Integrated Magnetic Element With Parallel Windings for Compact Current Sensing
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Solution Overview
Problem
Existing integrated magnetic elements are large and heavy due to their single winding method, making them unsuitable for high-power applications where miniaturization and reduced size are necessary.
Innovation Solution
An integrated magnetic element is designed with a current sensor and transformer integrated into one part, featuring a magnetic core, multiple parallel sub-windings, and a current sensor that detects current flowing through the transformer's wires using a shunt ratio, allowing for compact and efficient current measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single winding method is used in existing integrated magnetic elements, then the structure is simple, but the volume and weight become large
Solution Approach 1:
The first winding is divided into multiple parallel sub-windings (at least two), where each sub-winding carries a portion of the total current. This segmentation allows the magnetic element to handle high-power applications while reducing the volume and weight of individual winding components compared to a single large winding.
Solution Approach 2:
The current sensor is integrated within the transformer structure, with the sensor's magnetic core and winding arranged concentrically with the transformer's magnetic core. The sensor winding is nested inside the transformer winding structure, allowing both components to share the same spatial envelope and reducing overall volume.
2Power
If the power of the converter increases, then the power handling capability improves, but the size and weight of the magnetic element increase
Solution Approach 1:
By dividing the first winding into multiple parallel sub-windings, each sub-winding carries a fraction of the total high current. This allows the magnetic element to handle high-power applications while using thinner, lighter wire and smaller magnetic core cross-sections compared to a single large winding designed for the same total power.
Solution Approach 2:
The integrated magnetic element performs multiple functions simultaneously: the transformer provides power transformation and isolation, while the integrated current sensor provides real-time current measurement. This multi-functionality eliminates the need for separate current sensing components, reducing overall weight while maintaining high power handling capability.
3Power
If the power of the converter increases, then the power handling capability improves, but the volume of the magnetic element increases
Solution Approach 1:
The first winding is divided into multiple parallel sub-windings, allowing high power to be transmitted through multiple smaller conductors rather than one large conductor. This enables the use of a more compact magnetic core with smaller cross-sectional area while maintaining the same power handling capability, thus reducing overall volume.
Solution Approach 2:
The current sensor is nested within the transformer structure, with the sensor's magnetic core positioned inside the transformer's magnetic core or with windings arranged concentrically. This nested arrangement allows both the transformer and current sensor to occupy the same spatial envelope, significantly reducing the total volume compared to separate components.
4Measurement precision
If a current sensor is integrated with the transformer, then accurate current detection is achieved, but the device complexity increases
Solution Approach 1:
The current sensor is nested within the transformer structure, with the sensor's magnetic core and winding integrated into the transformer's magnetic path. The sensor winding is arranged concentrically with the transformer winding, and both share the same magnetic core material. This nested integration achieves accurate current measurement through magnetic coupling while minimizing the increase in device complexity by reusing the transformer's magnetic core and 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 minimizes the volume of the magnetic element, reduces weight, and enables high-power input while maintaining accurate current detection, addressing the issues of size and weight in existing technologies.
Implementation Method 1
a part of the plurality of wires passes through the current sensor to shunt and detect current flowing through the first winding
Data Source
AI summary
An integrated magnetic element includes an accommodating part; a current sensor disposed on the accommodating part; and a transformer disposed on the accommodating part. The transformer includes a magnetic core, a first winding including a plurality of wires, and a second winding, wherein some of the plurality of wires passes through the current sensor to shunt and detect current flowing through the first winding, and current values of the wires are detected by the current sensor to obtain a total current value of the first winding of the transformer according to a shunt ratio by the winding construction of the preset transformer.