Magnetic Winding Optimization for Eddy Current Loss Reduction

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Solution Overview

Problem

Existing magnetic components face inefficiencies due to high power dissipation from eddy currents, which are not adequately addressed by prior methods that assume constant layer thickness and neglect phase displacement, leading to suboptimal designs with increased size and temperature issues.

Innovation Solution

A method to calculate and optimize winding parameters such as layer thickness, number of layers, and turns per layer, considering magnetic field intensities and phase displacement, to minimize power dissipation, using expressions derived from Maxwell's equations and loss functions to determine optimal conductor geometries.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If conventional winding designs with constant layer thickness are used, then manufacturing is simpler, but power dissipation increases due to eddy currents

Engineering Contradiction:
Improvewinding layer thickness consistencyVSAvoidpower dissipation
Core Design Contradiction:
Ease of manufactureVSLoss of energy

Solution Approach 1:

The patent applies local quality by varying the thickness of individual winding layers based on their specific position and magnetic field conditions. Each layer's thickness is optimized independently according to the local magnetic field intensity and phase displacement characteristics, rather than using a uniform thickness throughout. This allows thinner layers in regions with higher eddy current losses while maintaining necessary thickness in other regions, thereby reducing overall power dissipation without excessive manufacturing complexity.

Inventive Principle:
Principle #3Local quality

Solution Approach 2:

The patent implements parameter changes by calculating and applying different thickness values for each winding layer based on mathematical expressions that consider magnetic field intensity ratios and phase displacements. The thickness parameter is dynamically adjusted for each layer rather than remaining constant, optimizing the balance between manufacturing feasibility and energy loss reduction.

Inventive Principle:
Principle #35Parameter changes

2Power

If larger conductor thickness is used, then current carrying capacity increases, but eddy current losses increase significantly

Engineering Contradiction:
Improvecurrent carrying capacityVSAvoideddy current power dissipation
Core Design Contradiction:
PowerVSLoss of energy

Solution Approach 1:

The patent applies local quality by determining the optimal thickness for each winding layer based on its specific magnetic field environment. Layers experiencing higher magnetic field intensities and phase displacements are made thinner to reduce eddy currents, while layers in more favorable positions can be thicker to maintain current carrying capacity. This localized optimization resolves the contradiction between power capacity and energy loss.

Inventive Principle:
Principle #3Local quality

Solution Approach 2:

The patent segments the winding structure into multiple layers with individually optimized thicknesses. Rather than using a single thick conductor, the winding is divided into several thinner layers, each with thickness calculated to minimize eddy current losses while collectively maintaining the required current carrying capacity. This segmentation approach allows the system to achieve both high power capacity and low energy loss.

Inventive Principle:
Principle #1Segmentation

3Loss of energy

If more winding layers are used, then power dissipation can be reduced through optimization, but device complexity and size increase

Engineering Contradiction:
Improvepower dissipationVSAvoidnumber of winding layers
Core Design Contradiction:
Loss of energyVSDevice complexity

Solution Approach 1:

The patent uses parameter changes by calculating the optimal number of layers and their respective thicknesses based on mathematical expressions involving magnetic field intensity ratios and phase displacements. The optimization process determines the minimum number of layers required to achieve significant power dissipation reduction, balancing the benefits of reduced energy loss against the increased complexity of more layers.

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

The patent converts the potentially harmful effect of increased device complexity into a benefit by demonstrating that the additional layers required for optimization lead to such significant reductions in power dissipation that the overall system performance is improved. The complexity increase is justified and converted into a net benefit through the substantial energy loss reduction achieved.

Inventive Principle:
Principle #22Blessing in disguise (Convert harm into benefit)

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 significantly reduces power dissipation, enhancing efficiency and allowing for smaller, cooler magnetic components by optimizing conductor thickness and geometry based on magnetic field boundary conditions.

Implementation Method 1

alternating current (AC) conduction generates eddy currents within the conductors of magnetic components. Such eddy currents are significant at high frequencies and/or for large conductor thicknesses.

Methodology Applied
Scientific EffectEddy currents: Eddy Currents

Implementation Method 2

Skin effect is the tendency of the current density in a wire to increase at and near the surface of the wire. In other words, skin effect is the tendency of current in a conductor to flow more toward the surface of the conductor as frequency is increased.

Methodology Applied
Scientific EffectSkin effect: Skin Effect

Implementation Method 3

Proximity effect occurs when one conductor is placed in an external field generated by one or more other conductors in close proximity. In that case, eddy currents are induced in the conductor which oppose the penetration of the external field.

Methodology Applied
Scientific EffectProximity effect:

Implementation Method 4

expressions derived from Maxwell's equations and loss functions to determine optimal conductor geometries

Methodology Applied
Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentUS7506280B2Magnetic winding and method of making same
Publication Date: 2009.03.17 EXXELIA USA INC
  • US7506280B2 patent drawing
  • US7506280B2 patent drawing
  • US7506280B2 patent drawing

AI summary

The present invention provides an improved magnetic winding and method of calculating desired winding parameters (winding layer thickness, number of winding layers and number of turns per winding layer) for a winding in a magnetic component. The invention may be applied to general boundary conditions in a magnetic winding or component and considers relative phase displacement for sinusoidal and nonsinusoidal winding currents. Ratios of magnetic surface field intensities at corresponding inner and outer boundaries of one or more winding layer(s) are calculated, and considered with relative phase displacement to select magnetic winding configurations having desired or optimal power dissipation. In certain aspects, a normalized loss function f(H,R,B,Φ) is utilized to determine a preferred construction among a plurality of iteratively generated selections.