Inlet wire reactor for die casting machine
By increasing the core cross-sectional area, reducing the coil cross-sectional area, increasing the air gap and using thermally conductive silicone to dissipate heat, the reactor saturation problem at high peak current of the die-casting machine is solved, achieving higher stability and low-cost reactance Device design.
Patent Information
- Application Number
- CN202420094107.6
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-01-15
- Publication Date
- 2024-12-20
- Estimated Expiration
- 2034-01-15
AI Technical Summary
The existing general iron core reactors are prone to saturation under high peak current conditions of die-casting machines, resulting in a decrease in reactance and inability to operate stably.
A line inlet reactor for die-casting machines is designed, using a core cross-sectional area larger than that of general-purpose reactor, a coil cross-sectional area smaller, an air gap larger, and heat dissipation through thermally conductive silicone to reduce temperature rise.
It improves the non-saturation performance of the reactor, adapts to the high peak current operation of the die-casting machine, reduces manufacturing costs and temperature fluctuations, and enhances stability and heat dissipation effects.
Smart Images
Figure CN222213920U_ABST
Abstract
Description
Technical Field
[0001] The utility model relates to die-casting machine equipment and a power supply device thereof, in particular to an incoming line reactor for the die-casting machine. Background Art
[0002] In the prior art, the common incoming line reactors are all iron core reactors. The current value of the reactor is based on the rated current of the motor (servo drive) (the following current multiples and percentages are based on the rated current of the motor, that is, the rated current of the motor is 1 times or 100%), and it can pass the rated current for a long time without heating; when the current exceeds the rated value, the reactance drops rapidly due to the saturation effect of the ferromagnetic material of the iron core reactor. The reactor used for the die casting machine is often overloaded with 1.60-2.00 times the current, so when the universal reactor is used in the die casting machine, when the peak current flows through the reactor, the reactance drops rapidly due to the saturation effect of the ferromagnetic material of the iron core reactor, and the current limiting effect and harmonic suppression effect of the reactor are significantly reduced.
[0003] The operation of the die casting machine is characterized by a short operating cycle (20-60 seconds), a small average current (generally less than 35%) and a large peak current (1.6-2.00 times). Traditional general reactors cannot operate stably under such load conditions, so a new reactor design is needed to solve this problem. Utility Model Content
[0004] In order to solve the above problems, the utility model provides an incoming line reactor for a die casting machine, the reactor comprising a reactor body, an input terminal, an output terminal, a thermal conductive silica gel and an installation part;
[0005] The reactor body comprises an iron core and a coil wound on the iron core, and the cross-sectional area of the iron core is larger than the cross-sectional area of a general reactor of the same specification;
[0006] The cross-sectional area of the coil is smaller than the cross-sectional area of the general reactor of the same specification;
[0007] An air gap is provided on the iron core to increase the linear part of the magnetization curve of the magnetic circuit of the reactor;
[0008] The outside of the reactor body is heat-conductive silica gel for heat dissipation and fixation, and the temperature rise of the reactor is reduced by conducting the heat of the reactor to the external heat sink.
[0009] In some possible implementations, the cross-sectional area of the iron core is 25% larger than the cross-sectional area of a common reactor of the same specification.
[0010] In some possible implementations, the cross-sectional area of the coil is 60% smaller than the cross-sectional area of a common reactor of the same specification.
[0011] In some possible implementations, the air gap is larger than the air gap of a common inductor with the same specifications.
[0012] In some possible implementations, the cross-sectional area of the iron core is greater than the cross-sectional area of the iron core of a general inductor of the same specification, and the number of turns of the coil is greater than the number of turns of a general inductor of the same specification.
[0013] In some possible implementations, the iron core is made of silicon steel sheets.
[0014] The beneficial effects brought by the technical solution provided by the embodiment of the utility model include at least:
[0015] Low manufacturing cost: The reactor provided by the utility model reduces the manufacturing cost by reducing the cross-sectional area of the copper wire and increasing the number of silicon steel sheets.
[0016] Adaptation to die-casting machine operation: Since the reactor provided by the utility model is less prone to saturation than general reactors of the same specifications, it is very suitable for the working condition where the die-casting machine always runs under a large overload (peak) current (when the peak current flows, the reactance of the reactor decreases slightly).
[0017] Small temperature fluctuation: In actual operation, the reactor provided by the utility model has a short operation cycle, large current changes, and small internal temperature fluctuations, thereby improving the stability and life of the reactor.
[0018] Good heat dissipation effect: the reactor provided by the utility model improves the heat dissipation effect by adopting copper terminals, multi-layer winding coils, thermal conductive silica gel and other measures. BRIEF DESCRIPTION OF THE DRAWINGS
[0019] In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the drawings required for use in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without creative work.
[0020] Figure 1 It is a schematic structural diagram of a reactor provided by an exemplary embodiment of the utility model.
[0021] Description of reference numerals:
[0022] Silicon steel sheet 1, air gap 2, coil 3. DETAILED DESCRIPTION
[0023] In order to make the purpose, technical solution and advantages of the present invention more clear, the implementation mode of the present invention will be further described in detail below with reference to the accompanying drawings.
[0024] The utility model is described in detail below in conjunction with specific embodiments. The following embodiments will help those skilled in the art to further understand the utility model, but do not limit the utility model in any form. It should be pointed out that for those of ordinary skill in the art, several changes and improvements can be made without departing from the concept of the utility model. These all belong to the protection scope of the utility model.
[0025] The following is an explanation of the operating characteristics of the die-casting machine to help readers better understand the utility model. The die-casting machine has the following operating characteristics:
[0026] 1) Short operation cycle (20-60 seconds)
[0027] 2) The average current is small (generally less than 35% of the motor rated current),
[0028] 3) Large peak current (1.6-2.0 times the rated current of the motor).
[0029] Load characteristics of die casting machine: die casting machine works in a cycle working system, and the cycle is short, generally 20-60 seconds. In its working cycle, its average load current is very small, about 20-35%, but in a very short time (1-2 seconds, generally not more than 5 seconds) the load current (peak value) is very large, up to 160-180%, or even 200%.
[0030] The general incoming line reactor generally takes the rated current of the motor (servo drive) as the reference value, and can pass the rated current for a long time without heating; when the current exceeds the rated value, the reactance value drops rapidly. For example, when the rated current is 1.80 times, the reactance value is only 0.6 times the rated value. The reactor used for die-casting machines is often overloaded with 1.60-2.00 times the current. Therefore, when the general reactor is used in the die-casting machine, when the peak current flows through the reactor, the reactance drops rapidly, and the current limiting effect and harmonic suppression effect of the reactor are significantly reduced. The die-casting machine always repeatedly runs at a large peak current state, so the general reactor is not suitable for the die-casting machine.
[0031] See also Figure 1 , In order to solve the above problems, the utility model provides an incoming line reactor for a die casting machine, the reactor includes a reactor body, an input terminal, an output terminal, a thermal conductive silica gel and an installation part;
[0032] The reactor body comprises an iron core and a coil 3 wound around the iron core, and the cross-sectional area of the iron core is larger than the cross-sectional area of a general reactor of the same specification;
[0033] The cross-sectional area of the coil 3 is smaller than that of a common reactor of the same specification;
[0034] An air gap 2 is provided on the iron core to increase the linear part of the magnetization curve of the magnetic circuit of the reactor;
[0035] The outside of the reactor body is made of thermally conductive silicone for heat dissipation and fixation, and the temperature rise of the reactor is reduced by conducting the heat of the reactor to the external heat sink.
[0036] The following is an introduction to the main structure and function of the iron core reactor. The iron core reactor consists of a coil, an iron core, and an air gap. The coil functions as follows: AC current flows through it, the alternating current excites the alternating magnetic flux, and the alternating magnetic flux induces an electric potential in the coil. The iron core functions as follows: it constitutes the main circuit of the magnetic flux, and the alternating magnetic flux induces an electric potential in the coil. The air gap functions as follows: it is an important part of the magnetic circuit, preventing the magnetic flux in the reactor from saturating.
[0037] In the iron core, when the coil current is not large, the magnetic flux is proportional to the coil current, but when the coil current increases to a certain level, the magnetic flux is no longer proportional to the current, and the ratio of magnetic flux to current decreases (the increase in magnetic flux is less than the increase in current, which is called the saturation effect of ferromagnetic materials). In the air gap, the magnetic flux is proportional to the coil current (called a linear relationship, the magnetic flux increases as many times as the current increases, and there is no saturation effect).
[0038] The relationship between the current and magnetic flux of a normal iron core reactor (magnetization characteristic curve) is between that of ferromagnetic materials and air gaps. When the air gap is reduced, the magnetization characteristics of the reactor are close to those of ferromagnetic materials (easy to saturate, and the reactance decreases rapidly when the current increases). When the air gap is increased, the magnetization characteristics of the reactor are close to those of the air gap (not easy to saturate, and the reactance value decreases slightly when the current increases).
[0039] Specifically, the cross-sectional area of the iron core is 25% larger than that of a general inductor of the same specification. The cross-sectional area of the coil 3 is 60% smaller than that of a general inductor of the same specification. The air gap 2 is larger than the air gap of a general inductor of the same specification. The cross-sectional area of the iron core is larger than that of the iron core of a general inductor of the same specification, and the number of turns of the coil is larger than that of a general inductor of the same specification. The iron core is made of silicon steel sheet 1.
[0040] Furthermore, the utility model provides specific measures including the following:
[0041] (1) Because the average current of the reactor used in the die-casting machine is small and the operating cycle is short (although the current changes greatly in the same cycle, the temperature fluctuation inside is very small). The utility model reduces the cross-sectional area of the copper wire of the reactor, which is about 60% of the general reactor of the same specification, but the current density (the current flowing through the unit cross-section) remains basically unchanged. The material cost of manufacturing the reactor is mainly copper wire and silicon steel sheet. When the quality is the same, the price of copper wire is about 15-20 times that of silicon steel sheet. After the quality of copper wire decreases by 60%, the total material cost is significantly reduced.
[0042] (2) To cope with the large peak current of the reactor, the length of the reactor air gap is increased to make it less likely to saturate. This solution increases the air gap of the reactor, and the magnetic circuit is more likely to be less likely to saturate. The magnetic circuit is divided into two parts, one part is ferromagnetic material with saturation characteristics; the other part is the air gap, which does not have saturation characteristics. Therefore, the utility model increases the less likely saturation performance of the magnetic circuit by increasing the air gap.
[0043] After increasing the air gap of the reactor, the magnetic flux of the reactor decreases. In order to keep its magnetic flux basically unchanged, the cross-sectional area of the iron core is increased (the corresponding silicon steel sheet mass is increased by about 25%), and the number of turns of the reactor coil is appropriately increased.
[0044] The reactor of the utility model has low manufacturing cost. For the reactor of the same specification, the copper usage is reduced by 60% and the silicon steel sheet usage is increased by 25%. Since the price of copper is about 15-20 times of that of silicon steel sheet, the total material cost is significantly reduced.
[0045] The reactor of the utility model is not easy to be saturated and is very suitable for the working condition where the die-casting machine often runs under a large overload (peak) current.
[0046] 1) The following are the characteristics of a reactor of this utility model:
[0047]
[0048] Note: The current and reactance values are all based on the rated value as 100%
[0049] It can be seen from the table that at 1.8 times the rated current, the reactor still has a reactance value of 0.857 times the rated current, which is fully sufficient for the operation of the die-casting machine.
[0050] The reactor provided by the utility model is an innovative design based on the actual operating environment and characteristics, and can effectively avoid the configuration waste and mismatch problems of general reactors.
[0051] After considering the specification and practicing the scheme disclosed herein, those skilled in the art will easily think of other embodiments of the utility model. The utility model is intended to cover any variation, use or adaptation of the utility model, which follows the general principles of the utility model and includes common knowledge or conventional technical means in the technical field not disclosed in the utility model.
[0052] It should be understood that the present invention is not limited to the precise structure described above and shown in the drawings, and various modifications and changes can be made without departing from the scope thereof. The scope of the present invention is limited only by the appended claims.
[0053] It should be understood that the "plurality" mentioned in this article refers to two or more. "And / or" describes the association relationship of the associated objects, indicating that there can be three relationships. For example, A and / or B can mean: A exists alone, A and B exist at the same time, and B exists alone. The character " / " generally indicates that the associated objects are in an "or" relationship.
[0054] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the protection scope of the present invention.
Claims
1. A line reactor for a die casting machine, characterized in that: The reactor comprises a reactor body, an input terminal, an output terminal, a thermally conductive silica gel and a mounting part; The reactor body comprises an iron core and a coil wound on the iron core, and the cross-sectional area of the iron core is larger than the cross-sectional area of a general reactor of the same specification; The cross-sectional area of the coil is smaller than the cross-sectional area of the general reactor of the same specification; An air gap is provided on the iron core to increase the linear part of the magnetization curve of the magnetic circuit of the reactor; The outside of the reactor body is heat-conductive silica gel for heat dissipation and fixation, and the temperature rise of the reactor is reduced by conducting the heat of the reactor to the external heat sink.
2. The reactor according to claim 1, characterized in that: The cross-sectional area of the iron core is 25% larger than that of a common reactor of the same specification.
3. The reactor according to claim 1, characterized in that: The cross-sectional area of the coil is 60% smaller than that of the general reactor of the same specification.
4. The reactor according to claim 1, characterized in that: The air gap is larger than the air gap of a common reactor of the same specification.
5. The reactor according to claim 4, characterized in that: The cross-sectional area of the iron core is greater than the cross-sectional area of the iron core of a general inductor of the same specification, and the number of turns of the coil is greater than the number of turns of a general inductor of the same specification.
6. The reactor according to claim 1, characterized in that: The iron core is made of silicon steel sheets.