A special insulation vertically wound reactor

Abstract

The present invention provides a special-insulation vertically wound reactor, which reduces the coil temperature rise under high flow conditions, and also reduces the overall cost and reliability of the reactor. The reactor comprises: a pair of clamping frames, including a first clamping frame and a second clamping frame; a plurality of vertically wound coil assemblies, each of which comprises a metal core, a vertical coil on the periphery, and a lateral protruding connecting frame. The vertical coil is wound around the periphery of the metal core according to the number of turns. Lateral protruding connecting frames are provided on both sides of the integral body formed by the metal core and the vertical coil, and the lateral protruding connecting frames are used to secure the vertical coil assembly to the corresponding clamping frame. The vertical coil is wound from bare metal wire, with a distance between each turn of the coil. An insulating layer is provided on the periphery of the bare metal wire corresponding to the vertical coil. The first and second clamping frames are arranged facing each other, and a cavity formed therebetween contains a plurality of vertically wound coil assemblies arranged in sequence along the length direction. The first and second clamping frames are connected by a pull screw.

Description

Technical Field

[0001] The present invention relates to the technical field of module transportation, in particular to a special-insulated vertically wound reactor. Background Art

[0002] In recent years, with the widespread application of high-power power electronic equipment, the demand for high-current reactors has increased. At present, the coils of high-current reactors are generally foil-wound structures or vertically wound structures. Each layer of the foil-wound coil winding needs to be protected by interlayer insulation paper. Since interlayer insulation must be placed between each layer of copper / aluminum foil, the operating efficiency is relatively low, which increases the cost of insulation materials. At the same time, in the foil-wound coil structure, the thermal conductivity of the insulating material is relatively low, resulting in a decrease in the overall heat dissipation capacity of the coil; the conventional vertically wound coil has a better heat dissipation capacity, but the insulation layer of the vertically wound wire is easily damaged, and the material scrap rate during the coil winding process is about 10%; at the same time, due to the constraints of material processing technology, the size of the vertically wound insulation wire cannot be too large, and the general wire cross-sectional area can only be 100mm 2 the following. Summary of the Invention

[0003] In view of the above problems, the present invention provides a special insulated vertically wound reactor, which reduces the coil temperature rise of the reactor under large flow, and has low cost and high reliability for the entire reactor.

[0004] A special-insulated vertically wound reactor, characterized in that it comprises:

[0005] A pair of clamping frames, including a first clamping frame and a second clamping frame;

[0006] Several vertical winding coil assemblies, each comprising a metal core, a vertical coil on the periphery, and a side-projecting connecting frame. The vertical coil is wound around the periphery of the metal core according to the number of turns. Side-projecting connecting frames are provided on both sides of the integral body formed by the combination of the metal core and the vertical coil. The side-projecting connecting frames are used to secure the vertical winding assembly to the clamping frame on the corresponding side.

[0007] The vertical coil is wound with a bare metal wire, with a distance between each turn of the coil, and an insulating layer is provided on the outer periphery of the bare metal wire corresponding to the vertical coil;

[0008] The first clamping frame and the second clamping frame are arranged facing each other, and a plurality of the vertically wound coil assemblies are arranged in sequence along the length direction in the cavity formed therebetween. The first clamping frame and the second clamping frame are connected by a pull screw to form a whole.

[0009] It is further characterized by:

[0010] The vertical coil is specifically formed by winding bare aluminum wire around a metal core. A number of insulating bars are arranged between adjacent turns along the length of the turns to ensure that the shape of the vertical coil is stable and reliable. The insulating bars are arranged at intervals to ensure that there is sufficient heat dissipation space.

[0011] The upper and lower parts of both sides of the integral body formed by the combination of the metal core and the vertical coil are respectively provided with side convex connecting frames, and corresponding positioning holes are provided on the side convex connecting frames. Positioning grooves are respectively provided on the corresponding inner walls of the first clamping frame and the second clamping frame. The vertically arranged through-core screws pass through the mounting holes and then pass through the positioning holes on the upper and lower side convex connecting frames respectively, and are fixed by nuts to ensure the stable and reliable installation of the vertical winding coil assembly;

[0012] The upper and lower parts of the first and second clamping frames are respectively provided with clamping head positioning blocks arranged opposite to each other. The pull screw passes through the clamping head positioning blocks between the first and second clamping frames and is then fastened and clamped by bolts to ensure stable and reliable assembly.

[0013] The metal core is formed by splicing silicon steel sheets or is an integral silicon steel sheet structure;

[0014] Pull plates are fixed to the upper and lower surfaces of the metal core respectively, and both sides of the pull plates are convex to form the convex connecting frame. After the vertical coil is wound on the vertical structure formed by the metal core and the pull plates, plug-in fasteners are inserted into the corresponding four side positions to ensure that the assembly of the vertical coil is stable and reliable.

[0015] After adopting the above structure of the present invention, since the wire is a bare metal wire without an insulating coating, the metal wire specification is no longer restricted by the processing technology, and the metal wire specification can reach a cross-sectional area of 150mm 2 ~200mm 2 , the loss of coil conductor is greatly reduced, thereby reducing the temperature rise of the product; at the same time, the raw material wire is a bare metal wire without an insulating coating, so the wire processing fee is low, 30% lower than that of conventional vertically wound insulated wire. After the coil is wound and formed, the entire coil is insulated by spraying or dipping the insulation layer. This insulation treatment method eliminates the possibility of damaging the coil insulation layer during the conventional winding process, greatly improving the insulation reliability; it reduces the coil temperature rise of the reactor under large flow, and the cost of the entire reactor is low and the reliability is high. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 It is a structural schematic diagram of the present invention;

[0017] Figure 2 for Figure 1 Schematic diagram of the main view structure;

[0018] Figure 3It is a schematic diagram of the three-dimensional structure of the vertical winding coil assembly of the present invention;

[0019] Figure 4 for Figure 3 Schematic diagram of the main view structure;

[0020] The names corresponding to the serial numbers in the figure are as follows:

[0021] The first clamping frame 10, the clamping head positioning block 11, the supporting foot 12, the positioning mounting hole 13, the second clamping frame 20, the coil assembly 30, the metal core 40, the vertical coil 50, the pull screw 60, the insulating support bar 70, the through screw 80, the pull plate 90, the positioning hole 91, and the plug-in fastener 100. DETAILED DESCRIPTION

[0022] A special insulated vertically wound reactor, see Figures 1-4 , which includes:

[0023] A pair of clamping frames, including a first clamping frame 10 and a second clamping frame 20;

[0024] Several vertical coil assemblies 30, each comprising a metal core 40, a vertical coil 50 on the periphery, and a side-projecting connecting frame. The vertical coil 50 is wound around the periphery of the metal core 40 according to the number of turns. Side-projecting connecting frames are provided on both sides of the integral body formed by the metal core 40 and the vertical coil 50. The side-projecting connecting frames are used to secure the vertical coil assembly 30 to the corresponding side clamping frame.

[0025] The vertical coil 50 is wound with bare metal wire, and the distance between each turn of the coil is small. The outer periphery of the bare metal wire corresponding to the vertical coil 50 is provided with an insulating layer. In a specific implementation, the vertical coil 50 is sprayed or dipped with an insulating layer after being wound and formed.

[0026] The first clamping frame 10 and the second clamping frame 20 are arranged facing each other, and a plurality of vertically wound coil assemblies 30 are arranged in sequence along the length direction in the cavity formed therebetween. The first clamping frame 10 and the second clamping frame 20 are connected by a pull screw 60 to form a whole.

[0027] The vertical coil 50 is specifically formed by winding bare aluminum wire vertically around the metal core 40. A number of insulating struts 70 are arranged between adjacent turns along the length direction of the turns to ensure that the shape of the vertical coil 50 is stable and reliable. The insulating struts 70 are arranged at intervals to ensure that there is sufficient space for heat dissipation.

[0028] In a specific implementation, the upper and lower parts of both sides of the integral body formed by the combination of the metal core 40 and the vertical coil 50 are respectively provided with side convex connecting frames, and corresponding positioning holes 91 are provided on the side convex connecting frames. Positioning grooves are respectively provided on the corresponding inner walls of the first clamping frame 10 and the second clamping frame 20. The vertically arranged through-core screw 80 passes through the mounting hole and then passes through the positioning holes 91 on the upper and lower side convex connecting frames respectively, and is fixed by nuts to ensure the stable and reliable installation of the vertical winding coil assembly 30.

[0029] The upper and lower parts of the first clamping frame 10 and the second clamping frame 20 are respectively provided with clamping head positioning blocks 11 arranged opposite to each other. The pulling screw 60 passes through the clamping head positioning blocks 11 between the first clamping frame 10 and the second clamping frame 20 and is then fastened and clamped by bolts to ensure stable and reliable assembly;

[0030] The metal core 40 is formed by splicing silicon steel sheets or is an integral silicon steel sheet structure;

[0031] Pull plates 90 are fixed to the upper and lower surfaces of the metal core 40, and both sides of the pull plates 90 are convex to form convex connecting frames. After the vertical coil 50 is wound around the vertical structure formed by the metal core 40 and the pull plates 90, plug-in fasteners 100 are inserted into the corresponding four side positions to ensure that the assembly of the vertical coil is stable and reliable. In a specific embodiment, the plug-in fasteners 100 are dog-bone structures.

[0032] In the specific implementation, it is a three-phase reactor. Three sets of vertical coil assemblies 30 are arranged in sequence along the length direction in the cavity formed between the first clamping frame 10 and the second clamping frame 20. The vertical coil 50 on each set of vertical coil assembly 30 is 30*5mm (150mm 2 ) bare aluminum wire is vertically wound and then subjected to insulation spraying treatment. Insulating stays 70 are added between turns to increase the heat dissipation area, which is beneficial to the heat dissipation of the product. The spacing between adjacent turns is 3mm; the bottom of the first clamping frame 10 and the second clamping frame 20 is also provided with supporting feet 12, and the supporting feet 12 are provided with positioning mounting holes 13 to facilitate the convenient installation of the entire inductor.

[0033] The beneficial effects are as follows: 1. Since the wire is a bare metal wire without an insulating coating, the metal wire specification is no longer restricted by the processing technology, and the metal wire specification can reach a cross-sectional area of 150mm 2 ~200mm 2, the loss of the coil conductor is greatly reduced, thereby reducing the temperature rise of the product; 2 The raw material wire is a bare metal wire without an insulating coating, so the wire processing fee is low, 30% lower than that of conventional vertically wound insulated wire; 3 After the coil is wound and formed, the entire coil is insulated by spraying or dipping the insulation layer. This insulation treatment method does not have the possibility of damaging the coil insulation layer during the conventional winding process, which greatly improves the insulation reliability; 4 Insulating supports are added between the turns of the vertically wound coil to further improve the heat dissipation capacity; and through actual tests, under the same conditions, the inductor of this technology is compared with the inductor of the prior art, and the comprehensive cost is reduced by 20% or more, and the temperature rise is reduced by more than 30% under air-cooling conditions.

[0034] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above and that the invention can be embodied in other specific forms without departing from the spirit or essential characteristics of the invention. Therefore, the embodiments should be considered in all respects as illustrative and non-restrictive, and the scope of the invention is defined by the appended claims, not the foregoing description, and all variations within the meaning and range of equivalents of the claims are intended to be included therein. Any reference sign in a claim should not be construed as limiting the claim to which it relates.

[0035] In addition, it should be understood that although this specification is described in terms of implementation methods, not every implementation method contains only one independent technical solution. This narrative method of the specification is only for the sake of clarity. Those skilled in the art should regard the specification as a whole. The technical solutions in each embodiment can also be appropriately combined to form other implementation methods that can be understood by those skilled in the art.

Claims

1. A special-insulated vertically wound reactor, characterized in that: It includes: A pair of clamping frames, including a first clamping frame and a second clamping frame; Several vertical winding coil assemblies, each comprising a metal core, a vertical coil on the periphery, and a side-projecting connecting frame. The vertical coil is wound around the periphery of the metal core according to the number of turns. Side-projecting connecting frames are provided on both sides of the integral body formed by the combination of the metal core and the vertical coil. The side-projecting connecting frames are used to secure the vertical winding assembly to the clamping frame on the corresponding side. The vertical coil is wound with a bare metal wire, with a distance between each turn of the coil, and an insulating layer is provided on the outer periphery of the bare metal wire corresponding to the vertical coil; The first clamping frame and the second clamping frame are arranged facing each other, and a plurality of the vertically wound coil assemblies are arranged in sequence along the length direction in the cavity formed therebetween. The first clamping frame and the second clamping frame are connected by a pull screw to form a whole.

2. A special-insulation vertically wound reactor according to claim 1, characterized in that: The vertical coil is specifically formed by vertically winding a bare aluminum wire around a metal core, and a plurality of insulating stays are arranged at intervals along the length direction of the turns between adjacent turns.

3. The vertically wound reactor with special insulation according to claim 1, characterized in that: The upper and lower parts of both sides of the whole formed by the combination of the metal core and the vertical coil are respectively provided with side convex connecting frames, and corresponding positioning holes are provided on the side convex connecting frames. Positioning grooves are respectively provided on the corresponding inner walls of the first clamping frame and the second clamping frame. The vertically arranged through-core screws pass through the mounting holes and then pass through the positioning holes on the upper and lower side convex connecting frames respectively, and are fixed by nuts.

4. A vertically wound reactor with special insulation according to claim 1, characterized in that: The upper and lower parts of the first clamping frame and the second clamping frame are respectively provided with clamping head positioning blocks arranged opposite to each other. The pulling screw passes through the clamping head positioning blocks between the first clamping frame and the second clamping frame and is then fastened and clamped by bolts.

5. The vertically wound reactor with special insulation according to claim 1, characterized in that: The metal core is formed by splicing silicon steel sheets or is an integral silicon steel sheet structure.

6. A vertically wound reactor with special insulation according to claim 3, characterized in that: Pull plates are fixed on the upper and lower surfaces of the metal core respectively, and both sides of the pull plates are convex to form the convex connecting frame. After the vertical coil is wound around the vertical structure formed by the metal core and the pull plates, plug-in fasteners are inserted corresponding to the four side positions.

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