Oriented Silicon Steel Coating Asymmetry for Magnetostriction Control
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Solution Overview
Problem
Existing methods for producing oriented silicon steel struggle with uneven stress distribution due to single-sided laser etching, leading to significant magnetostrictive deviations between etched and non-etched surfaces, which complicates the production of transformer cores with optimal noise characteristics and cost-effectiveness.
Innovation Solution
A manufacturing method for low-magnetostrictive oriented silicon steel involves single-sided laser etching, where the deflection difference between surfaces is determined to adjust the amount of insulating coatings, ensuring more coating on the non-etched surface than the etched surface, thereby reducing magnetostrictive deviations and optimizing magnetic domain refinement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If single-sided laser etching is performed to refine magnetic domains, then magnetic domain refinement is improved, but magnetostrictive deviation between surfaces increases
Solution Approach 1:
The patent applies different coating amounts to different surfaces of the steel substrate. The first surface (etched side) receives a different coating amount compared to the second surface (non-etched side), creating local quality differences that compensate for the uneven stress distribution caused by single-sided laser etching, thereby reducing magnetostrictive deviation while maintaining magnetic domain refinement
Solution Approach 2:
The patent pre-applies insulating coatings with specifically controlled amounts on both surfaces before final assembly. By determining the coating amounts in advance based on the laser etching parameters and surface deflection characteristics, the method preemptively counteracts the stress imbalance that would otherwise cause magnetostrictive deviation, achieving both magnetic domain refinement and surface stability
2Ease of manufacture
If uniform insulating coating is applied on both surfaces, then manufacturing simplicity is improved, but magnetostrictive deviation increases
Solution Approach 1:
The patent implements a differentiated coating strategy where the insulating coating amounts on the first and second surfaces are deliberately made different. The first surface receives a coating amount that compensates for laser etching effects, while the second surface receives a different amount to balance the overall stress distribution, thus reducing magnetostrictive deviation while maintaining reasonable manufacturing simplicity
3Manufacturing precision
If laser etching power is increased to improve magnetic domain refinement, then magnetic domain refinement is improved, but surface deflection difference increases
Solution Approach 1:
The patent calculates and pre-determines the appropriate insulating coating amounts on both surfaces based on the laser etching power and expected surface deflection. By establishing this compensatory coating scheme before coating application, the method counteracts the shape distortion caused by high-power laser etching, enabling effective magnetic domain refinement without excessive surface deflection
Solution Approach 2:
The patent adjusts the insulating coating parameters (coating amounts on different surfaces) in response to changes in laser etching power. When laser power is increased to improve magnetic domain refinement, the coating parameters are相应 adjusted to compensate for the increased surface deflection, maintaining the balance between magnetic domain refinement and shape stability
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 method achieves a magnetostrictive deviation of ≤2 db(A) and average magnetostriction of ≤55 db(A), resulting in reduced transformer noise levels by minimizing vibrations from the iron core, making the process more stable and cost-effective.
Implementation Method 1
performing single-sided laser etching on the silicon steel substrate
Implementation Method 2
single-sided laser etching
Implementation Method 3
the magnetostriction of the oriented silicon steel has become the main source of the transformer noise
Implementation Method 4
adjust the amount of the insulating coatings on the first surface and the second surface
Data Source
AI summary
A manufacturing method for low-magnetostrictive oriented silicon steel is provided, wherein the oriented silicon steel comprises a silicon steel substrate and an insulating coating on the surface of the silicon steel substrate. The manufacturing method comprises: performing single-sided laser etching on the silicon steel substrate, wherein the side of the silicon steel substrate, on which single-sided laser etching is performed, is a first surface, and the side opposite to the first surface is a second surface; determining a deflection difference between the first surface and the second surface based on the power of the laser etching, and determining a difference in the amount of the insulating coatings on the first surface and the second surface based on the deflection difference; and forming insulating coatings on the first surface and the second surface. The amount of the insulating coating on the second surface is greater than that on the first surface, and the amount of the insulating coating on the first surface and that on the second surface satisfy the difference in the amount of the insulating coatings. By using the manufacturing method in the present invention, the problem of a relatively large magnetostrictive deviation between two sides of oriented silicon steel caused by single-sided laser etching can be solved. Oriented silicon steel manufactured by the aforementioned manufacturing method is also provided. A transformer iron core prepared using the oriented silicon steel enables a transformer to have low noise during operation.