Magnetic Core Protrusion Layout for Winding Insulation
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Solution Overview
Problem
Conventional magnetic cores in rotary electric machines face challenges in achieving effective electrical insulation between the iron core and the winding, leading to potential performance issues and efficiency losses.
Innovation Solution
The magnetic core design incorporates a back yoke portion and tooth distal end portion with protrusions on the surfaces, allowing for a reduced contact area between the core and the winding, enhancing electrical insulation through strategic protrusion placement and winding configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the contact area between the iron core and the winding is increased to improve mechanical stability, then the mechanical strength is improved, but the electrical insulation deteriorates
Solution Approach 1:
The iron core surface is segmented into multiple protrusions distributed across the contact area. This segmentation reduces the continuous contact area between the iron core and winding, thereby improving electrical insulation while maintaining mechanical stability through the distributed support structure.
Solution Approach 2:
The protrusions create localized contact points with specific geometric properties (height, diameter, spacing) that differ from the surrounding areas. This local quality change allows the contact area to provide mechanical support where needed while maintaining electrical insulation in the non-contact regions.
2Reliability
If the contact area between the iron core and the winding is reduced to improve electrical insulation, then the electrical insulation is improved, but the mechanical strength deteriorates
Solution Approach 1:
The segmentation of the contact area into multiple discrete protrusions allows the total contact area to be reduced while distributing the mechanical load across multiple points, thereby maintaining mechanical stability despite the reduced overall contact area.
Solution Approach 2:
The protrusions extend in the radial direction from the iron core surface, adding a dimensional element to the contact structure. This radial extension provides mechanical support leverage while minimizing the axial contact area, thus improving electrical insulation without sacrificing mechanical strength.
Data Source
AI summary
A magnetic core that includes: a back yoke portion having a first lower surface aligned in an up-down direction; a tooth distal end portion having a second upper surface and a second lower surface aligned in the up-down direction; and extending in the up-down direction and having an upper end in contact with the first lower surface and a lower end in contact with the second upper surface, the tooth portion constructed to have a winding portion of a conductor wound around the tooth portion as viewed in the up-down direction, wherein the magnetic core has at least one structure of: (A) one or more first protrusions protruding from the first lower surface, and (B) one or more second protrusions protruding from the second upper surface.