Magnetic Core Recess for Reactor Weight Reduction
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Solution Overview
Problem
In hybrid automobiles, reducing the size of magnetic cores in reactors to minimize weight leads to deterioration of magnetic characteristics.
Innovation Solution
Incorporating a recessed portion in the magnetic core's end core, specifically designed to reduce material usage while minimizing the impact on magnetic flux paths, thereby maintaining excellent magnetic characteristics and reducing weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the size of magnetic core is reduced to minimize weight, then weight is reduced, but magnetic characteristics deteriorate
Solution Approach 1:
The end core is designed with a recessed portion that creates local structural differentiation. This allows the magnetic core to have varying material distribution - denser in critical magnetic flux path areas and reduced in less critical areas - thereby maintaining magnetic characteristics while reducing overall weight
Solution Approach 2:
The end core is segmented into multiple portions through the recessed portion, creating a multi-level structure. This segmentation allows strategic removal of material from non-critical areas while preserving the magnetic flux path integrity, achieving weight reduction without compromising magnetic performance
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 lightweight reactor with preserved magnetic performance, enhancing conversion efficiency in power conversion devices.
Implementation Method 1
the first recessed portion is located in a central portion of the first end core with respect to a Y direction
Data Source
AI summary
This reactor comprises a coil having a first winding part, and a magnetic core, wherein the magnetic core includes a middle core, a first end core, a second end core, a first side core, and a second side core, wherein: the first end core includes a first outer surface at a position separated from the first end face in an X direction, and a first recess provided to the first outer surface; in a plan view of the magnetic core from a Z direction, the first recess is provided in a middle portion of the first end core in a Y direction; the X direction is a direction along the axial direction of the middle core; the Y direction is a direction in which the middle core, the first side core, and the second side core are arranged next to one another; and the Z direction is a direction orthogonal to the X direction and the Y direction.