factor of the inner opening volume is low, resulting in low inductance
Solution Approach 1:
The busbars are designed with an asymmetric cross-sectional shape that corresponds to the inner opening of the magnetic core, replacing traditional symmetric rectangular or circular cross sections. This asymmetric design allows the busbars to fit more efficiently within the inner opening, increasing the utilization factor and thereby increasing the inductance without complicating the manufacturing process
Solution Approach 2:
The cross-sectional shape of the busbars is locally adapted to match the specific geometry of the inner opening in the magnetic core. By tailoring the busbar shape to the local requirements of the core's inner opening, the design maximizes volume utilization and inductance while maintaining manufacturing simplicity
2Manufacturing precision
If the depth of the magnetic core is extended in the axial direction to increase inductance, then the inductance increases, but the material expenditure, costs, installation space, and weight increase
Solution Approach 1:
Instead of increasing inductance by extending the axial depth of the magnetic core, the invention transitions to optimizing the cross-sectional geometry of the busbars. By improving the utilization factor in the radial and transverse dimensions through shape correspondence, the design achieves higher inductance without increasing the axial dimension, thereby reducing material expenditure, cost, installation space, and weight
3Manufacturing precision
If the depth of the magnetic core is extended in the axial direction to increase inductance, then the inductance increases, but the material expenditure and costs increase
Solution Approach 1:
The invention shifts the focus from increasing axial depth to optimizing cross-sectional geometry. By improving the fit between busbar and core inner opening in the radial and transverse dimensions, the design achieves higher inductance with reduced material volume, lowering material expenditure and costs
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 configuration enables a cost-effective, lightweight inductor with enhanced inductance, minimizing material and space requirements while effectively damping interference signals in high-voltage on-board power systems.
Implementation Method 1
current-compensated inductor for filtering interference signals transmitted between two high-voltage components
Implementation Method 2
toroidal magnetic core which surrounds an inner opening
Data Source
AI summary
A current-compensated inductor for filtering interference signals which are transmitted between two high-voltage components of a high-voltage on-board electrical system of a motor vehicle, includes a toroidal, in particular circular ring-shaped or oval ring-shaped, magnet core which surrounds an inner opening, and has at least two busbars for electrically connecting the two high-voltage components. The busbars are routed axially through the inner opening of the magnet core and are arranged at a distance from one another in the inner opening so as to form an air gap. An inner side of the magnet core, which inner side faces the inner opening, and regions of outer sides of the busbars, which regions face the inner side of the magnet core, have shapes which correspond to one another.