Reactor including peripheral core

Abstract

A core main body (5) of a reactor (6) includes an outer peripheral iron core (20), at least three iron cores (41-44), and at least three coils (51-54). Gaps (101-104) capable of being magnetically connected are formed between two adjacent iron cores. The reactor includes a vibration suppression part (90) to which at least three iron cores are fixed. The vibration suppression part comprises two fixing plates (91, 92) and a rod-shaped component (95) which fastens the two fixing plates to each other, and at least three notches (61-64) which extend from the edge of the fixing plate to the center are formed in at least one of the two fixing plates.

Description

Technical Field

[0001] The present invention relates to a reactor including a peripheral iron core. Background Art

[0002] In recent years, a reactor has been developed that includes an outer peripheral iron core and a plurality of iron core coils disposed inside the outer peripheral iron core. The plurality of iron core coils each include an iron core and a coil wound around the iron core.

[0003] Prior art literature

[0004] Patent Literature

[0005] Patent Document 1: Japanese Patent Application Publication No. 2018-206949

[0006] Patent Document 2: Japanese Patent Application Publication No. 2020-178081

[0007] Patent Document 3: Japanese Patent Application Publication No. 2018-117047 Summary of the invention

[0008] Problems to be solved by the invention

[0009] In order to suppress vibration or noise of multiple cores when using a reactor, Japanese Patent Publication No. 2018-206949 and Japanese Patent Publication No. 2020-178081 disclose a vibration suppression unit as a fixing member composed of two plate-like members and multiple rod-like members. Furthermore, the vibration suppression unit of Japanese Patent Publication No. 2018-117047 has an extension portion that engages with the upper surface of the core.

[0010] However, the core is made by stacking a plurality of magnetic plates, so when there is a deviation in the height of each core, it is difficult to firmly fix the core using the fixings of Japanese Patent Publication No. 2018-206949 and Japanese Patent Publication No. 2020-178081. Moreover, the extension of Japanese Patent Publication No. 2018-117047 only engages with a portion of the core in the width direction, so vibration and noise may become larger. In addition, it is also expected to simplify the structure of the vibration suppression unit and reduce manufacturing costs.

[0011] Therefore, a reactor is desired that can absorb variations in the heights of the respective cores and suppress noise and vibration at low cost.

[0012] Solutions to Solve Problems

[0013] According to a first embodiment of the present disclosure, a reactor is provided, which has a core body, the core body including: a peripheral iron core, which is composed of a plurality of peripheral iron core parts; at least three iron cores, which are combined with the plurality of peripheral iron core parts; and a coil, which is wound around the at least three iron cores, and a gap that can be magnetically connected is formed between one of the at least three iron cores and other iron cores adjacent to the one iron core. The reactor is also provided with a vibration suppression part, which fixes the at least three iron cores, and the vibration suppression part includes two fixing plates and a rod-shaped component that fastens the two fixing plates to each other, and at least one of the two fixing plates is formed with at least three cuts extending from the edge of the fixing plate toward the center.

[0014] Effects of the Invention

[0015] In the first embodiment, since the fixing plate has a cutout, the edge of the fixing plate between two adjacent cutouts can be bent separately. Therefore, each edge is bent according to the height of the corresponding iron core, and as a result, the height deviation of each iron core is absorbed. In addition, it is only necessary to form the cutout in the fixing plate, so it is easy to form and the manufacturing cost can be reduced. Moreover, since the rod-shaped component is single, even if the vibration suppression part is formed by a magnetic body, the current will not flow through the vibration suppression part in a ring shape, and the heating of the reactor can be prevented.

[0016] The objects, features and advantages of the present invention will become more apparent from the following description of the embodiments in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 It is a partial perspective view of the reactor according to the first embodiment.

[0018] Figure 2 It is a cross-sectional view of a core body of the reactor according to the first embodiment.

[0019] Figure 3 It is a perspective view of the vibration suppression unit in the first embodiment.

[0020] Figure 4A It is a top view of the fixing plate of the vibration suppression unit in the first embodiment.

[0021] Figure 4B It is a plan view of a fixing plate of a vibration suppression unit according to a fifth embodiment.

[0022] Figure 5 It is a partial perspective view of the reactor according to the second embodiment.

[0023] Figure 6 It is a partial perspective view of a reactor according to a third embodiment.

[0024] Figure 7 It is a perspective view of a reactor according to a fourth embodiment.

[0025] Figure 8 It is a perspective view of a vibration suppression unit in a fourth embodiment.

[0026] Fig. 9A It is a top view of the fixing plate in the fourth embodiment.

[0027] Fig. 9B It is along Fig. 9A Side view of the fixing plate viewed along line AA'.

[0028] Fig.10 This is a diagram for explaining how the vibration suppression unit is mounted on the reactor in the fourth embodiment.

[0029] Fig.11 This is a perspective view of a fixing plate after bending in still another embodiment.

[0030] Fig.12 It is a perspective view of a vibration suppression unit in another embodiment.

[0031] Fig.13 It is a partial perspective view of a reactor according to a fifth embodiment.

[0032] Fig.14 It is a cross-sectional view of a core body of a reactor according to a fifth embodiment. DETAILED DESCRIPTION

[0033] Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings. In all the drawings, corresponding components are denoted by common reference numerals.

[0034] In the following description, the three-phase reactor is mainly used as an example for explanation, but the application of the present disclosure is not limited to the three-phase reactor, and can be widely applied to multi-phase reactors that require fixed inductance in each phase. In addition, the reactor involved in the present disclosure is not limited to the primary side and secondary side of the inverter installed in industrial robots and machine tools, and can be applied to various equipment.

[0035] Figure 1 It is a partial perspective view of the reactor in the first embodiment. Figure 2 1 is a cross-sectional view of the core body of the reactor in the first embodiment. Figure 2 As shown in FIG. 1 , the core body 5 of the reactor 6 includes an outer peripheral iron core 20 and three iron core coils 31 to 33 arranged inside the outer peripheral iron core 20. Figure 2 In the embodiment, core coils 31 to 33 are arranged inside the substantially hexagonal outer peripheral core 20 . The core coils 31 to 33 are arranged at equal intervals in the circumferential direction of the core body 5 .

[0036] In addition, the outer peripheral core 20 may be in another rotationally symmetrical shape, for example, a circular shape. In addition, the number of core coils may be a multiple of 3, and in this case, the reactor 6 can be used as a three-phase reactor.

[0037] As can be seen from the drawings, each of the core coils 31 to 33 includes cores 41 to 43 extending only in the radial direction of the outer peripheral core 20, and coils 51 to 53 wound around the cores. Figure 1 In other drawings described later, the coils 51 to 53 , the iron core 42 , and the outer peripheral iron core portion 25 may be omitted for the purpose of simplicity.

[0038] The peripheral core 20 is composed of a plurality of, for example, three, peripheral core parts 24 to 26 divided in the circumferential direction. The peripheral core parts 24 to 26 are respectively formed integrally with the cores 41 to 43. The peripheral core parts 24 to 26 and the cores 41 to 43 are formed by stacking a plurality of magnetic plates, such as iron plates, carbon steel plates, and electromagnetic steel plates, along the axial direction of the reactor, or are formed by pressed powder iron cores. In this way, when the peripheral core 20 is composed of a plurality of peripheral core parts 24 to 26, even when the peripheral core 20 is large, such a peripheral core 20 can be easily manufactured. In addition, the number of cores 41 to 43 and the number of peripheral core parts 24 to 26 do not necessarily have to be the same.

[0039] The coils 51 to 53 are arranged in coil spaces 51a to 53a formed between the outer peripheral core portions 24 to 26 and the cores 41 to 43. In the coil spaces 51a to 53a, the inner and outer peripheral surfaces of the coils 51 to 53 are adjacent to the inner walls of the coil spaces 51a to 53a.

[0040] Furthermore, the radial inner end of each of the iron cores 41 to 43 is located near the center of the outer peripheral iron core 20. In the drawings, the radial inner end of each of the iron cores 41 to 43 converges toward the center of the outer peripheral iron core 20, and the tip angle thereof is approximately 120 degrees. Furthermore, the radial inner ends of the iron cores 41 to 43 are separated from each other by gaps 101 to 103 that can be magnetically coupled.

[0041] In other words, the radial inner end of the core 41 is separated from the radial inner ends of the two adjacent cores 42 and 43 by gaps 101 and 102. The same applies to the other cores 42 and 43. The gaps 101 to 103 are equal in size.

[0042] In this way, Figure 1In the structure shown, the central core located in the central part of the core body 5 is not required, so the core body 5 can be constructed lightly and simply. In addition, since the three core coils 31 to 33 are surrounded by the peripheral core 20, the magnetic field generated by the coils 51 to 53 will not leak to the outside of the peripheral core 20. In addition, the gaps 101 to 103 can be provided with any thickness and at low cost, which is advantageous in design compared to the reactor of the conventional structure.

[0043] Furthermore, in the core body 5 of the present disclosure, the difference in magnetic path length between phases is smaller than in the conventional reactor. Therefore, in the present disclosure, the inductance imbalance caused by the difference in magnetic path length can be reduced.

[0044] Refer again Figure 1 A vibration suppression portion 90 is disposed at the center of the end surface of the core body 5. The vibration suppression portion 90 serves to fix both end surfaces of the cores 41 to 43 to each other in the axial direction of the core body 5. Figure 3 : is a perspective view of the vibration suppression unit in the first embodiment. Figure 3 As shown, the vibration suppression portion 90 includes two fixing plates 91 , 92 and a single rod-shaped member 95 connecting these fixing plates 91 , 92 to each other.

[0045] from Figure 1 It can be seen that the fixing plates 91 and 92 are respectively arranged on the two end surfaces of the core body 5. In the first embodiment, the fixing plates 91 and 92 are preferably triangular flat plates having an area that can include the gaps 101 to 103, so that the fixing plates 91 and 92 do not interfere with the coils 51 to 53. In addition, the fixing plates 91 and 92 may also be other polygonal shapes or circular shapes.

[0046] Figure 4A It is a top view of the fixing plate of the vibration suppression unit in the first embodiment. Figure 4A , the fixing plate 91 is shown, but the fixing plate 92 is preferably of the same shape. However, the fixing plates 91 and 92 do not necessarily have to be of the same shape. Moreover, the cutout described later may be formed only in one fixing plate.

[0047] At least three cutouts 61 to 63 are formed extending from the outer peripheral edge of the fixing plate 91 toward the center. Figure 4A In the illustrated embodiment, at least three cutouts 61 to 63 partially extend from the vertices toward the center of the triangular fixing plate 91. As shown in the figure, the outer peripheral edge portions of the fixing plate 91 located between the cutouts 61 to 63 are referred to as edge portions 91a to 91c.

[0048] In a first embodiment, from Figure 1It can be seen that the rod-shaped member 95 is passed through the inner part of the outer peripheral iron core 20 at the intersection of the gaps 101 to 103. The rod-shaped member 95 is slightly larger than the height (height in the stacking direction) of the core body 5. The rod-shaped member 95 is typically a bolt, and a threaded portion 94 is formed on at least one end of the rod-shaped member 95. Therefore, the rod-shaped member 95 is screwed into the hole formed in the fixing plate 92.

[0049] As described above, the area of ​​the fixing plates 91 and 92 can include the gaps 101 to 103. Therefore, when the core body 5 is axially sandwiched between the fixing plates 91 and 92 by the rod-shaped member 95, both ends of the plurality of cores 41 to 43 are firmly held together.

[0050] As described above, the cutouts 61 to 63 are formed on at least one of the fixing plates 91. Therefore, the distance between the closed ends of two adjacent cutouts 61 to 63 is shorter than the distance between the open ends of the cutouts 61 to 63 (the length of each edge 91a to 91c). Therefore, a portion of the fixing plate 91 located between two adjacent cutouts 61 to 63 exhibits elasticity, and the edges 91a to 91c can be bent individually.

[0051] In this way, when assembling the vibration suppression unit 90, the edges 91a to 91c are bent according to the height of the corresponding cores 41 to 43, such as the stacking height. Moreover, in a state where the height deviation of each core 41 to 43 is absorbed, the fixing plates 91 and 92 act in a manner of stretching each other. As a result, the two ends of the plurality of cores 41 to 43 are firmly held to each other, and the generation of vibration and noise can be further suppressed when the reactor is driven. In addition, since it is sufficient to form the cutouts 61 to 63 only on the fixing plates 91 and 92, the formation of the vibration suppression unit 90 is also easy, and the manufacturing cost can also be reduced.

[0052] Furthermore, the parts of the vibration suppression unit 90 can be made of non-magnetic materials or magnetic materials. The reason is that in the present disclosure, the rod-shaped component 95 is single. In contrast, when the two fixing plates are fixed by multiple, for example, three, rod-shaped components, and the two fixing plates and the multiple rod-shaped components are magnetic bodies, when the inductor is driven, the current flows in a loop through the two fixing plates and the multiple rod-shaped components. As a result, the inductor heats up, which may become a cause of failure. In other words, in the present disclosure, even when the vibration suppression unit 90 is formed of a magnetic body as a whole, the current will not flow in a loop through the vibration suppression unit 90, and the heating of the inductor can be prevented.

[0053] Figure 5 It is a partial perspective view of the reactor in the second embodiment. Figure 5 The fixing plates 91, 92 shown are smaller than Figure 1The fixing plates 91 and 92 shown in the figure. Even in such a case, the distance between the open ends of two adjacent cutouts 61 to 63, for example, the length of each edge 91a to 91c is preferably at least half of the width of the corresponding core 41 to 43. Thus, each edge 91a to 91c of the fixing plates 91 and 92 fixes most of the width of the core 41 to 43, so that vibration and noise can be sufficiently and necessarily suppressed.

[0054] Figure 6 It is a partial perspective view of a reactor according to a third embodiment. Figure 6 The fixing plates 91 and 92 shown are circular. The diameter of the fixing plates 91 and 92 is preferably selected so as not to interfere with the coils 51 to 53. In addition, as mentioned above, the distance between the open ends of two adjacent cutouts 61 to 63 is preferably more than half the width of the corresponding cores 41 to 43. In the third embodiment, it can be seen that the fixing plates 91 and 92 can be simply formed.

[0055] Figure 7 is a perspective view of a reactor in a fourth embodiment, Figure 8 is a perspective view of a vibration suppression unit in a fourth embodiment. Fig. 9A is a top view of a fixing plate in a fourth embodiment, Fig. 9B It is along Fig. 9A Side view of the fixing plate viewed along line AA'.

[0056] In the fourth embodiment, at least one of the fixing plates 91 of the vibration suppression unit 90 is formed of a magnetic body, such as metal. Moreover, each edge 91a to 91c of the fixing plate 91 is bent at a predetermined angle, such as 90°, relative to the surface of the fixing plate 91. In this case, a portion of the fixing plate 91 located between two adjacent cutouts 61 to 63 further exhibits elasticity. As a result, it can be seen that when the reactor is driven, vibration and noise can be further suppressed at a low cost. Of course, the angle at which each edge 91a to 91c is bent can also be a value other than 90°.

[0057] Fig.10 FIG. 4 is a diagram for explaining how the vibration suppression unit is mounted on the reactor in the fourth embodiment. Fig.10 The outer peripheral core portion 25 is omitted from the illustration. First, the rod-shaped member 95 is inserted into the hole 60 of the fixing plate 91 .

[0058] Then, the fixing plate 91 is moved toward one end face of the core body 5, whereby the rod-shaped member 95 passes through the intersection of the gaps 101 to 103. When the fixing plate 91 reaches one end face of the core body 5, the front end of the rod-shaped member 95 protrudes from the other end of the core body 5. Next, the fixing plate 92 is arranged on the other end face side of the core body 5, and the rod-shaped member 95 is rotated to be screwed with the fixing plate 92. For this purpose, it is preferred to form threaded portions at the front end of the rod-shaped member 95 and the through hole 60 of the fixing plate 92, respectively. Of course, other fasteners may also be used to connect the fixing plates 91, 92 to the rod-shaped member 95.

[0059] Fig.11 FIG. 1 is a perspective view of a fixing plate after bending in another embodiment. Fig.11 In the embodiment, the protrusions 66 are formed at both ends of the edge of the fixed plate 91 after the bending process. Such protrusions 66 can be formed by cutting to remove the edges 91a to 91c before and after the bending process, or by bending a flat plate having the shape of the protrusions 66 in advance.

[0060] exist Fig.11 In the embodiment, each edge 91a to 91c includes two protrusions 66. Moreover, the inner dimension L between the two protrusions 66 is preferably substantially equal to the width of the corresponding iron core 41 to 43. In this case, both ends of each edge 91a to 91c are respectively engaged with the side surfaces of the iron core 41 to 43. That is, the iron core 41 to 43 is clamped by the two protrusions 66, so that vibration and noise caused by the movement of the iron core 41 to 43 in the circumferential direction of the reactor can be prevented.

[0061] Fig.12 : is a perspective view of a vibration suppression unit in another embodiment. Fig.12 In the embodiment, an elastic member 96 such as a spring is disposed in the middle portion of the rod-shaped member 95. Strictly speaking, Fig.12 The rod-shaped member 95 shown includes two rod bodies and an elastic member 96 connecting these rod bodies. In this case, the elastic member 96 urges the two fixing plates 91 and 92 to approach each other, so that noise and vibration can be further suppressed.

[0062] Fig.13 is a partial perspective view of a reactor according to a fifth embodiment, Fig.14 It is a cross-sectional view of a core body of a reactor according to a fifth embodiment. Fig.14The core body 5 shown includes a substantially octagonal outer core 20 and four core coils 31 to 34 arranged inside the outer core 20. These core coils 31 to 34 are arranged at equal intervals in the circumferential direction of the core body 5. In addition, the number of cores is preferably an even number of 4 or more, whereby the reactor having the core body 5 can be used as a single-phase reactor.

[0063] As can be seen from the accompanying drawings, the peripheral core 20 is composed of four peripheral core parts 24 to 27 divided in the circumferential direction. Each core coil 31 to 34 includes an iron core 41 to 44 extending in the radial direction and a coil 51 to 54 wound around the iron core. In addition, the radial outer end of each iron core 41 to 44 is formed integrally with the peripheral core parts 21 to 24. In addition, the number of iron cores 41 to 44 and the number of peripheral core parts 24 to 27 do not have to be the same.

[0064] Furthermore, the radial inner end of each of the iron cores 41 to 44 is located near the center of the outer peripheral iron core 20. Fig.14 In the embodiment, the inner radial ends of the cores 41 to 44 converge toward the center of the outer peripheral core 20, and the tip angles thereof are approximately 90 degrees. The inner radial ends of the cores 41 to 44 are separated from each other by gaps 101 to 104 that allow magnetic coupling.

[0065] Figure 4B It is a plan view of a fixing plate of a vibration suppression unit according to a fifth embodiment. Figure 4B The fixing plate 91 shown is a generally quadrilateral shape having an area that can include the gaps 101 to 104, and the same cutouts 61 to 64 as described above extend from the apex of the fixing plate 91 toward the center. As described above, if the core body 5 is axially sandwiched between the fixing plates 91 and 92 by the rod-shaped member 95, the two ends of the iron cores 41 to 44 are fixed to each other. It is understood that the same effect as described above can also be obtained in this case. In addition, the above-mentioned embodiments are appropriately combined and included in the scope of the present disclosure.

[0066] The solution of the present disclosure

[0067] According to a first embodiment, a reactor is provided, which has a core body, which includes: a peripheral iron core, which is composed of a plurality of peripheral iron core parts; at least three iron cores, which are combined with the plurality of peripheral iron core parts; and a coil, which is wound around the at least three iron cores, and a gap that can be magnetically connected is formed between one of the at least three iron cores and other iron cores adjacent to the one iron core. It also has a vibration suppression part, which fixes the at least three iron cores, and the vibration suppression part includes two fixing plates and a rod-shaped component that fastens the two fixing plates to each other, and at least one of the two fixing plates is formed with at least three cuts extending from the edge of the fixing plate toward the center.

[0068] According to a second aspect, in the first aspect, a distance between two adjacent cutouts of the at least three cutouts is greater than or equal to half of the width of the core.

[0069] According to a third embodiment, in the first or second embodiment, the fixing plate formed with the at least three cutouts is in a polygonal shape, the number of sides of the polygon is greater than the number of the at least three cores, and the at least three cutouts extend from the vertices of the polygon toward the center.

[0070] According to a fourth aspect, in the third aspect, each edge portion of the polygonal fixing plate is bent.

[0071] According to a fifth aspect, in the fourth aspect, an inner dimension between both ends of each edge portion after the bending process is substantially equal to a width of the core.

[0072] According to a sixth aspect, in the first or second aspect, the fixing plate formed with the at least three cutouts is circular.

[0073] According to a seventh aspect, in the first or second aspect, the rod-shaped member includes a bolt.

[0074] According to an eighth aspect, in the first or second aspect, the rod-shaped member has an elastic member.

[0075] According to a ninth aspect, in the first or second aspect, the number of the at least three core coils is a multiple of three.

[0076] According to a tenth aspect, in the first or second aspect, the number of the at least three core coils is an even number greater than 4.

[0077] Effect of the program

[0078] In the first embodiment, since the fixing plate has cutouts, the edges of the fixing plate between two adjacent cutouts can be bent respectively. Therefore, each edge is bent according to the height of the corresponding iron core, and as a result, the height deviation of each iron core is absorbed. In addition, since only the cutouts need to be formed in the fixing plate, it is easy to form and the manufacturing cost can be reduced.

[0079] In the second aspect, since the edges of the fixing plate fix most of the width of the core, vibration and noise can be sufficiently suppressed.

[0080] In the third aspect, the fixing plate can be formed simply.

[0081] In the fourth aspect, the fixing plate functions as a spring, and vibration and noise can be further suppressed at a low cost.

[0082] In the fifth aspect, since both ends of each edge portion are engaged with the side surfaces of the core, vibration and noise caused by movement of the core in the circumferential direction of the reactor can be prevented.

[0083] In the sixth aspect, the fixing plate can be formed simply.

[0084] In the seventh aspect, noise and vibration can be further suppressed, and the rod-shaped member can be manufactured at low cost.

[0085] In the eighth aspect, since the elastic member urges the two fixing plates to approach each other, noise and vibration can be further suppressed.

[0086] In the ninth aspect, the reactor can be used as a three-phase reactor.

[0087] In the tenth aspect, the reactor can be used as a single-phase reactor.

[0088] As mentioned above, although embodiment of this invention is described, it will be understood by those skilled in the art that various corrections and changes can be made without departing from the disclosure scope of the claims.

[0089] Explanation of symbols

[0090] 5—core body; 6—reactor; 20—peripheral iron core; 24~27—peripheral iron core portion; 31~34—core coil; 41~44—iron core; 51~54—coil; 61~64—cutout; 66—protrusion; 90—vibration suppression portion; 91, 92—fixing plates; 91a~91c—edge portion; 94—threaded portion; 95—rod-shaped component; 96—elastic component; 101~104—gap.

Claims

1. A reactor, characterized in that: A core body is provided, The core body comprises: An outer peripheral core, which is composed of a plurality of outer peripheral core parts; at least three cores combined with the plurality of peripheral core portions; and a coil wound around the at least three cores, A gap capable of magnetic connection is formed between one of the at least three cores and another core adjacent to the one core, A vibration suppression unit is further provided, the vibration suppression unit fixing the at least three cores, The vibration suppression unit includes two fixing plates and a rod-shaped member fastening the two fixing plates to each other. At least one of the two fixing plates is formed with at least three cutouts extending from an edge of the fixing plate toward a center thereof.

2. The reactor according to claim 1, characterized in that: The distance between two adjacent cutouts among the at least three cutouts is greater than or equal to half of the width of the core.

3. The reactor according to claim 1 or 2, characterized in that: The fixing plate formed with the at least three cutouts is in a polygonal shape, The number of sides of the polygon is greater than or equal to the number of the at least three cores. The at least three cutouts extend from vertices of the polygon toward the center.

4. The reactor according to claim 3, characterized in that: Each edge of the polygonal fixing plate is bent.

5. The reactor according to claim 4, characterized in that: The inner dimension between both ends of each edge portion after the bending process is substantially equal to the width of the core.

6. The reactor according to claim 1 or 2, characterized in that: The fixing plate formed with the at least three cutouts is circular.

7. The reactor according to claim 1 or 2, characterized in that: The rod-shaped member includes a bolt.

8. The reactor according to claim 1 or 2, characterized in that: The rod-shaped member has an elastic member.

9. The reactor according to claim 1 or 2, characterized in that: The number of the at least three core coils is a multiple of three.

10. The reactor according to claim 1 or 2, characterized in that: The number of the at least three core coils is an even number greater than 4.

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