Magnetic Core Assembly With Repositioned Elements for Lower Loss
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Solution Overview
Problem
Current transformer and reactor core designs result in significant energy losses and material scrap during manufacturing, with limited innovation in core design and inefficient manufacturing processes.
Innovation Solution
The proposed technology involves a method for manufacturing magnetic cores with reduced energy losses and scrap, using high power laser technology to cut and reposition building elements made of grain-oriented electrical steel, allowing for the creation of new joint patterns and core designs that minimize losses and waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If traditional core designs and manufacturing processes are used, then manufacturing simplicity is maintained, but energy losses remain high and material scrap increases
Solution Approach 1:
The core is divided into modular building elements (rectangular plates with standardized dimensions) that can be assembled in different configurations. This segmentation allows optimization of magnetic flux paths while maintaining manufacturing simplicity through standardized components.
Solution Approach 2:
The patent introduces a new spatial arrangement of core components by positioning building elements at specific coordinates (x, y, z) to optimize magnetic flux distribution. This dimensional optimization reduces energy losses without significantly increasing manufacturing complexity.
2Loss of substance
If traditional manufacturing processes are used, then manufacturing simplicity is maintained, but material scrap increases
Solution Approach 1:
Building elements are pre-cut with precise dimensions and magnetic orientation during the steel coil processing stage. This preliminary action ensures that when elements are assembled into cores, no additional material needs to be removed, eliminating scrap generation while maintaining ease of manufacture through standardized assembly.
Solution Approach 2:
The patent eliminates the need to discard any material by designing a manufacturing process where all cut building elements are utilized in core assembly. The standardized dimensions ensure complete utilization of steel coil material, recovering what would otherwise be scrap.
3Loss of energy
If core designs from 50-65 years ago are used, then design simplicity is maintained, but energy losses remain high
Solution Approach 1:
The patent creates adaptable core designs where building elements can be positioned in different configurations to suit various transformer and reactor applications. This dynamic adaptability allows optimization for different power ratings and requirements while maintaining reduced energy losses through standardized element designs.
Data Source
Figure 1a
Figure 1b~1c
Figure 2a
AI summary
A method and an apparatus for almost scrap-less manufacturing of magnetic cores (100; 150; 200; 250) for electrical power transformers or reactors are provided. The method comprises the steps of cutting (S10) a cut-out (41) from the middle of a long side of a rectangular yoke plate made of electrical steel such that a symmetric gap is formed in the yoke plate, forming (S20) building elements (40; 40') of grain oriented electrical steel either from the cut-out (41) or from a rectangular limb plate, repositioning (S30) the building elements such that at least some of the building elements get a new orientation and/or position in relation to the yoke plate or the limb plate, and building (S50) a magnetic core (100; 150; 200; 250) by assembling at least yoke plates and repositioned building elements such that the repositioned building elements fit into the symmetric gaps formed in the yoke plates. Magnetic cores (100; 150; 200; 250) for electrical power transformers or reactors are also provided, where the core losses and noise levels are reduced compared to prior art technology. In particular, magnetic hybrid cores with grain oriented electrical steel and amorphous steel are provided.