Wound Core Joint Layout to Reduce Iron Loss
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Solution Overview
Problem
Existing wound cores suffer from high iron loss, which hinders efficiency improvements.
Innovation Solution
A wound core design featuring laminated bent bodies made from grain-oriented electrical steel sheets with specific curvature radii and joint arrangements, along with defined imaginary lines and joint portions, to minimize strain interference and reduce iron loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional wound core designs are used, then manufacturing is simpler, but iron loss is high
Solution Approach 1:
The bent body is divided into multiple flat portions and corner portions, with joint portions strategically positioned in specific flat portions. This segmentation allows optimization of magnetic flux paths and reduction of iron loss by separating joint locations from high-stress bent regions
Solution Approach 2:
Different portions of the bent body are designed with different characteristics: flat portions contain joint portions with specific dimensional relationships (L1≥5mm, L2≥5mm) to minimize strain, while corner portions are optimized for bending. This local differentiation reduces overall iron loss by addressing specific regional requirements
2Loss of energy
If joint portions are placed in bent regions, then manufacturing is easier, but strain interference increases and iron loss rises
Solution Approach 1:
The design pre-defines specific flat portions as optimal locations for joint portions based on geometric relationships (distances L1 and L2 from corner portions). This preliminary positioning avoids strain interference zones in bent regions while maintaining manufacturing feasibility through clear design guidelines
3Loss of energy
If bent regions have small curvature radii, then the core fits better in compact spaces, but strain concentration increases and iron loss increases
Solution Approach 1:
The design optimizes the curvature radius parameter of bent regions to minimize iron loss while controlling core volume. By carefully selecting and positioning bent regions relative to joint portions (with specified distances L1 and L2), the design achieves optimal magnetic flux distribution that reduces iron loss without excessive volume increase
Data Source
AI summary
A wound core in which the average distance of first-group joint portions and the average distance of second-group joint portions determined under predetermined conditions are 25 mm or more.