Gapless Medium-Voltage Inductor Assembly for Compact Serviceable Design
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Inductors are often large, difficult to manufacture, and hard to service due to their construction, especially when operating at medium voltage levels, with potential for quality defects and failure.
Innovation Solution
A gapless inductor design featuring a magnetic core with a bobbin and spacers, allowing for adjustable permeability and easy assembly, which includes a coil wrapped around the core and bobbin, with a housing for improved cooling and mechanical stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional inductor construction is used, then inductance can be provided, but the inductor size becomes large and inconvenient
Solution Approach 1:
The magnetic core is segmented into multiple laminated sheets stacked together, with insulation between layers. This segmentation reduces eddy current losses while maintaining the required inductance in a more compact form factor suitable for medium voltage applications
Solution Approach 2:
The inductor uses composite construction combining magnetic core material with insulating layers and protective coatings, creating a multi-material structure that achieves both compact size and medium voltage operational reliability
2Ease of manufacture
If traditional inductor construction is used, then inductance can be provided, but manufacturing becomes difficult to automate and results in quality defects
Solution Approach 1:
The core is constructed from pre-manufactured laminated sheets that can be individually produced and then stacked, enabling automated manufacturing processes while maintaining consistent quality through standardized components
Solution Approach 2:
The manufacturing process utilizes controlled parameters such as laminate thickness, stacking sequence, and insulation material selection to achieve consistent quality outcomes that are suitable for automated production
3Ease of repair
If traditional inductor construction is used, then inductance can be provided, but the inductor is hard to service
Solution Approach 1:
The inductor is designed as an assembly of discrete laminated components that can be individually accessed and replaced, significantly improving serviceability despite the segmented construction
4Temperature
If traditional inductor construction is used, then inductance can be provided, but cooling becomes difficult
Solution Approach 1:
The laminated core construction creates inherent pathways for heat dissipation between the stacked layers, improving cooling efficiency without requiring additional complex cooling systems
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 design enables smaller components with improved performance, reduced manufacturing defects, and easier maintenance, while supporting medium voltage operations with enhanced short circuit current protection and common mode noise suppression.
Implementation Method 1
a coil extending through the longitudinal channel and wrapping around the core and the bobbin
Implementation Method 2
The core can have a relative permeability of 5 to 5000
Implementation Method 3
The first spacer and at least one of the first plate or second plate can be formed together as a single piece. The first spacer can electrically isolate the coil from the interior of the core
Data Source
AI summary
This disclosure provides a gapless medium voltage inductor. The inductor includes a magnetic core having an aperture extending therethrough, a bobbin comprising a first plate and a second plate, a spacer disposed within the aperture of the magnetic core, a longitudinal channel defined through the spacer, first plate, and second plate, and a coil extending through the longitudinal channel and wrapping around the core and the bobbin. The core is disposed between the first and second plates.