EP4189713A1 - Bobine d'arrêt pour un système électronique de puissance - Google Patents

Bobine d'arrêt pour un système électronique de puissance

Info

Publication number
EP4189713A1
EP4189713A1 EP21751794.5A EP21751794A EP4189713A1 EP 4189713 A1 EP4189713 A1 EP 4189713A1 EP 21751794 A EP21751794 A EP 21751794A EP 4189713 A1 EP4189713 A1 EP 4189713A1
Authority
EP
European Patent Office
Prior art keywords
choke
range
amorphous
core material
winding
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
EP21751794.5A
Other languages
German (de)
English (en)
Inventor
Florian Geling
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Individual
Original Assignee
Individual
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Individual filed Critical Individual
Publication of EP4189713A1 publication Critical patent/EP4189713A1/fr
Pending legal-status Critical Current

Links

Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F37/00—Fixed inductances not covered by group H01F17/00
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
    • H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
    • H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
    • H01F1/12—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials
    • H01F1/14—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys
    • H01F1/147—Alloys characterised by their composition
    • H01F1/153—Amorphous metallic alloys, e.g. glassy metals
    • H01F1/15308—Amorphous metallic alloys, e.g. glassy metals based on Fe/Ni
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/24—Magnetic cores
    • H01F27/25—Magnetic cores made from strips or ribbons
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • H01F27/2895—Windings disposed upon ring cores
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F3/00—Cores, Yokes, or armatures
    • H01F3/10—Composite arrangements of magnetic circuits
    • H01F3/14—Constrictions; Gaps, e.g. air-gaps
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/0206—Manufacturing of magnetic cores by mechanical means
    • H01F41/0213—Manufacturing of magnetic circuits made from strip(s) or ribbon(s)
    • H01F41/0226—Manufacturing of magnetic circuits made from strip(s) or ribbon(s) from amorphous ribbons
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F3/00—Cores, Yokes, or armatures
    • H01F3/10—Composite arrangements of magnetic circuits
    • H01F2003/103—Magnetic circuits with permanent magnets

Definitions

  • the invention relates to a choke for power electronics, in particular in heavy-current applications.
  • the invention relates in particular to a choke with an inductance in a range between 10 ⁇ H and 2 mH and a current carrying capacity of 1 A or more.
  • Such a choke comprises in particular a core material and at least one winding.
  • the invention also relates to a method for producing such a choke.
  • different core materials for the realization of chokes are known. Water-cooled and air-cooled SiFe cores, ie cores made of silicon and iron, ferrite cores, iron powder cores and amorphous and nanocrystalline cores are known as examples.
  • a choke with an iron powder pot core is known from the German utility model DE 202012104013 U1.
  • the known cores can be used for power electronics, they have several disadvantages. Condition the known cores a large design of the choke, have high losses, lead to a high level of noise and are complex and expensive to manufacture.
  • the object of the present invention is to eliminate the disadvantages of the prior art.
  • a choke is to be provided which is particularly small, low-loss, quiet and inexpensive to produce.
  • a method is to be specified with which such a choke can be produced, in particular can be produced particularly cost-effectively. According to the invention, this object is achieved by a throttle according to the subject matter of claim 1, by uses according to the subject matter of claims 20 to 22, and by a method according to the subject matter of claim 24.
  • Advantageous refinements of the invention are specified in each case in the dependent claims.
  • the core material has an amorphous core material.
  • the amorphous core material is preferably a metallic glass or an amorphous metal.
  • the winding is designed as an outer winding running around the amorphous core material.
  • the winding is preferably made of copper, a copper alloy or aluminum.
  • the winding preferably encircles the amorphous core material several times.
  • the amorphous core material has a saturation magnetostriction in a range between 10 -7 and 10 -5 and/or a static coercivity of at most 30 A/m.
  • this saturation magnetostriction and / or this static coercivity by a special heat treatment of the amorphous Core material, achieved in particular by a special tempering process for the amorphous core material.
  • a saturation magnetostriction in the range between 10 -7 and 10 -5 , a particularly low-noise choke is advantageously provided.
  • a choke with particularly low losses, in particular particularly low hysteresis losses or iron losses is advantageously provided.
  • the hysteresis losses or iron losses can advantageously be reduced by a factor of 2 compared to iron powder core chokes in DC operation, and by a factor of about 20 at a higher fundamental frequency.
  • a choke according to the invention advantageously has greatly improved heat dissipation through the external winding compared to iron-powder core chokes with pot cores.
  • Inductors according to the invention therefore advantageously have lower losses and are quieter than known inductors with comparable rated currents or inductances.
  • chokes according to the invention have a smaller design and are cheaper to manufacture.
  • the choke has an inductance in a range between 5 ⁇ H and 1 mH, preferably in a range between 10 ⁇ H and 200 ⁇ H, particularly preferably in a range between 10 ⁇ H and 100 ⁇ H.
  • the inductor has a current-carrying capacity in a range between 1 A and 5000 A.
  • This is preferably the permanent current carrying capacity. This therefore preferably corresponds to the nominal current.
  • the current carrying capacity is preferably greater than 10 A, for example in a range between 10 A and 2000 A.
  • the current carrying capacity is particularly preferably greater than 50 A, for example in a range between 200 A and 2000 A.
  • the current carrying capacity 350 A.
  • the amorphous core material is formed from iron, silicon and boron.
  • the amorphous core material is formed from 70 to 85 at.% iron, 5 to 20 at.% silicon and 5 to 20 at.% boron.
  • the amorphous core material consists of 78 at.% iron, 9 at.% silicon and 13 at.% boron.
  • the amorphous core material forms a ring core.
  • the toroidal core preferably has a rectangular or square shape in cross section.
  • the toroidal core preferably has a circular, elliptical, oval, rectangular or square shape when viewed from above.
  • an annular geometry is understood to mean a closed geometry. A more precise shape for the cross section or for the plan view is not specified.
  • the ring core is preferably in the form of a circular ring.
  • the toroidal core may have an elliptical, oval, rectangular, or square shape in plan view.
  • the toroidal core is formed from a wound amorphous strip and a trough accommodating the wound amorphous strip.
  • the toroidal core is therefore also referred to as a toroidal tape core.
  • the amorphous ribbon has a width ranging between 5 mm and 50 mm. Preferred examples are 5, 10, 15, 20, 25, 30, 50mm.
  • the width of the amorphous ribbon preferably determines the height of the toroidal core.
  • the amorphous ribbon preferably has a thickness of 20 to 35 ⁇ m, particularly preferably 25 to 30 ⁇ m.
  • the amorphous ribbon has a thickness of 27 ⁇ m.
  • the amorphous ribbon is preferably wrapped around an inner mandrel.
  • a winding tension is preferably exerted on the amorphous strip.
  • the winding tension per width and per thickness of the amorphous strip is preferably at least 10 N/mm2, preferably at least 50 N/mm2, particularly preferably at least 150 N/mm2.
  • a tensile stress of at least 10 N, preferably at least 30 N, particularly preferably at least 50 N, most preferably at least 100 N is preferably applied to the amorphous ribbon.
  • the wound amorphous ribbon is also referred to as a wound ribbon core.
  • the wound tape core immediately after winding is referred to as bare wound tape core.
  • the bare wound strip core is preferably subjected to a special heat treatment, in particular a special tempering process.
  • a fixed wound strip core after fixing and/or gluing the wound strip core is preferably subjected to a special heat treatment, in particular a special tempering process.
  • the wound tape core is fixed and/or glued, for example, by vacuum impregnation with a resin, particularly preferably with a synthetic resin, for example epoxy resin.
  • the vacuum impregnation is preferably carried out at a pressure of 0.01 to 1 mbar, preferably 0.05 to 0.5 mbar, particularly preferably 0.1 to 0.2 mbar.
  • the temperature during vacuum impregnation is preferably 40 to 200°C, preferably 60 to 140°C, particularly preferably 80 to 120°C.
  • the vacuum soaking is preferably carried out for a period of 20 to 40 minutes, preferably for a period of 25 to 35 minutes, more preferably for a period of about 30 minutes.
  • the fixed tape wound core is preferably dried in a drying oven for 1 to 3 hours, preferably for 1.5 to 2.5 hours.
  • the temperature in the drying oven is preferably 80 to 200.degree. C., preferably 100 to 140.degree. C., particularly preferably about 120.degree.
  • the wound tape core is preferably fixed by vacuum impregnation twice or more.
  • the fixed, wound strip core is particularly well bonded. It has been shown that the noise generated during the operation of a choke according to the invention equipped with a core material produced in this way is particularly low.
  • the fixed wound amorphous ribbon ie the fixed wound ribbon core, is accommodated in the trough.
  • the trough is preferably formed from plastic, in particular from glass fiber reinforced plastic.
  • the plastic preferably includes polyamide, for example PA 6.6.
  • the plastic is preferably reinforced with 20 to 30% glass fibers, for example GF20 or GF30.
  • the trough is preferably the carrier for the winding.
  • the trough may have grooves for guiding the winding, for example six grooves for a six-turn winding.
  • the ring core has an outside diameter in a range between 5 mm and 250 mm, preferably in a range between 50 mm and 200 mm, particularly preferably in a range between 80 mm and 150 mm. Preferred examples are 80mm, 90mm, 120mm, 150mm.
  • the toroidal core preferably has a height in a range between 5 mm and 60 mm.
  • the height of the toroidal core preferably corresponds essentially to the width of the amorphous ribbon.
  • the wall thickness of the trough can also influence the height of the toroid.
  • the wall thickness of the trough is preferably about 1 mm to 10 mm, for example 1.6 mm.
  • two or more fixed wound ribbon cores can be accommodated in a trough such that the height of the toroid essentially corresponds to the sum of the widths of the amorphous ribbons involved.
  • the ring core preferably has an inner diameter in a range between 3 mm and 200 mm, particularly preferably in a range between 30 mm and 150 mm.
  • the inner diameter of the toroid is 50 mm.
  • the inner diameter of the toroidal core is preferably determined by the inner mandrel around which the amorphous ribbon is wound to create the wound ribbon core.
  • the amorphous core material has at least one air gap. More precisely, the ring core has at least one air gap.
  • the amorphous core material or the toroidal core has precisely one air gap, two air gaps, four air gaps, five air gaps and/or six air gaps.
  • the toroidal core is designed as a cut strip core having two legs.
  • the cut tape core can, for example, an im Have a substantially oval shape.
  • Each of the two legs of the cut strip core preferably has at least one air gap.
  • each of the two legs of the cut strip core has one, two, four or eight air gaps.
  • the cut strip core has two, four, eight or sixteen air gaps.
  • the air gap has a width in a range between 50 ⁇ m and 8 mm, preferably in a range between 150 ⁇ m and 3 mm, particularly preferably in a range between 1 mm and 3 mm.
  • the air gap has a width of 1.5 mm.
  • the specified widths preferably relate to a single air gap.
  • the total width of the air gaps results from the sum of the widths of the individual air gaps. If there are six air gaps, each with a width of 1.5 mm, the total width of the air gaps is 9 mm, for example.
  • the air gap preferably has a constant width.
  • the air gap can deviate from a constant width.
  • a stepped and/or a V-shaped air gap can be provided.
  • the air gap can have a curved shape.
  • the saturation induction of the amorphous core material is in a range between 1.2 T and 1.8 T, preferably in a range between 1.5 T and 1.6 T, particularly preferably in a range between 1, 54 T and 1.55 T.
  • the saturation induction of the amorphous core material is 1.55 T.
  • the saturation magnetostriction of the amorphous core material is in a range between 5*10 -7 and 5*10 -6 , particularly preferably in a range between 2*10 -6 and 4*10 -6 . In a preferred example, the saturation magnetostriction is 3*10 -6 .
  • the saturation magnetostriction of the amorphous core material is in a range between 1*10 -7 and 1*10 -6 , preferably in a range between 1*10 -7 and 5*10 -7 , particularly preferably in one Range between 1*10 -7 and 2*10 -7 . It has been shown that the noise generated during operation of a choke according to the invention equipped with an amorphous core material is particularly low if the amorphous core material has a saturation magnetostriction in one of the stated ranges.
  • the amorphous core material has a static coercive field strength of at most 10 A/m, preferably at most 3 A/m, particularly preferably at most 1 A/m. In preferred examples, the static coercivity is 1 A/m or 0.3 A/m. According to a further advantageous embodiment of the invention, the amorphous core material has a dynamic coercive field strength in a range between 0.5 A/m and 2.5 A/m, preferably in a range between 0.7 A/m and 2.0 A/m , particularly preferably in a range between 0.75 A/m and 1.8 A/m measured at 200 A/m and 5 kHz.
  • the dynamic coercivity is 0.78 to 1.77 A/m measured at 200 A/m and 5 kHz.
  • the amorphous core material has a dynamic coercive field strength in a range between 1.0 A/m and 6.0 A/m, preferably in a range between 2.0 A/m and 4.0 A/m , particularly preferably in a range between 2.2 A/m and 3.4 A/m measured at 400 A/m and 5 kHz.
  • the dynamic coercivity is 2.26 to 3.33 A/m measured at 400 A/m and 5 kHz.
  • a choke equipped with an amorphous core material with a static and/or dynamic coercivity in one of the ranges mentioned is advantageously particularly low-noise.
  • the winding is formed from a stranded wire and/or from a wire.
  • the stranded wire and/or the wire are preferably formed from copper, from a copper alloy or from aluminium.
  • the cross section of the stranded wire and/or the wire is between 0.1 mm2 and 240 mm2, preferably between 35 mm2 and 120 mm2.
  • the cross-section of the stranded wire and/or the wire is 1 mm2, 1.5 mm2, 2.5 mm2, 4 mm2, 6 mm2, 10 mm2, 16 mm2, 25 mm2, 35 mm2, 50 mm2, 70 mm2, 95 mm2, 120 mm2, 150 mm2, 195 mm2 or 240 mm2.
  • the litz wire can be a high-frequency (HF) litz wire.
  • the winding preferably forms a rectangular and/or square ring around the trough.
  • the shape of the winding preferably results from the shape of the trough. For a trough with a rectangular cross-section, the result is a winding with a rectangular cross-section.
  • a trough with a square cross-section therefore results in a winding with a square cross-section.
  • the number of turns is preferably one to five.
  • the number of turns in a winding is preferably one to 500.
  • the wire and/or the stranded wire can be wrapped with an insulating material for insulation.
  • the insulating means can be made of polyethylene (PE), polyethylene terephthalate (PET) or a polyimide (PI), e.g. B. Kapton formed.
  • the insulating means is preferably wound as a foil around the stranded wire and/or the wire, for example spirally and/or in an overlapping manner.
  • the film can have a width of 10 mm, for example.
  • a stranded wire can also be wrapped or coated with PVC (polyvinyl chloride), silicone, TPE (thermoplastic elastomers) and/or ETFE (ethylene tetrafluoroethylene copolymer), for example coated by means of extrusion.
  • the winding is fixed using polyurethane, epoxy resin and/or adhesive tape.
  • the winding is preferably fixed by vacuum impregnation with epoxy resin.
  • the epoxy resin can comprise one or two components. The fixing of the winding by vacuum impregnation with epoxy resin advantageously ensures a particularly good heat radiation behavior.
  • the winding is connected via a cable lug.
  • the winding can be connected to the cable lug by plugging, clamping, squeezing, soldering and/or screwing.
  • the winding is preferably connected to the cable lug by crimping and screwing. So-called crimp cable lugs or tubular cable lugs are preferred.
  • the cable lugs can be arranged in a straight line or at an angle of, for example, 45° or 90°.
  • the receiving size of the cable lug preferably corresponds to the cross section of the stranded wire forming the winding or of the wire forming the winding.
  • the receiving size of the cable lug is therefore preferably between 0.1 mm2 and 240 mm2, particularly preferably between 35 mm2 and 120 mm2.
  • the size of the cable lug is 1 mm2, 1.5 mm2, 2.5 mm2, 4 mm2, 6 mm2, 10 mm2, 16 mm2, 25 mm2, 35 mm2, 50 mm2, 70 mm2, 95 mm2, 120 mm2, 150 mm2, 195 mm2 or 240 mm2.
  • the cable lug preferably has a hole for its attachment by means of screws, the diameter of the hole is preferably suitable for screws of sizes M3 to M20.
  • the throttle comprises a housing made of plastic, ceramic or metal, preferably aluminum or stainless steel.
  • the housing has an essentially cylindrical shape.
  • the housing preferably has cooling fins.
  • the housing may include fasteners. Particularly high vibration requirements can advantageously be met by providing suitable fastening means. High vibration requirements are required, for example, in traction, in ships, in aviation or in electromobility.
  • the housing can include a fan for improved heat dissipation. Alternatively, a fan for improved heat dissipation can be assigned to the housing and/or the throttle.
  • the housing has a diameter of 20 mm to 300 mm, preferably 60 mm mm to 150 mm, on.
  • the housing can have a length and/or a width of 20 mm to 300 mm, preferably 60 mm to 150 mm.
  • the housing has a height of 10 mm to 500 mm, preferably 40 mm to 150 mm.
  • the choke contains a permanent magnet or a plurality of permanent magnets in an air gap or in a plurality of air gaps. In this way, a compensation of the DC pre-magnetization can be achieved, particularly in the case of DC chokes.
  • the inductor has a dielectric strength of up to 1 kV, preferably 3 kV, most preferably 5 kV. The electric strength mentioned is preferably the nominal operating voltage and/or the rated voltage.
  • the inductor preferably has a test voltage of up to 20 kV.
  • an inverter, a servo amplifier or a frequency converter with at least one choke according to the invention preferably with one choke according to the invention or with three chokes according to the invention.
  • the inverter, servo amplifier or frequency converter is preferably used to drive electrically driven vehicles.
  • the inverter, servo amplifier or frequency converter is preferably accommodated in an electric vehicle.
  • the throttle according to the invention is preferably used as a motor throttle.
  • a power pack or a converter with a choke according to the invention is also claimed.
  • the choke according to the invention is preferably used as a smoothing choke or interference suppression choke.
  • the choke according to the invention can be used in one or three phases.
  • the claimed power pack or converter is used to generate renewable energy.
  • the throttle according to the invention is preferably used in medical technology applications.
  • a magnetic resonance tomography device (MRT), a computer tomograph (CT) or an angiography device with a throttle according to the invention is claimed.
  • MRT magnetic resonance tomography
  • CT computer tomograph
  • angiography device with a throttle according to the invention is claimed.
  • the use of a choke according to the invention is particularly suitable in medical technology, railway technology, general drive technology (particularly for chokes with a high fundamental frequency), aviation, shipping, military technology, electromobility and in the case of renewable energies.
  • the idea according to the invention also extends to a method for producing a choke, preferably a choke according to the invention. The method comprises the following steps, preferably in the order mentioned: Providing an amorphous core material.
  • the annealing step involves controlled heating of the amorphous core material.
  • the annealing step then includes controlled cooling of the amorphous core material.
  • the entire duration of the tempering step, ie the tempering period preferably includes a heating period, a holding period and a cooling period.
  • the total annealing time is preferably 2 to 10 hours.
  • the heating time is preferably 1 to 3 hours, for example 2 hours.
  • the holding time is preferably 1 to 5 hours, for example 3 hours.
  • the cooling time is preferably 0.5 minutes to 10 hours, for example 6 hours.
  • the temperature reached during the holding period is preferably 300°C to 500°C, particularly preferably 350°C to 430°C.
  • At least one annealing step can take place in a nitrogen atmosphere.
  • at least one annealing step can take place under the influence of a magnetic field, preferably under the influence of a vertical magnetic field.
  • no tempering step takes place under the influence of a magnetic field.
  • at least one annealing step can take place under the influence of a mechanical stress exerted on the amorphous core material. In this way, for example, the permeability of the amorphous core material can be influenced.
  • the provision of the amorphous core material comprises one or more of the following steps, preferably in the order mentioned: Production of a liquid melt, preferably of iron, silicon and boron.
  • the melt can contain, for example, 70 to 85 at.% Fe, 5 to 20 at.% Si and 5 to 20 at.% B.
  • the melt consists of 78 at. % Fe, 9 at. % Si and 13 at. % B. Production of an amorphous ribbon by spraying the liquid melt onto a rotating roller.
  • the melt is preferably solidified quickly, for example with a cooling rate of 1000° C./ms.
  • the wound tape core immediately after winding is referred to as bare wound tape core.
  • the cross section of the inner mandrel is preferably circular, rectangular, or square.
  • the wound strip core is preferably wound in a ring shape. In the context of the present application, an annular geometry is understood to mean a closed geometry. A more precise shape for the cross section or for the plan view is not specified.
  • the wound tape core is preferably circular. Alternatively, the tape wound core may have an elliptical, oval, rectangular, or square shape in plan view.
  • An elliptical or oval shape of the wound tape core can be achieved by wrapping a circular inner mandrel and then laterally compressing the wound tape core.
  • the above-mentioned carrying out at least one annealing step under the influence of a mechanical stress exerted on the amorphous core material preferably takes place after the production of the amorphous strip and before the winding of the amorphous strip to create the wound strip core.
  • at least one annealing step is under the influence a mechanical stress applied to the amorphous ribbon.
  • the amorphous strip can be guided under tensile stress through a tempering furnace, preferably through a tempering furnace three to ten meters long, particularly preferably through a tempering furnace four to eight meters long.
  • the tempering furnace can be six meters long.
  • a winding tension is preferably applied to the amorphous ribbon.
  • the winding tension per width and per thickness of the amorphous strip is preferably at least 10 N/mm2, preferably at least 50 N/mm2, particularly preferably at least 150 N/mm2.
  • a tensile stress of at least 10 N, preferably at least 30 N, particularly preferably at least 50 N, most preferably at least 100 N is preferably applied to the amorphous ribbon.
  • the winding tension is kept at a constant value.
  • the winding tension on the amorphous strip can be made larger in the area of radii than in flat areas.
  • the first annealing step is carried out in a nitrogen atmosphere without the influence of a magnetic field.
  • the first annealing step involves rapid cooling in air.
  • the cooling time is preferably 0.5 to 5 minutes, particularly preferably 0.5 to 1 minute.
  • the Cooling is preferably carried out with the aid of a fan or by blowing compressed air, in particular from pre-cooled air.
  • the second annealing step is carried out under the influence of a vertical magnetic field in a nitrogen atmosphere.
  • the second annealing step involves slow cooling in a nitrogen atmosphere.
  • the cooling time is preferably 4 to 8 hours, for example 6 hours.
  • the first annealing step is preferably performed before the second annealing step.
  • the wound strip core can be fixed by gluing.
  • the wound strip core is preferably fixed by vacuum impregnation with a resin, particularly preferably with a synthetic resin, for example with epoxy resin.
  • the vacuum impregnation is preferably carried out at a pressure of 0.01 to 1 mbar, preferably 0.05 to 0.5 mbar, particularly preferably 0.1 to 0.2 mbar.
  • the temperature during vacuum impregnation is preferably 40 to 200°C, preferably 60 to 140°C, particularly preferably 80 to 120°C.
  • the vacuum soaking is preferably carried out for a period of 20 to 40 minutes, preferably for a period of 25 to 35 minutes, more preferably for a period of about 30 minutes.
  • the fixed tape wound core is preferably dried in a drying oven for 1 to 3 hours, preferably for 1.5 to 2.5 hours.
  • the temperature in the drying oven is preferably 80 to 200.degree. C., preferably 100 to 140.degree. C., particularly preferably about 120.degree.
  • the wound tape core is preferably fixed by vacuum impregnation twice or more. As a result, the fixed, wound strip core is particularly well bonded. cutting at least one air gap into the fixed wound ribbon core.
  • the air gap or air gaps are preferably cut in by sawing with a saw blade, by grinding with a cutting disk, and/or by cutting using a laser.
  • the saw blade and/or the cutting disc can be set with diamonds, for example.
  • the cutting disc preferably has a thickness in a range between 0.1 and 8 mm.
  • the fixed wound tape core is preferably severed into a plurality of ring segments.
  • the fixed, wound tape core is severed, for example, in two halves or in four quarters. If only one air gap is provided, the fixed wound tape core remains as a ring that is only simply interrupted.
  • Insert a plastic plate into the air gap The plastic plate is preferably glued into the air gap.
  • the plastic plate is preferably inserted and/or glued into each of the air gaps.
  • the plastic plate is preferably made of plastic.
  • the plastic is preferably a polyamide, for example PA 6.6 or FR4.
  • adhesive is preferably applied to the end faces of the segments in each case.
  • the segments are thus glued together with the plastic plates to form a ring.
  • This ring can be fixed more stably by additionally wrapping it with adhesive tape.
  • the trough is preferably made of plastic, in particular glass fiber reinforced plastic.
  • the plastic preferably includes polyamide, for example PA 6.6.
  • the plastic is preferably reinforced with 20 to 30% glass fibers, for example GF20 or GF30.
  • the trough can contain an air gap web or several air gap webs.
  • a trough with an air gap ridge preferably receives a fixed wound tape core with an air gap cut therein.
  • a trough with a plurality of air gap webs preferably accommodates a fixed wound strip core which has been severed into individual segments by cutting a plurality of air gaps.
  • a fixed, wound strip core with an air gap cut into it is introduced into the trough in such a way that the air gap web is arranged in the air gap.
  • the fixed, wound strip core is preferably inserted into the trough with a precise fit.
  • the trough has individual sections into which the individual segments of the severed ring are introduced.
  • the segments are preferably introduced into the trough with a precise fit.
  • the step described above of inserting a small plastic plate into the air gap is not necessary.
  • the at least one tempering step is therefore preferably carried out on the bare wound strip core, i.e. before the wound strip core is fixed, before the at least one air gap is cut and/or before the fixed wound strip core is introduced into the trough.
  • the at least one air gap is preferably cut after the wound strip core has been fixed and before the fixed wound strip core is introduced into the trough.
  • the application of the at least one winding comprises one or more of the following steps, preferably in the order mentioned: fixing the winding by bandaging, casting and/or impregnating.
  • Bandaging is preferably done with adhesive tape.
  • the encapsulation is preferably carried out using polyurethane and/or epoxy resin.
  • the impregnation is preferably carried out by vacuum impregnation with epoxy resin.
  • the epoxy resin can comprise one or two components.
  • the epoxy resin can be cold or warm curing, preferably the epoxy resin cures at 20 to 100°C.
  • the winding Connecting the winding by plugging, clamping, squeezing, soldering and/or screwing.
  • the winding is preferably connected using a cable lug, particularly preferably by crimping and screwing. So-called crimp cable lugs or tubular cable lugs are preferred.
  • the present invention relates to various configurations of chokes with low-noise and low-loss amorphous toroidal cores.
  • the chokes can be PFC or linear chokes, for example.
  • the design of the low-noise and low-loss amorphous toroidal cores can vary depending on the application, including the following aspects: no air gap can be provided, one or more air gaps can be provided, a wire winding, a stranded wire winding, and/or a winding made of HF stranded wire.
  • the design can be open or encapsulated.
  • FIG. 1A shows a perspective view of an amorphous annular core material according to the invention
  • FIG. 1B shows a perspective view of a toroidal core according to the invention
  • FIG. 2A shows a schematic side view of a first choke according to the invention
  • FIG , 3A is a perspective view of a second throttle according to the invention with a first housing
  • FIG. 3B is a perspective view of a second housing
  • FIG. 3C is a perspective view of a third housing
  • FIG perspective view of a fourth throttle according to the invention The figures show exemplary configurations of the invention, which are not to be understood as limiting. A person skilled in the art can modify the configurations shown according to his or her technical ability, without departing from the scope of the invention as defined by the claims.
  • 1A shows a perspective view of a ring-shaped amorphous core material 1 according to the invention.
  • the amorphous core material 1 consists, for example, of 78 at.% iron, 9 at.% silicon and 13 at.% boron.
  • the amorphous core material 1 is annular.
  • the core material 1 is formed of a wound amorphous ribbon.
  • the height of the amorphous core material 1 corresponds approximately the width of the amorphous ribbon, e.g. 20 mm.
  • the amorphous strip originally has a thickness in the range from 25 ⁇ m to 30 ⁇ m, for example 27 ⁇ m, and is wound into a ring with a tensile stress in the range between 80 N and 130 N, preferably a tensile stress of for example 108 N, around an inner mandrel, not shown here and is fixed, for example, by twice vacuum impregnating epoxy resin to form the ring-shaped amorphous core material 1 .
  • the amorphous core material 1 is also referred to as a fixed tape wound core.
  • the outer diameter of the amorphous core material 1 is 90 mm, for example.
  • the inner diameter of the amorphous core material 1 is determined by the above-mentioned inner mandrel around which the amorphous ribbon is wound, and is 60 mm, for example. It is obvious to the person skilled in the art that other inside diameters or outside diameters are also possible.
  • the amorphous core material 1 has four air gaps 2 . Each air gap 2 has a width of 1.5 mm, for example. A small plate made of plastic is glued into each of the air gaps 2 .
  • the amorphous core material 1 is given a particularly low saturation magnetostriction by a temperature treatment as part of a special tempering process. In the present example, the saturation magnetostriction is 3*10 -6 or less.
  • FIG. 1B shows a perspective view of a toroidal core according to the invention.
  • the toroidal core 3 is formed from the amorphous core material 1 shown in FIG.
  • the trough 4 is made of glass fiber reinforced plastic.
  • the trough 4 is formed, for example, from polyamide PA 6.6 with 30% glass fiber GF30.
  • the trough 4 or the ring core 3 has an outside diameter of 93 mm, an inside diameter of 55 mm and a height of 24 mm. Other dimensions are of course also conceivable depending on the circumstances.
  • the trough 4 has a mark 4a.
  • the marking 4a shows the position of the air gaps 2.
  • the marking 4a can be formed, for example, by a drawn line or by protruding material.
  • Figures 2A and 2B show a throttle according to the invention according to a first embodiment. This is a cut ribbon core choke.
  • 2A shows a schematic side view of the cut ribbon core choke.
  • 2A shows a schematic plan view of the cut band core choke.
  • the cut ribbon core choke has an oval ring core, a so-called oval core 5 .
  • the oval core 5 is formed from an amorphous core material 1 .
  • Each of the two long legs of the oval core 5 has a winding 6 formed from a solid wire and formed by a coil former.
  • the cross-section of the solid wire is preferably between 1 mm2 and 100 mm2, for example 35 mm2.
  • Each of the two windings has around 20 to 100 turns.
  • the cut strip-core choke is preferably constructed by first winding the bobbins forming the two windings 6 and then the divided into two halves oval core 5 is assembled in such a way, in particular glued together, that the bobbins are finally arranged on the legs of the oval core 5.
  • Each leg of the oval core 5 has eight air gaps 2 .
  • the oval core 5 therefore has a total of 16 air gaps 2 .
  • the air gaps 2 are covered by the two windings 6 in FIGS. 2A and 2B.
  • each leg of the oval core 5 can have, for example, one, two, four or more air gaps 2 .
  • the cut band-core choke has a holding device 7 , which consists, for example, of two angle plates, each of which receives and supports one of the short legs of the oval core 5 .
  • the inductance of the choke according to the invention is 1.0 mH, for example.
  • 3A shows a perspective view of a throttle according to the invention according to a second embodiment with a first housing 8.
  • the first housing 8 is a cylinder made of aluminum, for example a cut aluminum tube.
  • the first housing 8 has a diameter of 80 to 150 mm and a height of 40 to 150 mm, for example.
  • three toroidal cores 3 are accommodated. This can involve the toroidal cores 3 shown in FIG. 1B with the core material 1 shown in FIG. 1A.
  • Each toroidal core has, for example, a winding with 5 to 100 turns.
  • the windings are formed from copper or copper alloy stranded wire.
  • Each of the three windings can each be assigned to a corresponding phase of a three-phase power connection.
  • the three windings can be assigned to one phase together.
  • the windings of the three ring cores 3 can be connected in series in order to increase the inductance of the choke.
  • the windings of the three Toroidal cores 3 be connected in parallel in order to increase the current carrying capacity and thereby the possible performance of the choke.
  • only one toroidal core 3 could also be accommodated.
  • the ring cores 3 are accommodated in the first housing 8 by means of a casting compound 9 .
  • the casting compound 9 can be polyurethane, epoxy resin and/or silicone.
  • the choke according to the invention also has two first electrical connection means 10 .
  • the first electrical connection means 10 each have an insulating tube 11 in which the stranded wire is routed up to a cable lug 12 .
  • the end of the insulating tube 11 is formed by a shrink tube 13.
  • FIG. 3B shows a perspective view of a second housing 14.
  • the second housing 14 can be provided instead of the first housing 8 in the choke according to the invention.
  • the second housing 14 has fastening means 15 .
  • the fastening means 15 are designed, for example, as receptacles for screws.
  • 3C shows a perspective view of a third housing 16.
  • the third housing 16 can be provided instead of the first housing 8 in the throttle according to the invention.
  • the third housing 16 has cooling ribs 17 .
  • the third housing 16 is characterized by particularly good heat radiation.
  • 4 shows a schematic perspective view of a throttle according to the invention according to a third embodiment.
  • the inventive Choke has three ring cores 3 arranged along the same central axis. This can involve the toroidal cores 3 shown in FIG. 1B with the core material 1 shown in FIG. 1A.
  • Each of the three ring cores 3 has a winding 6 of approximately 10 to 100 turns.
  • the three ring cores 3 are arranged in a fourth housing 18 .
  • Each winding 6 runs around the respective ring core 3 along its entire circumference or essentially along its entire circumference.
  • the fourth case 18 is formed of aluminum.
  • the toroidal cores 3 are partially cast in the fourth housing 18 with a casting compound 9 and thereby fixed.
  • the casting compound 9 can in turn be polyurethane, epoxy resin and/or silicone.
  • the fourth housing 18 has fastening means 15 .
  • the fastening means 15 are designed, for example, as receptacles for screws.
  • the choke according to the invention can be provided with a heat sink or screwed onto a heat sink.
  • the heat sink can have cooling ribs and/or water cooling.
  • the throttle according to the invention also has second electrical connection means 19 .
  • the second electrical connection means 19 are configured as Euro terminals, for example.
  • the choke according to the invention also has an insulating film 20 to prevent electrical contact between the windings 6 and the fourth housing 18 .
  • the insulating film 20 is only shown on one side of the ring cores 3 in FIG. 4, but is preferably arranged on both sides.
  • the choke according to the invention has, for example, a length of 180 to 200 mm directed in the axial direction of the ring cores 3, a width of 120 to 160 mm and a height of 100 to 140 mm.
  • each of the three windings is assigned to a corresponding phase of a three-phase power connection.
  • the current carrying capacity of the choke can vary.
  • the inductor preferably has a rated current of 15 A or greater.
  • the inductance of the choke according to the invention is, for example, 100 ⁇ H at a rated current of 50 A. In further examples, the inductance of the choke according to the invention is 80 ⁇ H at a rated current of 85 A or 150 ⁇ H at a rated current of 50 A.
  • the choke according to the invention has three toroidal cores 3 each accommodated individually in a cylindrical receptacle 21 . This can involve the toroidal cores 3 shown in FIG.
  • Each of the three ring cores 3 has a winding 6 of about 10 to 40 turns.
  • Each of the three ring cores 3 has a winding 6 of approximately 10 to 100 turns.
  • the three ring cores 3 are arranged in a fifth housing 22 .
  • Each winding 6 runs around the respective ring core 3 along its entire circumference or essentially along its entire circumference.
  • the toroidal cores 3 are partially cast in the receptacles 21 with a casting compound 9 and thereby fixed.
  • the casting compound 9 can in turn be polyurethane, epoxy resin and/or silicone.
  • the recordings 21 belong to a fifth housing 22 .
  • the receptacles 21 and/or the fifth housing 22 are made of plastic, aluminum and/or stainless steel, for example.
  • the throttle according to the invention has, for example, a length of 460 mm, a width of 110 mm and a height of 135 mm. in the In the present example, each of the three windings is assigned to a corresponding phase of a three-phase power connection.
  • the fifth housing 22 has fastening means 15 .
  • the fastening means 15 are designed, for example, as receptacles for screws.
  • the choke according to the invention can be provided with a heat sink or screwed onto a heat sink.
  • the heat sink can have cooling ribs and/or water cooling.
  • the inductance of the choke according to the invention is, for example, 100 ⁇ H at a rated current of 140 A. In a further example, the inductance of the choke according to the invention is 150 ⁇ H at a rated current of 120 A.
  • the choke according to the invention also has third electrical connection means 23 .
  • the third electrical connection means 23 are designed, for example, as DIN rail terminals. It is advantageous that the chokes according to the invention are smaller, have lower losses, are quieter and cheaper to manufacture than known chokes with comparable rated currents or inductances.
  • noise during operation of a choke according to the invention equipped with the amorphous core material 1 is significantly reduced compared to known chokes if there is an interaction between the claimed saturation magnetostriction of the amorphous core material 1, the claimed tensile stress when winding the amorphous ribbons, two or more vacuum impregnations of the wound ribbon core, and the claimed static and/or dynamic coercivity of the amorphous core material.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Dispersion Chemistry (AREA)
  • Manufacturing & Machinery (AREA)
  • Composite Materials (AREA)
  • Soft Magnetic Materials (AREA)
  • Manufacturing Cores, Coils, And Magnets (AREA)

Abstract

L'invention concerne une bobine d'arrêt pour un système électronique de puissance. La bobine d'arrêt a une inductance dans la région de 10 μΗ à 2 mH et une capacité de transport de courant supérieure ou égale à 1 A. La bobine d'arrêt comprend un matériau de noyau amorphe (1) et au moins un enroulement (6). L'enroulement (6) est réalisé sous la forme d'un enroulement extérieur entourant le matériau de noyau amorphe (1) et réalisé en cuivre ou en alliage de cuivre. Le matériau de noyau amorphe (1) a une magnétostriction de saturation dans la région de 10-7 et 10-5 et/ou une coercivité statique de 30 A/m maximum.
EP21751794.5A 2020-08-03 2021-07-28 Bobine d'arrêt pour un système électronique de puissance Pending EP4189713A1 (fr)

Applications Claiming Priority (2)

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DE102020120430.2A DE102020120430A1 (de) 2020-08-03 2020-08-03 Drossel für Leistungselektronik
PCT/EP2021/071141 WO2022028980A1 (fr) 2020-08-03 2021-07-28 Bobine d'arrêt pour un système électronique de puissance

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DE102022104850A1 (de) * 2022-03-01 2023-09-07 Magnetec Gmbh Induktives Bauelement, Verfahren zur Herstellung eines induktiven Bauelements, Verwendung eines induktiven Bauelements und Kraftfahrzeug
DE102022111654A1 (de) 2022-05-10 2023-11-16 Magnetec Gmbh Magnetfeldempfindliches Bauelement, Verwendung eines magnetfeldempfindlichen Bauelements und Transformator

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