The Machine Shop
Ferrite Lapping is a process used to remove material from the surface of a workpiece, which is beneficial for creating a smooth finish after machining (removing any grooves or indentations). By creating a flat surface finish, Ferrite Cores can attain a tighter mating which increases AL value.
As industry evolves and has increasing demands on performance and speed of electronic systems whilst simultaneously reducing costs, these requirements are most noticeable when looking at power transmission. As technology advances a simple solution is actually the answer, using wiring harnesses is becoming a thing of the past and the use of busbars is paving the way for the future of lower cost and higher reliability.
Gateway have made another significant investment within their UK based Machine Shop, by adding a new machine. The Haas Super Mini Mill 2 is a 3-axis CNC Milling machine that has allowed The Machine Shop to expand their capacity and capabilities, cutting their lead times in half on custom geometry cores!
Ferrite cores and single air gaps are very common as this technique of a single gap is able to delay the core saturation and as a results increase the cores performance. However its not all good as these relatively large single gaps cause higher fringing flux which will lead to additional copper losses in the windings, especially when operating at high frequencies. Now single gaps aren’t bad by any means as the pros out way the cons, however can we improve this technique even further and reduce the cons?