Segmented Magnetic Core Assembly for Precise End-Face Alignment
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Solution Overview
Problem
Existing magnetic cores face challenges in accurately joining end faces of soft magnetic sheets superposed in a thickness direction and bent at corner areas, leading to potential deformation and increased core loss.
Innovation Solution
A magnetic core design where first and second corner areas are arranged at intervals in one direction, and third and fourth corner areas are arranged at intervals in a perpendicular direction, with a third part having grain-oriented electrical steel sheets that contact the inner circumferential surfaces of the first and second parts to maintain precise alignment and prevent deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If soft magnetic sheets are superposed in the thickness direction with single joined parts at each layer, then the core structure is simple, but the lacing load becomes large and positioning precision deteriorates
Solution Approach 1:
The magnetic core is divided into multiple parts (first part, second part, third part) with multiple joined parts distributed at different locations. Instead of having a single joined part per layer, the structure segments the joined parts across multiple positions, which distributes the lacing load and improves positioning precision through the positioning members that engage with the inner circumferential surfaces.
2Force
If multiple joined parts are provided at different locations to reduce lacing load, then the lacing load is reduced, but soft magnetic sheets may enter between other sheets causing deformation and increased core loss
Solution Approach 1:
Positioning members are provided in advance at the joined parts to prevent soft magnetic sheets from entering between other sheets during assembly. These positioning members protrude from the end faces and engage with the inner circumferential surfaces, creating a preliminary constraint that prevents deformation before the lacing operation is completed.
Solution Approach 2:
Positioning members act as intermediary elements between the end faces of soft magnetic sheets and the inner circumferential surfaces. These members facilitate the joining process by providing precise positioning and preventing sheet insertion, thereby maintaining shape stability while allowing multiple joined parts to be used.
3Reliability
If end faces are made to abut with high precision to prevent deformation, then shape stability is improved, but positioning becomes difficult when sheets are stacked individually
Solution Approach 1:
The positioning members are integrated into the structure of the soft magnetic sheets themselves, allowing the sheets to self-position during assembly. The protruding positioning members automatically engage with the inner circumferential surfaces when sheets are stacked, providing self-aligning functionality that simplifies the assembly process while maintaining high positioning precision.
4Ease of manufacture
If bent soft magnetic sheets are used to form corner areas, then the core can be assembled from individual sheets, but strain is introduced causing core loss and heat generation
Solution Approach 1:
Bending operations are performed in advance on individual soft magnetic sheets before assembly, allowing precise control of the bending process. The sheets are bent to form corner areas with predetermined shapes, and then assembled with other sheets. This preliminary action enables the use of standard bending equipment and allows for quality control of the bending process.
Data Source
AI summary
When joining end faces of a plurality of soft magnetic sheets which are superposed in the sheet thickness direction and which are bent at parts forming corner areas of a core, offset of positions of the end faces from the desired positions is suppressed.In a region of a window part comprised of a region inside of a first part 110 and second part 120, a third part 130 with a length in a longitudinal direction (X-axial direction) the same as a length in the X-axial direction of the window part at the position where the third part 130 is arranged is arranged so as to contact the region of the inner circumferential surface between the first corner area 101 and third corner area 103.