Split Annular Magnetic Cores for Durable Rotary Power Transfer
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Solution Overview
Problem
The structural strength of magnetic cores in existing power transmission devices is inadequate, leading to potential durability issues and inefficiencies in power transmission.
Innovation Solution
The power transmission device features annular magnetic cores divided into multiple split cores, which are individually sized and held by resin-made holder members with engagement protrusions and claw mechanisms, enhancing structural integrity and manufacturing ease while maintaining power transmission efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If magnetic cores are made as single integrated pieces, then power transmission efficiency is maintained, but structural strength and fracture resistance are insufficient
Solution Approach 1:
The magnetic core is divided into multiple segments (first magnetic core and second magnetic core) that can be assembled together. Each segment has engagement protrusions and grooves that interlock to form the complete magnetic circuit, improving fracture resistance while maintaining magnetic flux continuity for efficient power transmission
2Ease of manufacture
If magnetic cores are divided into multiple segments, then structural strength and ease of manufacture are improved, but assembly complexity increases
Solution Approach 1:
The magnetic core is divided into multiple segments that can be manufactured separately using standard molding processes, improving manufacturability and allowing for easier replacement or repair of individual segments without replacing the entire magnetic core assembly
Solution Approach 2:
Multiple magnetic core segments are combined through engagement protrusions and grooves to form a complete magnetic circuit. The holder member integrates multiple functions including positioning, securing, and aligning the segments, simplifying the overall assembly process
3Reliability
If holder members are used to secure split cores, then structural integrity is enhanced, but device complexity increases
Solution Approach 1:
The holder member performs multiple functions simultaneously: it positions the magnetic core segments using engagement protrusions, secures them with clipping mechanisms, provides electrical insulation between segments, and facilitates thermal management. This multi-functionality reduces the need for separate components and simplifies the overall device 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 configuration significantly improves the fracture resistance and durability of the magnetic cores, ensuring stable power transmission and efficient energy transfer while allowing for easier manufacturing and thermal stress management.
Implementation Method 1
a transmission unit (10) having an annular first magnetic core (31) and a transmission coil (61), and an annular reception unit (20) having an annular second magnetic core (33) and a reception coil (62), wherein the transmission unit (10) and the reception unit (20) are arranged to face each other
Data Source
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AI summary
A power transmission device 100 includes an annular transmission unit 10 having an annular first magnetic core 31 and a transmission coil 61 and an annular reception unit 20 having an annular second magnetic core 33 and a reception coil 62. The transmission unit 10 and the reception unit 20 are arranged to face each other. The power transmission device 100 transmits power from the transmission unit 10 to the reception unit 20. The transmission unit 10 and the reception unit 20 are relatively rotatable about a rotation axis 95 passing through a cavity inside the transmission unit 10 and a cavity inside the reception unit 20, the first magnetic core 31 has a structure divided into a plurality of first split cores 32 in a circumferential direction, and the second magnetic core 33 has a structure divided into a plurality of second split cores 34 in the circumferential direction.