Magnetic Element Auxiliary Winding for Flux Distribution Control
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Solution Overview
Problem
Current magnetic elements with multiple magnetic legs face challenges in controlling magnetic flux distribution, making precise size adjustments difficult and mass production unfeasible due to the complexity of designing these elements for high efficiency and power density in power modules.
Innovation Solution
A magnetic element design featuring a magnetic core with a plurality of winding legs, lateral legs, and an auxiliary winding, where the auxiliary winding is connected in parallel with either the primary or secondary windings, allowing for controlled magnetic flux distribution by adjusting the turn ratio and winding directions to clamp magnetic potential, enabling precise flux control and simplifying the design for mass production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a magnetic element with multiple magnetic legs is used to reduce loss and size, then power density and efficiency are improved, but magnetic flux control becomes difficult and design complexity increases
Solution Approach 1:
An auxiliary winding is introduced as an intermediary component to control the magnetic flux distribution in the magnetic core. The auxiliary winding generates a magnetic flux that counteracts the uneven flux distribution caused by the multiple magnetic legs structure, thereby balancing the flux across different legs and enabling effective flux control without increasing structural complexity
Solution Approach 2:
The magnetic flux distribution is controlled by adjusting the turn ratio of the auxiliary winding relative to the parallel-connected winding set. By changing this parameter (turn ratio N:1), the magnitude of the magnetic flux generated by the auxiliary winding can be precisely controlled to achieve the desired flux balancing effect across the magnetic core
2Manufacturing precision
If the size of magnetic element parts is adjusted to control magnetic flux, then flux control precision is improved, but design difficulty increases and mass production becomes unfeasible
Solution Approach 1:
Instead of adjusting the physical dimensions of magnetic core parts, the invention controls magnetic flux precision by changing the electrical parameter (turn ratio) of the auxiliary winding. This approach maintains manufacturing simplicity and part standardization, making the design suitable for mass production while achieving precise flux control through parameter adjustment rather than geometric modification
3Power
If windings are arranged to achieve high power density, then efficiency is improved, but magnetic flux distribution control becomes difficult
Solution Approach 1:
The auxiliary winding serves as a mediator that decouples the relationship between power density and flux distribution control. It allows the magnetic element to maintain high power density through compact winding arrangement while independently controlling flux distribution through the auxiliary winding's magnetic field, which counteracts uneven flux without requiring changes to the power-transmitting winding structure
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
This design allows for controllable AC magnetic flux distribution, reducing flux through each part of the magnetic element, making it suitable for mass production while maintaining performance consistency and reducing the size of the magnetic element.
Implementation Method 1
The auxiliary winding is wound on one of the first lateral leg and the second lateral leg... A direction of a magnetic flux generated by the auxiliary winding is opposite to a direction of the magnetic flux through the adjacent winding leg
Data Source
AI summary
A magnetic element includes at least one primary winding, at least one secondary winding, a magnetic core, and an auxiliary winding. A winding segment or an entire of the primary winding or a winding segment or an entire of the secondary winding is defined as a parallel-connected winding set. The magnetic core includes a plurality of winding legs, two lateral legs, and two connection parts. The at least one primary winding and the at least one secondary winding are wound around each winding leg. The directions of magnetic fluxes through every two adjacent winding legs are opposite. The auxiliary winding is wound on one of two lateral legs, and electrically connected with the parallel-connected winding set. A direction of a magnetic flux generated by the auxiliary winding is opposite to a direction of the magnetic flux through the adjacent winding leg.