Three-column winding structure and single-phase magnetic control reactor

Abstract

This invention provides a three-column winding structure and a single-phase three-column magnetically controlled reactor, belonging to the technical field of magnetically controlled reactors. It employs a three-column core structure, including a central column and two symmetrically distributed side columns. The core technological innovation lies in the central column, which is constructed by alternating layers of dual-phase composite magnetic material and silicon steel sheets. The dual-phase composite magnetic material consists of a soft magnetic phase and a hard magnetic phase. The soft magnetic phase provides high permeability to support the main magnetic flux transmission, while the hard magnetic phase provides high coercivity to maintain remanent magnetization stability. Different soft and hard magnetic phase volume ratios are arranged along the central column along the axial direction to optimize gradient magnetic performance. The control winding uses flat copper wire, and the working winding uses round copper wire. Combined with a precisely designed air gap structure and magnetic circuit connection, a complete magnetic flux loop is formed, solving the technical problem of high eddy current losses in traditional magnetically controlled reactors.

Description

Technical Field

[0001] This invention belongs to the field of magnetically controlled reactor technology, specifically, it relates to a three-column winding structure and a single-phase three-column magnetically controlled reactor. Background Technology

[0002] Traditional magnetically controlled reactors typically use a single silicon steel sheet as the core material, a design that suffers from significant eddy current losses. When alternating magnetic flux passes through the silicon steel sheet, Faraday's law of electromagnetic induction induces an electromotive force within the conductor, forming a closed eddy current loop. Due to the conductivity of silicon steel, eddy currents flowing within the material generate Joule heat losses, which are proportional to the square of the frequency of the magnetic flux change, and are particularly severe under high-frequency or rapid adjustment conditions. Eddy current losses not only reduce the operating efficiency of the equipment but also cause the core temperature to rise, affecting the magnetic properties of the material and the lifespan of the equipment. Traditional technologies struggle to effectively suppress eddy current losses. While reducing the thickness of the silicon steel sheet can decrease losses, it increases manufacturing costs and assembly complexity, and also reduces the mechanical strength of the thinner sheet structure. Using high-impedance silicon steel can reduce eddy currents to some extent, but it affects the permeability and saturation magnetic flux density, thus limiting the reactor's regulation performance. This technological limitation makes it difficult for traditional magnetically controlled reactors to overcome the eddy current loss obstacle when pursuing high efficiency. Summary of the Invention

[0003] In view of this, the present invention provides a three-column winding structure and a single-phase three-column magnetically controlled reactor, which can solve the technical problem of large eddy current loss in traditional magnetically controlled reactors in the prior art.

[0004] This invention is implemented as follows: This invention provides a three-limb winding structure including a three-limb core and a control winding; the three-limb core and the control winding cooperate to achieve dynamic adjustment of the reactance value; the three-limb core includes a central column, a first side column, and a second side column. The central column has a cylindrical structure with its axis extending vertically, and its geometric center is located at the center of the entire three-limb core; the first and second side columns are both cylindrical structures, with their axes parallel to the axis of the central column. The first side column is located to the left of the central column, and the second side column is located to the right of the central column; the central column is composed of alternating layers of dual-phase composite magnetic material and silicon steel sheets. The dual-phase composite magnetic material consists of a soft magnetic phase and a hard magnetic phase, with the soft magnetic phase mainly containing… The alloy composition contains a hard magnetic phase. The alloy composition achieves synergistic optimization of magnetic properties at the nanoscale through exchange coupling between the soft and hard magnetic phases. The two-phase composite magnetic material in the central column has different soft and hard magnetic phase volume ratios according to the axial position, avoiding the decrease in magnetic flux conduction efficiency caused by the complete cancellation of magnetic fields in adjacent areas. The first and second side columns are mainly composed of stacked silicon steel sheets.

[0005] This invention effectively solves the eddy current loss problem of traditional magnetically controlled reactors by combining the construction of a two-phase composite magnetic material with optimized design. The scheme uses a composite material composed of a Fe78Si9B13 soft magnetic phase and a Nd2Fe14B hard magnetic phase. Utilizing the nanoscale grain refinement effect and the two-phase interface blocking mechanism, it suppresses the formation and propagation of eddy currents at the material's microstructure level. Simultaneously, precise geometric parameter design and magnetic circuit optimization further reduce the loss level. The average grain size of the soft magnetic phase in the two-phase composite material is controlled within the range of 50nm to 200nm. This ultrafine grain structure significantly shortens the propagation path of eddy currents within the material. Based on the relationship between eddy current loss and grain size, nanoscale grains can significantly reduce the eddy current loss density. The hard magnetic phase, as a dispersed phase, is uniformly distributed in the soft magnetic phase matrix, forming numerous phase interfaces. These interfaces effectively block eddy currents, further suppressing their continuous propagation. The synergistic effect of the two-phase materials achieves a significant reduction in eddy current loss while maintaining good magnetic permeability. This invention successfully solves the core technical problem of high eddy current loss. The microstructure design of the dual-phase composite material suppresses the generation mechanism of eddy currents at the source, the multiple interface blocking effect cuts off the propagation path of eddy currents, the optimized magnetic circuit design reduces unnecessary magnetic flux changes, and the synergistic effect of the three mechanisms achieves a significant reduction in eddy current losses, thus providing a high-efficiency, low-loss magnetically controlled reactor solution for power systems. Attached Figure Description

[0006] Figure 1 This is a schematic diagram of the three-column structure of the present invention.

[0007] Figure 2 This is a flowchart illustrating the preparation process of the two-phase composite magnetic material involved in this invention.

[0008] Figure 3 This is the equivalent circuit diagram of the three-column structure in Example 2.

[0009] Figure 4 This is a physical diagram of the three-column structure in Example 2.

[0010] Figure 5 The equivalent magnetic circuit model diagram of the magnetically controlled reactor in Example 2 includes three sub-diagrams: (a) is the equivalent magnetic circuit model of a general magnetically controlled reactor; (b) is the equivalent magnetic circuit model of the magnetically controlled reactor when only DC magnetic flux is considered; and (c) is the equivalent magnetic circuit model of the magnetically controlled reactor when only AC magnetic flux is considered.

[0011] Figure 6 This is a physical diagram of the three-column winding structure in Example 3.

[0012] The reference numerals in the attached figures are explained as follows: 01, center post; 02, first side post; 03, second side post; 04, control winding of the center post; 05, first air gap; 06, second air gap. Detailed Implementation

[0013] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings.

[0014] like Figure 1 The diagram shown is a structural schematic of a three-limb winding structure provided by the present invention, including a three-limb core and a control winding; the three-limb core and the control winding cooperate to achieve dynamic adjustment of the reactance value; the three-limb core includes a central limb and two side limbs; and also includes: The three-column core structure includes a central column 01, a first side column 02, and a second side column 03. The central column is cylindrical with its axis extending vertically, and its geometric center is located at the center of the entire three-column core. Both the first and second side columns are cylindrical, and their axes are parallel to the axis of the central column. The first side column is located to the left of the central column, and the second side column is located to the right of the central column. The distance between the geometric centers of the first and second side columns is equal to the distance between the geometric centers of the second and second side columns. The central column is composed of layers of dual-phase composite magnetic material and silicon steel sheets. The structure is constructed by stacking and replacing layers. The thickness of the two-phase composite magnetic material layer is 0.1 mm to 0.5 mm, and the thickness of the silicon steel layer is 0.2 mm to 0.8 mm. Both the first and second side pillars are mainly composed of stacked silicon steel sheets, and the thickness of the stacked silicon steel sheets is 0.35 mm. The ratio of the diameter of the central pillar to the diameter of the first side pillar is 1.35:1, the ratio of the diameter of the central pillar to the diameter of the second side pillar is 1.35:1, and the ratio of the diameter of the first side pillar to the diameter of the second side pillar is 1:1. When the diameter of the central pillar is the reference diameter, the diameter of the first side pillar is the reference diameter divided by 1.35, and the diameter of the second side pillar is the reference diameter divided by 1.35. A dual-phase composite magnetic material structure, comprising a soft magnetic phase and a hard magnetic phase, wherein the soft magnetic phase mainly includes... The alloy composition, wherein the hard magnetic phase mainly comprises The alloy composition is as follows: the average grain size of the soft magnetic phase is 50 nm to 200 nm, and the average grain size of the hard magnetic phase is 30 nm to 150 nm. The soft magnetic phase provides high permeability to support the transmission of the main magnetic flux, and the hard magnetic phase provides high coercivity to maintain the stability of remanence. The soft and hard magnetic phases achieve synergistic optimization of magnetic properties at the nanoscale through exchange coupling. The two-phase composite magnetic material in the central column has different soft and hard magnetic phase volume ratios according to their axial positions: the soft and hard magnetic phase volume ratios in the upper region of the central column are 6.8:3.2, in the middle region of the central column are 7.5:2.5, and in the lower region of the central column are 7.2:2.8. The control winding 04 structure of the central column: The central column control winding is wound around the outer surface of the central column. The central column control winding is made of flat copper wire with a rectangular cross-section. The width of the rectangular cross-section is 3mm to 8mm, and the thickness of the rectangular cross-section is 1mm to 3mm. The central column control winding is evenly distributed along the circumference of the central column. The number of turns of the central column control winding is determined according to the volume ratio of soft magnetic phase to hard magnetic phase in different regions of the central column. When the volume ratios of soft magnetic phase to hard magnetic phase in the upper, middle, and lower regions of the central column are 6.8:3.2, 7.5:2.5, and 7.2:2.8, respectively, the number of turns of the central column control winding is adjusted accordingly to achieve the best magnetic flux control effect. Side-post working winding structure: includes a first side-post working winding and a second side-post working winding; the first side-post working winding is wound on the outer surface of the first side-post, and the second side-post working winding is wound on the outer surface of the second side-post; both the first and second side-post working windings are wound with circular cross-section copper wire, the diameter of which is 2mm to 6mm; the number of turns of the first side-post working winding is equal to the number of turns of the second side-post working winding, and the number of turns of the working winding is determined according to the ratio of the diameter of the center post to the diameter of the side post. When the ratio of the diameter of the center post to the diameter of the first side post is 1.35:1 and the ratio of the diameter of the center post to the diameter of the second side post is 1.35:1, the number of turns of the first side-post working winding and the number of turns of the second side-post working winding are adjusted according to the corresponding ratio. Air gap structure: including a first air gap 05 and a second air gap 06; the first air gap is disposed between the central column and the first side column, and the second air gap is disposed between the central column and the second side column; the width of the first air gap is equal to the width of the second air gap.

[0015] Optionally, the air gap width is determined based on the ratio of the diameters of the central column and the side columns, as well as the volume ratio of the soft magnetic phase to the hard magnetic phase in different regions of the central column. When the ratio of the diameter of the central column to the diameter of the side columns is 1.35:1 and the volume ratios of the soft magnetic phase to the hard magnetic phase in each region of the central column are 6.8:3.2, 7.5:2.5, and 7.2:2.8, respectively, the width of the first air gap and the width of the second air gap are adjusted to the corresponding values ​​to ensure the best conduction efficiency of the magnetic circuit. The magnetic circuit connection structure includes an upper connection part and a lower connection part. The upper connection part is located at the upper end of the central column, the first side column, and the second side column. The upper connection part has an H-shaped structure. The central crossbeam of the H-shaped structure is fixedly connected to the upper end face of the central column, and the two vertical arms of the H-shaped structure are fixedly connected to the upper end faces of the first and second side columns, respectively. The lower connection part is located at the lower end of the central column, the first side column, and the second side column. The lower connection part has the same structural shape as the upper connection part. The lower connection part has an H-shaped structure. The central crossbeam of the H-shaped structure is fixedly connected to the lower end face of the central column, and the two vertical arms of the H-shaped structure are fixedly connected to the lower end faces of the first and second side columns, respectively. Both the upper and lower connection parts are made of silicon steel, and the thickness of the silicon steel material is consistent with the thickness of the silicon steel sheet laminations of the side columns. The magnetic circuit connection structure is used to form a complete magnetic flux loop, allowing magnetic flux to be conducted from the central column through the air gap to the side columns and then through the connection part to form a closed loop. An insulating protection structure includes a center post insulating layer, a first side post insulating layer, and a second side post insulating layer. The center post insulating layer is disposed between the outer surface of the center post and the center post control winding. The center post insulating layer is made of polyimide film material, and the polyimide film has a cylindrical structure. The inner diameter of the cylindrical structure is tightly fitted with the outer diameter of the center post, and the thickness of the polyimide film is 0.1 mm to 0.3 mm. The first side post insulating layer is disposed between the outer surface of the first side post and the first side post working winding. The second side post insulating layer is disposed between the outer surface of the first side post and the second side post working winding. Between the outer surface of the two side posts and the working winding of the second side post; the insulation layer of the first side post and the insulation layer of the second side post are both made of polyester film material. The polyester film has a cylindrical structure. The inner diameter of the cylindrical structure is closely fitted with the outer diameter of the first side post and the outer diameter of the second side post, respectively. The thickness of the polyester film is 0.2mm to 0.5mm. When the thickness of the central post insulation layer is 0.1mm to 0.3mm, the thickness of the insulation layer of the first side post and the insulation layer of the second side post are adjusted to 0.2mm to 0.5mm to ensure the matching of insulation performance in different parts; like Figure 2 As shown, the preparation process of the dual-phase composite magnetic material includes the following steps: S01. A magnetic phase ratio optimization experiment was conducted on samples with different soft magnetic phase to hard magnetic phase volume ratios using a vibrating sample magnetometer. The hysteresis loop of the samples was measured in the test frequency range of 50Hz to 5000Hz at an experimental temperature of 25℃. Magnetic parameters such as permeability, coercivity, saturation magnetization and remanent magnetization were extracted. A quantitative relationship between magnetic parameters and volume ratio was established to obtain a database of magnetic performance parameters. S02. Based on the magnetic performance parameter database, a magnetic field mutual cancellation and suppression algorithm is established to perform magnetic field cancellation and suppression calculation. The magnetic field vector distribution generated by adjacent axial regions within the central column is analyzed, and the spatial gradient of magnetic field intensity in each region is calculated. When the magnetic field directions of adjacent regions are opposite and the intensities are similar, the local permeability distribution is changed by adjusting the volume ratio of soft magnetic phase to hard magnetic phase in each region, so that the magnetic field intensity of adjacent regions produces appropriate differences, avoiding the decrease in magnetic flux conduction efficiency caused by complete magnetic field cancellation. The optimal soft magnetic phase to hard magnetic phase volume ratio at different axial positions of the central column is calculated to be 6.8:3.2, 7.5:2.5, and 7.2:2.8, respectively. S03. Establish a three-dimensional electromagnetic field simulation model based on the finite element analysis method to simulate the magnetic flux conduction efficiency. The geometric structural parameters, material magnetic parameters and boundary conditions of the three-column iron core are used as inputs to calculate the magnetic flux distribution, magnetic reluctance distribution and eddy current loss distribution under different diameter ratios. The simulation frequency range is from 50Hz to 2000Hz. By comparing and analyzing the magnetic flux conduction efficiency and saturation risk of various diameter ratio combinations, the optimal diameter ratio coefficient that maximizes the magnetic flux conduction efficiency and minimizes the saturation risk is determined. That is, the diameter ratio of the central column to the first side column is 1.35:1, the diameter ratio of the central column to the second side column is 1.35:1, and the diameter ratio of the first side column to the second side column is 1:1. S04, Using vacuum induction melting method to... Alloy powder and The alloy powder was prepared into three different proportions of mixtures according to the determined volume ratio of soft magnetic phase and hard magnetic phase, and then melted at 1450℃ to form the corresponding alloy melts. S05. Various alloy melts are cooled at a rate using a single-roller rapid quenching equipment. Rapid cooling at K / s is used to form an amorphous alloy strip with a thickness of 25μm to 35μm. During the rapid quenching process, the surface linear velocity of the roller is controlled at 25m / s to 35m / s. S06. The amorphous alloy strip is subjected to graded heat treatment in a vacuum annealing furnace. First, it is held at 480℃ for 45 min to achieve structural relaxation to eliminate quenching stress and adjust atomic arrangement. Then, it is held at 620℃ for 75 min to promote the crystallization separation of soft magnetic phase and hard magnetic phase, ensuring the uniform distribution and gradient distribution of the two phases at the nanoscale. S07. The processed two-phase composite magnetic material strip is processed into corresponding sheet materials according to the determined soft magnetic phase and hard magnetic phase volume ratio, and assembled into the upper, middle and lower regions of the central column. The central column, the first side column and the second side column are processed according to the optimal diameter ratio coefficient, and the central column control winding, the first side column working winding and the second side column working winding are wound according to the corresponding winding turn parameters.

[0016] The air gap width adjustment function is used to determine the first air gap width and the second air gap width based on the diameter ratio between the central column and the side columns and the volume ratio of soft magnetic phase to hard magnetic phase in different regions within the central column. The inputs include the diameter of the central column, the diameter of the first side column, the diameter of the second side column, the volume ratio of soft magnetic phase to hard magnetic phase in the upper region of the central column, the volume ratio of soft magnetic phase to hard magnetic phase in the middle region of the central column, and the volume ratio of soft magnetic phase to hard magnetic phase in the lower region of the central column. The output is the numerical values ​​of the first air gap width and the second air gap width.

[0017] The insulation layer thickness matching function is used to determine the correspondence between the insulation layer thickness of the center pillar and the insulation layer thickness of the side pillars. The input includes the insulation layer thickness of the center pillar, and the output is the insulation layer thickness of the first side pillar and the insulation layer thickness of the second side pillar. When the insulation layer of the center pillar is a polyimide film with a thickness of 0.1 mm, the insulation layers of the first and second side pillars are polyester films with a thickness of 0.2 mm. When the insulation layer of the center pillar is a polyimide film with a thickness of 0.3 mm, the insulation layers of the first and second side pillars are polyester films with a thickness of 0.5 mm.

[0018] The layer thickness matching function is used to determine the matching relationship between the layer thickness of the two-phase composite magnetic material and the layer thickness of the silicon steel. The input includes the layer thickness of the two-phase composite magnetic material, and the output is the layer thickness of the silicon steel. When the layer thickness of the two-phase composite magnetic material is 0.1 mm, the layer thickness of the silicon steel is 0.2 mm. When the layer thickness of the two-phase composite magnetic material is 0.5 mm, the layer thickness of the silicon steel is 0.8 mm. The layer thickness matching function is used to ensure the uniformity of magnetic flux distribution within the central column.

[0019] The working winding turns adjustment function is used to adjust the number of turns of the working winding of the first side column and the working winding of the second side column according to the diameter of the side column. The input includes the diameter of the first side column and the diameter of the second side column, and the output is the number of turns of the working winding of the first side column and the working winding of the second side column. When the diameter of the first side column increases, the number of turns of the working winding of the first side column increases accordingly. When the diameter of the second side column increases, the number of turns of the working winding of the second side column increases accordingly. The working winding turns adjustment function is used to maintain the magnetic flux balance between the side columns.

[0020] Specifically, the magnetic parameters refer to magnetic permeability, coercivity, saturation magnetization, and remanent magnetization.

[0021] Specifically, the magnetic property parameter database refers to a set of quantitative relationship data between permeability, coercivity, saturation magnetization, remanent magnetization and the volume ratio of soft magnetic phase to hard magnetic phase obtained through experimental measurements.

[0022] The magnetic field mutual cancellation suppression algorithm specifically refers to a calculation method that analyzes the magnetic field vector distribution generated in adjacent axial regions within the central column, calculates the spatial gradient of the magnetic field intensity in each region, and adjusts the volume ratio of soft magnetic phase to hard magnetic phase in each region to avoid complete magnetic field cancellation.

[0023] The optimal diameter ratio coefficient specifically refers to the diameter ratio between the center column and the side columns that maximizes the magnetic flux conduction efficiency and minimizes the risk of saturation in the three-column core.

[0024] The specific implementation methods of the above steps are described in detail below.

[0025] The three-column core structure, as the core hardware module of the entire magnetically controlled reactor, adopts a symmetrical layout design with a central column and two side columns. The central column is a cylindrical structure with a diameter of 135 mm, its axis extending vertically, and its geometric center located at the center of the entire three-column core. The first and second side columns are both cylindrical structures with a diameter of 100 mm, their axes parallel to the central column's axis. The first side column is located to the left of the central column, and the second side column is located to the right of the central column. The distance between the geometric centers of the two side columns and the geometric center of the central column is 180 mm. The interior of the central column uses a composite structure of alternating layers of two-phase composite magnetic material sheets and silicon steel sheets. The thickness of the two-phase composite magnetic material sheets is 0.3 mm, and the thickness of the silicon steel sheets is 0.5 mm. This alternating stacking structure achieves a gradient distribution of magnetic permeability. The first and second side columns are both composed of stacked silicon steel sheets with a thickness of 0.35 mm. The silicon steel sheets are made of oriented silicon steel to achieve lower core losses.

[0026] Dual-phase composite magnetic material structures, as key hardware components providing tunable magnetic properties, consist of two nanocrystalline phases: a soft magnetic phase and a hard magnetic phase. The soft magnetic phase mainly comprises... The alloy composition, with an average grain size of 120 nanometers, provides high permeability to support efficient transmission of the main magnetic flux. The hard magnetic phase mainly consists of... The alloy composition, with an average grain size of 90 nanometers, provides high coercivity to maintain the long-term stability of remanence. Soft and hard magnetic phases achieve synergistic optimization of magnetic properties at the nanoscale through exchange coupling, forming a continuous magnetic domain structure. The two-phase composite magnetic material within the central pillar exhibits a differentiated phase ratio distribution according to axial position: a soft-to-hard magnetic phase volume ratio of 6.8:3.2 in the upper region, 7.5:2.5 in the middle region, and 7.2:2.8 in the lower region. This gradient distribution effectively suppresses the mutual cancellation effect of magnetic fields in adjacent regions.

[0027] The center column control winding structure, serving as the hardware module for dynamically adjusting the reactance value, is made of flat copper wire with a rectangular cross-section, 5 mm wide and 2 mm thick. The control winding is evenly distributed along the circumference of the center column, with a total of 480 turns, divided into three sections corresponding to the upper, middle, and lower ends of the center column, each with 160 turns. The control winding is connected to a DC power supply module, and the magnetization state within the center column is changed by adjusting the magnitude and direction of the DC excitation current, thereby achieving continuous adjustment of the reactance value. The outer layer of the control winding is covered with polyimide insulation material, with an insulation layer thickness of 0.2 mm and a temperature resistance rating of 180 degrees Celsius.

[0028] The side-column working winding structure, serving as the hardware module for carrying the main current, includes a first side-column working winding and a second side-column working winding. Both working windings are wound with 4 mm diameter circular cross-section copper wire. The first side-column working winding has 320 turns, and both windings have 320 turns, connected in series. The working windings are connected to the AC power system, carrying the main current and generating the main magnetic flux, which forms a closed loop between the center column and the side column. The outer layer of the working windings is covered with a 0.4 mm thick polyester film insulation material, providing excellent electrical insulation performance.

[0029] The air gap structure, as a hardware component for controlling the magnetic reluctance distribution, includes a first air gap located between the central post and the first side post, and a second air gap located between the central post and the second side post. Both the first and second air gaps are 3 mm wide and filled with air. The presence of the air gaps means that the total magnetic reluctance of the magnetic circuit is primarily determined by the air gap reluctance. By controlling the magnetization state of the central post, the magnetic flux distribution at the air gaps can be adjusted, thereby achieving adjustable control of the reactance value. Precise control of the air gap width is achieved through a mechanical positioning device with a positioning accuracy of 0.05 mm.

[0030] The magnetic circuit connection structure, as a hardware component forming a complete magnetic flux loop, includes an upper connection part and a lower connection part. The upper connection part adopts an H-shaped structure, constructed from stacked silicon steel sheets with a thickness of 0.35 mm. The central crossbeam of the H-shaped structure is fixedly connected to the upper surface of the central column by bolts, and the two vertical arms are fixedly connected to the upper surfaces of the first and second side columns, respectively. The lower connection part has the same structural shape as the upper connection part, also employing an H-shaped silicon steel stacked structure. The function of the magnetic circuit connection structure is to allow magnetic flux to be conducted from the central column through the air gap to the side columns, and then through the connection part to form a complete closed magnetic circuit, ensuring the continuity and efficiency of magnetic flux conduction.

[0031] The insulation protection structure, as a hardware component ensuring electrical safety, includes a center column insulation layer, a first side column insulation layer, and a second side column insulation layer. The center column insulation layer is made of polyimide film material, has a cylindrical structure, and its inner diameter is tightly fitted to the outer diameter of the center column; the film thickness is 0.2 mm. The first and second side column insulation layers are both made of polyester film material, also with a cylindrical structure, and their inner diameters are tightly fitted to the outer diameters of their respective side columns; the film thickness is 0.4 mm. The function of the insulation protection structure is to prevent electrical short circuits between the windings and the core, ensuring the safe and reliable operation of the equipment.

[0032] The preparation process of the dual-phase composite magnetic material includes the following steps: The specific implementation of step S01 involves using a vibrating sample magnetometer to test the magnetic properties and collect data from samples with different soft-to-hard magnetic phase volume ratios. First, five groups of samples with soft-to-hard magnetic phase volume ratios of 5:5, 6:4, 7:3, 8:2, and 9:1 are prepared, with three parallel samples prepared for each group to ensure data reliability. Then, the samples are placed in the sample holder of the vibrating sample magnetometer and tested under a constant temperature environment of 25 degrees Celsius. The test frequency range is set from 50 Hz to 5000 Hz, with a frequency interval of 50 Hz. During the test, an alternating magnetic field with an amplitude of 5000 Oersted is applied to obtain the hysteresis loop of each sample, and four key magnetic parameters—permeability, coercivity, saturation magnetization, and remanent magnetization—are extracted from the hysteresis loop. After data acquisition, a numerical mapping relationship is established between the magnetic parameters and the soft-to-hard magnetic phase volume ratios, forming a magnetic property parameter database containing 500 data points, providing basic data support for subsequent optimization calculations.

[0033] The specific implementation of step S02 is based on establishing and optimizing a magnetic field cancellation suppression algorithm using a magnetic performance parameter database. First, a three-dimensional geometric model of the central column is established, dividing it axially into three regions: upper, middle, and lower, each region being one-third the column height. Then, the finite difference method is used to calculate the magnetic field vector distribution within each region, with a mesh size of 1 mm and continuous magnetic flux density as the boundary condition. Next, the spatial gradient of the magnetic field strength in adjacent regions is calculated. When adjacent regions are found to have opposite magnetic field directions and a strength difference of less than 100 Oersted, a risk of magnetic field cancellation is identified. The algorithm adjusts the volume ratio of soft to hard magnetic phases in each region through iterative optimization, ensuring a difference of more than 20% in the magnetic field strength between adjacent regions, thus avoiding a decrease in magnetic flux conduction efficiency due to complete magnetic field cancellation. After 50 iterations, the optimal soft to hard magnetic phase volume ratios for the upper, middle, and lower regions of the central column are determined to be 6.8:3.2, 7.5:2.5, and 7.2:2.8, respectively, at which point the magnetic field cancellation effect is reduced to below 5%.

[0034] The specific implementation of step S03 involves establishing a three-dimensional electromagnetic field simulation model based on the finite element analysis method to optimize the diameter ratio. First, a complete three-dimensional geometric model including a three-column core, windings, and air gap is constructed. Spatial discretization is performed using tetrahedral meshes, with a total of approximately 500,000 mesh elements and a minimum mesh size of 0.5 mm. Then, the magnetic parameters, geometric parameters, and boundary conditions of each material are input into the simulation model. The magnetic parameters are derived from the database established in step S01, and the boundary conditions are set to zero magnetic potential at the outer boundary. Next, the simulation frequency range is set from 50 Hz to 2000 Hz, with a frequency step of 50 Hz. Simulation calculations are performed on nine combinations of central column to side column diameter ratios ranging from 1.2:1 to 1.5:1. The simulation calculations use the time-domain finite element method to solve Maxwell's equations, obtaining the magnetic flux distribution, magnetic reluctance distribution, and eddy current loss distribution for each scheme. Comparative analysis revealed that when the diameter ratio of the central column to the side column is 1.35:1, the magnetic flux conduction efficiency reaches its highest value of 96.8%, while the saturation risk coefficient drops to its lowest value of 0.15. Therefore, the optimal diameter ratio coefficient is determined to be 1.35:1.

[0035] The specific implementation of step S04 involves preparing alloy melts of different proportions using a vacuum induction melting method. First, according to the soft magnetic phase-hard magnetic phase volume ratio determined in step S02, three mixed raw materials are prepared respectively. The first mixture contains... Alloy powder and The mass ratio of the first alloy powder was 68:32, the second mixture was 75:25, and the third mixture was 72:28. The purity of the alloy powder was required to be above 99.5%, with a particle size range of 50 to 100 micrometers. The three mixtures were then separately loaded into graphite crucibles and melted in a vacuum induction melting furnace, with the vacuum level controlled at [value missing]. Below Pascal, the melting temperature was set at 1450 degrees Celsius. During melting, electromagnetic stirring at a frequency of 2 Hz was used to ensure the homogeneity of the alloy composition, and the melting time was 45 minutes. After melting, three alloy melts with different phase ratios were obtained, and the melt temperature was maintained at 1400 degrees Celsius to ensure good fluidity.

[0036] The specific implementation of step S05 involves using a single-roll rapid quenching device to quickly cool the alloy melt to form an amorphous alloy strip. The rapid quenching device uses a 300mm diameter copper cooling roller, the surface of which is precision polished to ensure a smooth strip surface. First, the linear velocity of the roller surface is adjusted to 30 meters per second, and circulating water is used as the cooling medium, with the water temperature controlled at 15 degrees Celsius. Then, the 1400°C alloy melt is sprayed at a stable flow rate onto the high-speed rotating roller surface through a ceramic nozzle. The distance between the nozzle and the roller surface is 2mm, and the spray pressure is 0.1 MPa. The alloy melt cools on the roller surface at a cooling rate... Kelvin was used for rapid cooling, forming an amorphous alloy ribbon with a thickness of 30 micrometers. The rapid quenching process was carried out under an argon protective atmosphere with a purity of 99.99% and a flow rate of 20 liters per minute to prevent oxidation of the ribbon. After cooling, the amorphous alloy ribbon exhibited a uniform metallic luster and showed no signs of oxidation on its surface.

[0037] The specific implementation of step S06 involves performing graded heat treatment on the amorphous alloy strip to obtain a two-phase structure. The heat treatment process is carried out in a vacuum annealing furnace, with the vacuum level controlled at [value missing]. Below Pascal, a molybdenum wire heating element is used to ensure uniform temperature distribution. First, the amorphous alloy ribbon is placed on a quartz substrate and heated to 480°C at a heating rate of 5°C per minute, held at this temperature for 45 minutes to achieve structural relaxation. Structural relaxation eliminates internal stress generated during rapid quenching, adjusts atomic arrangement to a stable state, and creates favorable conditions for subsequent crystallization. Then, heating continues at a rate of 3°C per minute to 620°C, held at this temperature for 75 minutes to promote the crystallization separation of the soft and hard magnetic phases. During crystallization, atoms rearrange to form nanoscale soft and hard magnetic phase grains, achieving a uniform and gradient spatial distribution. After heat treatment, it is furnace cooled to room temperature for approximately 8 hours, yielding a composite magnetic material ribbon with a dual-phase structure.

[0038] The specific implementation of step S07 involves processing the processed two-phase composite magnetic material strip into sheet materials and assembling them into a complete magnetically controlled reactor. First, a laser cutting device is used to process the strip into corresponding sheet materials according to different soft magnetic phase to hard magnetic phase volume ratios. The sheet size is determined based on the geometric parameters of the central column, with a diameter of 135 mm and a thickness of 0.3 mm. During the cutting process, the laser power is set to 200 watts, the cutting speed is 50 mm / min, and the nitrogen-assisted blowing pressure is 0.3 MPa to ensure smooth, burr-free cutting edges. Then, the sheet materials of different proportions are assembled axially into the upper, middle, and lower regions of the central column. The upper region uses sheets with a soft magnetic phase to hard magnetic phase volume ratio of 6.8:3.2, the middle region uses sheets with a ratio of 7.5:2.5, and the lower region uses sheets with a ratio of 7.2:2.8. During assembly, 0.5 mm thick silicon steel sheets are inserted between the sheets to form an alternating stacked structure. Next, the center column and side columns are machined according to the optimal diameter ratio of 1.35:1. The center column has a diameter of 135 mm, and the first and second side columns each have a diameter of 100 mm and a height of 400 mm. Finally, each winding is wound according to the calculated winding turn parameters. The total number of turns in the center column control winding is 480, and the number of turns in the first and second side column working windings is 320 each. After winding, insulation treatment and final assembly are performed to form a complete single-phase three-column magnetically controlled reactor based on two-phase composite magnetic materials.

[0039] Furthermore, the air gap width adjustment function determines the optimal air gap size based on the geometric parameters of the central column and side columns, as well as the phase ratio distribution of different regions within the central column. The input data for this function includes the diameter of the central column, the diameter of the first side column, the diameter of the second side column, the volume ratio of soft to hard magnetic phases in the upper region of the central column, the volume ratio of soft to hard magnetic phases in the middle region of the central column, and the volume ratio of soft to hard magnetic phases in the lower region of the central column. These input parameters are derived from the diameter ratio optimization results in step S03 and the phase ratio optimization results in step S02, respectively. The function first establishes a magnetic flux continuity equation based on Kirchhoff's laws for magnetic circuits, equating the three-column magnetic circuit to a series-parallel magnetic circuit network containing the magnetic reluctance of the central column, the magnetic reluctance of the side columns, the air gap magnetic reluctance, and the magnetic reluctance of the connecting parts. Then, a magnetic reluctance network analysis method is used to calculate the magnetic flux distribution under different air gap widths, and an iterative optimization algorithm is used to find the air gap width combination that maximizes magnetic flux conduction efficiency. The function integrates a magnetic saturation detection algorithm; when the magnetic flux density in any region exceeds the saturation threshold of 1.8 Tesla, the corresponding air gap width is automatically increased to reduce the magnetic flux density. The optimization process also considers the impact of the phase ratio differences in different regions of the central column on the local permeability. The equivalent permeability is calculated using a weighted average method to ensure the matching between the air gap design and material properties. The function outputs the widths of the first and second air gaps with an accuracy of 0.1 mm, providing accurate dimensional parameters for subsequent machining.

[0040] Furthermore, the insulation thickness matching function determines the corresponding insulation thickness requirements based on the voltage level and thermal load characteristics of different windings. The input data for this function is the insulation thickness of the center post, which is determined based on the DC voltage level and expected operating temperature of the center post control winding. Typically, the control winding operating voltage is 48 volts DC, and the operating temperature range is -20°C to 80°C. Based on electrical insulation design theory, the function establishes a mathematical relationship between the insulation thicknesses of different parts using insulation matching principles. The function integrates a material thermal aging model, considering the insulation performance degradation of polyimide and polyester films under long-term operating conditions, and predicts the service life of the insulation material using the Arrhenius equation. The function also considers the thermal expansion effect of the winding conductors; as the temperature rises, the conductor diameter increases, generating additional mechanical stress on the insulation layer, thus requiring a certain margin in the thickness design. The function uses a safety factor method to ensure insulation reliability, setting the safety factor for the center post insulation layer to 2.5 and the safety factor for the side post insulation layer to 2.0, establishing the thickness matching relationship based on these safety factors. The function outputs the thickness of the insulation layer of the first side post and the thickness of the insulation layer of the second side post. When the insulation layer thickness of the center post is 0.1 mm, the insulation layer thickness of the side post is output as 0.2 mm. When the insulation layer thickness of the center post is 0.3 mm, the insulation layer thickness of the side post is output as 0.5 mm.

[0041] Furthermore, the sheet thickness matching function determines the optimal thickness combination between the two-phase composite magnetic material sheets and the silicon steel sheets based on the principle of magnetic flux distribution uniformity. The input data for this function is the thickness of the two-phase composite magnetic material sheets, a parameter determined comprehensively based on material preparation process capabilities and magnetic performance requirements. Typically, sheet thickness is limited by the rapid quenching cooling rate and subsequent heat treatment processes. The function establishes a quantitative relationship between sheet thickness and magnetic flux distribution uniformity based on the principle of minimizing the magnetic flux density gradient. Internally, the function employs a finite element method, dividing the central column radially into multiple thin-layer units and calculating the magnetic flux density distribution within each unit under different thickness combinations. An optimization algorithm is used to find the thickness combination that minimizes the standard deviation of the magnetic flux density, ensuring the uniformity of magnetic flux distribution within the central column. The function also considers the impact of eddy current losses. When the sheet thickness is too large, significant eddy current losses will occur within the sheet, reducing overall efficiency. Therefore, a balance needs to be found between magnetic flux uniformity and loss control. The function uses a multi-objective optimization algorithm, simultaneously optimizing magnetic flux uniformity and eddy current losses, and determines the optimal solution through Pareto front analysis. The function outputs the thickness of the silicon steel sheet. When the thickness of the two-phase composite magnetic material sheet is 0.1 mm, the output of the silicon steel sheet thickness is 0.2 mm. When the thickness of the two-phase composite magnetic material sheet is 0.5 mm, the output of the silicon steel sheet thickness is 0.8 mm, ensuring the efficiency and uniformity of magnetic flux conduction within the central column.

[0042] Furthermore, the working winding turns adjustment function determines the optimal turns configuration of the working winding based on the side post geometric parameters and magnetic flux balance requirements. The input data for this function includes the diameters of the first and second side posts, which are derived from the geometric optimization results in step S03. Typically, the diameters of both side posts are equal to ensure the symmetry of the magnetic circuit. Based on Ampere's circuital law and the principle of magnetic flux continuity, the function establishes a mathematical relationship between the side post magnetomotive force and the number of winding turns. Internally, the function employs a magnetic circuit equivalence analysis method, treating each side post as a series circuit of a magnetomotive force source and a magnetoresistive element, and calculates the transfer function between the winding current and magnetic flux through circuit analysis. The function considers the impact of changes in side post diameter on the winding inductance. When the side post diameter increases, both the geometric inductance and magnetic coupling inductance of the winding increase accordingly, requiring adjustment of the turns to maintain the preset inductance value. The function also integrates a magnetic flux balance control algorithm. By monitoring the magnetic flux distribution in the two side posts in real time, when a magnetic flux imbalance exceeds 5%, the function automatically adjusts the number of turns in the corresponding winding to restore balance. The function employs the proportional-integral-derivative (PID) control principle to establish a closed-loop control system for adjusting the number of turns, ensuring the stability of magnetic flux balance during long-term operation. The function outputs the number of turns in the working winding of the first and second side columns. When the diameter of the side column increases by 10%, the corresponding number of winding turns increases by 8%; when the diameter of the side column decreases by 10%, the corresponding number of winding turns decreases by 8%. This dynamic adjustment mechanism maintains the magnetic flux balance between the side columns and the stable operation of the overall system.

[0043] It should be noted that the present invention adopts Alloy powder and Two-phase composite materials composed of a hard magnetic phase offer significant technological advantages over traditional single-phase silicon steel. While traditional silicon steel possesses excellent magnetic permeability, its single-phase structure is prone to forming large-scale continuous eddy current loops under alternating magnetic fields, leading to severe energy loss. The two-phase design of this invention fundamentally restricts the formation space of eddy currents by controlling the grain size of the soft magnetic phase to the nanometer level. Simultaneously, the hard magnetic phase, as a dispersed phase, forms numerous heterogeneous interfaces within the soft magnetic phase matrix, effectively blocking eddy current propagation. The synergistic effect of the two-phase material not only maintains excellent magnetic permeability but also significantly reduces eddy current losses through precise microstructural control, fundamentally solving the loss problem that traditional single-phase materials cannot overcome.

[0044] This invention employs a differentiated volume ratio of soft and hard magnetic phases in different axial regions of the central column. This gradient design offers unique technical advantages over traditional uniform material distribution. Traditional magnetically controlled reactors typically use the same material properties and structural parameters throughout the entire core. This uniform design ignores the spatial inhomogeneity of the magnetic field distribution, easily leading to magnetic field concentration or mutual cancellation in some areas, affecting the overall magnetic flux conduction efficiency. This invention precisely calculates the optimal volume ratio for each axial region through a magnetic field mutual cancellation suppression algorithm, resulting in a reasonable gradient distribution of magnetic field strength in adjacent regions, avoiding conduction efficiency loss caused by complete magnetic field vector cancellation. This precise spatial control not only optimizes the magnetic flux conduction path but also further enhances the eddy current suppression effect by controlling the spatial distribution of interface density, achieving spatially optimized configuration of magnetic properties.

[0045] This invention employs a three-column symmetrical structure and determines the optimal diameter ratio, offering significant technical advantages over traditional four-column or complex multi-column structures. While traditional complex structures can achieve basic magnetic flux regulation, their complex magnetic circuits and uneven magnetic flux distribution easily lead to magnetic flux leakage and local magnetic field distortion at structural connections, all of which increase the likelihood of eddy current generation. The three-column symmetrical design of this invention, through finite element simulation optimization of the determined diameter ratio, achieves uniform distribution and rational conduction of magnetic flux among the columns. The simplified magnetic circuit structure reduces unnecessary magnetic flux variations and magnetic field distortion. The symmetrical design not only ensures the stability and predictability of the magnetic circuit but also reduces the root cause of eddy current generation by decreasing the complexity of the magnetic flux path, providing strong support for eddy current suppression at the structural level.

[0046] The synergistic effect of these three core technological approaches has produced a comprehensive effect far exceeding that of a single technological improvement, forming a systematic eddy current suppression solution. At the microscale, two-phase materials suppress eddy current generation through grain refinement and interface blocking mechanisms; axial gradient configuration at the mesoscale eliminates magnetic field inhomogeneity through spatial optimization; and the three-column symmetric structure at the macroscale reduces magnetic circuit complexity through geometric optimization. These three levels of technological improvements form a comprehensive eddy current control system from materials to structure. This multi-scale synergy not only achieves breakthroughs over traditional methods at each technological level, but more importantly, through the mutual promotion and complementarity between different technological approaches, it constructs a complete low-loss magnetic circuit system, fundamentally solving the technical problem of high eddy current losses in traditional magnetically controlled reactors.

[0047] Specifically, the principle of this invention is as follows: This invention can solve the core problem of high eddy current loss, and its technical principle is based on the size effect of nanomaterials and the interface effect of multiphase composite materials. The suppression mechanism of eddy current loss is first reflected in the size effect of nanocrystals, when the soft magnetic phase When the grain size is reduced to the range of 50 nm to 200 nm, the space for eddy current formation within a single grain is severely limited. According to the eddy current loss formula, the loss power is proportional to the square of the conductor geometry. The introduction of nanoscale grains significantly reduces the effective conductor size, thereby reducing the eddy current loss density by orders of magnitude. Simultaneously, numerous grain boundaries exist between nanocrystals, which possess high resistivity and form a natural barrier to eddy current propagation.

[0048] The blocking effect of the two-phase interface is another important mechanism for suppressing eddy current losses. Hard magnetic phase Dispersed as nanoparticles within a soft magnetic matrix, the interfaces between the two phases possess distinct electrical and magnetic properties. When eddy currents attempt to propagate across these interfaces, they encounter reflection and scattering effects due to impedance mismatch, forcing the eddy current path to be interrupted or its direction altered, preventing the formation of large-scale continuous loops. This multi-interface segmentation decomposes what could have formed a large circular eddy current into numerous tiny localized eddy currents, each with a significantly reduced spatial extent and current intensity.

[0049] The differentiated volume ratio configuration of soft and hard magnetic phases within the central column further optimizes the eddy current suppression effect. By setting volume ratio gradients of 6.8:3.2, 7.5:2.5, and 7.2:2.8 in different axial regions, spatial control of the interface density is achieved. This increases the interface blocking effect in regions with high eddy current density and optimizes magnetic permeability in regions with high magnetic flux conduction requirements. This gradient design ensures both the continuity of magnetic flux conduction and maximizes the eddy current suppression effect.

[0050] The technical solution of this invention has a solid physical foundation and rigorous logic. Material design follows the fundamental principles of nanomaterials science, utilizing the synergistic effect of size and interface effects to achieve performance optimization. Structural design is based on electromagnetic field theory and magnetic circuit analysis, reducing ineffective magnetic flux changes through geometric parameter optimization. Process control ensures the precise formation and stable existence of the two-phase structure. The overall technical solution, through a multi-level eddy current suppression mechanism, fundamentally solves the eddy current loss problem of traditional magnetically controlled reactors from a material perspective.

[0051] The following provides a specific embodiment 1 of the present invention, and the specific implementation of each step in this embodiment 1 is described in detail below.

[0052] The specific implementation of step S01 involves establishing a magnetic property parameter database using a vibrating sample magnetometer, and obtaining a quantitative relationship between magnetic parameters and volume ratio by measuring the hysteresis loops of samples with different soft and hard magnetic phase volume ratios. The expression for the relationship between magnetic parameters and the soft and hard magnetic phase volume ratio is as follows: ; ; ; .

[0053] In the formula, The relative permeability, Coercivity, measured in A / m. The saturation magnetization is expressed in tons (T). Remanent magnetization, in tons (T). The volume ratio of the soft magnetic phase to the hard magnetic phase. The coefficient of the quadratic term, The coefficient of the linear term, is a constant term. Where, The value range is 0.15 to 0.25. The value range is 2.8 to 3.5. The value range is 850 to 950. The value range is -0.08 to -0.05. The value range is -1.2 to -0.8. The value range is 180 to 220. The formula for calculating the area of ​​the hysteresis loop is... In the formula The area of ​​the hysteresis loop is expressed in J / m². , The magnetic field strength, Let be the magnetic flux density, where the integral path is a complete hysteresis loop. The coefficients were obtained by fitting the experimental data points using the least squares method, with the fitting error controlled within 5%.

[0054] The specific implementation of step S02 is to establish a magnetic field mutual cancellation and suppression algorithm based on the magnetic performance parameter database to perform magnetic field cancellation and suppression calculations. The formula for calculating the spatial gradient of magnetic field intensity in adjacent axial regions within the central column is: .

[0055] In the formula, For the first The magnetic field strength gradient of each region, in A / , For the first The magnetic field strength of each region is expressed in A / m. This is the axial coordinate, in meters. The spacing between zones is one-third of the column height. The criteria for determining the risk of magnetic field cancellation are: .

[0056] In the formula, The gradient threshold is set to 100 A / , The strength difference threshold is set to 100 A / m. The objective function for optimizing the volume ratio is: .

[0057] In the formula, To optimize the objective function, This is the weighting coefficient, with a value of 1.0. For the first The target magnetic field strength of each region The equilibrium factor is set to 0.5. The optimal volume ratio is determined iteratively using the gradient descent algorithm.

[0058] The specific implementation of step S03 involves establishing a three-dimensional electromagnetic field simulation model based on the finite element analysis method to simulate magnetic flux conduction efficiency. The finite element discretization form of Maxwell's equations is as follows: .

[0059] In the formula, This is a vector magnetic potential, measured in Wb / m. Permeability, in H / m. Angular frequency, in rad / s. Electrical conductivity, measured in S / m. Source current density, in A / , The imaginary unit, For curl operator, This is the gradient operator. The formula for calculating magnetic flux conduction efficiency is: .

[0060] In the formula, For magnetic flux conduction efficiency, Output magnetic flux, measured in Wb. Input magnetic flux, in Wb. Magnetic flux density For the output cross section, The input cross-section is used. Diameter ratio optimization employs a genetic algorithm, with the fitness function being: .

[0061] In the formula, For the fitness function, As an efficiency weight, it is set to a value of 0.7. The saturation risk weight is set to 0.3. The saturation risk factor is calculated when the magnetic flux density exceeds 1.8T. ,otherwise .

[0062] The specific implementation methods for steps S04-S05 are the same as those described above, and will not be repeated in detail here.

[0063] The specific implementation of step S06 involves performing graded heat treatment on the amorphous alloy strip. The crystallization kinetic equation during the heat treatment process is as follows: .

[0064] In the formula, Crystallization fraction, Time, in seconds. For frequency factors, the value is... s , The activation energy is set to 285 kJ / mol. The gas constant is 8.314 J / (mol·K). This is absolute temperature, measured in Kelvin (K). The Avramie index is set to 1.5. Grain size is calculated using the Scherrer formula: .

[0065] In the formula, The average grain size is expressed in nm. The wavelength of the X-ray is 0.154 nm. The full width at half maximum (FWHM) of the diffraction peak. The diffraction angle is expressed in radians.

[0066] The specific implementation method of step S07 is the same as described above, and will not be repeated in detail here.

[0067] The specific implementation of the air gap width adjustment function involves optimizing the air gap width by establishing a magnetic flux continuity equation based on Kirchhoff's laws for magnetic circuits. The formula for calculating the air gap width is: .

[0068] In the formula, The optimal air gap width, in meters. Let be the vacuum permeability, with a value of . H / m, This is the cross-sectional area of ​​the air gap, in units of... , The air gap magnetic field strength, Let be the air gap magnetic flux density. The total magnetic reluctance is calculated in the magnetoresistive network analysis as follows: .

[0069] In the formula, Total magnetic reluctance, in ohms (H). , For iron core magnetic reluctance, For the first air gap reluctance, For the second air gap reluctance, The magnetic reluctance is for the connecting part. In the formula This refers to the length of the magnetic circuit in the iron core, in meters (m). The magnetic permeability of the iron core is expressed in H / m. The cross-sectional area of ​​the iron core is given in units of... The formula for calculating air gap magnetic reluctance is as follows: In the formula The width of the air gap. This represents the cross-sectional area of ​​the air gap.

[0070] The specific implementation of the insulation layer thickness matching function is based on establishing a thickness matching relationship according to electrical insulation design theory. The insulation thickness calculation formula is: .

[0071] In the formula, The insulation layer thickness is expressed in meters (m). For safety, the value for the center column is set at 2.5, and the value for the side columns is set at 2.0. This refers to the operating voltage, measured in volts (V). To achieve the breakdown field strength, the polyimide film is set to a value of [value missing]. V / m, for polyester film, is a value of V / m. Thermal aging life prediction uses the Arrhenius equation: .

[0072] In the formula, Service life, in hours. For reference lifespan, the value is taken as follows: h, The aging activation energy is set to 105 kJ / mol.

[0073] The specific implementation of the sheet thickness matching function is based on the principle of magnetic flux distribution uniformity to determine the optimal thickness matching. The formula for calculating the standard deviation of magnetic flux density is: .

[0074] In the formula, This represents the standard deviation of magnetic flux density, in tons (T). To calculate the number of units, For the first The magnetic flux density of each unit Let be the average magnetic flux density. The formula for calculating eddy current loss density is: .

[0075] In the formula, Eddy current loss density, in W / , For electrical conductivity, For the thickness of the sheet, For frequency, To maximize magnetic flux density. The multi-objective optimization function is: .

[0076] In the formula, It is a multi-objective function. The uniformity weight is set to 0.6. The loss weight is set to 0.4.

[0077] The specific implementation of the working winding turns adjustment function is based on establishing the relationship between turns and magnetomotive force according to Ampere's circuital law. The formula for calculating the number of turns is: .

[0078] In the formula, The number of turns in the winding. The magnetic field strength of the magnetic circuit. This is the length of the magnetic circuit, in meters. This is the operating current, expressed in amperes (A). The formula for calculating winding inductance is: .

[0079] In the formula, The winding inductance is expressed in ohms (H). For effective permeability, This is the cross-sectional area of ​​the winding. Where is the winding length. The magnetic flux balance criterion is: .

[0080] In the formula, For the first side column magnetic flux, For the second side column magnetic flux, To balance the error threshold, a value of 5% of the total magnetic flux is set. The number of turns is adjusted using a proportional-integral-derivative (PID) control algorithm, with the following adjustment formula: .

[0081] In the formula, For the number of turns adjustment, For magnetic flux error, This is the proportionality coefficient, with a value of 0.8. This is the integral coefficient, with a value of 0.2. is the differential coefficient, with a value of 0.1.

[0082] It should be noted that the quadratic function relationship between the magnetic parameters and the volume ratio of the soft magnetic phase to the hard magnetic phase is... The principle of the four equations is based on the magnetic synergistic effect theory of two-phase composite materials. By establishing the quantitative relationship between magnetic permeability, coercivity, saturation magnetization and remanent magnetization and phase ratio, the magnetic properties of two-phase composite magnetic materials can be accurately predicted and controlled. Compared with traditional single magnetic materials, this mathematical model can achieve continuous adjustment of magnetic properties by adjusting the phase ratio, providing a wide range of reactance adjustment capability for magnetically controlled reactors and avoiding the limitation of adjustment range caused by the fixed magnetic properties of traditional magnetically controlled reactors.

[0083] Formula for calculating the spatial gradient of magnetic field strength The principle is based on the finite difference numerical method. By calculating the spatial rate of change of magnetic field intensity in adjacent axial regions within the central column, the non-uniformity of magnetic field distribution can be quantitatively analyzed. The effect of this formula is that it can identify and prevent the phenomenon of mutual cancellation of magnetic fields in adjacent regions. Compared with the traditional design method of magnetically controlled reactors that ignores the gradient of magnetic field distribution, this gradient calculation model significantly improves the magnetic flux conduction efficiency and avoids the problem of reactance value adjustment failure caused by magnetic field cancellation.

[0084] Magnetic field cancellation risk assessment conditions The principle is based on the principle of magnetic field vector superposition and electromagnetic field boundary condition theory. By setting gradient threshold and intensity difference threshold, potential magnetic field cancellation risk areas are identified. The effect of this judgment condition is that it can provide early warning of magnetic field cancellation phenomena and trigger a proportional adjustment mechanism. Compared with the traditional magnetically controlled reactor design that passively bears the influence of magnetic field cancellation, this risk judgment model realizes active prevention and intelligent control of magnetic field cancellation, ensuring the stability of the reactor under all operating conditions.

[0085] Volume ratio optimization objective function The principle is based on multi-objective optimization theory and weighted least squares method. By simultaneously optimizing the deviation of the magnetic field strength of each region from the target value and the difference of the magnetic field strength of adjacent regions, the optimal configuration of the volume ratio of soft magnetic phase and hard magnetic phase is achieved. The effect of this objective function is to minimize the risk of magnetic field cancellation while meeting the magnetic field distribution requirements. Compared with the traditional single-objective optimization method, this multi-objective function achieves synergistic optimization of magnetic properties and stability, and significantly improves the overall performance of the magnetically controlled reactor.

[0086] Formula for calculating magnetic flux conduction efficiency The principle is based on the flux continuity theorem and the principle of energy conservation. It quantifies the flux conduction performance by calculating the ratio of output flux to input flux. The effect of this efficiency formula is that it can objectively evaluate the flux conduction capability of different design schemes and guide structural optimization. Compared with the traditional method of judging flux conduction performance based on experience, this quantitative calculation model realizes the accurate measurement and optimization of flux conduction efficiency, ensuring that the magnetically controlled reactor reaches the highest energy transmission efficiency.

[0087] fitness function The principle is based on genetic algorithm optimization theory and multi-objective decision-making theory. By comprehensively considering two key performance indicators, magnetic flux conduction efficiency and saturation risk, it achieves intelligent optimization selection of diameter ratio. The fitness function can avoid magnetic saturation while ensuring high conduction efficiency. Compared with the traditional single index optimization method, this comprehensive evaluation model achieves a balance between performance and safety, ensuring that the magnetically controlled reactor reaches the best balance between high efficiency and high reliability.

[0088] Crystallization kinetic equation The principle is based on the phase transition kinetics theory and Arrhenius reaction rate theory in solid-state physics. By describing the time evolution process of the transformation from amorphous to nanocrystalline state, it achieves precise control of crystallization behavior during heat treatment. The effect of this kinetic equation is that it can predict and control the crystallization separation process of soft magnetic phase and hard magnetic phase. Compared with traditional empirical heat treatment processes, this kinetic model realizes the precise preparation of dual-phase structures, ensuring the controllability of the microstructure and magnetic properties of composite magnetic materials.

[0089] Air gap width calculation formula And magnetoresistive network calculation The principle is based on Ohm's law for magnetic circuits and the theory of magnetoresistive network analysis. By equating the complex three-dimensional magnetic field problem to a magnetoresistive network circuit problem, it achieves quantitative design of air gap width and precise control of magnetic flux distribution. The effect of these formulas is that the optimal air gap size can be accurately determined according to material properties and geometric parameters. Compared with the traditional qualitative design method, this quantitative calculation model significantly improves the accuracy and rationality of air gap design, and ensures the magnetic flux control accuracy and adjustment linearity of the magnetically controlled reactor.

[0090] Formula for calculating the number of turns of the working winding and flux balance control Based on Ampere's circuital law and modern control theory, the principle is to establish a precise relationship between the number of winding turns and the magnetomotive force and to achieve dynamic adjustment by using a proportional-integral-derivative control algorithm. The effect of these formulas is to ensure that the magnetic flux between the two side columns is always in a balanced state. Compared with the traditional static turns design, this dynamic adjustment model realizes real-time control and long-term stability of magnetic flux balance, eliminates harmonic and vibration problems caused by magnetic flux imbalance, and significantly improves the operating quality of the magnetically controlled reactor.

[0091] It should be noted that the variables involved in this invention are explained in detail in Table 1.

[0092] Table 1. Variable Explanation Table

[0093]

[0094] To better understand and implement this invention, the following is a specific application scenario of the invention, Example 2: A power research team received a technical task to design a reactive power compensation device for a 35kV power distribution system. This system is characterized by large voltage fluctuations and frequent load changes. Traditional capacitor bank reactive power compensation methods suffer from slow response speed and low adjustment accuracy. The research team decided to adopt a single-phase three-column magnetically controlled reactor technology based on two-phase composite magnetic materials.

[0095] The equivalent circuit of a three-column structure is as follows: Figure 3 The equivalent circuit is shown below, where U1 is the power supply electromotive force, UK is the control voltage, iG is the working circuit current, ik is the control circuit current, W1 and W2 are the working windings connected in reverse series, and W3 is the control winding. Assume that in the reactor, the induced electromotive force of the working winding W1 is E1, the induced electromotive force of the working winding W2 is E2, and the induced electromotive force of the control winding W3 is E3. Neglect the leakage flux on the primary and secondary sides.

[0096] The research team first conducted system parameter analysis to determine the basic design parameters of the reactor. The system's rated voltage is 35kV, rated current is 500A, and the required reactance adjustment range is 20–120mH with an adjustment accuracy of ±2%. Based on these parameter requirements, the team designed a three-column core structure. The diameter of the central column was set at 135mm, and the diameters of the first and second side columns were both set at 100mm, maintaining a diameter ratio of 1.35:1. The axis of the central column extends vertically, with its geometric center located at the center of the entire three-column core. The first side column is located 180mm to the left of the central column, and the second side column is located 180mm to the right of the central column, forming a symmetrical layout.

[0097] The team precisely designed the proportions of the two-phase composite magnetic material. The soft magnetic phase employs... The alloy composition, with an average grain size controlled at 120 nm, uses a hard magnetic phase. The alloy composition has an average grain size controlled at 90 nm. Differentiated phase ratios are arranged along the axial direction within the central column: the volume ratio of soft magnetic phase to hard magnetic phase is 6.8:3.2 in the upper region, 7.5:2.5 in the middle region, and 7.2:2.8 in the lower region. This gradient distribution structure is achieved through precise powder metallurgy, with the phase ratio control accuracy for each region reaching ±0.1.

[0098] The research team used an alternating stacking process to fabricate the central pillar composite structure. The thickness of the two-phase composite magnetic material sheets was set to 0.3 mm, and the thickness of the silicon steel sheets was set to 0.5 mm. The optimal combination was determined according to the sheet thickness matching function. Through magnetic flux distribution uniformity calculations, the standard deviation of the magnetic flux density was controlled within 0.05 T. Both the first and second side pillars were constructed from stacked 0.35 mm thick oriented silicon steel sheets. The silicon steel sheets used were grade 30Q120, with an iron loss coefficient of 1.2 W / kg.

[0099] The design of the control winding system is a key technical aspect. The center column control winding is made of flat copper wire with a cross-section of 5mm × 2mm, with a total of 480 turns. It is divided into three sections corresponding to the upper, middle, and lower ends of the center column, with 160 turns in each section. The control winding is connected to a controllable DC power supply with an output voltage range of 0–50V, a current range of 0–20A, and a current regulation accuracy of ±0.1A. The outer layer of the control winding is covered with a 0.2mm thick polyimide insulation material, with a temperature resistance rating of 180℃.

[0100] The side-column working windings carry the main current. Both the first and second side-column working windings are wound with 4mm diameter circular cross-section copper wire, each with 320 turns, and are connected in series. The working windings are designed to carry a current of 550A, and the wire is made of T2 copper material with a conductivity of [missing information]. S / m. The outer layer of the working winding is covered with a 0.4mm thick polyester film insulation material, with a dielectric strength reaching [value missing]. V / m.

[0101] Precise control of the air gap structure is crucial to reactor performance. The widths of both the first and second air gaps are set to 3.0 mm, and a high-precision mechanical positioning device ensures the air gap width error is within ±0.05 mm. The air gap width is determined by calculation using an air gap width adjustment function, based on the magnetic flux continuity equation established according to Kirchhoff's laws for magnetic circuits, to find the optimal air gap width. The vacuum permeability Value H / m, air gap cross-sectional area for air gap magnetic field strength for A / m, air gap magnetic induction intensity It is 1.2T.

[0102] The magnetic circuit connection structure adopts an H-shaped silicon steel laminate structure, with both the upper and lower connection parts constructed from 0.35mm thick silicon steel laminates. The central crossbeam of the H-shaped structure has a cross-sectional dimension of 180mm × 40mm, and the vertical arm has a cross-sectional dimension of 120mm × 40mm. It is fixedly connected to the central column and side columns using M12 bolts, with a connection torque of 80 N·m. The connection part is made of 50W470 grade silicon steel sheets, with a magnetic permeability reaching [missing information]. H / m. The resulting three-column structure is as follows: Figure 4 As shown.

[0103] In a magnetically controlled reactor, coupling effects inevitably exist between the two windings; therefore, effective decoupling between the two independent magnetic circuits is necessary. The equivalent magnetic circuit model of a magnetically controlled reactor is as follows: Figure 5 As shown, Figure 5 (a) is the most common model in the prior art.

[0104] Figure 5 (b) is the equivalent magnetic circuit of the magnetically controlled reactor model considering only DC flux. According to Kirchhoff's voltage and current laws (equivalent to magnetomotive force and magnetic flux), we can obtain: ; RS is a known magnetic reluctance of the silicon steel sheet. , Given the DC magnetic flux and R2 as the reluctance of the two-phase composite magnetic material, the air gap reluctance R1 can be calculated, and thus the air gap length can be determined.

[0105] Figure 5 (c) is the equivalent magnetic circuit of the magnetically controlled reactor model considering only AC magnetic flux. According to Kirchhoff's voltage and current laws (equivalent to magnetomotive force and magnetic flux), we can obtain: ; , Given that the alternating magnetic flux is known, and it is undesirable for the alternating magnetic flux to flow through the two-phase composite magnetic material, then let It is 0.

[0106] The winding design in this embodiment fully leverages the characteristics of a three-column structure, employing a separate winding arrangement. The working windings are symmetrically wound on the two side columns. By optimizing the turn distribution and wire diameter design, uniform conduction of the main magnetic flux is ensured, and electromagnetic losses are reduced. The control winding is specifically wound on the central column, and its turn count and current density are precisely calculated to achieve rapid response and precise adjustment to the magnetic saturation state of the central column. Unlike traditional structures, this invention uses a distributed winding design to minimize magnetic flux leakage and coupling interference. The winding material is selected from highly conductive flat copper wire, and multi-layer insulation technology is employed during installation to improve the winding's thermal stability and electrical insulation performance.

[0107] Subsequently, the team established a complete testing and verification system. Reactance was measured using an LCR digital bridge at a frequency of 50Hz, with a testing accuracy of ±0.1%. By adjusting the DC current of the control winding, continuous adjustment of the reactance within the range of 22–115 mH was achieved, with an adjustment accuracy of ±1.8%, meeting the design requirements. The test results of the magnetic performance parameters are shown in Table 2.

[0108] Table 2 Test results of magnetic property parameters of dual-phase composite magnetic materials

[0109] The team conducted dynamic response tests on the control system. When the control winding current was adjusted from 0A to 15A, the reactance response time was 0.8s, an improvement of 84% compared to the 5s response time of traditional capacitor banks. The harmonic distortion rate during reactance adjustment remained below 2.5%, far below the national standard requirement of 5%. Temperature rise tests showed that after 2 hours of continuous operation under rated load, the center column temperature was 65℃, the side column temperature was 58℃, and the control winding temperature was 72℃, all within the design limits.

[0110] The system stability test lasted for 1000 hours, during which 5000 reactance value adjustments were performed. Test results showed that the reactance value adjustment accuracy remained stable, with the adjustment error consistently controlled within ±2%. Insulation resistance tests showed that the working winding's insulation resistance to ground was 500 MΩ, and the control winding's insulation resistance to ground was 800 MΩ, meeting the requirements for safe operation of the power system.

[0111] The team also conducted electromagnetic compatibility (EMC) tests to verify the equipment's impact on the power grid. The electromagnetic radiation intensity generated by the reactor during operation was measured at a distance of 1 meter at 35 dBμV / m, which meets the EMC standards for power equipment. Tests on the reactor's impact on grid harmonics showed that the 5th harmonic content was 1.2%, the 7th harmonic content was 0.8%, and the total harmonic distortion rate was 2.1%, all meeting grid connection standards.

[0112] The winding utilizes a two-phase composite magnetic material composed of a soft magnetic phase and a hard magnetic phase, prepared using a melt fast quenching method combined with a directional magnetic field treatment process to further optimize material properties. The melt fast quenching method rapidly cools molten metal alloys to form nanoscale microstructures, while the directional magnetic field treatment applies an external magnetic field during material solidification, ensuring the directional distribution of the soft and hard magnetic phases at the microscale, thereby enhancing magnetic properties. Furthermore, the soft magnetic phase is primarily composed of alloys with high permeability, effectively improving the material's magnetic flux conduction capability; the hard magnetic phase achieves long-term stability of remanence through highly coercive metal oxides. The exchange coupling between the two phases significantly enhances the response speed and dynamic adjustment capability of the magnetic material at the nanoscale. Finally, precise heat treatment controls the grain size and distribution of the material, ensuring the uniformity of the nanostructure and high magnetic properties.

[0113] The practical application effect was verified through a 6-month on-site trial run at a substation. The substation's load power factor varied between 0.75 and 0.95. After reactive power compensation using a magnetically controlled reactor, the power factor stabilized above 0.98. Voltage fluctuations decreased from ±8% to ±3%, significantly improving power quality. No faults occurred during equipment operation, and maintenance workload was reduced by 60% compared to traditional capacitor banks.

[0114] Operational data statistics show that the magnetically controlled reactor exhibits excellent energy efficiency. The device itself consumes 2.5kW, accounting for 0.8% of the compensation capacity, a 33% reduction compared to the 1.2% of traditional reactors. The device achieves a power density of 85kVA / Compared to the 70kVA of traditional equipment This represents a 21% improvement. Noise testing showed that the equipment's operating noise was 45dB, lower than the national standard requirement of 50dB.

[0115] The results of the load change adaptability test are shown in Table 3.

[0116] Table 3 Reactor performance parameters under different load conditions

[0117] Environmental adaptability testing verified the equipment's reliability under different operating conditions. High-temperature testing was conducted at an ambient temperature of 50℃, during which the equipment operated normally, with performance parameters varying within ±3%. Low-temperature testing was conducted at an ambient temperature of -25℃, during which the equipment started normally, and its steady-state performance met requirements. Humidity testing was conducted at a relative humidity of 95%, during which insulation performance remained stable, with no condensation occurring.

[0118] The team conducted accelerated aging tests on the material's aging characteristics. The material was continuously operated for 500 hours at 120℃ and 1.5 times the rated voltage, simulating 20 years of equipment operation. After the test, the change rate of magnetic properties was within ±5%, insulation performance remained good, and the expected service life reached 25 years. Thermal stability tests on the two-phase composite magnetic material showed that the material structure remained stable at 200℃, with magnetic properties changing by less than 3%.

[0119] Fault simulation tests verified the equipment's safety protection capabilities. In the control winding short-circuit test, the protection system cut off the fault current within 50ms, preventing equipment damage. The working winding overload test showed that when the load current reached 120% of the rated value, the temperature protection system activated, and the equipment safely shut down. In the insulation breakdown test, when the insulation resistance dropped to 1MΩ, the monitoring system promptly alarmed and disconnected the equipment.

[0120] The magnetically controlled reactor employing two-phase composite magnetic material technology significantly outperforms traditional solutions in terms of technical performance. Traditional thyristor-controlled reactors use silicon steel cores and conventional control methods, resulting in a narrow reactance adjustment range, slow response speed, and severe harmonic pollution. This invention, through the application of two-phase composite magnetic materials, achieves precise controllability of magnetic permeability, expands the reactance adjustment range by 15%, and improves adjustment accuracy by 18%. The control response time is shortened by 80% compared to traditional solutions, and the harmonic distortion rate is reduced by 50%. The equipment power density is increased by 21%, operating losses are reduced by 33%, and maintenance workload is reduced by 60%, resulting in a significant improvement in overall technical performance.

[0121] The following provides a specific embodiment 3 of the present invention, focusing on the preparation of the two-phase composite magnetic material applied to the present invention.

[0122] The research team first conducted magnetic property parameter testing and data acquisition. Following the technical solution of this invention, five groups of samples were prepared with soft magnetic phase to hard magnetic phase volume ratios of 5:5, 6:4, 7:3, 8:2, and 9:1. Three parallel samples were prepared for each group to ensure data reliability. A VSM-7400 vibrating sample magnetometer was used for magnetic property testing. The testing environment temperature was controlled at 25℃, and the testing frequency range was set to 50–5000 Hz with a frequency interval of 50 Hz. Hysteresis loops of each sample were obtained by applying an alternating magnetic field with an amplitude of 5000 Oe, and four key magnetic parameters—permeability, coercivity, saturation magnetization, and remanent magnetization—were extracted from the hysteresis loops. The test results are shown in Table 4.

[0123] Table 4. Test results of magnetic parameters for samples with different volume ratios

[0124] Based on the experimental data in Table 4, the research team used the least squares method to establish a quantitative relationship between magnetic parameters and volume ratio, constructing a database of magnetic performance parameters containing 500 data points. The expression for the relationship between relative permeability and volume ratio is as follows: The expression for the relationship between coercivity and volume ratio is: The correlation coefficients of the fitted data are all greater than 0.95, which meets the accuracy requirements for engineering applications.

[0125] Next, the research team established a magnetic field cancellation suppression algorithm for optimization calculations. The central column was divided into three regions along the axial direction: upper, middle, and lower, each with a length of 133 mm. The finite difference method was used to calculate the magnetic field vector distribution in each region, with a mesh size accuracy of 1 mm and a boundary condition of continuous magnetic flux density. The spatial gradient of magnetic field intensity between adjacent regions was calculated. When the magnetic field directions of adjacent regions were detected to be opposite and the intensity difference was less than 100 A / m, it was determined that there was a risk of magnetic field cancellation. The volume ratio of soft magnetic phase to hard magnetic phase in each region was adjusted through an iterative optimization method. After 52 iterations, the optimal volume ratios of soft magnetic phase to hard magnetic phase in the upper, middle, and lower regions of the central column were determined to be 6.8:3.2, 7.5:2.5, and 7.2:2.8, respectively. At this point, the magnetic field cancellation effect was reduced to 3.8%.

[0126] The research team established a three-dimensional electromagnetic field simulation model based on the finite element method to optimize the diameter ratio. A complete three-dimensional geometric model including a three-column core, windings, and air gap was constructed. Tetrahedral meshes were used for spatial discretization, with a total of approximately 480,000 mesh elements and a minimum mesh size of 0.5 mm. The simulation frequency range was set to 50–2000 Hz, with a frequency step of 50 Hz. Simulation calculations were performed on nine combinations of central column to side column diameter ratios ranging from 1.2:1 to 1.5:1. The simulation results are shown in Table 5.

[0127] Table 5 Simulation results of magnetic flux conduction efficiency for different diameter ratios

[0128] As can be seen from the simulation results in Table 5, when the diameter ratio of the central column to the side column is 1.35:1, the magnetic flux conduction efficiency reaches the highest value of 96.8%, while the saturation risk coefficient drops to the lowest value of 0.15, and the comprehensive evaluation index reaches 0.873. Therefore, the optimal diameter ratio coefficient is determined to be 1.35:1.

[0129] Based on the optimized calculation results, the research team began to prepare two-phase composite magnetic materials. They used vacuum induction melting to prepare alloy melts with different proportions, and formulated three mixed raw materials according to a determined volume ratio of soft and hard magnetic phases. In the first mixture... Alloy powder and The mass ratio of the first alloy powder was 68:32, the second mixture was 75:25, and the third mixture was 72:28. The purity of the alloy powder reached 99.6%, and the particle size ranged from 65 to 85 μm. The three mixtures were separately loaded into graphite crucibles and melted in a vacuum induction melting furnace, with the vacuum level controlled at [value missing]. For Pa below 1450℃, the melting temperature is set at 1450℃. During the melting process, electromagnetic stirring is used to ensure the uniformity of the alloy composition, with a stirring frequency of 2Hz and a melting time of 45 minutes.

[0130] A single-roll rapid quenching device is used to rapidly cool the alloy melt to form an amorphous alloy ribbon. The rapid quenching device employs a 300mm diameter copper cooling roller, with the roller surface linear velocity adjusted to 30m / s. Circulating water is used as the cooling medium, and the water temperature is controlled at 15℃. The 1400℃ alloy melt is sprayed at a stable flow rate onto the surface of the high-speed rotating roller through a ceramic nozzle. The distance between the nozzle and the roller surface is 2mm, and the spray pressure is 0.1MPa. The alloy melt cools on the roller surface at a rate... Rapid cooling at K / s was performed to form an amorphous alloy ribbon with a thickness of 30 μm. The rapid quenching process was carried out under an argon protective atmosphere with an argon purity of 99.99% and a flow rate of 20 L / min.

[0131] Amorphous alloy strips are subjected to graded heat treatment to obtain a two-phase structure. The heat treatment process is carried out in a vacuum annealing furnace, with the vacuum level controlled at [value missing]. Below Pa. First, the amorphous alloy ribbon was placed on a quartz substrate and heated to 480℃ at a heating rate of 5℃ / min, holding at this temperature for 45 minutes to achieve structural relaxation. Then, it was heated further to 620℃ at a heating rate of 3℃ / min, holding at this temperature for 75 minutes to promote the crystallization and separation of the soft and hard magnetic phases. After heat treatment, it was furnace cooled to room temperature for approximately 8 hours. X-ray diffraction analysis of the phase structure of the heat-treated sample showed that the average grain size of the soft magnetic phase was 118 nm, and the average grain size of the hard magnetic phase was 89 nm, meeting the design requirements.

[0132] The research team processed the completed two-phase composite magnetic material strips into sheet materials and introduced them into a segmented winding process to assemble them into a complete magnetically controlled reactor, such as... Figure 6As shown, a laser cutting device was used to process the thin strip into corresponding sheet materials with different soft magnetic phase-to-hard magnetic phase volume ratios. The sheet diameter was 135 mm and the thickness was 0.3 mm. During the cutting process, the laser power was set to 200 W, the cutting speed was 50 mm / min, and the nitrogen-assisted blowing pressure was 0.3 MPa. The sheet materials with different proportions were assembled into the upper, middle, and lower regions of the central column according to their axial positions. Silicon steel sheets with a thickness of 0.5 mm were inserted between the sheets to form an alternating superimposed structure. The central column and side columns were processed according to the optimal diameter ratio coefficient of 1.35:1. The diameter of the central column was 135 mm, and the diameters of the first and second side columns were both 100 mm, with a column height of 400 mm for both. The windings were wound according to the calculated winding turn parameters. The total number of turns in the central column control winding was 480, and the number of turns in the first and second side column working windings was 320 each.

[0133] After assembly, the research team conducted performance tests on the magnetically controlled reactor. The test results are shown in Table 6.

[0134] Table 6 Performance test results of magnetically controlled reactor

[0135] Test results show that the performance indicators of the magnetically controlled reactor made of two-phase composite magnetic material all meet the design requirements, and successfully solve the technical problem of insufficient reactive power regulation accuracy in the power system.

Claims

1. A three-column winding structure, characterized in that, It includes a three-limb iron core and a control winding; the three-limb iron core and the control winding work together to achieve dynamic adjustment of the reactance value; the three-limb iron core includes a central column, a first side column, and a second side column. The central column has a cylindrical structure with its axis extending vertically, and its geometric center is located at the center of the entire three-limb iron core; the first side column and the second side column also have cylindrical structures, and their axes are parallel to the axis of the central column. The first side column is located to the left of the central column, and the second side column is located to the right of the central column; the central column is composed of alternating layers of two-phase composite magnetic material and silicon steel sheets. The two-phase composite magnetic material consists of a soft magnetic phase and a hard magnetic phase. The soft magnetic phase mainly contains The alloy composition includes a hard magnetic phase. The alloy composition includes a two-phase composite magnetic material within the central column with different soft and hard magnetic phase volume ratios according to their axial positions. Both the first and second side columns are constructed from stacked silicon steel sheets. The diameter ratio of the central column to the first side column is 1.35:1, the diameter ratio of the central column to the second side column is 1.35:1, and the diameter ratio of the first side column to the second side column is 1:

1. When the diameter of the central column is the reference diameter, the diameter of the first side column is the reference diameter divided by 1.35, and the diameter of the second side column is the reference diameter divided by 1.

35.

2. The three-column winding structure according to claim 1, characterized in that, The volume ratio of soft magnetic phase to hard magnetic phase in the upper region of the central column is 6.8 to 3.2, the volume ratio of soft magnetic phase to hard magnetic phase in the middle region of the central column is 7.5 to 2.5, and the volume ratio of soft magnetic phase to hard magnetic phase in the lower region of the central column is 7.2 to 2.

8.

3. The three-column winding structure according to claim 2, characterized in that, The thickness of the dual-phase composite magnetic material sheet is 0.1 mm to 0.5 mm, and the thickness of the silicon steel sheet is 0.2 mm to 0.8 mm; the average grain size of the soft magnetic phase is 50 nm to 200 nm, and the average grain size of the hard magnetic phase is 30 nm to 150 nm.

4. The three-column winding structure according to claim 3, characterized in that, It also includes a center post control winding structure, which is wound around the outer surface of the center post and is made of flat copper wire. The flat copper wire has a rectangular cross-section with a width of 3mm to 8mm and a thickness of 1mm to 3mm.

5. The three-column winding structure according to claim 4, characterized in that, The central column control winding is evenly distributed along the circumference of the central column. The number of turns of the central column control winding is determined according to the volume ratio of soft magnetic phase to hard magnetic phase in different regions of the central column. When the volume ratio of soft magnetic phase to hard magnetic phase in the upper, middle and lower regions of the central column is 6.8:3.2, 7.5:2.5 and 7.2:2.8 respectively, the number of turns of the central column control winding is adjusted accordingly.

6. The three-column winding structure according to claim 5, characterized in that, It also includes a side column working winding structure, which includes a first side column working winding and a second side column working winding; the first side column working winding is wound on the outer surface of the first side column, and the second side column working winding is wound on the outer surface of the second side column; both the first side column working winding and the second side column working winding are wound with circular cross-section copper wire, and the diameter of the circular cross-section copper wire is 2mm to 6mm.

7. The three-column winding structure according to claim 6, characterized in that, The number of turns in the working winding of the first side column is equal to the number of turns in the working winding of the second side column. The number of turns in the working winding is determined according to the ratio of the diameter of the center column to the diameter of the side column. When the ratio of the diameter of the center column to the diameter of the first side column is 1.35:1 and the ratio of the diameter of the center column to the diameter of the second side column is 1.35:1, the number of turns in the working winding of the first side column and the number of turns in the working winding of the second side column are adjusted according to the corresponding ratio.

8. The three-column winding structure according to claim 7, characterized in that, It also includes an air gap structure, which includes a first air gap and a second air gap; the first air gap is set between the central column and the first side column, and the second air gap is set between the central column and the second side column; the width of the first air gap is equal to the width of the second air gap, and the air gap width is determined by comprehensive calculation based on the diameter ratio of the central column and the side column and the volume ratio of soft magnetic phase and hard magnetic phase in different regions of the central column.

9. A single-phase three-column magnetically controlled reactor, characterized in that, Includes the three-column winding structure as described in any one of claims 1-8.

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