Tape-Wound Toroidal Core Forming With Movable Winding Mandrels
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Solution Overview
Problem
Existing methods for producing ring band cores, used in transformers and throttles, face challenges in efficiently wrapping and cutting the soft-magnetic bands to minimize vertebral current losses and achieve optimal magnetic properties.
Innovation Solution
A device and process are proposed that utilize two rotating winding ports with adjustable distance, band coils of different widths, and a separation device for gradual cutting of the band wraps, allowing for the creation of a closed ring core with optimized geometry and magnetic performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the tape is wound into a compact toroidal core, then the magnetic circuit is optimized with uniform cross-section and minimal transition losses, but the winding process becomes complex requiring precise control of tape tension, layer alignment, and geometric parameters
Solution Approach 1:
The patent applies preliminary action by pre-forming the tape into a cylindrical shape around a mandrel before the actual toroidal winding process. This preliminary cylindrical formation simplifies the subsequent toroidal winding by providing a pre-organized tape structure that can be more easily transformed into the final toroidal geometry, reducing the complexity of direct toroidal winding while maintaining magnetic circuit optimization.
2Reliability
If heat treatment is performed to achieve optimal magnetic properties, then the magnetic permeability and saturation flux density are improved, but the amorphous and nanocrystalline alloys become brittle and susceptible to mechanical damage
Solution Approach 1:
The patent applies dynamics by making the winding mandrels movable and adjustable during the winding process. The mandrels can be positioned at different distances from each other and adjusted perpendicular to their rotation axes, allowing dynamic adaptation to different core geometries and tape widths. This dynamic adjustability enables optimal winding geometry that can accommodate the material's mechanical constraints after heat treatment while achieving the desired magnetic properties.
3Ease of manufacture
If the winding mandrels are fixed at a constant distance, then the manufacturing process is simplified, but the flexibility to produce different core geometries and accommodate various tape widths is reduced
Solution Approach 1:
The patent applies dynamics by making the winding mandrels movable and adjustable during the winding process. The mandrels can be positioned at different distances from each other and adjusted perpendicular to their rotation axes, allowing dynamic adaptation to different core geometries and tape widths. This dynamic adjustability enables optimal winding geometry that can accommodate the material's mechanical constraints after heat treatment while achieving the desired magnetic properties.
Solution Approach 2:
The patent applies universality by designing the winding device with mandrels that can perform multiple functions: rotating about their own axes for winding, moving along their axes to adjust distance for different core sizes, and moving perpendicular to their axes for geometric adaptation. This multi-functional design allows a single device to produce various core geometries with different tape widths, enhancing versatility while maintaining manufacturing simplicity.
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 proposed solution enables the production of ring band cores with improved magnetic properties and reduced vertebral current losses, allowing for higher operating frequencies and more efficient energy storage and transmission.
Implementation Method 1
unwinding a soft-magnetic tape (1) from two tape reels (3) and winding the tape (1) onto two winding mandrels (5) rotating around two first axes of rotation (6)
Implementation Method 2
cutting the tape rolls into a plurality of tape sections (2) and shaping the free ends of the tape sections (2) and joining the ends of the tape sections (2) to one another to form a closed ring
Implementation Method 3
After winding, a heat treatment is performed to adjust or achieve the core's magnetic properties, at temperatures between approximately 200°C and 600°C, depending on the alloy
Data Source
Figure 1a~1d
Figure 2a~2b
Figure 3a~3c
AI summary
The invention relates to a method for producing a tape-wound toroidal core, comprising the steps of: • providing a soft-magnetic tape (1) on at least two tape reels (3), • unwinding the tape (1) from two tape reels (3) and winding the tape (1) onto two winding mandrels (5), which are arranged at a distance from each other, to form in each case a multilayer first tape roll (8) by rotating the winding mandrels (5) about a respective first rotation axis (6), wherein, after in each case several layers, a separating plate (11) is inserted into the first tape rolls (8) that have formed, • reducing the distance between the winding mandrels (5) until the first tape rolls (8) touch each other, • unwinding the tape (1) from two tape reels (3) and winding up the tape (1) to form a multilayer second tape roll (9), which wraps around the first tape rolls (8), by rotating the winding mandrels (5) about a common second rotation axis (7), wherein, after in each case several layers, a separating plate (11) is inserted into the second tape roll (9) that has formed, • severing the tape rolls (8, 9) in steps to form a plurality of tape sections (2), • picking up at least one reel (13) and placing the reel (13) onto the tape sections (2), • reshaping free ends of the tape sections (2) and connecting the ends of the tape sections (2) to form a closed ring, and to a device for carrying out the method.