Fe-Si Magnetic Powder Reactor Core for HV Vehicle Cost Reduction
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Solution Overview
Problem
Conventional reactors for hybrid electric vehicles (HEVs) face challenges in cost reduction while maintaining specific performance specifications, particularly due to the high material and processing costs associated with iron cores and compound magnetic cores.
Innovation Solution
A reactor design featuring an annular core configuration with U-shaped core members made from Fe-Si system magnetic powder, arranged with intervening gaps and coils wound around these core members, optimizing gap length, cross-sectional area, and coil turns to reduce material and processing costs while ensuring performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If iron core strips are laminated to form core members, then magnetic performance is improved, but material cost and processing cost increase
Solution Approach 1:
The patent changes the material parameter from laminated iron core strips to Fe-Si system magnetic powder pressed as a one-body structure. This parameter change maintains magnetic performance while eliminating the need for lamination processing, thereby reducing both material and processing costs.
Solution Approach 2:
The patent uses Fe-Si system magnetic powder as a composite material to create core members with desirable magnetic properties. This composite approach achieves the required magnetic performance without the complexity and cost of laminating multiple iron core strips.
2Loss of energy
If ferrite magnetic core and pressurized powder magnetic core are combined, then copper loss is reduced, but material cost and processing complexity increase
Solution Approach 1:
The patent uses uniform Fe-Si system magnetic powder for all core members, creating a homogeneous structure. This simplifies processing compared to combining different magnetic core materials, while still achieving low copper loss through optimized magnetic properties and gap configuration.
3Manufacturing precision
If multiple core members are successively arranged with gaps, then inductance control is improved, but manufacturing complexity increases
Solution Approach 1:
The patent divides the magnetic core into multiple core members (first, second, third core members) that are successively arranged with gaps between them. This segmentation allows precise control of inductance by adjusting gap dimensions while maintaining manageable manufacturing complexity through standardized assembly.
Solution Approach 2:
The patent controls inductance by changing the gap parameters (gap length and positioning) between core members rather than changing the core members themselves. This approach provides precise inductance control while keeping the core members themselves simple and easy to manufacture.
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 effectively reduces material and processing costs while maintaining performance specifications, minimizing coil loss and noise, and improving gas mileage by using a uniform Fe-Si system magnetic powder core with fewer components and optimized gap placement.
Implementation Method 1
a chopper boosting operation is performed in which electrical energy supplied from the DC power supply is temporarily stored as magnetic energy in the reactor cores
Implementation Method 2
two or more core members made of magnetic materials are successively arranged via intervening gaps to form an annular shape
Data Source
AI summary
A reactor, which enables costs to be reduced while ensuring specific specifications for an electric vehicle such as an HV vehicle, is provided. The reactor for an HV vehicle includes: a reactor core in which a pair of roughly U-shaped core members, which have been integrally formed using an Fe—Si magnetic powder, are arranged in a circular shape by aligning two leg sections of each core member opposite to each other with gaps therebetween; and coils wound around the periphery of the leg sections of the core members, which are positioned opposite to each other with the gaps therebetween.