Magnetic characteristics of threaded cores with round iron wires in AC magnetic fields

Abstract

This study explores the magnetic characteristics of threaded cores constructed with round cross-sectional iron wires, designed to mitigate eddy currents in magnetic devices. The threaded core comprised iron threads separated by an insulating material. Previous studies have demonstrated the remarkable efficacy of threaded cores in reducing eddy currents. These investigations employed iron threads with square cross-sectional structures. However, round cross-sectional wires are more prevalent in industrial applications owing to their productivity, cost-effectiveness, and superior mechanical properties. In this study, numerical and experimental analyses are conducted to examine the characteristics of round-wire threaded cores. In the numerical analysis, we compare the round-wire threaded core with other core types, namely the laminated core and square-wire threaded core, to assess their geometric attributes and magnetic performances. Additionally, further analysis is performed to examine the impact of round wire diameter on the magnetic performance of the threaded cores. The findings obtained from the numerical analysis are verified through experimental testing, which involves lab-made threaded cores using a commercially available round iron wire. This study reveals that round-wire threaded cores offer promising performance in reducing eddy currents, with smaller wire diameters exhibiting superior magnetic properties, particularly in high-frequency applications.