Soft Magnetic Strip Tension Control for Uniform Permeability
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Solution Overview
Problem
The existing production methods for soft magnetic strip material result in a tape thickness that changes locally along the longitudinal direction, leading to fluctuations in tensile stress and permeability due to varying cross-sectional areas, making it challenging to achieve consistent magnetic properties.
Innovation Solution
A method involving the preparation of band-shaped material, heat-treatment, and application of tensile force to induce stress, with real-time magnetic measurement and control of tensile force to maintain constant tensile stress and achieve consistent permeability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If continuous annealing with tensile stress is applied to rapidly solidified magnetic material, then soft magnetic properties with defined permeability are achieved, but local variations in tape thickness cause fluctuations in tensile stress and permeability along the longitudinal direction
Solution Approach 1:
The patent implements a feedback control system where magnetic measurement values (permeability) are continuously determined along the longitudinal direction of the produced soft magnetic strip material. Based on these measurements, the tensile force is dynamically controlled to maintain constant tensile stress, compensating for local thickness variations. This closed-loop feedback mechanism resolves the contradiction by using permeability measurements to adjust tensile force, thereby maintaining manufacturing precision despite composition instability.
Solution Approach 2:
The patent changes the tensile force parameter dynamically along the longitudinal direction based on measured permeability values and local thickness variations. By adjusting the tensile force to compensate for thickness fluctuations, the tensile stress is kept constant, which in turn maintains constant induced anisotropy and permeability. This parameter change approach directly addresses the contradiction by making the tensile force variable rather than constant.
2Manufacturing precision
If tensile force is applied during heat treatment to induce anisotropy, then defined permeability along the tensile stress direction is achieved, but the required tensile force varies with local cross-sectional area
Solution Approach 1:
The patent uses magnetic measurement values obtained during production as feedback to control the tensile force. The system continuously measures permeability and uses this information to adjust the tensile force, creating a closed-loop control that simplifies the overall system by using readily available magnetic measurements rather than requiring separate thickness measurement and calculation systems.
Solution Approach 2:
The patent replaces a purely mechanical tensile force control system (which would require direct thickness measurement and mechanical adjustment) with a system that uses magnetic field measurements and corresponding tensile force control. This substitution leverages the ease of magnetic measurement to achieve more precise and simpler control of the mechanical tensile force parameter.
3Manufacturing precision
If real-time magnetic measurement and tensile force control are implemented, then constant permeability is achieved, but measurement and control systems are added to the production process
Solution Approach 1:
The patent implements feedback control using magnetic measurement values that are determined during the production process. These measurements provide information about local permeability, which is then used to adjust the tensile force to maintain constant tensile stress. This feedback mechanism achieves constant permeability output despite variations in input material properties.
Solution Approach 2:
The production system uses its own magnetic measurement capability to automatically control the tensile force parameter. The system essentially monitors and adjusts itself using the magnetic properties of the material being produced, reducing the need for external complex control systems and enabling self-regulation of the manufacturing process.
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 approach enables the production of soft magnetic strip material with consistently constant permeability along its length, reducing variations in magnetic properties and improving the accuracy of roll tape-wound cores.
Implementation Method 1
heat-treating the band-shaped material at a heat-treatment temperature
Implementation Method 2
applying a tensile force to the heat-treated band-shaped material in the longitudinal direction of the band-shaped material in order to produce a tensile stress in the band-shaped material
Data Source
AI summary
A method for producing soft magnetic strip material for roll tape-wound cores with the following steps: preparing a band-shaped material, applying a heat-treatment temperature to the band-shaped material, and applying a tensile force to the temperature-applied band-shaped material in one longitudinal direction of the band-shaped material in order to produce a tensile stress in the band-shaped material, to produce the soft magnetic strip material from the band-shaped material, the method, moreover, comprising determining at least one magnetic measurement value of the soft magnetic strip material that has been produced and controlling the tensile force for setting the tensile stress in a reaction to the determined magnetic measurement value. Furthermore, a device for carrying out the method and a roll tape-wound core produced by means of the method are made available.