Reactor Core Assembly for Tolerance-Accurate Inductance
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Solution Overview
Problem
In combining multiple core pieces for a reactor, dimensional tolerances can lead to inaccurate assembly, resulting in unnecessary intervals and a failure to achieve desired inductance.
Innovation Solution
The reactor design includes a magnetic core with specific surface properties and configurations, such as E-shaped and U-shaped core pieces, where the surfaces are pressed together to form contact regions and non-contact regions, allowing for precise alignment and absorption of dimensional tolerances, thereby ensuring accurate assembly and adjustable inductance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple core pieces are combined to form a magnetic core, then the reactor can be manufactured with modular components, but dimensional tolerances cause inaccurate assembly and unnecessary intervals between core pieces
Solution Approach 1:
The patent applies preliminary action by forming a protrusion on one core piece and a corresponding recess on the other core piece before assembly. These pre-formed features guide the core pieces into accurate alignment during assembly, compensating for dimensional tolerances and preventing unnecessary intervals between the core pieces.
Solution Approach 2:
The protrusion and recess act as intermediary elements that mediate the connection between core pieces. The protrusion fits into the recess to provide precise positioning and alignment, serving as an intermediary mechanism that eliminates assembly inaccuracies caused by dimensional tolerances.
2Manufacturing precision
If core pieces are pressed together to form contact regions, then assembly accuracy improves, but the manufacturing process becomes more complex
Solution Approach 1:
The patent segments the contact surface between core pieces into distinct contact regions and non-contact regions. The protrusion and recess create defined contact areas where core pieces press together, while non-contact regions allow for thermal expansion and manufacturing variations. This segmentation simplifies the manufacturing process by providing clear guidelines for assembly without requiring complex pressing operations across the entire surface.
3Reliability
If unnecessary intervals are eliminated between core pieces, then desired inductance is achieved, but manufacturing tolerances make this difficult to accomplish
Solution Approach 1:
The protrusion and recess are pre-formed on the core pieces before assembly to ensure that when assembled, the core pieces achieve the desired close contact without unnecessary intervals. This preliminary formation of alignment features guarantees that the magnetic path is continuous and the inductance performance meets design requirements, compensating for manufacturing tolerances.
Solution Approach 2:
The patent replaces complex mechanical adjustment systems with a simple protrusion-recess mechanical fit. This substitution provides automatic alignment and contact pressure distribution, ensuring consistent inductance performance without requiring precision mechanical adjustments during assembly.
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 reactor to easily achieve desired inductance while enhancing thermal conductivity and manufacturing workability, reducing the likelihood of unnecessary intervals between core pieces.
Implementation Method 1
a magnetic core having a first surface made of a material mainly containing a magnetic material and a second surface facing the first surface, the first surface having a first region with a surface property following that of the second surface
Data Source
AI summary
A reactor is provided with a coil and a magnetic core. The magnetic core has a first surface made of a material mainly containing a magnetic material, and a second surface facing the first surface. The first surface has a first region with a surface property following that of the second surface.