Interleaved Inductor Winding for Magnetic Core Saturation
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Solution Overview
Problem
Magnetic fluxes generated by power frequency currents in three windings of a coupling inductor do not counteract each other completely, leading to magnetic core saturation and increased inductor loss, which hampers efficiency optimization in multi-state switching circuits.
Innovation Solution
The inductor winding method involves dividing the turns of each winding into two portions based on a preset ratio and winding them alternately on different magnetic columns, ensuring that magnetic lines generated by windings on the same column have opposite directions, thereby allowing power frequency magnetic fluxes to counteract each other.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a large air gap is needed in the magnetic core to prevent saturation, then magnetic core saturation is avoided, but inductor loss is increased
Solution Approach 1:
The patent segments the windings into multiple groups and distributes them across different magnetic columns in an interleaved pattern. This segmentation allows magnetic fluxes from different windings to counteract each other more effectively, reducing the net flux density in the magnetic core and preventing saturation without requiring a large air gap, thus avoiding the associated inductor losses.
Solution Approach 2:
The patent employs an asymmetric winding distribution where windings are interleaved across magnetic columns rather than uniformly distributed. This asymmetric arrangement creates opposing magnetic flux paths that cancel each other, reducing the overall magnetic flux density and enabling saturation prevention with minimal or no air gap, thereby reducing inductor loss.
2Ease of manufacture
If windings are wound on separate magnetic columns without interleaving, then manufacturing is simpler, but magnetic fluxes cannot counteract completely leading to core saturation
Solution Approach 1:
The patent divides the total number of windings into multiple groups and assigns them to different magnetic columns in an interleaved sequence. This segmentation approach maintains relative manufacturing simplicity while achieving the critical effect of flux counteraction, as each winding group can still be manufactured separately and then assembled in the interleaved configuration.
Solution Approach 2:
The patent transitions from a single-dimension winding approach (all windings on one column or sequential winding) to a multi-dimensional interleaved arrangement across multiple magnetic columns. This dimensional change enables magnetic fluxes to counteract each other spatially, preventing core saturation while maintaining manufacturing feasibility through systematic distribution.
3Reliability
If an interleaved winding structure is implemented, then magnetic flux density is reduced and coupling coefficient is increased, but winding complexity increases
Solution Approach 1:
The patent segments windings into discrete groups that are systematically distributed across magnetic columns. This segmentation creates a structured interleaved pattern that achieves flux density reduction and improved coupling, while the modular nature of the segmentation makes the complexity manageable through systematic assembly rather than random or overly complex arrangements.
Solution Approach 2:
The patent employs preliminary planning in the winding distribution design, where the interleaved pattern is predetermined and systematically implemented. This preliminary action allows the complex interleaved structure to be manufactured with precision and consistency, reducing the actual manufacturing complexity by having a clear, pre-planned arrangement rather than requiring complex real-time adjustments.
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 interleaving-wound structure reduces magnetic flux density in the core, achieves certain leakage inductance, and increases coupling coefficients among windings, thereby addressing the issue of core saturation and enhancing efficiency.
Implementation Method 1
magnetic lines generated by each of the three inductors counteract the magnetic lines generated by other inductors after flowing through the other two magnetic columns
Implementation Method 2
magnetic fluxes generated by power frequency currents in respective windings
Implementation Method 3
current sharing can be achieved automatically between the circuits for respective phases without current sharing control due to the presence of an auto-transformer
Data Source
AI summary
Provided is an inductor winding method and an inductor winding device. The inductor winding method comprises steps of: A. dividing turns of coil of each winding of the inductor into a first winding and a second winding based on a preset ratio; B. winding the first winding on one of multiple magnetic columns, and winding the second winding on another one of the multiple magnetic columns which is different from the magnetic column on which the first winding is wound; and C. performing step A and step B cyclically until all the windings of the inductor are wound. With a coupling inductor having interleaving-wound structure, power frequency magnetic fluxes generated by magnetic lines in magnetic columns counteract one another, thereby solving the problem of high magnetic flux density in a magnetic core while achieving certain leakage inductance.