Internal Characterization of Magnetic Cores, Comparison to Finite Element Simulations: A Route for Dimensioning and Condition Monitoring

Magnetic cores are typically used in every stage of an electrical energy production and distribution chain. Local defects, including edge burrs and interlaminar faults (ILFs), are detrimental to system performance and should be detected swiftly to ensure high reliability and durability. Real-time magnetic core condition monitoring (MCCM) is a promising solution for rapid fault detection. However, similar to dimensioning or performance evaluation, this monitoring has always been performed through averaged magnetic properties, which limits efficiency. In this domain, significant progress is forecast by achieving precise local measurements. In this study, an innovative solution is proposed to measure local magnetic properties, which is adapted to real-time monitoring and magnetic circuit evaluation. The proposed sensor is a one-piece device that is flat enough to be placed noninvasively between the laminations at distinct positions in the magnetic core. It measures the magnetic excitation and induction fields in two dimensions, which can be used as local inputs for real-time condition monitoring. In this article, the proposed sensor was first detailed, experimental results were provided, and finite-element simulations were performed. The sensor capability was validated both experimentally and through simulation. The results of this study contribute to the development of an intelligent magnetic core that includes an effective real-time monitoring system. The study provides a local validation of the most advanced high-fidelity simulation method, which could be used to predict the responses of magnetic cores and electromagnetic converters to defects of various natures, as well as geometrical and property changes.