DescriptionER core assembly exploded.png	exploded view of a ER core-based inductor
Date	24 June 2006
Source	Own work
Author	Cyril BUTTAY
Permission (Reusing this file)	as licensed
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• to remix – to adapt the work

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• share alike – If you remix, transform, or build upon the material, you must distribute your contributions under the same or compatible license as the original.

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made using povray 3.5 and the following source:

#declare RAD = on;   // use radiosity?
#declare Exploded=on; // exploded view or not?
#declare CoilLength = 2.6;

#include "functions.inc"
#include "metals.inc"
#include "colors.inc"
global_settings {
  #if(RAD)
    radiosity {
      brightness 0.60 
      count 100
      error_bound 0.2
      gray_threshold 0.0
      low_error_factor 0.2
      minimum_reuse 0.015
      nearest_count 10
      recursion_limit 1
      #if (version>3.1)
        adc_bailout 0.01
        max_sample -1.0
        media off
        normal off
        always_sample 1
        pretrace_start 0.08
        pretrace_end 0.01
      #end
    }
  #end
}

background { color White }

// declarations for the magnetic core------------------------------------------------
#declare corner = lathe { // a quarter of cyclindic volume used to "round" the corners
    linear_spline
    6
    <0,0>,<0.05,0>, <0.1,0.05>, <0.1,0.95>,<0.05,1>, <0,1>
    rotate 90*x 
}
#declare side =  prism { // the extrusions of the volume
  linear_sweep
  linear_spline
  0, 1, 9,
  <0.05,0>, <0,0.05>, <0,0.95>, <0.05,1>, <0.45,1>, <0.5,0.95>, <0.5,0.05>, <0.45,0>, <0.05,0>
}
#declare bottom = prism { // The bottom of the core
  linear_sweep
  linear_spline
  0, 1, 9,
  <0.25,0>, <0,0.05>, <0,0.95>, <0.25,1>, <0.35,1>, <0.4,0.95>, <0.4,0.05>, <0.35,0>, <0.25,0>
}
#declare middle =  cylinder { // the extrusion of the middle leg
  <0,0,0>,<0,1,0>,0.5
}
#declare core = union {
  difference{
    union{
      object {side scale <1,1.7,1> translate -1.7*x  }
      object {side scale <1,1.7,1> translate 1.2*x  }
    }
    cylinder{<0,-10,0.5>,<0,10,0.5>,1.3 translate 0.3*y}
  }
  object {bottom scale <1,3.2,1> rotate -90*z translate <-1.6,0.3,0> }
  object {corner translate -1.6*x}
  object {corner translate 1.6*x} 
  object {middle scale <1,1.7,1> translate <0,0,0.5>  }
  pigment { Gray50}
}

//declaration of the coil element-------------------------------------------------------- 
#declare coil = isosurface {
  function {f_helix1(x,y,z, 1, 60, 0.05, 1, 1, 1, 0)}
  contained_by { box { -CoilLength/2, CoilLength/2 }}
  pigment { P_Copper4 }
  finish {F_MetalB}//C
}

//declarations for the bobbin-------------------------------------------------------------
declare pin = union {
  box{<0,-0.3,-1>,<0.3,0,0> pigment {Gray20 } 
    translate<-0.15,0,0>
  }
  cylinder{<0,-0.15,-1.5>,<0,-0.15,0>,0.05 
    pigment{ P_Copper4 }
    finish {F_MetalB}
  }
}
#declare bobin_extremity = difference{
  union {
    cylinder{<0,0,0>,<0,0.1,0>,1.15}
    box {<-1.8,-0.3,-0.6>,<1.8,0.1,0.6>}
    prism {
      linear_sweep
      linear_spline
      0, 0.2, 4,
      <1.8,0>,<1.92,0.15>,<-1.92,0.15>,<-1.8,0>
      rotate -90*x
      translate <0,-0.15,0.1>
    } 
    #declare Index = 0.3;
    #while(Index <= 1.7)
      object{pin translate <-Index,0,0>}
      object{pin translate <Index,0,0>}
      #declare Index = Index + 0.6;
    #end
  }
  merge {
    box {<-1.1501,-1,-0.55>,<1.1501,0,0.55>}
    box {<-1.75,-1,-0.55>,<-1.15,1,0.55>}
    box {<1.75,-1,-0.55>,<1.15,1,0.55>}
  }
}
#declare bobbin = difference {
  union {
    cylinder{<0,-0.1,0>,<0,CoilLength+0.1,0>,0.6}
    object{bobin_extremity translate <0,-0.1,0>}
    object{bobin_extremity rotate 180*z translate <0,CoilLength+0.1,0>}
  }
  cylinder{<0,-10,0>,<0,10,0>,0.55 pigment { Gray20 } }
  pigment { Gray20 } 
}

//declarations for the clip
#declare halfclip = difference { 
  prism {
    linear_sweep
    bezier_spline
    0, 1, 32, 
    <0,0>,<1.2,0>,<0,0>,<1.2,0>,
    <1.2,0>,<1.3,0>,<1.6,-0.2>,<1.7,-0.2>,
    <1.7,-0.2>,<1.8,-0.2>,<1.8,-0.2>,<1.8,0.5>,
    <1.8,0.5>,<1.9,0.5>,<1.8,0.5>,<1.9,0.5>,
    <1.9,0.5>,<1.9,-0.3>,<1.9,-0.3>,<1.7,-0.3>,
    <1.7,-0.3>,<1.6,-0.3>,<1.3,-0.1>,<1.2,-0.1>,
    <1.2,-0.1>,<0,-0.1>,<1.2,-0.1>,<0,-0.1>,
    <0,-0.1>,<0,0>,<0,-0.1>,<0,0>
    pigment {P_Chrome1}
    finish {F_MetalC}
  }
  box {<0,0.2,0.25>,<10,0.8,0.4>
    pigment {P_Chrome1}
    finish {F_MetalC}
  }
}
#declare completeclip = union {
  object{halfclip scale 0.5*y}
  object{halfclip scale 0.5*y rotate 180*z translate 0.5*y} 
}

// the final union-------------------------------------------------
union {
  object {bobbin rotate -90*x translate <0,0.5,-0.4>}
  object {coil rotate -90*x translate <0,0.5,-CoilLength/2-0.4>}
  object {core rotate -90*x translate <0,0,0>}
  #if(Exploded)  
    object {core rotate 90*x translate <0,1,-6.5>} 
    object {completeclip translate <0,0.25,-8>}
  #else
    object {core rotate 90*x translate <0,1,-3.4>} 
    object {completeclip translate <0,0.25,-3.5>}
  #end
  object {completeclip rotate 180*y  translate <0,0.25,0.1>}
  rotate <0, 30, 0>
  finish {
    #if(RAD)  
      ambient 0
      diffuse 0.7 
    #else
      ambient 0.8 
      diffuse 0.5      
    #end   
    phong 1
    phong_size 60
  } 
}
light_source { <0, 14, -10> color White}
light_source { <2, 4, -10> color White}
#if(Exploded)  
  camera {location <1,10,-15> look_at <-3.3,-3.5> angle 33}
#else
  camera {location <1,10,-15> look_at <-1.25,-1,0> angle 20}
#end
<pre>

And then compiled using the following command:
<pre>
povray -IER_core_assembly_exploded.pov +a -Q11 -W1280 -H960