A low-noise, low-loss self-saturating reactor and its manufacturing method

Abstract

The present invention discloses a low-noise, low-loss self-saturating inductor and a manufacturing method thereof, wherein the inductor comprises: a single-arm iron core, a control winding and a mounting frame; the single-arm iron core is mounted on the mounting frame, and the control winding is arranged on the single-arm iron core; the single-arm iron core is formed by stacking a plurality of quasi-elliptical iron core cakes; shock-absorbing pads are arranged between adjacent quasi-elliptical iron core cakes; the top of the quasi-elliptical iron core cake at the top and the bottom of the quasi-elliptical iron core cake at the bottom are both provided with shock-absorbing pads; a polyester belt for tightening the quasi-elliptical iron core cake and the shock-absorbing pads is provided on the iron core; the present invention adopts the quasi-elliptical iron core cake, thereby reducing the amount of silicon steel sheets used, and at the same time, provides shock-absorbing pads and tightens the iron core cake with polyester belts, thereby effectively reducing noise during operation; in addition, the insulating base is made of special insulating material and glass fiber reinforced plastic screws and nuts are used, thereby eliminating the eddy current loss of the copper busbar current on the insulating base of the inductor, thereby reducing operating losses.

Description

Technical Field

[0001] The present invention relates to the technical field of reactors, and in particular to a low-noise, low-loss, self-saturating reactor and a manufacturing method thereof. Background Art

[0002] As an important electrical device, self-saturated reactor plays a key role in power systems. However, traditional self-saturated reactors have many problems in structure and performance.

[0003] Traditional self-saturating reactor cores typically utilize a toroidal discus structure. To achieve the same voltage regulation depth, this structure requires more silicon steel sheets, resulting in high material consumption and increased production costs. Furthermore, since core losses in self-saturating reactors are proportional to their core weight during operation, the toroidal discus structure results in a heavier core, leading to higher core losses and lowering the reactor's operating efficiency and economics.

[0004] In terms of manufacturing, the cores of traditional self-saturated reactors are not vacuum-pressure-impregnated after winding, leaving gaps between the cores. This makes the silicon steel sheets susceptible to electromagnetic vibrations during operation, with large amplitudes. This significantly increases operating noise, impacting both the surrounding environment and the normal operation of the equipment.

[0005] Furthermore, the core structure design of traditional self-saturating reactors also has flaws. The entire core is typically placed on a carbon steel frame and tightened with M24 iron screws. When the reactor is operating, a huge current often flows through the copper busbar, often exceeding 10,000A, and this current contains a large number of harmonics. This causes significant eddy current losses in the steel components surrounding the busbar. If the reactor design is not appropriate, localized overheating of the steel components can easily occur, causing the chromatographic analysis results of the transformer oil to seriously exceed the standard, posing a serious threat to the safe and stable operation of the product.

[0006] In summary, traditional self-saturated reactors have obvious deficiencies in material utilization, loss control, noise suppression, and electromagnetic compatibility, and urgently need to be improved and optimized to meet the requirements of modern power systems for high performance, high reliability, energy saving and environmental protection of reactors. Summary of the Invention

[0007] In view of the deficiencies in the prior art, the present invention provides a low-noise, low-loss, self-saturating reactor, the purpose of which is to solve the problems in the background technology.

[0008] To achieve the above-mentioned objectives, the present invention provides the following technical solutions: a low-noise, low-loss self-saturated inductor, comprising: a single-arm iron core, a control winding and a mounting frame; the single-arm iron core is mounted on the mounting frame, and the control winding is arranged on the single-arm iron core; the single-arm iron core is formed by stacking a plurality of quasi-elliptical iron core cakes; shock-absorbing pads are arranged between adjacent quasi-elliptical iron core cakes; shock-absorbing pads are provided on the top of the quasi-elliptical iron core cake at the top and the bottom of the quasi-elliptical iron core cake at the bottom; a polyester belt for tightening the quasi-elliptical iron core cake and the shock-absorbing pads is provided on the iron core.

[0009] Furthermore, the mounting frame includes an insulating base of the reactor and an insulating pressure plate; a plurality of vertically arranged vertical copper bars are provided on the top of the insulating pressure plate; the single-arm iron core is sleeved on the vertical copper bar on the top of the insulating base of the reactor; an insulating pressure plate is provided on the top of the single-arm iron core; a fiberglass pull screw for tightening is provided between the insulating pressure plate and the insulating base of the reactor; and a through hole for the vertical copper bar to pass through is provided on the insulating pressure plate.

[0010] Furthermore, the insulating base of the reactor includes an insulating base plate and insulating vertical plates arranged on both sides of the bottom of the insulating base plate; the insulating vertical plates on both sides of the bottom of the insulating base plate are connected by insulating cross-connecting plates and insulating cross bars; L-shaped insulating columns and T-shaped insulating columns are provided at the bottom of the insulating base plate; through holes for installing vertical copper busbars are provided on the insulating base plate, and the vertical copper busbars are installed on the insulating base plate through the through holes, and the single-arm iron core is sleeved on the vertical copper busbar on the top of the insulating base plate.

[0011] Furthermore, the insulating bottom plate, the insulating vertical plate, the insulating cross-connecting plate and the insulating cross bar are connected by low-magnetic steel connectors and stainless steel bolts and nuts.

[0012] Furthermore, the control winding is formed by welding a U-shaped winding; and through holes for the U-shaped winding to pass through are provided on the insulating pressure plate and the insulating bottom plate.

[0013] A method for manufacturing a low-noise, low-loss self-saturating reactor comprises the following steps:

[0014] Step S1: using silicon steel sheets to wind a quasi-elliptical core cake, and then annealing and injecting glue into the quasi-elliptical core cake;

[0015] Step S2: using a nitrile rubber sheet to make a shock-absorbing pad;

[0016] Step S3: stacking several elliptical core cakes that have been annealed and injected with glue alternately with shock-absorbing pads, and tying them up with polyester tape to obtain a single-arm core;

[0017] Step S4: placing the single-arm core on top of the insulating base plate, inserting the vertical copper busbar through the single-arm core into the through hole on the insulating base plate; pressing the insulating pressing plate on top of the single-arm core;

[0018] Step S5: insert the U-shaped winding from the bottom through-hole of the insulating base plate, pass through the single-arm iron core and the insulating pressing plate, and then tie the U-shaped winding to the insulating base plate;

[0019] Step S6: installing a glass fiber reinforced plastic pull screw between the insulating pressure plate and the insulating bottom plate and tightening them;

[0020] Step S7: Welding is performed on the portion where the U-shaped winding passes through the insulating pressing plate to form the U-shaped winding into a control winding, thereby completing the production.

[0021] Compared with the existing technology, the present invention has the following beneficial effects: the present invention adopts an elliptical core cake, which reduces the amount of silicon steel sheets used and reduces material costs. At the same time, a shock-absorbing pad is provided and the core cake is tightened with a polyester belt, which effectively reduces noise during operation. In addition, the insulating base is made of special insulating material and fiberglass screws and nuts are used to eliminate the eddy current loss of the copper busbar current on the insulating base of the reactor, reduce operating losses, prevent overheating of structural parts, and ensure the safety and stability of the reactor operation. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 It is a schematic diagram of the overall structure of the present invention.

[0023] Figure 2 This is a schematic diagram of the single-arm core structure of the present invention.

[0024] Figure 3 This is a schematic diagram of the structure of the insulating base of the reactor of the present invention.

[0025] Figure 4 This is a structural schematic diagram of the low-magnetic steel connector of the present invention.

[0026] Figure 5 This is a schematic diagram of the control winding structure of the present invention.

[0027] In the figure, 1. Vertical copper busbar; 2. Fiberglass pull screw; 3. Insulation pressure plate; 4. Control winding; 5. Shock-absorbing pad; 6. Oval-shaped iron core; 7. Insulation base of reactor; 8. Insulation bottom plate; 9. Insulation vertical plate; 10. Insulation cross-connecting plate; 11. L-shaped insulating column; 12. Insulation cross bar; 13. T-shaped insulating column; 14. Low-magnetic steel connector; 15. Polyester tape. DETAILED DESCRIPTION

[0028] like Figure 1 As shown, the present invention provides a technical solution: a low-noise, low-loss self-saturated inductor, comprising: a single-arm iron core, a control winding 4 and a mounting frame; the single-arm iron core is installed on the mounting frame, and the control winding 4 is arranged on the single-arm iron core.

[0029] like Figure 2As shown, the single-arm iron core is formed by stacking multiple elliptical iron core cakes 6; shock-absorbing pads 5 are provided between adjacent elliptical iron core cakes 6; and shock-absorbing pads 5 are provided on the top of the elliptical iron core cake 6 at the top and the bottom of the elliptical iron core cake 6 at the bottom.

[0030] The iron core is provided with a polyester belt 15 for tightening the elliptical iron core cake 6 and the shock-absorbing pad 5 .

[0031] The mounting frame includes an insulating base 7 of the reactor and an insulating pressure plate 3; a plurality of vertically arranged vertical copper bars 1 are arranged on the top of the insulating pressure plate 3; the single-arm iron core is sleeved on the vertical copper bars 1 on the top of the insulating base 7 of the reactor; an insulating pressure plate 3 is provided on the top of the single-arm iron core; a glass fiber reinforced plastic pull screw 2 for tightening is provided between the insulating pressure plate 3 and the insulating base 7 of the reactor; a through hole is provided on the insulating pressure plate 3 for the vertical copper bars 1 to pass through.

[0032] like Figure 3 As shown, the insulating base 7 of the reactor includes an insulating base plate 8 and insulating vertical plates 9 arranged on both sides of the bottom of the insulating base plate 8; the insulating vertical plates 9 on both sides of the bottom of the insulating base plate 8 are connected by insulating cross-connecting plates 10 and insulating cross bars 12; L-shaped insulating columns 11 and T-shaped insulating columns 13 are provided at the bottom of the insulating base plate 8; through holes for installing vertical copper bars 1 are provided on the insulating base plate 8, and the vertical copper bars 1 are installed on the insulating base plate 8 through the through holes, and the single-arm iron core is sleeved on the vertical copper bars 1 on the top of the insulating base plate 8.

[0033] The connection between the insulating bottom plate 8, the insulating vertical plate 9, the insulating cross-connecting plate 10 and the insulating cross bar 12 is as follows Figure 4 The low magnetic steel connector 14 and stainless steel bolts and nuts are shown for connection.

[0034] like Figure 5 As shown, the control winding 4 is formed by welding a U-shaped winding.

[0035] The insulating pressing plate 3 and the insulating bottom plate 8 are provided with through holes for the U-shaped winding to pass through.

[0036] Comparative tests have shown that the noise level of the reactor of the present invention is 6-8dB lower than that of the traditional reactor. The factory-measured load noise level of the rectifier transformer using the traditional reactor is about 84dB, while the measured noise level of the reactor of the present invention is about 77dB.

[0037] A method for manufacturing a low-noise, low-loss self-saturating reactor comprises the following steps:

[0038] Step S1: using a 0.27 mm thick non-notched cold-rolled silicon steel sheet to wind a quasi-elliptical core cake 6, and performing annealing and glue injection treatment on the quasi-elliptical core cake 6.

[0039] Step S2: Use a 2 mm thick nitrile rubber sheet to make the shock-absorbing pad 5.

[0040] Step S3: stacking several elliptical core cakes 6 and shock-absorbing pads 5 after annealing and glue injection, and tying them up with polyester tape 15 to obtain a single-arm core.

[0041] Step S4: Place the single-arm iron core on top of the insulating base plate 8, insert the vertical copper bus 1 through the single-arm iron core into the through hole on the insulating base plate 8; and press the insulating pressing plate 3 on the top of the single-arm iron core.

[0042] Step S5: insert the U-shaped winding from the bottom through-hole of the insulating bottom plate 8 , pass through the single-arm iron core and the insulating pressing plate 3 , and then tie the U-shaped winding to the insulating bottom plate 8 and fix it.

[0043] Step S6: Arrange the glass fiber reinforced plastic pull screw 2 between the insulating pressure plate 3 and the insulating bottom plate 8 and tighten them.

[0044] Step S7: Welding is performed on the portion where the U-shaped winding passes through the insulating pressing plate 3 to form a control winding 4 with 2 or 3 turns of the U-shaped winding, thereby completing the production.

[0045] Among them, after the low-noise, low-loss, self-saturated reactor is dried as a whole, all fasteners in the low-noise, low-loss, self-saturated reactor are coated with anti-fall glue to loosen them. The anti-fall glue uses Loctite 414 glue.

[0046] The fasteners refer to low-magnetic steel connectors 14 and stainless steel bolts and nuts.

[0047] While embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions, and variations may be made to these embodiments without departing from the principles and spirit of the invention, and that the scope of the invention is defined by the appended claims and their equivalents.

Claims

1. A low-noise, low-loss, self-saturating reactor, characterized in that: include: Single-arm core, control winding and mounting frame; The single-arm iron core is mounted on a mounting frame, and the control winding is provided on the single-arm iron core; the single-arm iron core is formed by stacking a plurality of quasi-elliptical iron core cakes; shock-absorbing pads are provided between adjacent quasi-elliptical iron core cakes; shock-absorbing pads are provided on the top of the quasi-elliptical iron core cake at the top and the bottom of the quasi-elliptical iron core cake at the bottom; a polyester belt is provided on the iron core for tightening the quasi-elliptical iron core cake and the shock-absorbing pads; the shock-absorbing pads are made of nitrile rubber sheets; The mounting frame includes an insulating base of the reactor and an insulating pressure plate; a plurality of vertically arranged vertical copper bars are provided on the top of the insulating pressure plate; the single-arm iron core is sleeved on the vertical copper bars on the top of the insulating base of the reactor; an insulating pressure plate is provided on the top of the single-arm iron core; a glass fiber reinforced plastic tension screw for tightening is provided between the insulating pressure plate and the insulating base of the reactor; the insulating pressure plate is provided with a through hole for the vertical copper bars to pass through; The reactor insulation base includes an insulation base plate and insulation vertical plates arranged on both sides of the bottom of the insulation base plate; the insulation vertical plates on both sides of the bottom of the insulation base plate are connected by insulation cross-connecting plates and insulation cross bars; the bottom of the insulation base plate is provided with L-shaped insulation columns and T-shaped insulation columns; the insulation base plate is provided with through holes for installing vertical copper bars, the vertical copper bars are installed on the insulation base plate through the through holes, and the single-arm iron core is sleeved on the vertical copper bars on the top of the insulation base plate; The insulation base plate, insulation vertical plate, insulation cross connecting plate and insulation cross bar are connected by low magnetic steel connectors and stainless steel bolts and nuts; The control winding is formed by welding a U-shaped winding; through holes for the U-shaped winding to pass through are provided on the insulating pressing plate and the insulating bottom plate.

2. A method for manufacturing a low-noise, low-loss, self-saturating reactor, applied to the low-noise, low-loss, self-saturating reactor according to claim 1, characterized in that: The steps include: Step S1: using silicon steel sheets to wind a quasi-elliptical core cake, and then annealing and injecting glue into the quasi-elliptical core cake; Step S2: using a nitrile rubber sheet to make a shock-absorbing pad; Step S3: stacking several elliptical core cakes that have been annealed and injected with glue alternately with shock-absorbing pads, and tying them up with polyester tape to obtain a single-arm core; Step S4: placing the single-arm core on top of the insulating base plate, inserting the vertical copper busbar through the single-arm core into the through hole on the insulating base plate; pressing the insulating pressing plate on top of the single-arm core; Step S5: insert the U-shaped winding from the bottom through-hole of the insulating base plate, pass through the single-arm iron core and the insulating pressing plate, and then tie the U-shaped winding to the insulating base plate; Step S6: installing a glass fiber reinforced plastic pull screw between the insulating pressure plate and the insulating bottom plate and tightening them; Step S7: Welding is performed on the portion where the U-shaped winding passes through the insulating pressing plate to form the U-shaped winding into a control winding, thereby completing the production.

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