Ring-Shaped Noise Filter Core Assembly for Inverter Systems
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Solution Overview
Problem
Conventional noise filters face challenges in efficient assembly and effective reduction of both common-mode and normal-mode noise, with cumbersome assembly processes and difficulties in attaching lead wires, leading to suboptimal noise reduction performance.
Innovation Solution
A noise filter comprising a ring-shaped core made of magnetic material with divisional cores and a magnetic flux adjusting member, forming both common-mode and normal-mode magnetic paths, allowing for efficient assembly and improved noise reduction by arranging conductors in a row and adjusting magnetic flux, which can be housed in a low-profile unit for installation in narrow spaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional noise filter structures are used, then noise reduction function is provided, but assembly work becomes cumbersome and efficiency decreases
Solution Approach 1:
The ring-shaped core is divided into two divisional cores that can be assembled separately and then joined together. This segmentation allows conductors to be inserted through the winding portion before the cores are combined, significantly simplifying the assembly process and eliminating the need for complex winding operations around pre-assembled cores.
2Ease of operation
If lead wires are inserted through rectangular core, then structure is simplified, but attaching lead wires in later step becomes difficult
Solution Approach 1:
The core structure transitions from a rectangular shape to a ring-shaped configuration. This dimensional change creates a through-hole structure that allows lead wires to pass through easily during assembly, while the ring shape maintains the necessary magnetic path for noise reduction functionality.
3Object-affected harmful factors
If conventional noise filter design is used, then noise reduction is provided, but height increases making installation in narrow spaces difficult
Solution Approach 1:
The core is designed with a ring-shaped (curved) geometry instead of a linear or rectangular structure. This curvature allows the magnetic path to be formed in a compact, planar configuration that reduces the overall height of the noise filter, enabling installation in narrow spaces while maintaining effective noise reduction through the closed magnetic path.
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
The solution effectively suppresses both common-mode and normal-mode noise, enhances assembly efficiency, and allows for compact installation, particularly reducing noise generated by high-speed switching in inverter systems, while protecting the noise filter with a housing.
Implementation Method 1
the ring-shaped core being configured to form a common-mode magnetic path surrounding all of the plurality of conductors and a normal-mode magnetic path passing through the partition wall and surrounding each of the plurality of conductors
Implementation Method 2
a noise filter comprising a plurality of conductors (20) each having a winding portion (21); and a ring-shaped core (30) made from a magnetic material and being inserted through the winding portion (21)
Implementation Method 3
a magnetic flux adjusting member containing a magnetic material is provided in the gap
Implementation Method 4
a magnetic flux adjusting member containing a magnetic material is provided in the gap
Data Source
AI summary
A noise filter (10) is equipped with a plurality of conductors (20) having respective winding portions (21) and a ring-shaped core (30) which is inserted through the winding portions of the a plurality of conductors and made of a magnetic material. The ring-shaped core is composed of a pair of divisional cores (41) and (42) which are combined together by joining each pair of joining surfaces (43) and (44), located at each end, of the pair of divisional cores and. The one divisional core is straight and is inserted through the winding portions of the a plurality of conductors. The other divisional core has partition walls (45) each of which is located between adjacent ones of the a plurality of conductors, projects toward the one divisional core, and serves to form a magnetic path between the partition wall and the one divisional core.