Magnetic Component with Segmented Core for Onboard Charger
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Solution Overview
Problem
Magnetic components in onboard battery chargers are oversized, occupying excessive space and affecting the installation of other electrical components, while reducing their size compromises energy conversion efficiency.
Innovation Solution
A magnetic component design featuring a primary coil group, secondary coil group, and magnetic core with specific winding configurations and air gaps, allowing for downsizing without compromising energy conversion efficiency by optimizing the number of turns and wire diameters of coils, and incorporating supporting columns for structural stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the size of the magnetic component is reduced, then the space occupied by the overall circuit is reduced, but the energy conversion efficiency deteriorates
Solution Approach 1:
The magnetic core is divided into multiple segments including a first magnetic core, second magnetic core, third magnetic core, and fourth magnetic core arranged in parallel. This segmentation allows for optimized magnetic flux distribution and reduced core losses while maintaining a compact overall structure, thereby achieving both size reduction and energy efficiency improvement
Solution Approach 2:
Air gaps are selectively introduced at specific locations within the magnetic core structure, particularly between certain magnetic core segments. This local modification optimizes the magnetic circuit characteristics, reduces eddy current losses, and improves energy conversion efficiency without requiring an increase in overall component size
2Area of stationary object
If the size of the magnetic component is reduced, then the installation space for other electrical components is improved, but the winding space for coil deteriorates
Solution Approach 1:
The magnetic core structure utilizes a three-dimensional arrangement with multiple cores positioned at different spatial locations (first, second, third, and fourth magnetic cores). This dimensional optimization allows for efficient use of winding space while keeping the overall footprint compact, enabling adequate coil winding space without increasing the installation area
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 achieves a compact size while maintaining excellent energy conversion efficiency by reducing total core and copper losses during AC charging, and enhances electromagnetic compatibility by containing leakage magnetic flux.
Implementation Method 1
a primary coil group comprising a first primary coil and a second primary coil; a secondary coil group comprising a first secondary coil and a second secondary coil
Implementation Method 2
An air gap exists between the first winding column and the second cover and between the second winding column and the second cover
Data Source
AI summary
A magnetic component is provided. The magnetic component comprises a primary coil group, a secondary coil group, and a magnetic core. A first primary coil and a second primary coil of the primary coil group are winding around a first winding column and a second winding column of the magnetic core, respectively. The number of turns of the first primary coil is different from the number of turns of the second primary coil. A first secondary coil and a second secondary coil of the secondary coil group are winding around the first winding column and the second winding column, respectively. The number of turns of the first secondary coil is different from the turns of the second secondary coil.