Magnetic core coil process

The reasons for abnormal heating of magnetic ring inductor coils may include the following aspects:   Design problems:   Improper inductance selection: The inductance value is too large or too small, resulting in abnormal circuit operation, which causes heating.   Improper core material selection: The saturation flux density and loss characteristics of the core material are not suitable for the operating frequency and operating current, resulting in excessive core loss and heating.   Process problems:   Poor coil winding process: Loose winding and poor interlayer insulation during coil winding lead to increased copper loss.   Improper wire diameter selection: The cross-sectional area of ​​the wire is too small, resulting in excessive current passing through, causing excessive copper loss and heating.   Electrical performance problems:   The operating frequency is too high: At high frequencies, the hysteresis loss and eddy current loss of the core increase, resulting in heating of the core.   Excessive current: Exceeding the maximum current designed for the inductor, resulting in overheating of the inductor.   Heat dissipation problems:   Poor heat dissipation conditions: The ambient temperature around the inductor is high or the heat dissipation measures are improper (such as lack of a heat sink), resulting in the inability to dissipate heat in time.   Magnetic saturation:   Core saturation: The working current exceeds the core saturation current, causing the core to enter the saturation zone, resulting in a sharp increase in core loss.   Problems with inductor use:   Overload use: The inductor is used for a long time under conditions exceeding the rated power, resulting in overheating.   Poor working environment: Environmental conditions such as high temperature and high humidity will accelerate the aging and heating of the inductor.   For these reasons, the following measures can be taken to investigate and deal with them:   Optimize design: Select appropriate inductance value and core material according to actual working conditions.   Improve process: Ensure the quality of coil winding and select appropriate wire cross-sectional area.   Control working parameters: Ensure that the working frequency and working current are within the design range.   Strengthen heat dissipation: Improve heat dissipation conditions, add heat sinks or fans and other measures.   Avoid magnetic saturation: Select appropriate core materials to avoid the working current exceeding the saturation current of the core.