Reactor

Abstract

Provided is a reactor which can be easily manufactured, transported, and installed, and which is provided with a core body including an outer peripheral iron core, at least three iron cores disposed so as to be in contact with or joined to the inner surface of the outer peripheral iron core, and coils wound around the iron cores. Gaps capable of being magnetically coupled are formed between one iron core of the at least three iron cores and other iron cores adjacent to the one iron core. The reactor is provided with an end plate attached to one end surface of the core body, and the end plate includes a protruding portion that partially protrudes in a direction away from the outer peripheral surface of the core body.

Description

[0001] This application is a divisional application of an application with a filing date of March 13, 2020, application number 202010175911.3, and invention name “Reactor”. Technical Field

[0002] The present invention relates to a reactor having an end plate. Background Art

[0003] The reactor includes a plurality of core coils, each core coil including an iron core and a coil wound around the iron core. A predetermined gap is formed between the plurality of cores. In addition, there is also a reactor in which a plurality of core coils are arranged inside the outer peripheral core. For example, refer to Japanese Patent Publication No. 2010-252539 and Japanese Patent Publication No. 2008-177500. Summary of the invention

[0004] Problem that the invention aims to solve

[0005] The outer peripheral core of the reactor is usually polygonal or circular, and no protrusions or the like are provided on the outer peripheral surface and end surface of the outer peripheral core in order to obtain a desired inductance. Therefore, it is difficult for an operator or a robot to hold the reactor.

[0006] In addition, the coil partially protrudes from the end surface of the outer peripheral core. However, when an operator or a robot holds the protruding portion of the coil, there is a possibility that the coil will be damaged. Therefore, it is not easy for an operator or a robot to manufacture, transport, and install the reactor.

[0007] Therefore, a reactor that can be easily manufactured, transported, and installed by a worker or a robot is desired.

[0008] Solutions for solving problems

[0009] According to the first technical solution of the present disclosure, there is provided an inductor, which includes a core body, the core body comprising: an outer peripheral iron core, at least three iron cores arranged in contact with or combined with the inner surface of the outer peripheral iron core, and a coil wound on the iron core, a gap capable of magnetic coupling is formed between one of the at least three iron cores and other iron cores adjacent to the one iron core, the inductor also includes an end plate installed on an end face of the core body, the end plate including a protrusion that locally protrudes in a direction away from the outer peripheral surface of the core body.

[0010] According to a second aspect, in the first aspect, the reactor further includes a pedestal fastened to the other end surface of the core body, and the protrusion extends within a range corresponding to a region from the outer peripheral surface of the outer peripheral core to the outer edge of the pedestal.

[0011] According to a third aspect, in the first or second aspect, an opening is formed in the protruding portion.

[0012] According to a fourth technical solution, in any one of the first to third technical solutions, the cross section of the outer peripheral core is a regular even-sided polygon, and the protrusion protrudes corresponding to at least one side of the regular even-sided polygon.

[0013] According to the fifth technical solution, in any one of the first to third technical solutions, the cross-section of the peripheral iron core is a regular even-numbered polygon, and the protrusion is configured not to protrude corresponding to at least one group of two opposing sides of the regular even-numbered polygon, but to protrude corresponding to the remaining sides of the regular even-numbered polygon.

[0014] According to a sixth aspect, in any one of the first to third aspects, the cross section of the outer peripheral core is a circle, and the protrusion protrudes corresponding to at least a portion of the circumference of the circle.

[0015] According to the seventh technical solution, in any one of the first to third technical solutions, the cross-section of the outer peripheral iron core is a circle, and the protrusion is set to not protrude corresponding to at least one group of arc portions facing each other in the diameter direction of the circumference of the circle, but protrude corresponding to the remaining arc portions of the circumference.

[0016] According to an eighth technical solution, in any one of the first to seventh technical solutions, the number of the at least three cores is a multiple of three.

[0017] According to a ninth technical solution, in any one of the first to seventh technical solutions, the number of the at least three cores is an even number greater than 4.

[0018] Effects of the Invention

[0019] In the first aspect, since the protrusion is provided on the end plate, an operator or a robot can hold the protrusion to easily manufacture, transport, install, etc. the reactor. Therefore, the operability and safety during manufacturing can be improved.

[0020] In the second technical solution, the protrusion extends within a range corresponding to the area from the outer peripheral surface of the outer peripheral core to the outer edge of the base. In other words, the protrusion can only protrude to the outer edge of the base at most. Therefore, the reactor can be prevented from being enlarged.

[0021] In the third aspect, by passing the wire through the opening, it is possible to improve convenience in manufacturing, transporting, installing, etc. of the reactor.

[0022] In the fourth aspect, since an operator or a robot can easily grip the protruding portion, operability and safety during manufacturing can be further improved.

[0023] In the fifth aspect, since the side of one reactor where the protrusion does not protrude is brought into contact with the side of another reactor where the protrusion does not protrude, a plurality of reactors can be adjacently arranged in parallel.

[0024] In the sixth technical solution, since an operator or a robot can easily grip the protruding portion, operability and safety during manufacturing can be further improved.

[0025] In the seventh aspect, since the portion of one reactor where the protrusion does not protrude is brought into contact with the portion of another reactor where the protrusion does not protrude, a plurality of reactors can be adjacently arranged in parallel.

[0026] In the eighth aspect of the present invention, the reactor can be used as a three-phase reactor.

[0027] In the ninth aspect of the present invention, the reactor can be used as a single-phase reactor. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] 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.

[0029] Figure 1A This is an exploded perspective view of the reactor according to the first embodiment.

[0030] Figure 1B yes Figure 1A A perspective view of the reactor shown.

[0031] Figure 2 This is a cross-sectional view of a core body included in the reactor according to the first embodiment.

[0032] Figure 3 It is a top view of the reactor according to the first embodiment.

[0033] Figure 4 It is a perspective view of a reactor according to another embodiment.

[0034] Figure 5 It is a cross-sectional view of a core body included in the reactor according to the second embodiment.

[0035] Figure 6 It is a perspective view of a reactor according to the third embodiment.

[0036] Figure 7 It is a cross-sectional view of a core body included in the reactor according to the third embodiment.

[0037] Figure 8 It is a cross-sectional view of a core body included in the reactor according to the fourth embodiment.

[0038] Fig. 9 It is a cross-sectional view of a core body included in a reactor according to the fifth embodiment. DETAILED DESCRIPTION

[0039] Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings. Corresponding components in all the drawings are denoted by common reference numerals.

[0040] 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 it 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 reactors provided on the primary side and the secondary side of the inverter of the industrial robot or machine tool, but can be applied to various devices.

[0041] 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 and Figure 1B The reactor 6 shown mainly includes a core body 5 and an annular end plate 81 and a base 60 fastened in a manner of axially sandwiching the core body 5. The end plate 81 and the base 60 are in contact with the outer peripheral core 20 of the core body 5 over the entire edge of the end surface of the outer peripheral core 20 described later.

[0042] Preferably, the end plate 81 and the base 60 are formed of non-magnetic materials such as aluminum, SUS, and resin. An opening 69 having an outer shape suitable for placing the end face of the core body 5 is formed on the base 60. The end plate 81 has an outer shape corresponding to a part of the end face of the peripheral iron core 20, and the shape of the opening 89 formed in the end plate 81 roughly corresponds to the inner peripheral face of the peripheral iron core 20. The opening 69 formed in the base 60 and the opening 89 formed in the end plate 81 are set large enough to allow the coils 51 to 53 (described later) to protrude from the end face of the core body 5. In addition, the height of the base 60 is set 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.

[0043] 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, 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 2In the embodiment, the 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, whereby the reactor 6 can be used as a three-phase reactor.

[0044] 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. The radially outer ends of the cores 41 to 43 are in contact with the outer peripheral core 20 or are formed integrally with the outer peripheral core 20. In addition, in some drawings, the coils 51 to 53 are omitted for simplicity.

[0045] In addition, Figure 2 In the embodiment, the outer peripheral core 20 is composed of a plurality of, for example, three, outer peripheral core portions 24 to 26 divided at equal intervals in the circumferential direction. The outer peripheral core portions 24 to 26 are integrally formed with the respective cores 41 to 43. In the case where the outer peripheral core 20 is composed of a plurality of outer peripheral core portions 24 to 26, it is possible to easily manufacture such an outer peripheral core 20 even if the outer peripheral core 20 is large. In addition, through holes 29a to 29c are formed in the outer peripheral core portions 24 to 26.

[0046] Furthermore, the radial inner ends of the cores 41 to 43 are located near the center of the outer peripheral core 20. In the figure, the radial inner ends of the cores 41 to 43 converge toward the center of the outer peripheral core 20, and the top angle is about 120 degrees. In addition, the radial inner ends of the cores 41 to 43 are separated from each other by gaps 101 to 103 that enable magnetic coupling.

[0047] In other words, the radially inner end of the core 41 is separated from the radially 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.

[0048] 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 to the reactor of the conventional structure.

[0049] Furthermore, the difference in magnetic path length between phases of the core body 5 of the present invention is smaller than that of the conventional reactor. Therefore, the present invention can also reduce the imbalance of inductance caused by the difference in magnetic path length.

[0050] Figure 3 This is a top view of the reactor according to the first embodiment. Figure 1A , Figure 1B and Figure 3 It can be seen that the end plate 81 includes a protrusion 91 that partially protrudes in a direction away from the outer peripheral surface of the core body 5. In other words, the protrusion 91 extends radially outward relative to the central axis of the core body 5.

[0051] In addition, through holes 81a to 81c corresponding to the through holes 29a to 29c of the outer peripheral iron core 20 are formed in the end plate 81. After the end plate 81 is mounted on the core body 5 around which the coils 51 to 53 are wound, screws or bolts (not shown) are inserted into the through holes 81a to 81c of the end plate 81 and the through holes 29a to 29c of the outer peripheral iron core 20 and fastened. In addition, similar through holes may be formed in the base 60. The same is true in the embodiments described later.

[0052] The protrusion 91 protrudes corresponding to at least one side of a substantially regular even-numbered polygon, for example, a substantially hexagon. By having an operator or a robot (not shown) hold the protrusion 91, the reactor 6 can be easily manufactured, transported, installed, etc. Therefore, the operability and safety during manufacturing can be improved.

[0053] like Figure 3 As shown in FIG. 1 , when the outer peripheral core 20 is substantially hexagonal, the four protrusions 91 protrude corresponding to the four sides of the substantially hexagonal shape. Figure 3 In the embodiment, two sides adjacent to one side provided with the protrusion 91 are composed of a side provided with the protrusion 91 and a side not provided with the protrusion 91. When a plurality of protrusions 91, for example, four protrusions 91 are provided, the reactor 6 can be manufactured, transported, installed, etc. more stably, especially when the protrusions 91 are held by a robot.

[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 circumscribed to the outer periphery of the 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 this case, it is preferred that at least one protrusion 91 protrudes within the range of the footprint of the base 60. In other words, it is preferred that the protrusion 91 extends within a substantially triangular range A corresponding to the area from the outer peripheral surface of the peripheral core 20 to the outer edge of the base 60.

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

[0056] in addition, Figure 4 It is a perspective view of a reactor according to another embodiment. Figure 4 In the embodiment, the openings 85 are formed in the protruding portions 91 of the end plates 81. In this case, the reactor 6 can be suspended by passing a wire or the like through the openings 85. Therefore, the convenience of manufacturing, transporting, installing, etc. the reactor 6 can be improved.

[0057] Figure 5 It is a cross-sectional view of a core body included in the reactor according to the second embodiment. Figure 5 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 the same as the previously described iron core coils and are arranged inside the outer peripheral iron core 20. 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 greater than 4, whereby the reactor having the core body 5 can be used as a single-phase reactor.

[0058] As can be seen from the accompanying drawings, the outer peripheral core 20 is composed of four outer 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 only 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 each outer peripheral core part 24 to 27. In addition, through holes 29a to 29d similar to the through holes described above are formed in the outer peripheral core parts 24 to 27. In addition, the number of iron cores 41 to 44 and the number of outer peripheral core parts 24 to 27 may not necessarily be the same. Figure 2 The same applies to the core body 5 shown.

[0059] Furthermore, the radially inner end of each of the iron cores 41 to 44 is located near the center of the outer peripheral iron core 20. Figure 5 In the embodiment, the radial inner 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 radial inner ends of the cores 41 to 44 are separated from each other by gaps 101 to 104 that enable magnetic coupling.

[0060] Figure 5 The dotted line shown corresponds roughly to the footprint shape of the base 60 of the second embodiment. That is, the base 60 is a circumscribed rectangle circumscribing the outer periphery of the outer peripheral core 20. Figure 5 The illustrated one-dot chain line corresponds to the end plate 81 and the opening 89 of the second embodiment.

[0061] like Figure 5 As shown, when the outer peripheral core 20 is substantially octagonal, the four protrusions 91 protrude corresponding to the four sides of the substantially octagon. Figure 5 In the embodiment, the protrusion 91 is not provided on two sides adjacent to the side provided with the protrusion 91. Furthermore, the protrusion 91 extends within a substantially triangular range A corresponding to the area from the outer peripheral surface of the outer peripheral core 20 to the outer edge of the base 60. Therefore, it is obvious that Figure 5 The same effects as those of the above-described embodiments can be obtained in the illustrated embodiment as well.

[0062] Furthermore, Figure 6 It is a perspective view of a reactor according to the third embodiment. Figure 6 The reactor 6 shown is the same as the reactor 6 shown in FIG. 1 except that the base 60 is excluded. Figure 1B The reactor 6 shown is the same, so the detailed description is omitted.

[0063] Figure 7 2 is a cross-sectional view of a core body included in the reactor according to the third embodiment. Figure 2 The core body described above is the same, so detailed description is omitted. Figure 7 The dashed lines shown illustrate the end plate 81 and the opening 89. Thus, Figure 7 The end plate 81 shown includes four protrusions 91 that are generally triangular in shape. Figure 7 It can be seen that when the outer peripheral core 20 is substantially hexagonal, the protrusions 91 are not provided corresponding to a set of two opposing sides, but the protrusions 91 are provided corresponding to the remaining four sides.

[0064] Likewise, Figure 8 4 is a cross-sectional view of a core body included in the reactor according to the fourth embodiment. Figure 5 The core body described above is the same, so detailed description is omitted. Figure 8 The dashed lines shown illustrate the end plate 81 and the opening 89. Figure 8 The end plate 81 shown includes four protrusions 91 that are generally triangular in shape. Figure 8 It can be seen that when the outer peripheral core 20 is substantially octagonal, the protrusions 91 are not provided corresponding to two sets of opposing sides, but the protrusions 91 are provided corresponding to the remaining four sides.

[0065] Therefore, when the outer peripheral core 20 is a substantially even-polygonal shape, the protrusion 91 is not provided corresponding to at least two sides facing each other, and the protrusion 91 is provided corresponding to the remaining sides. In this case, the side of a reactor without the protrusion is brought into contact with the side of another reactor without the protrusion. Figure 7 In the case of , multiple reactors can be arranged adjacent to each other in the vertical direction of the paper. Figure 8 In the case of , a plurality of reactors can be arranged adjacent to each other in the left-right direction of the paper. Thus, the working space can be reduced.

[0066] Furthermore, Fig. 9 2 is a cross-sectional view of a core body included in a reactor according to the fifth embodiment. Fig. 9 The core body 5 including the outer peripheral iron core 20 having a circular cross section is shown in FIG. Figure 2 The core body 5 shown is the same, so the detailed description is omitted. Fig. 9 The dashed lines shown show the end plate 81 which is substantially elliptical and the opening 89 which is the same as the opening described previously. Fig. 9 The end plate 81 shown includes two protrusions 91 that are substantially C-shaped. Fig. 9 It can be seen that when the outer peripheral core 20 is substantially circular, the protrusion 91 is not provided corresponding to at least one set of arc portions facing each other in the diameter direction of the circumference, and the protrusion 91 is provided in the remaining arc portions. In this case, a plurality of reactors can be arranged adjacent to each other in the left-right direction of the paper, so that the working space can be reduced.

[0067] 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 reactor, characterized in that: The reactor includes a core body including: a circular outer peripheral iron core, at least three iron cores arranged in contact with or coupled to an inner surface of the outer peripheral iron core, and a coil wound around the iron core. A gap capable of magnetic coupling is formed between one of the at least three cores and the other cores adjacent to the one core, The reactor further includes a substantially elliptical end plate attached to one end surface of the core body and circumscribing the outer peripheral iron core. The end plate includes two substantially C-shaped protrusions that partially protrude in a direction away from the outer peripheral surface of the core body and face each other in a radial direction of the core body.

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

3. The reactor according to claim 1, characterized in that: The number of the at least three cores is an even number greater than 4.

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