Magnetic Core Data Medium for Inductivity Tolerance
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Solution Overview
Problem
Current methods for adjusting the inductivity of tape wound magnetic cores, particularly those made of amorphous or nanocrystalline materials, are inefficient, leading to significant tolerance variations due to material composition, geometric irregularities, and temperature dependencies, making it challenging to achieve precise inductivity values within a wide temperature range.
Innovation Solution
Integration of a data medium with machine-readable data representing magnetic and electrical parameters measured at different temperatures, allowing for automatic calculation and adjustment of compensation values to minimize inductivity tolerance, enabling precise inductivity control across a temperature range of -40°C to 120°C.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If thermal field treatment is used to adjust permeability, then magnetic core permeability can be adjusted, but the inductivity tolerance varies by ±10% to ±15%
Solution Approach 1:
The patent applies preliminary action by measuring and storing the actual permeability values of individual magnetic cores during manufacturing, then using these pre-acquired data to calculate compensation values that are applied during operation. This prevents inductivity deviations rather than correcting them after the fact, achieving tight tolerance (±3% or less) without requiring complex real-time adjustment mechanisms.
Solution Approach 2:
The patent implements feedback by storing measured permeability data on data media associated with each magnetic core, then using this feedback information to calculate compensation values that adjust the operating parameters of inductive components. This closed-loop approach ensures that each core operates at its optimal performance point despite manufacturing variations.
2Ease of manufacture
If uniform thermal treatment is applied to production batch, then manufacturing process is simplified, but permeability variation remains at ±10%
Solution Approach 1:
The patent applies parameter changes by measuring the actual permeability of each magnetic core and using this measured parameter to calculate individual compensation values. Instead of attempting to control manufacturing parameters to achieve uniformity, the patent accepts the natural variations and compensates for them through parameter adjustment during operation, maintaining both ease of manufacture and high precision.
3Manufacturing precision
If material composition and geometric irregularities are controlled, then manufacturing complexity increases, but inductivity tolerance cannot be reduced below ±15%
Solution Approach 1:
The patent introduces an intermediary element - a data medium storing measured permeability values - that bridges the gap between manufacturing variations and performance requirements. This intermediary allows the system to accept simple manufacturing processes while achieving high precision through data-driven compensation, avoiding the need for complex real-time control systems during manufacturing.
4Adaptability or versatility
If inductivity adjustment methods from other magnetic cores are applied, then existing manufacturing knowledge is utilized, but adjustment is not possible with tape wound cores
Solution Approach 1:
The patent replaces mechanical adjustment methods (such as grinding or screw adjustment used with ferrite cores) with a data-driven electronic compensation system. By measuring permeability and calculating compensation values based on stored data, the system achieves adjustment without physical modification of the tape wound core structure, maintaining both versatility and ease of manufacture.
Data Source
AI summary
Magnetic core made of soft magnetic material with a data medium attached to, mounted on or integrated in the magnetic core, with data in machine-readable form being stored on the data medium, the data representing at least one magnetic parameter of the magnetic core or its corresponding electrical parameter, measured at at least two different temperatures.