Magnetic Core Cooling with Non-Magnetic Master Sheet
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Solution Overview
Problem
Iron inductors in high-speed motors experience significant iron losses and conduction losses due to high-frequency currents, leading to increased size and energy dissipation, while air inductors are bulky and prone to radiation and eddy currents.
Innovation Solution
A magnetic core for induction coils comprising bundles of magnetic material with air gaps and tie rods, where a heat-conducting non-magnetic master sheet acts as a heat collector and radiator, with cooling tubes connected to a fluid circulation circuit to manage temperature and reduce losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If iron core is used in inductors for high-speed motors, then magnetic flux is better channeled and inductor size is reduced, but iron losses increase rapidly with frequency
Solution Approach 1:
The iron core is segmented into multiple bundles of sheets separated by air gaps. This segmentation reduces the continuous magnetic path, limiting the magnetic field strength and thereby reducing iron losses (hysteresis and eddy currents) while maintaining compact inductor dimensions through the concentrated flux paths in each bundle.
Solution Approach 2:
The invention changes the physical parameters of the core by introducing air gaps between bundles of sheets. This modifies the magnetic circuit properties, reducing the effective permeability and limiting the magnetic field, which directly reduces iron losses at high frequencies while maintaining acceptable inductance through increased winding turns.
2Loss of energy
If air gaps are added to limit magnetic field and reduce iron losses, then energy losses decrease, but number of windings and iron section must be increased
Solution Approach 1:
The core is divided into multiple bundles of sheets with air gaps between them. This segmentation allows the magnetic field to be confined within each bundle, reducing the overall field strength and iron losses. The segmented structure achieves loss reduction without requiring a proportional increase in total iron section, as each bundle operates independently with lower flux density.
3Loss of energy
If inductor section is increased to handle high-frequency currents, then conduction losses are managed, but inductor dimensions become very large
Solution Approach 1:
The segmented core structure with multiple bundles of sheets separated by air gaps creates multiple parallel magnetic paths. This allows the inductor to handle high-frequency currents more efficiently by distributing the flux, reducing conduction losses without requiring a large single continuous iron section, thereby maintaining compact overall dimensions.
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 solution effectively mitigates iron and conduction losses by efficiently cooling the magnetic core, maintaining proper functioning and reducing the size and energy dissipation of the inductors.
Implementation Method 1
The master sheet, in addition to its traditional function of mechanical support, acts as a heat collector and radiator, the fluid circulating in the cooling tubes carrying the calories collected by the master sheet
Implementation Method 2
the fluid circulating in the cooling tubes carrying the calories collected by the master sheet and ensuring the temperature maintenance of the magnetic core
Data Source
Figure 1
Figure 2
AI summary
The core has link sticks traversing packets of sheets perpendicular to an axis (6) for assuring connection of the sheets of each packet. A main sheet (12) is plated by the link sticks parallel to the sheets for assuring the connection of core elements, where the main sheet is made of non-magnetic heat conducting material i.e. aluminum. A cooling tube (15) is welded on the main sheet, and a connector (16) connects the cooling tube with a coolant circulation circuit (17).