Core body, reactor, and method for manufacturing reactor

Abstract

The present invention provides a core body, a reactor and a method for manufacturing a reactor. Its operability will not be reduced during transportation and installation. The core body includes a peripheral iron core and at least three iron cores. A gap that enables magnetic coupling is formed between two adjacent iron cores. The peripheral iron core includes a first peripheral iron core block and a second peripheral iron core block formed by stacking a plurality of magnetic plates, and an intermediate plate arranged between these peripheral iron core blocks. The intermediate plate includes a corresponding portion of the peripheral iron core corresponding to the peripheral iron core, a plurality of protrusions protruding from the outer peripheral surface of the peripheral iron core, and a snap-fit ​​portion provided on the plurality of protrusions.

Description

Technical Field

[0001] The present invention relates to a core body, a reactor, and a method for manufacturing the reactor. Background Art

[0002] In recent years, a reactor having a core body has been developed, the core body including an outer peripheral iron core and a plurality of iron cores arranged inside the outer peripheral iron core. Coils are installed on each of the plurality of iron cores. The core body of such a reactor is sandwiched between an end plate and a base. Refer to, for example, Japanese Patent Publication No. 2019-029449. Summary of the invention

[0003] Problem that the invention aims to solve

[0004] Generally, the reactor is installed on a vertical surface, such as a wall of a switchboard. In this case, a wire or the like is inserted into an opening formed at a corner of an end plate, the reactor is lifted and transported to a desired position, and then the base of the reactor is installed on the vertical surface.

[0005] However, since the end plate is mounted at one end of the core body, the end plate is located away from the center of gravity of the reactor. Therefore, when the reactor is lifted, the reactor tilts, resulting in a problem of reduced operability during transportation and installation on a vertical surface. In addition, even when only the core body with the end plate mounted is lifted, the core body tilts, causing the same problem.

[0006] Therefore, a core body, a reactor, and a method for manufacturing such a reactor in which workability during transportation and installation is not reduced are desired.

[0007] Solutions for solving problems

[0008] According to the first technical solution, a core body is provided, which includes: an outer peripheral iron core; and at least three iron cores, which are arranged on the inner side of the outer peripheral iron core, and the radial inner ends of each of the at least three iron cores converge toward the center of the outer peripheral iron core, and a gap capable of magnetic coupling is formed between one of the at least three iron cores and another iron core adjacent to the one iron core, and the radial inner ends of the at least three iron cores are separated from each other by the gap capable of magnetic coupling, and at least the outer peripheral iron core includes: a first outer peripheral iron core block formed by stacking a plurality of magnetic plates, a second outer peripheral iron core block formed by stacking a plurality of magnetic plates, and an intermediate plate arranged between the first outer peripheral iron core block and the second outer peripheral iron core block, and the intermediate plate includes: a corresponding portion of the outer peripheral iron core corresponding to the outer peripheral iron core, a plurality of protrusions protruding from the outer peripheral surface of the outer peripheral iron core, and a snap-fit ​​portion provided on the plurality of protrusions.

[0009] According to a second technical solution, in the first technical solution, the first peripheral core block and the second peripheral core block include a plurality of peripheral core partial blocks, and the intermediate plate includes a plurality of intermediate plate portions respectively corresponding to the plurality of peripheral core partial blocks.

[0010] According to a third technical solution, in the first technical solution, the intermediate plate further includes an iron core corresponding portion corresponding to the at least three iron cores.

[0011] According to a fourth aspect, there is provided a reactor comprising: the core body according to any one of the first to third aspects; coils respectively mounted on the at least three cores; and a base mounted on one end of the core body.

[0012] According to a fifth aspect, in the fourth aspect, the position of the engagement portion in the axial direction of the reactor is set to be substantially the same as the position of the center of gravity of the reactor.

[0013] According to a sixth technical solution, in the fourth or fifth technical solution, the number of the coils is a multiple of three.

[0014] According to a seventh technical solution, in the fourth or fifth technical solution, the number of the coils is an even number greater than 4.

[0015] According to the eighth technical solution, a method for manufacturing a reactor is provided, and the method for manufacturing a reactor manufactures the reactor according to the following contents: stacking a plurality of magnetic plates to form a plurality of first peripheral core part blocks, stacking a plurality of magnetic plates to form a plurality of second peripheral core part blocks, preparing a plurality of intermediate plate parts corresponding to each of the plurality of first peripheral core part blocks, arranging each of the plurality of intermediate plate parts on each of the plurality of second peripheral core part blocks, arranging each of the plurality of first peripheral core part blocks on each of the plurality of intermediate plate parts, and forming a plurality of peripheral core parts having at least three cores, installing coils on the at least three cores respectively, assembling the plurality of peripheral core parts to each other to form a core body, installing a base at one end of the core body and fixing the core body and the base to each other.

[0016] Effects of the Invention

[0017] In the first and eighth technical solutions, since the intermediate plate is disposed between the first peripheral core block and the second peripheral core block, the engaging portion of the intermediate plate is close to the center of gravity of the core body. Therefore, when the core body is lifted using the engaging portion, the core body hardly tilts. Therefore, it is possible to suppress a reduction in operability during transportation and installation.

[0018] In the second aspect, a large outer peripheral core can be easily manufactured without reducing the workability during transportation and installation.

[0019] In the third aspect, it is possible to suppress the generation of noise due to vibration of the iron core when the reactor including the core body is driven.

[0020] In the fourth aspect, it is possible to suppress a decrease in workability when transporting and installing the reactor.

[0021] In the fifth aspect, it is possible to further suppress a decrease in workability when transporting and installing the reactor.

[0022] In the sixth aspect of the present invention, the reactor can be used as a three-phase reactor.

[0023] In the seventh aspect, the reactor can be used as a single-phase reactor. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] The objects, features and advantages of the present invention will become more apparent from the following description of the embodiments with reference to the accompanying drawings.

[0025] Figure 1A This is an exploded perspective view of the reactor according to the first embodiment.

[0026] Figure 1B yes Figure 1A A perspective view of the reactor shown.

[0027] Figure 2 This is a cross-sectional view of a core body included in the reactor according to the first embodiment.

[0028] Figure 3 This is another perspective view of the reactor according to the first embodiment.

[0029] Figure 4 It is a perspective view of a reactor in the prior art.

[0030] Figure 5A It is a perspective view of another middle plate.

[0031] Figure 5B This is the first diagram showing a method for manufacturing a reactor.

[0032] Figure 5C This is a second diagram showing a method for manufacturing a reactor.

[0033] Figure 5D It is a three-dimensional diagram of another middle plate.

[0034] Figure 6 This is a cross-sectional view of a core body included in the reactor according to the second embodiment. DETAILED DESCRIPTION

[0035] 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.

[0036] In the following description, a 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, but can be widely applied to multi-phase reactors that require a certain inductance in each phase. In addition, the reactor of the present disclosure is not limited to the reactor provided on the primary side and the secondary side of the inverter of an industrial robot or a machine tool, but can be applied to various equipment.

[0037] Figure 1A is an exploded perspective view of the reactor according to the first embodiment, Figure 1B yes Figure 1A A perspective view of the reactor shown. Figure 1A as well as Figure 1B The reactor 6 shown mainly includes a core body 5 and a base 60 mounted on one end of the core body 5 .

[0038] The core body 5 includes: a first peripheral core block 20A, a second peripheral core block 20B, and an intermediate plate 81 sandwiched between the first peripheral core block 20A and the second peripheral core block 20B. The first peripheral core block 20A and the second peripheral core block 20B are each formed by stacking a plurality of magnetic plates, such as iron plates, carbon steel plates, and electromagnetic steel plates, in the axial direction of the reactor 6. The magnetic plates used to form the first peripheral core block 20A and the magnetic plates used to form the second peripheral core block 20B are the same as each other. In addition, the number of magnetic plates stacked by the first peripheral core block 20A and the second peripheral core block 20B can be the same as each other or different from each other. If the first peripheral core block 20A, the intermediate plate 81, and the second peripheral core block 20B are assembled in the axial direction, the peripheral core 20 is formed.

[0039] The intermediate plate 81 includes: an outer peripheral core corresponding portion 82 corresponding to the outer peripheral core 20, a plurality of protrusions 91 protruding from the outer peripheral surface of the outer peripheral core 20, and a snap-fit ​​portion 91a provided on the plurality of protrusions. The opening 89 formed in the intermediate plate 81 has a shape substantially corresponding to the inner peripheral surface of the outer peripheral core 20. The intermediate plate 81 is preferably formed of a non-magnetic material.

[0040] The base 60 is in contact with the peripheral core 20 in a manner that covers the entire edge of the end surface of the peripheral core 20 of the core body 5. The base 60 is preferably formed of a non-magnetic material such as aluminum, SUS, and resin. An opening 69 is formed in the base 60, and the opening 69 has a shape suitable for supporting the end surface of the core body 5. The opening 69 formed in the base 60 and the opening 89 formed in the intermediate plate 81 are set to be large enough so that the coils 51 to 53 (described later) protrude from the end surface of the core body 5. In addition, the height of the base 60 is set to a height slightly longer than the protruding height of the coils 51 to 53 protruding from the end of the core body 5. The notch 65 formed on the lower surface of the base 60 is used to fix the reactor 6 having the base 60 at a predetermined position.

[0041] Figure 2 2 is a cross-sectional view of a core body included in the reactor according to the first embodiment. Figure 2 As shown in FIG. 1 , the core body 5 includes an outer peripheral iron core 20 and three iron core coils 31 to 33 that are magnetically coupled to the outer peripheral iron core 20. Figure 2 In the embodiment, core coils 31 to 33 are arranged inside the outer peripheral core 20 having a substantially hexagonal cross section. These core coils 31 to 33 are arranged at equal intervals in the circumferential direction of the core body 5. In addition, the outer peripheral core 20 may also be a circle or other substantially even-numbered polygon. In addition, it is preferred that the number of core coils is a multiple of 3, so that the reactor 6 can be used as a three-phase reactor.

[0042] As can be seen from the drawings, each core coil 31 to 33 includes cores 41 to 43 extending only along the radial direction of the outer peripheral core 20, and coils 51 to 53 mounted on the cores. The radial outer ends of each core 41 to 43 are in contact with the outer peripheral core 20, or are formed integrally with the outer peripheral core 20. That is, the cores 41 to 43 may also be components independent of the outer peripheral core 20. In addition, in some drawings, the coils 51 to 53 are omitted for simplicity.

[0043] In addition, Figure 2 In the embodiment, the peripheral core 20 is composed of a plurality of, for example, three, peripheral core parts 24 to 26 divided at equal intervals in the circumferential direction. The peripheral core parts 24 to 26 are respectively formed integrally with the cores 41 to 43. 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, through holes 29a to 29c are respectively formed in the peripheral core parts 24 to 26.

[0044] In such a case, Figure 1AAs shown, the first peripheral core block 20A is composed of a plurality of, for example, three, peripheral core blocks 20A1 to 20A3. Similarly, the second peripheral core block 20B is composed of a plurality of, for example, three, peripheral core blocks 20B1 to 20B3. The peripheral core blocks 20A1 to 20A3 and 20B1 to 20B3 are formed by stacking a plurality of magnetic plates, such as iron plates, carbon steel plates, and electromagnetic steel plates. In addition, it is also possible that only one of the first peripheral core block 20A and the second peripheral core block 20B is composed of a plurality of peripheral core blocks.

[0045] 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 top angle thereof is about 120 degrees. In addition, the radial inner ends of the iron cores 41 to 43 are separated from each other by gaps 101 to 103 that enable magnetic coupling.

[0046] 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 is true for the other cores 42 and 43. The gaps 101 to 103 are set to be equal in size.

[0047] As described above, in the present invention, since the central core located in the central part of the core body 5 is not required, the core body 5 can be constructed lightly and simply. Furthermore, 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, since the gaps 101 to 103 can be provided at any thickness at low cost, it is advantageous in design compared with the reactor of the conventional structure.

[0048] Furthermore, the difference in magnetic path length between phases is smaller in the reactor 6 of the present invention than in the reactor of the conventional structure. Therefore, the present invention can also reduce the imbalance of inductance caused by the difference in magnetic path length.

[0049] If you refer to Figure 1A as well as Figure 1B , the intermediate plate 81 includes a plurality of protrusions 91 that partially protrude in a direction away from the outer peripheral surface of the core body 5. In other words, the protrusions 91 extend radially outward relative to the central axis of the core body 5. An opening 91a serving as a snap-fit ​​portion is formed in each protrusion 91. In addition, through holes 81a to 81c are formed in the intermediate plate 81 corresponding to the through holes 29a to 29c of the outer peripheral iron core 20.

[0050] The protrusion 91 protrudes in correspondence with at least one side of a substantially regular even-numbered polygon, for example, a substantially hexagon. Figure 3 is another perspective view of the reactor based on the first embodiment. Figure 3 As shown, a linear body L such as a wire is inserted into the engaging portion 91a of the protruding portion 91 to lift up the reactor 6. In order to stably lift up the reactor 6, it is preferable that the intermediate plate 81 has at least two engaging portions 91a adjacent to each other.

[0051] In the present invention, since the intermediate plate 81 is arranged between the first peripheral core block 20A and the second peripheral core block 20B, the snap-fit ​​portion 91a of the intermediate plate 81 is close to the center of gravity of the core body 5. Therefore, when the reactor 6 is lifted using the snap-fit ​​portion 91a, the reactor 6 hardly tilts. Therefore, when the reactor 6 is transported and the reactor 6 is installed in a desired position, such as a vertical plane, the operability is not reduced. In order to achieve this purpose, it is preferred that the position of the opening portion 91a in the axial direction of the core body 5 is the same as the position of the center of gravity of the core body 5 or the reactor 6 in the axial direction.

[0052] In addition, when only lifting, transporting, or installing the core body 5, the decrease in operability can also be avoided. In addition, the protrusion 91 can also be partially bent relative to the end surface of the first peripheral core block 20A. Furthermore, other structures that engage with the linear body L, such as hooks, convex parts, etc., can also be used as engaging parts instead of the opening 91a.

[0053] Figure 4 This is a perspective view of a reactor of the prior art. In the prior art, an end plate 81' having a protrusion 91' is installed at the end of the reactor 6'. Since the end plate 81' is located at a position far from the center of gravity of the reactor 6', if the linear body L is passed through the opening 91a' and the reactor 6' is lifted, there is a problem that the reactor 6' tilts. The present invention solves such a problem.

[0054] In addition, by Figure 1A It can be seen that the footprint of the base 60 is a rectangle, which is a circumscribed rectangle circumscribing the outer periphery of the outer peripheral core 20. Therefore, the footprint of the base 60 is different from the outer peripheral shape of the core body 5, such as a substantially regular even-sided polygon or a circle. In such a case, it is preferred that at least one protrusion 91 protrudes within the footprint of the base 60.

[0055] In such a case, the protrusion 91 protrudes only to the outer edge of the base at most. Therefore, the footprint of the reactor 6 is equal to or smaller than the footprint of the base 60, and the reactor 6 can be prevented from being enlarged.

[0056] Figure 5A It is a perspective view of another middle plate. Figure 5AThe intermediate plate 81 shown is composed of a plurality of, for example, three, intermediate plate portions 84, 85, and 86. These intermediate plate portions 84 to 86 correspond to the outer peripheral core portions 24 to 26, respectively. In addition, each of the intermediate plate portions 84 to 86 has at least one protrusion 91. As described above, the intermediate plate 81 can be composed of a plurality of intermediate plate portions 84 to 86, or can be composed of a plurality of intermediate plate portions 84 to 86. Figure 1A It is understood that in such a structure, a large outer peripheral core 20 can be easily manufactured without reducing the workability during transportation and installation.

[0057] Figure 5B as well as Figure 5C FIG. 1 is a diagram showing a method for manufacturing a reactor. Figure 5B As shown in the figure, after the peripheral core blocks 20A1 and 20B1 are formed, the intermediate plate portion 84 is sandwiched between the peripheral core blocks 20A1 and 20B1 to form the peripheral core portion 24. Although not shown in the figure, the intermediate plate portions 85 and 86 are similarly sandwiched between the peripheral core blocks 20A2 and 20B2 and between the peripheral core blocks 20A3 and 20B3 to form the peripheral core portions 25 and 26, respectively.

[0058] Then, if Figure 5C As shown, the core 41 of the peripheral core portion 24 is inserted into the coil 51 to install the coil 51. Also, although not shown in the drawings, similarly, coils 52, 53 are also installed in the core 42 of the other peripheral core portion 25 and the core 43 of the peripheral core portion 26, respectively.

[0059] Then, these peripheral core parts 24 to 26 are assembled to each other. Next, screws or bolts (not shown) are inserted into the through holes 29a to 29c of the peripheral core 20 and the through holes 81a to 81c of the intermediate plate 81 and fastened to manufacture the core body 5. Thereafter, a base 60 is arranged at one end of the core body 5 and fastened with screws or bolts (not shown) in the same manner. Thus, the core body 5 and the base 60 are fixed to each other to manufacture the reactor 6. In order to achieve this purpose, a through hole may also be formed in the base 60.

[0060] Furthermore, Figure 5D It is a three-dimensional diagram of another middle plate. Figure 5D The intermediate plate 81 shown includes an iron core corresponding portion 83 corresponding to the iron cores 41 to 43 in addition to the outer peripheral iron core corresponding portion 82 and the protrusion 91. In this case, it is preferable that the intermediate plate 81 is formed of the same magnetic plate as the outer peripheral iron core 20 and the iron cores 41 to 43. Alternatively, a plurality of such magnetic plates may be stacked to form Figure 5DIn this case, no gap is formed between the first peripheral core block 20A and the second peripheral core block 20B. Therefore, it is possible to suppress the vibration of the cores 41 to 43 and the generation of noise when the reactor 6 is driven. Figure 5D As shown by the dotted lines in FIG. 8 , the intermediate plate 81 may also be composed of at least three intermediate plate parts 84 - 86 , and the at least three intermediate plate parts 84 - 86 all have an iron core corresponding part 83 .

[0061] Figure 6 This is a cross-sectional view of a core body included in the reactor according to the second embodiment. Figure 6 The core body 5 shown includes an outer peripheral iron core 20 having a substantially octagonal cross section, and four iron core coils 31 to 34, which are arranged inside the outer peripheral iron core 20 and are the same as the aforementioned iron core coils. These iron core coils 31 to 34 are arranged at equal intervals in the circumferential direction of the core body 5. In addition, it is preferred that the number of iron cores is an even number of 4 or more, thereby enabling the reactor having the core body 5 to be used as a single-phase reactor.

[0062] 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 mounted on the iron core. In addition, the radial outer end of each iron core 41 to 44 is formed integrally with each peripheral core part 24 to 27. In addition, through holes 29a to 29d similar to the aforementioned through holes are formed in the peripheral core parts 24 to 27. In addition, the number of iron cores 41 to 44 and the number of peripheral core parts 24 to 27 may not necessarily be the same. Figure 2 The same is true for the core body 5 shown.

[0063] 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. Figure 6 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 angle is about 90 degrees. The inner radial ends of the cores 41 to 44 are separated from each other by gaps 101 to 104 that enable magnetic coupling.

[0064] Figure 6 The dashed line shown in FIG. 8 corresponds to the intermediate plate 81 and the opening 89 thereof in the second embodiment. Figure 6 As shown in FIG. 1 , when the outer peripheral core 20 is substantially octagonal, four protrusions 91 protrude corresponding to the four sides of the substantially octagon. Even with such a structure, the linear body L can pass through the openings 91a of two adjacent protrusions 91 to lift the reactor 6, so it can be seen that the same effect as the above effect can be obtained. In addition, as Figure 6 As shown, the intermediate plate 81 may be composed of a plurality of intermediate plate portions 84 to 87 corresponding to the plurality of outer peripheral core portions 24 to 27. In this case, it is preferred that each of the intermediate plate portions 84 to 87 has an opening 91a as an engagement portion.

[0065] Although the embodiments of the present invention have been described above, it should be understood by those skilled in the art that various modifications and changes can be made without departing from the scope of the disclosure of the claims.

Claims

1. A core body, characterized in that: The core body comprises: an outer peripheral core; and at least three iron cores, which are arranged inside the outer peripheral iron core, The radial inner ends of the at least three cores converge toward the center of the outer peripheral core. A gap capable of magnetic coupling is formed between one of the at least three cores and another core adjacent to the one core, and the radial inner ends of the at least three cores are separated from each other by the gap capable of magnetic coupling. At least the peripheral core includes: a first peripheral core block formed by stacking a plurality of magnetic plates, a second peripheral core block formed by stacking a plurality of magnetic plates, and an intermediate plate disposed between the first peripheral core block and the second peripheral core block. The intermediate plate includes an outer peripheral core corresponding portion corresponding to the outer peripheral core, a plurality of protrusions protruding from an outer peripheral surface of the outer peripheral core, and engaging portions provided on the plurality of protrusions.

2. The core body according to claim 1, characterized in that The first peripheral core block and the second peripheral core block include a plurality of peripheral core partial blocks. The intermediate plate includes a plurality of intermediate plate portions respectively corresponding to the plurality of outer peripheral core section blocks.

3. The core body according to claim 1, characterized in that The middle plate further includes core corresponding portions corresponding to the at least three cores.

4. A reactor, characterized in that: The reactor has: The core body according to any one of claims 1 to 3; Coils, which are respectively mounted on the at least three cores; and A base is mounted on one end of the core body.

5. The reactor according to claim 4, characterized in that: The position of the engagement portion in the axial direction of the reactor is set to be substantially the same as the position of the center of gravity of the reactor.

6. The reactor according to claim 4 or 5, characterized in that: The number of the coils is a multiple of three.

7. The reactor according to claim 4 or 5, characterized in that: The number of the coils is an even number greater than 4.

8. A method for manufacturing a reactor, characterized in that: The manufacturing method of the reactor manufactures the reactor according to the following contents: A plurality of magnetic plates are stacked to form a plurality of first peripheral core blocks, A plurality of magnetic plates are stacked to form a plurality of second peripheral core blocks, preparing a plurality of intermediate plate portions corresponding to each of the plurality of first peripheral core portion blocks, The plurality of intermediate plate portions are arranged on the plurality of second peripheral core portion blocks, The plurality of first outer peripheral core sections are arranged on the plurality of intermediate plate sections to form a plurality of outer peripheral core sections having at least three cores. installing coils on the at least three cores respectively, The plurality of peripheral core parts are assembled to form a core body. A base is installed at one end of the core body and the core body and the base are fixed to each other.

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