Multi-Gapped Three-Phase Inductor for Flux and Noise Reduction
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Solution Overview
Problem
Existing three-phase inductors either have common mode or differential mode magnetic paths, lacking the ability to incorporate both flux paths efficiently, leading to issues such as external magnetic flux fields, heating, and audible noise.
Innovation Solution
A three-phase inductor design with both common mode and differential mode magnetic flux paths, constructed from multiple core segments with adjustable gaps, allowing independent tuning of inductances to reduce external magnetic flux and noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a three-phase inductor uses a single magnetic path (either common mode or differential mode), then the structure is simple, but it cannot effectively reduce external magnetic flux fields and audible noise
Solution Approach 1:
The inductor core is divided into multiple core segments (first core segments and second core segments) that can be independently positioned and adjusted. This segmentation allows the creation of separate common mode and differential mode magnetic paths within a single inductor structure, enabling effective reduction of external magnetic flux fields while maintaining manageable structural complexity through modular assembly
Solution Approach 2:
The inductor is designed to provide both common mode and differential mode magnetic paths within a single device structure. The core segments can be configured to create multiple flux paths simultaneously, allowing the inductor to perform multiple functions (filtering common mode noise and differential mode signals) while managing the complexity through integrated design
2Object-affected harmful factors
If gaps are added to reduce external magnetic flux fields and audible noise, then harmful factors are reduced, but the device complexity increases
Solution Approach 1:
The core is segmented into multiple pieces with gaps between them. These gaps are strategically positioned to interrupt magnetic flux paths, thereby reducing audible noise generated by magnetostriction and core vibrations. The segmented structure allows independent adjustment of each core segment to optimize gap sizes for noise reduction while maintaining structural integrity
Solution Approach 2:
Non-magnetic materials or insulation layers are introduced as intermediaries between core segments to create controlled gaps. These intermediary elements manage the magnetic flux distribution, reduce noise, and facilitate independent adjustment of core segments without requiring complex mechanical fastening systems
3Adaptability or versatility
If multiple core segments with adjustable gaps are used, then inductances can be independently tuned, but manufacturing complexity increases
Solution Approach 1:
The core is divided into standardized segments that can be manufactured separately using conventional techniques. Each segment is designed with features that allow independent positioning and adjustment, enabling flexible inductance tuning. The segmentation allows for modular assembly where segments can be pre-manufactured and then configured during assembly to achieve desired inductance values
Solution Approach 2:
The core segments are designed with adjustable positioning mechanisms that allow the gaps between segments to be varied during assembly or operation. This dynamic adjustability enables independent tuning of common mode and differential mode inductances. The design incorporates features such as adjustable spacers, movable core pieces, or shims that facilitate easy inductance optimization without requiring complex manufacturing processes
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 design effectively reduces external magnetic flux fields and audible noise while enabling independent adjustment of inductances for improved performance.
Implementation Method 1
a three-phase inductor with both common mode and differential mode magnetic flux paths
Implementation Method 2
the multiple gaps may provide benefits, including: reduction of external magnetic flux fields
Implementation Method 3
reduction of external magnetic flux fields
Implementation Method 4
reduction of audible noise
Data Source
AI summary
Systems and methods of the present disclosure enable adjustable multi-gapped combined common mode and differential mode three phase inductors using at least one core. The at least one core may include: a first core segments and at least one second core segment, where each first core segment has at least one first shape and where the first core segments are arranged in a first pattern so as to form differential mode gaps between each first core segment and the at least one second core segment. The first shape is such that the first pattern permits to independently adjust a thickness of each differential mode gap. The at least one second core segment has a second shape and the first core segments are in an interior of the core and the at least one second core segment at least partially encompasses the first core segments.