Wound Iron Core Bending With Heated Steel Sheet to Reduce Iron Loss
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Solution Overview
Problem
Existing wound core manufacturing methods face challenges in suppressing iron loss, particularly due to damage and strain-induced coating peeling during the bending process, which affects the magnetic properties and efficiency of the core.
Innovation Solution
A manufacturing method involving coated grain-oriented electrical steel sheets, where the bending is performed with the bent region heated to 45°C or higher and 500°C or lower, and a controlled temperature gradient in the adjacent flat region to minimize deformation twins and coating damage, resulting in a wound core with reduced iron loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the steel sheet is bent to form corner portions with small radius of curvature (3 mm or less), then the manufacturing process is simplified and shape retention is improved, but deformation twins increase and coating damage occurs leading to increased iron loss
Solution Approach 1:
The patent applies parameter changes by controlling the temperature of the steel sheet during bending to be 150°C or higher and 500°C or lower. This temperature parameter modification suppresses the formation of deformation twins and prevents coating peeling, thereby reducing iron loss while maintaining the simplified bending manufacturing process with small radius of curvature corner portions
2Device complexity
If the steel sheet is bent at room temperature, then the manufacturing process is simpler without heating, but deformation twins increase and coating peeling occurs
Solution Approach 1:
The patent changes the temperature parameter from room temperature to 150°C or higher and 500°C or lower during the bending process. This parameter modification prevents coating peeling and deformation twin formation, ensuring coating integrity while accepting the addition of heating equipment
3Productivity
If conventional bending methods are used without temperature control, then manufacturing is faster and easier, but iron loss increases due to deformation twins and coating damage
Solution Approach 1:
The patent implements temperature parameter control at 150°C or higher and 500°C or lower during bending operations. This enables rapid manufacturing through simplified bending processes while simultaneously suppressing deformation twins and coating damage, thereby reducing iron loss without sacrificing productivity
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 method effectively suppresses iron loss by maintaining a high coating soundness rate and reducing deformation twins, leading to improved magnetic performance and efficiency in wound cores.
Implementation Method 1
a portion of the bent body to be the bent region is heated to 45°C or higher and 500°C or lower
Implementation Method 2
a temperature gradient at any position of a portion to be the flat region within the strain affected region in the longitudinal direction of the coated grain-oriented electrical steel sheet is less than 400°C/mm
Data Source
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AI summary
Provided is a wound core formed by laminating a plurality of bent bodies obtained by forming a coated grain-oriented electrical steel sheet in which a coating is formed on at least one surface of a grain-oriented electrical steel sheet so that the coating is on an outside, in a sheet thickness direction, in which the bent body has a bent region obtained by bending the coated grain-oriented electrical steel sheet and a flat region adjacent to the bent region, the number of deformation twins present in the bent region in a side view is five or less per 1 mm of a length of a center line in the sheet thickness direction in the bent region, and when a region extending 40 times a sheet thickness to both sides in a circumferential direction from a center of the bent region on an outer circumferential surface of the bent body is defined as a strain affected region, a proportion of an area where the coating is not damaged at any position along the circumferential direction in a flat region within the strain affected region is 90% or more.