New structure of iron core reactor and its manufacturing method

Abstract

The present invention relates to the technical field of reactors, and in particular to a new structure of an iron core reactor, including an iron core column, an insulation tube to ground, an insulation tube, an airway and a coil; the iron core column, the insulation tube to ground, the insulation tube, the airway and the coil are cast into one piece, the iron core column is located in the center, the insulation tube is provided with an airway, the insulation tube to ground is arranged on the outside of the iron core column, the insulation tube is arranged on the outside of the insulation tube to ground, and the coil is wound on the outside of the insulation tube. After adopting this new iron core, the new technology of casting the insulation tube to ground, the airway, the insulation tube and the coil at one time, the product quality has been significantly improved, the inner film of the reactor has been reduced, the support bars have been saved, the materials and time have been saved, the insulation tube between the iron core and the coil is conducive to heat dissipation, effectively reducing the iron core noise, and eliminating the hidden danger of iron core deviation.

Description

Technical Field

[0001] The present invention relates to the technical field of reactors, and in particular to a novel structure of an iron core reactor and a manufacturing method thereof. Background Art

[0002] Reactors are indispensable power equipment in power systems. Shunt reactors and series reactors are widely used as reactive power compensation devices in power grids of all voltage levels in power systems. Current-limiting reactors are used to limit impact current or fault current. High-voltage shunt reactors are directly used to compensate for capacitive current in high-voltage and ultra-high-voltage lines.

[0003] The iron core reactor is an iron core column with an air gap, the outer surface of which is covered with an insulating tube and a winding. The iron core column with an air gap is formed by connecting a plurality of iron core cakes and the air gaps between each adjacent iron core cake in series.

[0004] Air-core reactors have no core, and the magnetic flux generated by unit current in the winding is small, so the inductance of this type of reactor is small and stable, with a large volume and high material consumption. Iron-core reactors have a core with high magnetic permeability, so more magnetic flux is generated by unit current in the winding, that is, the inductance is larger. The reactance of iron-core reactors can be expressed by the following formula: X = ωN2Sμμ0 / l (1) where: X is reactance, ω is angular frequency, N is number of turns, S is cross-sectional area of ​​magnetic circuit, μ is core magnetic permeability, μ0 is air magnetic permeability, and l is average magnetic circuit length.

[0005] In the case of a given reactor, the angular frequency ω, number of turns N, magnetic circuit cross-sectional area S, and air permeability μ0 are all constants, while the iron core permeability μ in the iron core changes with the current passing through the iron core reactor, causing the reactance X to also change with the current. Therefore, the inductance value of the iron core reactor is not stable. The iron core reactor with an air gap combines the advantages of the above two reactors and has an iron core with high magnetic permeability, so the inductance value is large and the volume is small. Moreover, the air gap in the iron core column makes the inductance value of the reactor basically not change with the change of the current passing through. Therefore, the inductance value of the iron core reactor with an air gap is large and stable, and the height of the air gap between the iron core cakes can be adjusted to change the inductance value of the iron core reactor with an air gap. Therefore, the iron core reactor with an air gap has a wide range of applications.

[0006] Although the iron core reactor with air gap can obtain a larger and more stable inductance value, its iron core column is composed of a plurality of iron core cakes and an air gap arranged between each two adjacent iron core cakes connected in series. The iron core cakes and the air gap will inevitably produce vibration and noise under the action of magnetostrictive force. If such vibration and noise cannot be effectively controlled, it will bring great safety hazards to the operation of the iron core reactor with air gap.

[0007] In the existing technology center, the iron core reactor with air gap generally adoptsFigure 1 The solid structure shown in the figure: 1-nut; 2-upper yoke; 3-iron core; 4-air gap; 5-clamp; 6-lower yoke; 7-double-headed screw; 8-coil; 9-lower yoke pad; 10-support plate; 11-upper yoke pad.

[0008] Traditional crafts: Figure 2 As shown, the core column is composed of a plurality of core cakes 3 and an air gap 4 between two adjacent core cakes, which are connected in series in sequence. The two sides of the core column are clamped with a clamping plate 5, and the outside is tied firmly with a heat shrink tape or a weft-free tape (or cast into one piece with epoxy resin). The upper iron yoke 2 and the lower iron yoke are respectively placed at the upper and lower ends of the core column. The double-headed screw 7 passes through the addition holes of the upper iron yoke 2 and the iron yoke 6 to connect the upper iron yoke 2, the core column and the lower iron yoke 6 into one.

[0009] After the core column and the lower iron yoke 6 are fixed, the lower yoke pad 9 is placed, and the cast coil 8 is put on the core column, and the support plate 10 is used to tighten the inside to prevent the coil and the core from shifting. The end of the support plate 10 is sloped, which is convenient for inserting the upper iron yoke 2. The upper iron yoke pad 11 is placed, and the upper iron yoke 2, the core column, the coil 8 and the lower iron yoke 6 are tightened with the double-headed screw 7. Thereby achieving the purpose of controlling the amplitude of the vibration of the core cake 3, fixing the position of the coil 8 and the core column to eliminate the influence of noise, but this fixed structure has the following defects.

[0010] a. The fixing structure controls the vibration of the core cake by the pressing force applied by tightening the nut 1, and the core cake 3 is loosened and displaced by the magnetostriction.

[0011] b. The fixing force of the support plate 10 is difficult to control. A large support force may damage the internal insulation of the coil 8 to the ground; a small support force may not achieve the fixing effect.

[0012] c. When inserting the upper iron yoke 2, the insulation to the ground is easily damaged, affecting the electrical performance of the reactor.

[0013] d. The core column casting process is complicated and the labor cost is high.

[0014] e. The heat between the coil 8 and the core column is mutually conductive, which is not conducive to heat dissipation and causes the temperature of the reactor to rise. Summary of the invention

[0015] The purpose of the present invention is to overcome the deficiencies of the above-mentioned technology and provide a new structure of an iron core reactor.

[0016] In order to achieve the above-mentioned purpose, the present invention adopts the following technical scheme: a new structure of an iron core inductor, characterized in that it includes an iron core column, an earth insulation cylinder, an insulating cylinder, an airway and a coil; the iron core column, the earth insulation cylinder, the insulating cylinder, the airway and the coil are cast into one body, the iron core column is located in the center, the insulating cylinder is provided with an airway, the earth insulation cylinder is arranged on the outside of the iron core column, the insulating cylinder is arranged on the outside of the earth insulation cylinder, and the coil is wound around the outside of the insulating cylinder.

[0017] A method for manufacturing a new structure of an iron core reactor, characterized in that it comprises the following steps: 1. Welding a transmission shaft and a mold plate firmly; laying a silicone rubber pad on the mold plate;

[0018] 2. The lower boss is fixed to the mold plate with screws;

[0019] 3. The airway plate is fixed vertically to the mold plate;

[0020] 4. Place the required air gap plate and discus on the lower boss as required;

[0021] 5. Put the boss on when the height of the discus and the air gap plate meet the drawing dimensions;

[0022] 6. Place reinforcing channel steel on the upper boss;

[0023] 7. After shaping with some strength, the core column is perpendicular to the mold plate, support plates are placed on both sides, and tied to the core column with a non-weft belt;

[0024] 8. Tighten the clamping channel steel nut and measure the core column size;

[0025] 9. Wrap three layers of 1mm thick mesh on the outside of the core column, lay the core column flat after wrapping it tightly, and then fix the core column to the horizontal winding machine;

[0026] 10. Winding of the main airway: After completing item 9, place the lead-out braces, and evenly distribute the lead-out braces; then wind the grid around the lead-out braces, and then place the lead-out braces;

[0027] 11. After completing item 10, place the grid and then wind the coil;

[0028] 12. After winding the coil, seal the mold and cast it. After the casting solidifies, pull out the guide support bar and airway plate and grind them into shape.

[0029] The beneficial effects of the present invention are as follows: compared with the prior art, the new technology of casting the ground insulation, airway, insulation tube and coil at one time by adopting this new iron core has significantly improved the product quality, reduced the inner film of the reactor, saved the stays, saved materials and time, and the insulation tube between the iron core and the coil is conducive to heat dissipation, effectively reducing the iron core noise and eliminating the hidden danger of iron core deviation. The reactor coil is light in weight, the upper and lower yoke pads can be omitted, and the short-circuit resistance is strong. After a long period of production practice, it has been well received by users. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Figure 1 It is a structural schematic diagram of the prior art;

[0031] Figure 2 It is an assembly effect diagram of the prior art;

[0032] Figure 3a is a cross-sectional view of the core column of the present invention;

[0033] Figure 3b yes Figure 3a Sectional view at AA in the middle;

[0034] Figure 4a is a top view of the core column of the present invention;

[0035] Figure 4b yes Figure 4a A top view of

[0036] Figure 5a It is a layout diagram of ground insulation, air duct, insulation cylinder and coil in the present invention;

[0037] Figure 5b yes Figure 5a A top view of

[0038] Figure 6 is a top view of the present invention;

[0039] Figure 7 yes Figure 6 A cross-sectional view of

[0040] Figure 8 This is the structural diagram of the iron core reactor without pads;

[0041] Fig. 9 This is the structural diagram of the iron core reactor pad. DETAILED DESCRIPTION

[0042] The specific implementation of the present invention is described in detail below with reference to the accompanying drawings and preferred embodiments.

[0043] like Figure 3a-Figure 5bAs shown, a new structure of an iron core reactor includes an iron core column (discus) 1', an earth insulation cylinder 2', an insulation cylinder 3', an airway 4' and a coil 5'; the iron core column, the earth insulation cylinder, the insulation cylinder, the airway and the coil are cast as one body, the iron core column is located in the center, the insulation cylinder is provided with an airway, the earth insulation cylinder is arranged on the outside of the iron core column, the insulation cylinder is arranged on the outside of the earth insulation cylinder, and the coil is wound on the outside of the insulation cylinder. After the iron core column is fixed, it is installed on a horizontal winding machine, the earth insulation grid is wound, the lead-pull support bar is placed, the insulation cylinder grid is wound, the lead-pull support bar is placed, the insulation grid inside the coil is placed, the coil is wound according to the drawing, and the outer mold is installed and then cast. After molding, the mold is removed, and the upper and lower yokes are installed according to the reactor process. The iron core coil is cast in one time, eliminating the inner mold of the reactor to save costs.

[0044] In the figure: 01, transmission shaft; 02, mold plate; 03, silicone rubber pad; 04, lower boss; 05, airway plate; 06, air gap plate; 7, discus; 08, upper boss; 09, fixed channel steel; 10, nut; 11, support plate; 12, ground grid; 13, pull-out support bar; 14, insulation tube grid; 15, coil insulation grid; 16, wire.

[0045] 1. The transmission shaft and the mold plate are welded firmly; the silicone rubber pad is laid flat on the mold plate.

[0046] 2. Fix the lower boss to the mold plate with screws.

[0047] 3. The airway plate is fixed vertically to the mold plate. ( Figure 3a-4b )

[0048] 4. Place the required air gap plate and discus on the lower boss as required. (The heights of the three core columns must be the same)

[0049] 5. Put the boss on when the discus and air gap plate are in accordance with the drawing dimensions. (Place the grounding sheet on one side)

[0050] 6. Place the reinforcing channel steel on the upper boss. Open a positioning hole in the middle of the reinforcing channel steel and fixation holes at both ends. Fix it with clamping channel steel.

[0051] 7. After some strength, shape the core column perpendicular to the mold plate, place support plates on both sides, and tie it to the core column with a non-weft belt.

[0052] 8. Tighten the clamping channel nut and measure the core column size.

[0053] 9. Wrap three layers of 1mm thick mesh on the outside of the core column. (The height of the mesh is equal to the height of the coil) After wrapping tightly, lay the core column flat, and then fix the core column to the horizontal winding machine.

[0054] 10. Winding of the main airway. After completing item 9, place the lead-out brace, and evenly distribute the lead-out brace. Then wind the grid around the lead-out brace, and then place the lead-out brace.

[0055] 11. Coil winding. After completing item 10, place the grid (DMD can be added inside to strengthen the bonding), and then wind the coil. (The coil winding process is the same as the iron core reactor design specification)

[0056] 12. After winding the coil, seal the mold and cast. After the casting solidifies, pull out the guide support bar and airway plate and grind them into shape. Figure 6 and Figure 7 .

[0057] like Figure 8 and Fig. 9 , is an assembly effect diagram. The technical solution of the present invention is to scientifically cast the iron core column, ground insulation, insulation tube, airway and coil of the iron core reactor into one body; the ground insulation is strengthened, and the insulation tube effectively prevents the heat between the iron core and the coil from conducting each other, forming an independent heat dissipation system and reducing the temperature rise.

[0058] The assembly of small and medium-sized reactors eliminates the need for upper and lower iron yoke pads. Long holes are opened in the lower clamps of large-capacity reactors, and tightening screws are used to strengthen the fixation of the coil.

[0059] The above is only a preferred embodiment of the present invention. It should be pointed out that for ordinary technicians in this technical field, several improvements and modifications can be made without departing from the principle of the present invention. These improvements and modifications should also be regarded as the scope of protection of the present invention.

Claims

1. A method for manufacturing a novel structure of an iron core reactor, characterized in that: It includes an iron core column, an earth insulation cylinder, an insulation cylinder, an airway and a coil; the iron core column, the earth insulation cylinder, the insulation cylinder, the airway and the coil are cast into one piece, the iron core column is located in the center, the insulation cylinder is provided with an airway, the earth insulation cylinder is arranged outside the iron core column, the insulation cylinder is arranged outside the earth insulation cylinder, and the coil is wound outside the insulation cylinder; it includes the following steps:

1. The transmission shaft and the mold plate are welded firmly; the silicone rubber pad is laid flat on the mold plate; 2. The lower boss is fixed to the mold plate with screws; 3. The airway plate is fixed vertically to the mold plate; 4. Place the required air gap plate and discus on the lower boss as required; 5. Put the boss on when the height of the discus and the air gap plate meet the drawing dimensions; 6. Place reinforcing channel steel on the upper boss; 7. After shaping with some strength, the core column is perpendicular to the mold plate, support plates are placed on both sides, and tied to the core column with a non-weft belt; 8. Tighten the clamping channel steel nut and measure the core column size; 9. Wrap three layers of 1mm thick mesh on the outside of the core column, lay the core column flat after wrapping it tightly, and then fix the core column to the horizontal winding machine; 10. Winding of the main airway: After completing item 9, place the lead-out braces, and evenly distribute the lead-out braces; then wind the grid around the lead-out braces, and then place the lead-out braces; 11. After completing item 10, place the grid and then wind the coil; 12. After winding the coil, seal the mold and cast it. After the casting solidifies, pull out the guide support bar and airway plate and grind them into shape.

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