Search Results (32)

Grain-oriented (GO) silicon steel cores in low-voltage current transformers suffer magnetic degradation from residual stress and increased dislocation density during slitting and winding. This study addresses the gap in systematic optimization of secondary annealing on assembled toroidal cores using a 3² full-factorial design varying temperature (650, 850, 1050 °C) and holding time (60, 90, 120 min) on M4 grade cores. Results showed temperature is the dominant factor, while holding time exhibits a synergistic non-linear effect. The optimal condition (850 °C, 90 min) reduced specific losses from 0.85 W/kg to 0.43 W/kg (49% reduction). Mechanistic analysis confirmed this improvement is driven by complete primary recrystallization (equiaxed grains ~50–60 µm), dislocation annihilation (~10 HV hardness reduction), and reinforcement of the Goss texture ({110} <001>). SEM, EDS, and ICP-OES demonstrated that the Carlite coating remained dimensionally (1.67–1.83 µm) and chemically stable, with beneficial decarburization. Temperatures above 850 °C caused magnetic deterioration due to excessive grain growth. These results provide a validated, industrial framework for recovering magnetic efficiency in wound toroidal cores without compromising coating integrity. Full article

Recently, unmanned aerial vehicles (UAVs) based on electric propulsion systems are being increasingly adopted in various fields, including industrial and military applications. Outer-rotor surface-mounted permanent magnet synchronous motors (SPMSMs) are predominantly applied in UAV propulsion systems. However, these motors are vulnerable to the price fluctuations of rare-earth materials and supply chain instability. In addition, the magnets in these motors are prone to detachment at high rotational speeds, and demagnetization under high-temperature conditions may reduce output performance. To address these limitations, research is being actively conducted on non-permanent magnet motors, among which, wound-rotor synchronous motors (WRSMs) offer the advantage of controllable field excitation at high speeds. Furthermore, WRSMs can use both magnetic and reluctance torques, thereby increasing power density relative to other non-permanent magnet motors. However, the adoption of an additional field winding increases copper loss, thus reducing motor efficiency. This study investigates the application of the toroidal winding structure, which is already widely applied in permanent magnet and brushless direct current machines, to WRSMs. The performance of these motors is compared with that of motors using conventional tooth-coil windings. The toroidal windings are circumferentially distributed along both the inner and outer stator yoke paths, effectively reducing the end-turn length relative to that of conventional tooth-coil windings. Two WRSMs, one with tooth-coil and another with toroidal windings, are designed using identical specifications to compare performances via finite element analysis. The armature copper loss in the proposed model decreased by approximately 28% because the toroidal winding structure reduced the end-turn length. As a result, the efficiency increased by about 1.9% due to the reductions in copper, core, and eddy current losses. Full article

In order to break through the difficulties with a very-low-frequency (VLF) miniaturized antenna with small power capacity and low radiation efficiency, this paper proposes a high-radiation-field-strength magnetic loop antenna based on a nanocrystalline alloy magnetic core. A high-permeability nanocrystalline toroidal core (μ_r = 50,000, B_s = 1.2 T) is used to optimize the thickness-to-diameter ratio (t = 0.08) and increase the effective permeability to 11,000. The Leeds wires, characterized by their substantial carrying capacity, are manufactured through a toroidal winding process. This method results in a 68% reduction in leakage compared to traditional radial winding techniques and enhances magnetic induction strength by a factor of 1.5. Additionally, this approach effectively minimizes losses, thereby facilitating support for kilowatt-level power inputs. A cascaded LC resonant network (resonant capacitance 2.3 μF) and ferrite balun transformer (power capacity 3.37 kW) realize a 20-times amplification of the input current. A series connection of a high-voltage isolation capacitor blocks DC bias noise, guaranteeing the stable transmission of 1200 W power, which is 6 times higher than the power capacity of traditional ring antenna. At 7.8 kHz frequency, the magnetic field strength at 120 m reaches 47.32 dBμA/m, and, if 0.16 pT is used as the threshold, the communication distance can reach 1446 m, which is significantly better than the traditional solution. This design marks the first instance of achieving kilowatt-class VLF effective radiation in a compact 51 cm-diameter magnetic loop antenna, offering a highly efficient solution for applications such as mine communication and geological exploration. Full article

In this paper, a new fault-tolerant consequent-pole hybrid excited (FTCPHE) machine with toroidal winding (TW) is designed for electric vehicles (EVs). In this proposed machine, U-type permanent magnets (PMs) are adopted in the consequent-pole rotor with the sequence of PM–iron–PM–iron. The stator tooth placed in the stator is classified into two groups to achieve hybrid excitation. The TW is positioned on the stator yoke to achieve the simple structure and excellent fault-tolerant ability. First, the topology of this proposed FTCPHE machine with the TW is briefly introduced and compared to that with the traditional combined winding. Second, the operation principle, the magnetic circuit, and the design procedure of the FTCPHE machine are analyzed and illustrated. Third, several key structural parameters of the proposed FTCPHE machine are discussed and designed to improve electromagnetic performances. Next, some electromagnetic properties, including the flux distribution, the no-load back-EMF, the electromagnetic torque, the cogging torque, and the fault-tolerant ability, are discussed in detail. Finally, a prototype of this proposed FTCPHE machine is manufactured to validate the simulated results. Full article

A high-frequency model of the toroidal powder core inductor with litz wire winding is presented. In the analyzed model, the power losses that occurred in both the winding and the magnetic core were taken into account. A new method of determining the power losses in the winding of a magnetic element made of a litz wire with a circular cross-section, wound on a toroidal magnetic core, for both sinusoidal and deformed currents, by transforming the parameters of the wire to the Dowell equation has been proposed. The methodology of estimating the resistance for the alternating component of the current flowing through a litz wire with a circular cross-section wound on a toroidal core is shown. The influence of the type of winding wire, the shape of the core, the number of winding layers, the winding angle, and the frequency range for which the litz wire obtains lower power losses than a solid-round wire are discussed. Full article

This paper compares the electromagnetic performances of radial-flux, dual-rotor, permanent magnet (DRPM) machines with series (S) and parallel (P) magnetic circuits for two rotors, i.e., SDRPM and PDRPM, accounting for different slot/pole number combinations, stator winding configurations, and machine sizes. The machines are optimized using the finite element analysis (FEA) based on the genetic algorithm. It shows that the PDRPM machine with the tooth coil (TC) configuration has the highest permanent magnet (PM) utilisation compared to the PDRPM with toroidal winding (TW) configuration and the SDRPM machine with the TC configuration under different slot/pole number combinations. The scaling effects of the machine size on the torque have been investigated. The TW-PDRPM machine is suitable for large-radius and short-axial length applications due to the short end-winding length of the TW configuration, while the TC-PDRPM is better for small-radius and long-axial length applications. The TC-SDRPM performs well when both the machine outer radius and axial length increase. Finally, the TC-SDRPM and TW-PDRPM machines are prototyped and validated experimentally. Full article

In the high-frequency (HF) region, specifically within the 150 kHz to 30 MHz range for conducting electromagnetic interference (EMI) modeling, NiZn inductors exhibit enhanced efficiency due to their low core losses and stable permeability. Consequently, the accurate modeling of NiZn ferrite toroidal inductors is essential, given their widespread applications in the HF domain, with the aim of addressing existing knowledge gaps. Previous inductor models often relied on the perfect electric conductor (PEC) assumption, which simplifies the analysis but does not fully represent the electromagnetic behavior of the cores to which the PEC assumption cannot be applied. This study investigates the actual electromagnetic behavior of NiZn cores, treating them as dielectrics, which diverges from the traditional PEC-based models. Furthermore, this research fully considers the actual geometry of the inductors, proposing a comprehensive and precise analytical model for NiZn ferrite toroidal inductors. The impact of various winding methods on core capacitance is also explored. The paper provides a detailed explanation of the physical significance underlying the proposed model. A comparative analysis of both modeling methods is presented, and the efficacy of the suggested approach is validated through simulations and experimental results in several distinct scenarios. Full article

Electrodeless Low-Frequency (LF)/Radio-Frequency (RF) plasma sources often suffer from low power coupling efficiencies due to the lack of overlapping field with the dynamic plasma load. However, the power supplies for these plasma sources typically have very high power efficiencies (>90%) and are more cost-effective compared to microwave sources. If the coupling efficiency to the plasma can be increased, these plasma sources offer a competitive technology for the sustainable electrification of the chemical industry. This work experimentally investigates five power coupling methods, applied to toroidal CO₂ plasmas in a quartz vessel. The research was based on similar ferrite coupling as used in energy-efficient plasma lamps. The higher resistance of the CO₂ plasma decreased the power coupling from 90% (for mercury-vapor plasma) to 66% at 1 mbar. High coupling efficiencies in LF/RF powered discharges can be achieved in two manners: either the inductance of the transformer cores can be increased, or the electromagnetic wave frequency can be increased. Furthermore, additional ferrite cores in parallel with the primary coils can be used to increase the impedance transformation. An experiment with six ferrite cores with a single primary winding in parallel, at a frequency of about 10 MHz and a power of 1 kW, showed that this frequency has a detrimental effect on the magnetic permeability and the losses in the ferrite result in a decrease of coupling to 33% at 1.5 mbar. At a frequency of 66 kHz with a nanocrystalline soft magnetic material core, a coupling of 89% was achieved in 1.5 mbar plasma for a power of 3.1 kW. This configuration exhibits decreasing coupling efficiencies at higher pressures since the plasma impedance increases, which again limits the coupling of the transformer due to a lack of inductance. The investigation of alternative coreless coil plasma configurations resulted in coupling efficiencies up to 89% decreasing to 50% at 102 mbar for a toroidal plasma enclosed by toroidally spiraling coils. Full article

This paper presents a novel Continuous Variable Transmission (CVT) design. CVT is highly beneficial for actuators with rotary output as it can improve the energy efficiency of the actuators by providing an optimum transmission ratio. This property of CVT is highly beneficial for fossil-fuel-based vehicles, electric vehicles, wind turbines, industrial robots, etc. With the exception of Spherical CVT and DH CVT, all known CVTs like push belt CVTs, toroidal CVTs, Milner CVTs, etc., require additional gear sets and clutches for direction reversal and neutral gear ratio. However, Spherical CVT and DH CVT have low torque capacity due to a single traction point constraint. Foregoing in view, a new CVT named CAD CVT has been developed. The paper presents the design conception, the operating principle, the transmission ratio, the torque capacity, frictional losses, and experimental verification of the basic functionality by manufacturing a Proof of Concept (PoC). The proposed CVT is the only CVT capable of independent direction reversal and high torque capacity as it can transmit torque through multiple traction points. The new CVT will significantly impact high-torque applications in different engineering applications, especially land transport consisting of heavy vehicles like trucks, buses, and trailers. Full article

Multipulse laser–matter interactions initiate nonlinear and nonequilibrium plasma fluid flow dynamics and their instability creating microscale vortex filaments, loop-soliton chains, and helically paired structures, similar to those at the astrophysical mega scale. We show that the equation with the Hasimoto structure describes both, the creation of loop solitons by torsion of vortex filaments and the creation of solitons by helical winding of magnetic field lines in the Crab Nebula. Our experiments demonstrate that the breakup of the loop solitons creates vortex rings with (i) quasistatic toroidal Kelvin waves and (ii) parametric oscillatory modes—i.e., with the hierarchical instability order. For the first time, we show that the same hierarchical instability at the micro- and the megascale establishes the conceptual frame for their unique classification based on the hierarchical order of Bessel functions. Present findings reveal that conditions created in the laser-target regions of a high filament density lead to their collective behavior and formation of helically paired and filament-braided “complexes”. We also show, for the first time, that morphological and topological characteristics of the filament-bundle “complexes” with the loop solitons indicate the analogy between similar laser-induced plasma instabilities and those of the Crab and Double-Helix Nebulas—thus enabling conceptualization of fundamental characteristics. These results reveal that the same rotating metric accommodates the complexity of the instabilities of helical filaments, vortex rings, and filament jets in the plasmatic micro- and megascale astrophysical objects. Full article

This paper has investigated a method for calculating the frequency-dependent winding resistance of toroidal inductor windings with Litz-wire as well as solid-round wire. The modified Dowell’s model is employed to address the effectiveness for inductor windings with the low and high filling factors. To overcome the limitation of this model, especially for a winding densely wound around the core, an alternative approach based on the complex permeability and iterative calculations is proposed. For the calculated AC-resistance factor of five inductors with different numbers of turns, layers with the same wire diameters are compared with that of FEA, and the three air-core toroidal windings are manufactured and tested within the frequency where the self-resonance can be neglected. The proposed model demonstrates the versality of the AC-resistance calculation of both solid- and Litz-wire windings within an error of 15% across a wide range of frequencies up to 1 MHz, compared with FEA. Full article

The performance and efficiency of high-frequency transformers (HFTs) are significantly influenced by leakage inductance. To improve the efficiency of HFTs, it is crucial to consider the effects of leakage inductance during the design and analysis processes. This research study aims to investigate a high-frequency toroidal transformer by examining different magnetic materials (Ferrite, Amorphas, and Iron-Powdered Alloy), winding configurations (solid, twisted, and LITZ wire), and operating frequencies (10 kHz and 50 kHz). To validate the effectiveness of parametric optimization in enhancing the system efficiency, the designed toroidal HFT was constructed and tested in a 600/300 V 3 kW dual active bridge (DAB) converter. The leakage inductances were measured using a frequency sweeping LCR meter. Full article

Frames made of polymer composites are increasingly used in the aerospace, automotive, and agricultural industries. A frequently used technology in the production line of composite frames is winding rovings onto a non-load-bearing frame to form the structure using an industrial robot and a winding head, which is solidified through a subsequent heat-treatment pressure process. In this technology, the most difficult procedure is the winding of the curved parts of a composite frame. The primary concern is to ensure the proper winding angles, minimize the gaps and overlaps, and ensure the homogeneity of the wound layers. In practice, the curved frame parts very often geometrically form sections of a torus. In this work, the difficulty of achieving a uniform winding of toroidal parts is described and quantified. It is shown that attaining the required winding quality depends significantly on the geometrical parameters of the torus in question. A mathematical model with a detailed procedure describing how to determine the number of rovings of a given width on toroidal parts is presented. The results of this work are illustrated with practical examples of today’s industrial problems. Full article

The theory of equatorward moving east-west elongated auroral arcs associated with field line resonance (FLR) has been proposed for decades. However, confirming this theory requires in-situ observations of FLR within the magnetosphere and simultaneous all-sky imager observations of equatorward moving auroral arcs near satellite footpoints. In this study, we present the first observations of multiple equatorward moving auroral arcs related to impulse-excited FLR, using datasets from the WIND, Geotail satellites, and an all-sky imager at China’s Zhongshan Station (ZHS) in Antarctica. In the presented event, the ultra-low-frequency waves associated with solar wind dynamic pressure pulse was mainly toroidal mode, which is consistent with the theory that the toroidal mode waves usually related with external source. The all-sky imager located in Zhongshan station recorded several equatorward moving auroral arcs, followed by reverse propagating ones. The latitudinal width of the equatorward moving auroral arcs was on the order of 25 km and had an average equatorward propagation of ~0.37 km/s, which is very similar to the value from previous work. To better illustrate the observed evolution of auroral arcs related with the FLRs we proposed a simple model to evaluate the FACs induced by the FLRs in different latitudes. The latitudinal distribution evolution of FACs agrees well with the ground-based optical observations. Full article

Based on the discovery of the surge absorption capability of supercapacitors, a transient protector named supercapacitor-assisted surge absorber (SCASA) was designed and implemented in a commercial device. Despite its simplicity, the circuit topology consisted of a coupled inductor wound around a specially selected magnetic core. This paper elucidates the design aspects of SCASA coupled-inductor topologies with a special focus on the magnetic action of core windings during transient propagation. The non-ideal operation of the SCASA transformer was studied based on a semi-empirical approach with predictions made by using magnetizing and leakage permeances. The toroidal flux distribution through the transformer was also determined for a 6 kV/3 kA combinational surge, and these findings were validated by using a lightning surge simulator. In predicting the possible effects of magnetic saturation, the hysteresis properties of different powdered-iron and ferrite core types were considered to select the optimal design for surge absorption. The test results presented in this research revealed that X-Flux powdered-iron toroid and air-gapped EER ferrite yielded exceptional performance with ∼10% and ∼20% lower load–voltage clamping compared to that of the existing Kool $\mathsf{\mu }$u design. These prototypes further demonstrated a remarkable surge endurance, withstanding over 250 consecutive transients. This paper also covers details of three-winding design optimizations of SCASA and LTSpice simulations under the IEC 61000/IEEE C62.45 standard transient conditions. Full article