Wound Core Design Reducing Iron Loss via Preliminary Joint Bonding
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Solution Overview
Problem
The existing manufacturing process of wound cores requires precise dimensional control and additional steps to minimize gaps at joint portions, leading to increased iron loss and manufacturing complexity.
Innovation Solution
A wound core design with a lower space factor in corner portions and a manufacturing method that involves loosely winding and bending core materials, followed by annealing, to prevent joint portions from opening and eliminate the need for precise dimensional control and tightening bands.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If precise dimensional control is implemented in manufacturing steps to minimize gaps at joint portions, then iron loss is reduced, but manufacturing complexity and steps increase
Solution Approach 1:
The joint portions are preliminarily bonded together before the final winding process. This preliminary bonding action ensures that when the core materials are wound and formed, the joint portions remain closed and aligned without requiring precise dimensional control during subsequent manufacturing steps, thereby reducing both iron loss and manufacturing complexity
Solution Approach 2:
Instead of trying to achieve precise dimensional control to prevent gap formation at joint portions, the invention inverts the approach by preliminarily bonding the joint portions and accepting dimensional variations. This reverse approach eliminates the need for tight tolerances while maintaining closed joint portions, thus reducing manufacturing complexity without compromising iron loss performance
2Loss of energy
If tightening bands are applied to prevent gap creation at joint portions, then iron loss is reduced, but manufacturing steps increase
Solution Approach 1:
The joint portions are preliminarily bonded together before winding and forming operations. This preliminary action ensures that the joint portions remain closed throughout the manufacturing process without requiring additional tightening bands, thereby eliminating extra manufacturing steps while maintaining low iron loss
Solution Approach 2:
The invention extracts and eliminates the need for tightening bands from the manufacturing process. By preliminarily bonding the joint portions, the function that tightening bands would serve (preventing gap creation) is achieved through the preliminary bonding action itself, allowing the tightening band step to be removed entirely and improving manufacturing efficiency
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 solution reduces iron loss and simplifies the manufacturing process by maintaining closed joint portions without precise dimensional control, thereby reducing manufacturing steps and preventing iron loss increases.
Implementation Method 1
an annealing process is carried out in which the wound core is cooled after being heated for example to approximately 800 degrees Celsius
Data Source
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AI summary
A wound core is provided with plural wound core materials each having at least one cut portion for every one winding thereof. The wound core is provided with a rectangular window portion at the center thereof. A space factor of the core materials at each of corner portions is less than a space factor of the core materials at each of side portions.