Cooled Toroidal Inductor With Distributed Gap Core for Harmonic Filtering
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Industrial power filtering systems using traditional inductors overheat due to high frequency harmonics, leading to increased AC resistance and inefficiency, as these systems are not designed to handle frequencies in the 50-100 kHz range effectively.
Innovation Solution
A cooled/cast inductor apparatus with a toroid-shaped inductor and a cooling jacket, utilizing a distributed gap core material that efficiently filters high frequency harmonics while maintaining low core losses, and is integrated with a cooling system to manage heat effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional inductors are used for power filtering, then the system can handle 60 Hz current, but the inductors overheat when frequencies in the 50-100 kHz range are added due to increased AC resistance
Solution Approach 1:
The inductor core is segmented into multiple sections with distributed gaps between them. This segmentation reduces the overall core losses by breaking up the magnetic path into smaller segments, thereby reducing eddy current losses and improving the inductor's ability to handle high frequency currents without excessive heating.
Solution Approach 2:
The inductor incorporates a cooling jacket that provides localized cooling to the core and winding areas. This local quality improvement addresses the overheating problem by directly applying cooling where the heat is generated, allowing the inductor to maintain lower operating temperatures despite high frequency operation.
2Object-generated harmful factors
If the inductor is designed to filter high frequency harmonics, then harmonic amplitudes are reduced, but the device complexity increases due to the cooling system and distributed gap core
Solution Approach 1:
The cooling jacket is integrated directly with the inductor core structure, merging the cooling function with the magnetic core. This combination reduces device complexity by eliminating separate cooling components and simplifying the overall structure while maintaining effective harmonic filtering capabilities.
Solution Approach 2:
The distributed gap core structure serves multiple functions: it reduces core losses, improves high frequency performance, and provides a framework for the cooling jacket integration. This multi-functionality reduces the need for additional components, thereby reducing overall device complexity.
3Loss of energy
If the inductor uses distributed gap core material, then core losses are reduced and high frequency filtering is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The distributed gap structure uses standardized gap dimensions and spacing parameters that can be consistently manufactured. By defining specific gap parameters (width, spacing, depth), the design allows for controlled manufacturing processes that achieve the required precision without excessive complexity.
Solution Approach 2:
The casting process itself creates the distributed gap structure, allowing the core material to form the gaps automatically during manufacturing. This self-service approach reduces the need for post-manufacturing adjustments and simplifies the achievement of uniform gap distribution.
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 passes carrier frequencies above 700 Hz while attenuating fundamental frequencies, reducing harmonic amplitudes by up to 99%, thereby preventing overheating and enhancing energy processing efficiency in high frequency applications.
Implementation Method 1
a cooling system to manage heat effectively
Implementation Method 2
cooling jacket including at least two sections joined to encase the toroid shaped inductor
Implementation Method 3
utilizing a distributed gap core material that efficiently filters high frequency harmonics
Implementation Method 4
distributed gap core material that efficiently filters high frequency harmonics while maintaining low core losses
Implementation Method 5
efficiently filters high frequency harmonics while maintaining low core losses
Implementation Method 6
resonant points, inductor impedance, inductance at desired frequencies
Data Source
AI summary
The invention comprises an apparatus, comprising: a toroid shaped inductor and a cooling jacket including at least two sections joined to encase the toroid shaped inductor, where the cooling jacket has an inner toroid shaped surface separated by a coolant flow gap from the toroid shaped inductor. Optionally, the inductor comprises a cast winding, a cast heat sink element of the cast winding protruding from a longitudinal length of a turn of the winding, and/or a distributed gap pressed powder inductor core.