DC Inductor with Adjustable Magnetic Slabs for Variable Current Ratings
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Solution Overview
Problem
Existing DC inductors with permanent magnets face challenges in modifying core structures for different current levels and are prone to demagnetization due to mechanical failures and fixed current ratings, limiting their adaptability and efficiency.
Innovation Solution
A DC inductor design featuring a core structure with a supporting member and adjustable magnetic slabs to create varying magnetic gaps, allowing for modification of inductance and magnetic flux paths, enabling the same core structure to be used for different current levels and applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If permanent magnets are merely attached to one or two surfaces of the core structure, then the attachment structure is simple, but the attachments are vulnerable to mechanical failures
Solution Approach 1:
The core structure is divided into a supporting member and separate magnetic slabs. The supporting member provides a robust base while the magnetic slabs can be independently positioned and secured, distributing mechanical stresses and improving overall attachment reliability without requiring complex multi-point attachment systems.
Solution Approach 2:
Magnetic slabs are introduced as intermediary elements between the permanent magnets and the supporting member. These slabs create magnetic gaps and serve as adjustable mediators that secure the permanent magnets in position while allowing for easy modification of magnetic properties without compromising attachment reliability.
2Ease of manufacture
If the core structure is fixed to a specific current or inductance rating, then the manufacturing process is simplified, but there is no possibility of expanding the rating using the same core structure
Solution Approach 1:
The core structure incorporates adjustable magnetic slabs that can be repositioned or removed to dynamically change the magnetic gap characteristics. This allows the same core structure to be adapted for different current ratings and inductance values without requiring complete manufacturing of new structures, maintaining manufacturing simplicity while enabling versatility.
Solution Approach 2:
The magnetic properties of the inductor are made changeable by modifying the magnetic slabs. By adjusting the position, material, or dimensions of the magnetic slabs, the inductance and current rating can be modified to match different application requirements while using the same basic core structure.
3Productivity
If the same core structure is used for different current levels, then production costs are reduced, but the structure must accommodate varying magnetic flux requirements
Solution Approach 1:
The core structure is designed as a universal platform that can serve multiple current rating applications. The supporting member provides a standardized base structure, while the magnetic slabs serve as configurable elements that can be adjusted to meet different magnetic flux requirements, enabling one core structure design to fulfill multiple functions across different current levels.
4Ease of manufacture
If magnetic gaps are provided using fixed core structures, then the manufacturing is straightforward, but the inductance and magnetic flux properties cannot be modified
Solution Approach 1:
The magnetic path is segmented into fixed core structure portions and adjustable magnetic slab portions. This segmentation allows the straightforward manufacturing of the basic core structure while enabling easy modification of the magnetic gap properties by changing the magnetic slabs, thus achieving both manufacturing simplicity and adaptability.
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 design allows for flexible modification of the DC inductor to accommodate various current levels and applications, reducing production costs and preventing demagnetization by securely positioning and protecting the permanent magnets, while maintaining compact dimensions.
Implementation Method 1
The permanent magnets are arranged to the core structure in such a way that the magnetic flux or magnetization produced by the permanent magnets is opposite to that obtainable from the coil wound on the core structure
Implementation Method 2
permanent magnets having an ability to become demagnetized if an external magnetic field is applied to them
Implementation Method 3
one or more magnetic gaps formed by one or more magnetic slabs
Data Source
AI summary
A DC inductor comprising a core structure (11) comprising one or more magnetic gaps (12, 13), a coil (14) wound on the core structure (11), at least one permanent magnet (15) positioned in the core structure, the magnetization of the permanent magnet (15) opposing the magnetization producible by the coil (14). The DC inductor further comprises at least one magnetic slab (16) inserted to the core structure which forms the one or more magnetic gaps (12, 13), at least one supporting member (17) made of magnetic material extending from the core structure inside the core structure and supporting the at least one permanent magnet (15), and that the at least one supporting member (17) is arranged to form a magnetic path for the at least one permanent magnet.