Reactor Core Permeability Layout for Accurate Sensor Measurement
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Solution Overview
Problem
Sensors measuring physical quantities in reactors face instability and reduced accuracy due to the influence of leakage magnetic flux from the magnetic core, which is exacerbated by the θ-shaped core configuration, necessitating a solution to minimize this interference without distancing the sensor or using expensive magnetic shields.
Innovation Solution
The reactor design features a magnetic core with a second end core portion having higher relative magnetic permeability than the first end core portion, with the sensor positioned closer to the second end core portion to reduce leakage magnetic flux impact, allowing for precise measurement while maintaining flexibility in sensor placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the sensor is positioned closer to the magnetic core to improve measurement sensitivity, then measurement sensitivity is improved, but measurement accuracy deteriorates due to leakage magnetic flux interference
Solution Approach 1:
The magnetic core is designed with non-uniform magnetic permeability distribution, where the first end core portion has higher magnetic permeability than the second end core portion. This local quality differentiation directs the magnetic flux distribution such that leakage flux is reduced in the region where the sensor is positioned (near the second end core portion), thereby improving measurement accuracy without compromising sensitivity
Solution Approach 2:
The magnetic core employs an asymmetric configuration in terms of magnetic permeability between its two end core portions. This asymmetry creates an uneven magnetic flux distribution pattern that strategically directs leakage flux away from the sensor placement area, resolving the contradiction between close positioning (for sensitivity) and interference reduction (for accuracy)
2Object-affected harmful factors
If the sensor is positioned farther from the magnetic core to reduce leakage magnetic flux interference, then measurement accuracy is improved, but measurement sensitivity deteriorates
Solution Approach 1:
By creating localized high magnetic permeability regions in the first end core portion, the design concentrates magnetic flux in specific areas, allowing the sensor positioned at the second end core portion to operate in a low-interference zone while maintaining adequate flux levels for sensitive measurement
3Measurement precision
If a magnetic shield is used to block leakage magnetic flux, then measurement accuracy is improved, but device complexity and cost increase
Solution Approach 1:
The harmful leakage magnetic flux is extracted and redirected through the high-permeability first end core portion, which acts as a flux sink. This eliminates the need for separate magnetic shielding components, reducing device complexity while maintaining measurement accuracy
Solution Approach 2:
The design converts the potentially harmful leakage magnetic flux into a beneficial element by providing a designated path through the high-permeability first end core portion. This approach transforms the interference problem into a controlled flux distribution pattern, improving accuracy without adding shielding complexity
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 effectively minimizes the influence of leakage magnetic flux on sensors, enabling precise measurement of physical quantities in reactors without increasing costs or limiting sensor placement, thus enhancing measurement accuracy and operational flexibility.
Implementation Method 1
a relative magnetic permeability of the second end core portion being larger than that of the first end core portion
Data Source
AI summary
A reactor includes a coil, a magnetic core and a sensor for measuring a physical quantity of the reactor. The coil includes a tubular winding portion. The magnetic core includes a first end core portion, a second end core portion, a middle core portion, a first side core portion and a second side core portion. The middle core portion includes a part to be arranged inside the winding portion. The first side core portion and the second side core portion are arranged in parallel outside the winding portion to sandwich the middle core portion. The middle core portion, the first side core portion and the second side core portion connect the first end core portion and the second end core portion. A relative magnetic permeability of the second end core portion is larger than that of the first end core portion.