Wound Core Bent-Section Stacking for Lower Noise and Iron Loss
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Wound cores generate noise due to magnetostriction, and there is a need for further reduction in noise and iron loss.
Innovation Solution
A laminated wound core design with plural bent portions, where at least one bent portion has a higher stacking factor than the average, and a compression means is used to compress these portions, reducing gaps between electrical steel sheets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If electrical steel sheets are stacked to form a wound core, then iron loss is reduced, but noise is generated due to magnetostriction
Solution Approach 1:
The patent applies different stacking factors to different regions of the wound core. Specifically, the first bent portion has a stacking factor of 95% or higher, while other portions have lower stacking factors. This local differentiation reduces gaps at critical bent portions where noise is generated, without requiring uniform high-density stacking throughout the entire core, thus reducing noise while maintaining reasonable manufacturing complexity.
2Object-generated harmful factors
If the stacking factor is increased to reduce gaps between sheets, then noise is reduced, but manufacturing complexity increases
Solution Approach 1:
The patent applies different stacking factors to different regions of the wound core. Specifically, the first bent portion has a stacking factor of 95% or higher, while other portions have lower stacking factors. This local differentiation reduces gaps at critical bent portions where noise is generated, without requiring uniform high-density stacking throughout the entire core, thus reducing noise while maintaining reasonable manufacturing complexity.
3Object-generated harmful factors
If gaps between electrical steel sheets are reduced, then noise from magnetostriction is reduced, but iron loss may increase due to tighter stacking
Solution Approach 1:
The patent applies different stacking factors to different regions of the wound core. Specifically, the first bent portion has a stacking factor of 95% or higher, while other portions have lower stacking factors. This local differentiation reduces gaps at critical bent portions where noise is generated, without requiring uniform high-density stacking throughout the entire core, thus reducing noise while maintaining reasonable manufacturing 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
The design achieves reduced noise and iron loss by minimizing gaps at bent portions, leading to a quieter and more efficient wound core.
Implementation Method 1
When an alternative magnetic field is applied to a wound transformer core, electrical steel sheets vibrate in the stacking direction due to magnetostriction generated in the electrical steel sheets. An acoustic wave is generated by the vibration from the gaps between the electrical steel sheets.
Data Source
AI summary
A wound core equipped with a laminated body including plural electrical steel sheets stacked in a ring shape in side view. The laminated body includes plural bent portions, and plural block-shaped portions at positions between adjacent bent portions. At least one bent portion among the plural bent portions is a high stacking factor bent portion, wherein a stacking factor of the electrical steel sheets at the high stacking bent portion is higher than an average stacking factor of the steel sheets at the plural block-shaped portions.