Special reactor for high-power three-phase charger

Abstract

According to the design scheme of the electric reactor special for the high-power three-phase charger, due to the fact that the 3D printing and laser irradiation technologies are adopted for the electric reactor iron core special for the charger, and the polymer composed of the insulating ionic glue sensitive to laser and the iron-nickel-based amorphous alloy powder is doped, the electric reactor iron core has the high inductance value and the low loss; the traditional design thought that cold-rolled silicon steel sheets are subjected to heat treatment, annealing, dipping in insulating paint and then separated and overlapped through epoxy glass cloth to form gaps is changed at one stroke; the novel iron core body shaped like the Arabic numeral eight is formed by stacking a plurality of iron core sheets, and due to the fact that each iron core sheet is not provided with an obvious cutting opening, magnetic flux leakage is particularly reduced, and the energy-saving effect of the electric reactor is greatly improved. In the embodiment, the iron loss of the reactor special for the three-phase charger can be reduced to three fifths of that of a traditional reactor, the weight of the reactor is only two thirds of that of a cold-rolled silicon steel sheet, the calorific value of the reactor during working is only half of the original calorific value, and the application prospect is very wide.

Description

Technical Field

[0001] The present invention relates to a reactor dedicated to a high-power three-phase charger. The iron core of the three-phase reactor adopts an amorphous alloy iron core body that combines 3D printing and laser irradiation technology. The iron loss is small and the interference caused by large current surge is reduced, providing a complete three-phase charging front-end solution for high-power electronic equipment. Background Art

[0002] The input voltage of the AC bus of a high-power three-phase charger is 380V, while the DC bus voltage is less than or equal to 700V, the carrier frequency is greater than or equal to 20KHz, the charging power ranges from 10KW to 30KW, the rated current ranges from 20A to 200A, and the inductance ranges from 0.2mH to 1mH. In such a high-power working scenario, in order to prevent the occurrence of surge, creepage and skin phenomenon under high-frequency conditions, a special reactor to reduce its own weight has become the first choice for engineers.

[0003] At present, the most commonly used core material for three-phase reactors is non-oriented electromagnetic steel plates with a high silicon content, that is, 1% to 3% silicon is added to the steel plates, which are then subjected to heat treatment and annealing to form cold-rolled silicon steel sheets. The surfaces of the cold-rolled silicon steel sheets are coated with an insulating paint, and then cut into EI shapes, and then staggered and assembled together. However, the problems brought about by this traditional reactor design are serious self-weight problems and poor efficiency caused by iron loss, resulting in a serious imbalance in cost-performance.

[0004] Based on this, the present invention proposes a solution of a special reactor for a high-power three-phase charger using an amorphous alloy iron core body that combines 3D printing and laser irradiation technology. The amorphous alloy iron core body adopts an "8"-shaped structure. After multiple "8"-shaped films are stacked together and formed, the entire cross-section of this new type of amorphous alloy iron core body is approximately circular, has high-strength inductance value and low loss characteristics, and has the advantages of small leakage flux, strong short-circuit resistance, light weight, uniform temperature rise, low noise, three-phase balance, and low no-load current.

[0005] It is of great significance that the special reactor described above has the characteristics of being resistant to salt spray, moisture and corrosion due to the use of a special design and manufacturing process and a core material with a unique topological structure. In addition, it has low noise during operation. Therefore, it can be widely used in various high-power charging fields and provide stable and efficient power conversion. This is of particular significance for eliminating people's "anxiety" about the inexplicable leakage and numbness interference caused by high-power three-phase chargers during surge and creepage.

[0006] The applicant and the inventor also encountered many difficulties in the embodiments of the present invention. The biggest difficulty was how to shape the amorphous alloy body known as "metallic glass" into an "8"-shaped structure with a nearly circular cross-section. Therefore, the inventor ingeniously introduced a preparation technology that combines 3D printing and laser irradiation methods and a polymer printing material solution composed of an insulating ion glue amorphous alloy powder that is sensitive to lasers. Through the alternating operations of 3D digital printing and laser irradiation, this thorny problem was solved. Summary of the invention

[0007] A reactor dedicated to a high-power three-phase charger includes an amorphous alloy iron core, a copper wire package, a bracket, and an iron core sheath. The main features are: The amorphous alloy core film is in the shape of "8". The cross section of the amorphous alloy core body formed after the film is stacked is approximately circular. Each layer of the amorphous alloy core film is printed by a precision 3D printer. Based on the limitation of the accuracy of the 3D printer, the thickness of each layer of the film is set to 0.25mm. The printing material of the 3D printer is a polymer composed of an insulating ion glue doped with laser-sensitive insulating ion glue and amorphous alloy powder. The amorphous alloy powder is an iron-nickel-based amorphous alloy suitable for high-frequency environments. It has excellent magnetism, corrosion resistance, wear resistance and strong high-frequency electromechanical coupling performance. In view of the fact that amorphous alloy powder is prone to crystallization and composition segregation in 3D printing, it is also necessary to add insulating ion glue to the printing material to inhibit the generation of cracks in the amorphous alloy core film and increase the adhesion between the film layers. After each layer of the amorphous alloy core film is printed, it must be laser irradiated and scanned. The insulating ion glue sensitive to laser is activated, the surface of the printed film begins to coarsen, the amorphous alloy powder is exposed, and is firmly embedded in the film interface of the upper layer of amorphous alloy iron core. The amorphous alloy iron core is printed in the shape of "8" by analogy. After the amorphous alloy core body is printed, the cross-section of the amorphous alloy core body is approximately circular. At this time, by adjusting the offset, rotation and intensity of the laser beam, the laser irradiation scan is used for 0.3 minutes, so that the polymer composed of the amorphous alloy powder doped with insulating ion glue is completely denatured, so as to completely eliminate the voids and spheroidization defects left in the 3D printing process. Then, the anhydrous alcohol treatment is carried out in the post-process to remove the support residues left by 3D printing; The core sheath is installed on the amorphous alloy core body with a nearly circular cross section. For easy installation, the core sheath is divided into two halves, and the screws are connected to the core sheath through the sheath reinforcement rib holes on the sheath reinforcement ribs. The support of the reactor is provided with a support mounting hole, a support convex strip and a support support column of the reactor. The relationship between the support and the core sheath is as follows: the support convex strip can be inserted into the core sheath, and then connected with the sheath reinforcement rib hole on the sheath reinforcement rib through the mounting hole on the support support column, so that the core sheath and the support form a whole; When installing the reactor, screws can be passed through the bracket mounting holes to fix the entire reactor on the mounting base; The copper bar wire package is wound on the iron core sheath, wherein the copper bar input end is and the copper bar output end is.

[0008] Furthermore, the core sheath and the bracket are both made of insulating, high temperature resistant and flame retardant engineering plastics by one-time injection molding.

[0009] Furthermore, the reactor is usually installed on a base in a horizontal manner, and is particularly suitable for installation in a low control box space.

[0010] Furthermore, the diameter of the laser beam used is less than 100 micrometers.

[0011] Furthermore, the copper strip wire package used is made of red copper with good electrical conductivity.

[0012] Furthermore, the 3D printer used is a LA 3D high-precision digital printer that is less affected by ambient temperature. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] In order to clearly illustrate the technical solution of the embodiment of the present invention, the following briefly introduces the drawings required for use in the embodiment. Obviously, the drawings described below are only one embodiment of the present invention. For those skilled in the art, without paying creative labor, they can also draw inferences from one example and obtain other similar drawings based on these drawings.

[0014] Figure 1 Appearance of a reactor dedicated to a high-power three-phase charger Figure 1 ; Figure 2 Appearance of a reactor dedicated to a high-power three-phase charger Figure 2 ; Figure 3 Appearance of a reactor dedicated to a high-power three-phase charger Figure 3 ; Figure 4 Appearance of a reactor dedicated to a high-power three-phase charger Figure 4 ; Figure 5 An amorphous alloy iron core body of a reactor specially used for a high-power three-phase charger; Figure 6 A high-power three-phase charger dedicated reactor amorphous alloy core body 2; Figure 7 A special reactor bracket for a high-power three-phase charger; Figure 8 A special reactor bracket for a high-power three-phase charger; Fig. 9 A reactor core sheath for a high-power three-phase charger; Fig.10 A reactor core sheath 2 specially used for a high-power three-phase charger; Fig.11 A core sheath after separation of a reactor dedicated to a high-power three-phase charger; Fig.12 A core sheath 2 after separation of a reactor dedicated to a high-power three-phase charger; Fig.13 A copper wire package diagram of a reactor specially used for high-power three-phase chargers.

[0015] 1 Amorphous alloy core 2 Copper wire packages 2-1 Copper bar input terminal 2-2 Copper strip output end 3 Bracket 3-1 Bracket mounting hole 3-2 Bracket rib 3-3 Bracket support 4 Core sheath 4-1 Sheath reinforcement 4-2 Sheath reinforcement hole DETAILED DESCRIPTION

[0016] The specific implementation of the present invention is described below in conjunction with the accompanying drawings: A reactor dedicated to a high-power three-phase charger comprises an amorphous alloy iron core (1), a copper wire package (2), a bracket (3), and an iron core sheath (4), the main features of which are: The amorphous alloy core body (1) is in the shape of a figure "8". The cross section of the amorphous alloy core body (1) formed after the film is stacked is approximately circular. Each layer of the amorphous alloy core film is printed by a precision 3D printer. Based on the limitation of the accuracy of the 3D printer, the thickness of each layer of the amorphous alloy core film is set to 0.25 mm. The printing material of the 3D printer is a polymer composed of an insulating ion glue doped with laser-sensitive insulating ion glue and an amorphous alloy powder. The amorphous alloy powder is an iron-nickel-based amorphous alloy. The iron-nickel-based amorphous alloy has excellent magnetic properties, corrosion resistance, wear resistance and strong high-frequency electromechanical coupling performance. In view of the fact that amorphous alloy powder is prone to crystallization and component segregation during 3D printing, it is also necessary to add an insulating ion glue to the printing material to inhibit the generation of cracks in the amorphous alloy core film so as to increase the adhesion between the film layers. After each layer of the amorphous alloy core film is printed, it is subjected to laser irradiation scanning. The insulating ion glue sensitive to the laser is activated, the surface of the printed film begins to coarsen, the amorphous alloy powder is exposed, and is firmly embedded in the film interface of the upper layer of the amorphous alloy iron core body. Similarly, the amorphous alloy iron core body (1) is 3D digitally printed into an "8" shape; After the amorphous alloy iron core body (1) is printed, the cross section of the amorphous alloy iron core body (1) is approximately circular. At this time, the offset, rotation and intensity of the laser beam need to be adjusted, and the laser irradiation scanning is performed for 0.3 minutes, so that the polymer composed of the amorphous alloy powder doped with insulating ion glue is completely denatured, so as to completely eliminate the irregular gaps and spheroidization defects left in the 3D printing process. Then, anhydrous alcohol treatment is performed in the post-process to remove the support residues left by the 3D printing. The core sheath (4) is installed on an amorphous alloy core body (1) having a substantially circular cross section. For ease of installation, the core sheath (4) is divided into two halves, and screws are connected to the core sheath (4) through sheath reinforcement rib holes (4-2) on the sheath reinforcement rib (4-1). The support (3) of the reactor is provided with a support mounting hole (3-1), a support convex strip (3-2) and a support pillar (3-3) of the reactor, and the relationship between the support (3) and the core jacket (4) is as follows: the support convex strip (3-2) can be inserted into the core jacket (4), and connected to the jacket reinforcement rib hole (4-2) on the jacket reinforcement rib (4-1) through the mounting hole on the support pillar (3-3), so that the core jacket (4) and the support (3) form a whole; When installing the reactor, screws are inserted through the bracket mounting holes (3-1) to fix the entire reactor on the mounting base. The copper bar wire package (2) is wound on the iron core sheath (4), wherein the copper bar input end is (2-1) and the copper bar output end is (2-2).

[0017] Furthermore, the core sheath (4) and the bracket (3) are both made of insulating, high temperature resistant and flame retardant engineering plastics by one-step injection molding.

[0018] Furthermore, the reactor is usually installed on the base in a horizontal manner, thereby greatly reducing the installation height of the reactor, which is particularly suitable for a low control box space.

[0019] Furthermore, the laser beam used has a diameter of less than 100 microns.

[0020] Furthermore, the copper strip wire package (2) used is made of red copper with good electrical conductivity.

[0021] Furthermore, the 3D printer used is a LA 3D high-precision digital printer that is less affected by ambient temperature. Beneficial Effects

[0022] The high-power three-phase charger dedicated reactor using 3D printing and laser irradiation technology proposed in the embodiment of the present invention has the following significant beneficial effects: The most substantial improvement of the present invention is that it proposes a design scheme of a special reactor for high-power three-phase chargers that integrates 3D printing and laser irradiation technology, which is completely different from the traditional technical ideas. This polymer doped with laser-sensitive insulating ion glue and amorphous alloy powder has a higher inductance value and lower loss, thus changing the traditional design scheme of cold-rolled silicon steel sheets that are heat-treated, annealed, impregnated with insulating varnish, and then separated and overlapped by epoxy glass cloth to form a gap.

[0023] This "8"-shaped iron core body is designed by stacking several iron core sheets, which breaks through the conventional flat rolled iron core structure. Each iron core sheet has no obvious cutting opening, so it is particularly helpful to reduce the magnetic leakage of the iron core, thereby greatly improving the efficiency and energy saving effect of the reactor. Through computer simulation, it is known that in this embodiment, the iron loss of the high-power three-phase charger dedicated reactor composed of this new iron core body can be reduced to three-fifths of the original traditional reactor, the weight is only two-thirds of the cold-rolled silicon steel sheet, and the heat generated by the reactor during operation is only half of the original.

[0024] In the present invention, the flexible production process of 3D printing and laser irradiation completely eliminates the stamping die of the silicon steel sheet, and the laser irradiation forming modification provides comprehensive flexible operation and realizes extremely simplified process processing.

[0025] From the perspective of application prospects, at present, there has not been any high-power three-phase charger-specific inductor made of an amorphous alloy iron core body that uses a combination of 3D printing and laser irradiation technology on the market. Because the three-phase inductor is light in weight, corrosion-resistant, and has low iron loss, its application prospects are very broad.

[0026] In this specification, specific implementation examples are used to illustrate the principles and operation modes of the present invention, which are only used to help understand the core idea of ​​the present invention and should not be understood as limiting the present invention. It is understood by those skilled in the art that various changes made to the present invention in form and detail without departing from the spirit and scope of the present invention defined in the attached claims are within the scope of protection of the present invention.

Claims

1. A reactor for a high-power three-phase charger, comprising an amorphous alloy iron core (1), a copper wire package (2), a bracket (3), and an iron core sheath (4), characterized in that: The amorphous alloy core body (1) is in the shape of an "8". The cross section of the amorphous alloy core body (1) formed after the thin film is stacked is approximately circular. It is printed and stacked in layers by a precision 3D printer. The printing thickness of each layer is 0.25 mm. The printing material of the 3D printer is a polymer composed of amorphous alloy powder mixed with insulating ion glue that is sensitive to laser. The amorphous alloy powder is an iron-nickel based amorphous alloy material. It has excellent magnetic properties, corrosion resistance, wear resistance and strong high-frequency electromechanical coupling performance. Since the amorphous alloy powder is prone to crystallization and component segregation during 3D printing, it is also necessary to add insulating ion glue to the printing material to inhibit the generation of cracks in the amorphous alloy core film to increase the adhesion between the film layers. After each layer of the amorphous alloy core film is printed, it is necessary to perform laser irradiation scanning. The insulating ion glue sensitive to the laser is activated, the surface of the printed film begins to coarsen, the amorphous alloy powder is exposed, and is firmly embedded in the film interface of the upper layer of the amorphous alloy iron core body. By analogy, the amorphous alloy iron core body (1) is printed into an "8" shape; After the amorphous alloy iron core body (1) is printed, the cross section of the amorphous alloy iron core body (1) is approximately circular. At this time, by adjusting the offset, rotation and intensity of the laser beam, the laser irradiation scanning is performed for 0.3 minutes, so that the polymer composed of the amorphous alloy powder doped with insulating ion glue is completely denatured, so as to completely eliminate the voids and spheroidization defects left in the 3D printing process. Then, the pure alcohol treatment is performed in the post-process to remove the support residues left by the 3D printing. The core sheath (4) is installed on an amorphous alloy core body (1) having a substantially circular cross section. For ease of installation, the core sheath (4) is divided into two halves, and screws are connected to the core sheath (4) through sheath reinforcement rib holes (4-2) on the sheath reinforcement rib (4-1). The support (3) of the reactor is provided with a support mounting hole (3-1), a support convex strip (3-2) and a support pillar (3-3) of the reactor, and the relationship between the support (3) and the core jacket (4) is as follows: the support convex strip (3-2) can be inserted into the core jacket (4), and connected to the jacket reinforcement rib hole (4-2) on the jacket reinforcement rib (4-1) through the mounting hole on the support pillar (3-3), so that the core jacket (4) and the support (3) form a whole; When installing the reactor, screws are inserted through the bracket mounting holes (3-1) to fix the entire reactor on the mounting base. The copper bar wire package (2) is wound on the iron core sheath (4), wherein the copper bar input end is (2-1) and the copper bar output end is (2-2).

2. A high-power three-phase charger dedicated reactor according to claim 1, characterized in that: The core sheath (4) and the bracket (3) are both made of insulating, high temperature resistant and flame retardant engineering plastics by one-step injection molding.

3. The reactor for high-power three-phase charger according to claim 1 is characterized in that: The reactor is usually installed on a base in a horizontal manner.

4. The reactor for high-power three-phase charger according to claim 1 is characterized in that: The laser beam used has a diameter of less than 100 micrometers.

5. The high-power three-phase charger dedicated reactor according to claim 1 is characterized in that: The copper strip wire package (2) used is made of red copper.

6. The reactor for high-power three-phase charger according to claim 1 is characterized in that: The 3D printer used is a LA 3D high-precision digital printer that is less affected by ambient temperature.

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