Reactor Core Gap Structure for Stable Inductance Control
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Solution Overview
Problem
The challenge is to design a reactor with adjustable gap volume to maintain stable inductance characteristics and prevent magnetic saturation, which is crucial for efficient power conversion in hybrid vehicles.
Innovation Solution
The reactor features a magnetic core with divided middle core portions and adjustable gap portions, where the gap volume is adjusted by fitting recesses and protrusions with inclined surfaces, allowing for precise positioning and assembly, and using composite materials with controlled Young's modulus to maintain inductance and prevent magnetic saturation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the magnetic core is provided with a gap portion to prevent magnetic saturation, then the inductance becomes adjustable, but the manufacturing precision and assembly difficulty increase due to the need for precise gap volume control
Solution Approach 1:
The magnetic core is divided into multiple core pieces with recesses and protrusions that can be assembled together. The gap portion is segmented into multiple regions (first gap portion between bottom surfaces, second gap portion between outer peripheral surfaces). This segmentation allows independent adjustment of each gap region to achieve precise total gap volume control while simplifying manufacturing of individual core pieces.
Solution Approach 2:
The recesses and protrusions are designed with inclined surfaces that enable adjustable positioning. By varying the depth, diameter, or inclination angle of recesses and protrusions, the gap volume can be dynamically adjusted to achieve predetermined inductance values. This provides flexibility in designing reactors with different inductance requirements using the same basic core structure.
2Reliability
If the gap volume is increased to reduce magnetic saturation, then the inductance decreases, but the reactor size increases
Solution Approach 1:
Instead of uniformly increasing the entire gap volume, the invention creates localized gap regions at specific positions on the core pieces. The first gap portion is formed between bottom surfaces of recesses, and the second gap portion is formed between outer peripheral surfaces. This localized gap creation reduces magnetic saturation at critical points while minimizing the overall reactor volume increase.
3Ease of manufacture
If multiple core pieces are assembled with recesses and protrusions to form gap portions, then the assembly workability improves, but the device complexity increases
Solution Approach 1:
Multiple core pieces with recesses and protrusions are assembled to form the complete magnetic core. The recesses and protrusions are designed to fit together, automatically forming the gap portions when assembled. This merging approach simplifies assembly workability as the pieces naturally align and form the required gap structure, while the complexity is managed through standardized recess and protrusion designs.
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 configuration enables easy adjustment of gap volume for predetermined inductance, reduces magnetic saturation, and enhances assembly workability, resulting in stable inductance characteristics and improved inductance performance.
Implementation Method 1
The inner peripheral surface of the recess includes an inclined surface intersecting an axis along the axial direction, the inclined surface of the recess including a contact portion in contact with the protrusion
Implementation Method 2
a gap portion provided between the first and second middle core portions... reduces magnetic saturation, and enhances assembly workability, resulting in stable inductance characteristics
Data Source
AI summary
This reactor is provided with a coil and a magnetic core and is configured such that: a winding section of the coil is disposed on a middle core section of the magnetic core; the middle core section comprises a first middle core section, a second middle core section, and a gap section; the first middle core section comprises a first end section; the second middle core section comprises a second end section; the first end section comprises a recessed section and an annular first surface in which the recessed section opens; the second end section comprises a protruding section that fits into the recessed section and an annular second surface that faces the first surface with a space therebetween; a base surface of the recessed section faces a peak surface of the protruding section with a space therebetween; an inner peripheral surface of the recessed section includes an oblique surface; the oblique surface of the recessed section comprises a contact section that is in contact with the protruding section; and the gap section comprises a first gap section, formed between the base surface and the peak surface, and an annular second gap section, formed between the first surface and the second surface.