Novel semi-air-gap iron core assembly based on 5G base station embedded circuit breaker

Abstract

The utility model discloses a novel semi-air-gap iron core assembly based on a 5G base station embedded circuit breaker, which comprises a bottom plate and an iron core body on the bottom plate, and is characterized in that the whole iron core body is a circular ring body and is formed by staggering and laminating a plurality of permalloy sheets and resin layers from top to bottom; the two opposite sides of the iron core body are each provided with an air gap opening penetrating through the circular ring body, the iron core body is divided into an arc-shaped left half body and an arc-shaped right half body, and coils are wound around the outer walls of the left half body and the right half body. A circular conductive chassis is arranged in the iron core body, the bottom of the conductive chassis is fixedly connected with the bottom plate and is coaxial with the iron core body, an air pipe is arranged at each air gap opening, two opposite sides of the outer wall of the iron core body are respectively connected with a conductive wire, and the direction of the conductive wire is vertical to the air pipe. According to the utility model, the hysteresis loss can be reduced, the magnetic conductivity can be improved, and the fault can be accurately and quickly sensed at a low current level; and the sensitivity and efficiency of the product can be improved, and the method is more competitive and adaptive in the application of small-current fault identification of the embedded circuit breaker in the 5G base station.

Description

Technical Field

[0001] The utility model relates to an embedded circuit breaker, and in particular to a novel semi-air gap core component based on a 5G base station embedded circuit breaker. Background Art

[0002] In the field of 5G communications, with the rapid increase in data transmission rate and the increase in the density of communication base stations, higher requirements are placed on the reliability and economy of base station power systems. Especially in terms of power protection and fault detection, the demand is more urgent. As the core component of the base station power management system, the performance of the embedded circuit breaker directly affects the stability and efficiency of the entire system.

[0003] The core assembly is one of the key components of the circuit breaker, which is used to drive the moving contact of the circuit breaker to close and open. When the closing operation occurs, the closing and opening coils are energized through the control circuit, and the core drives the moving contact of the circuit breaker to close at a specified speed. This design ensures that the circuit breaker can reliably complete the opening and closing operations. Traditional circuit breakers for communication base stations usually adopt a gapless core structure. The main function is to cut off the power supply in the event of current overload or short circuit to protect the circuit from damage. This design relies on the magnetic properties of the core material to achieve current induction and disconnection. In normal use, it can effectively cope with large current faults. When encountering small current faults, due to the nonlinearity of magnetic permeability and hysteresis loss, it is not sensitive enough to the fault, and cannot effectively identify and cut off the fault current, resulting in fault processing delays or failures.

[0004] In order to solve the problem of no air gap design, some circuit breakers adopt a fully air gap core structure, which increases the air gap to improve the circuit breaking performance and the linearity of magnetic induction, thereby improving the sensitivity of fault current detection. However, the increase in air gap leads to an increase in magnetic resistance, requiring a larger excitation current to drive the circuit breaker, which increases energy consumption and may cause the core to overheat, affecting the reliability and life of the circuit breaker.

[0005] In addition, these two traditional circuit breakers have problems such as large size and poor heat dissipation performance, which are particularly prominent in densely deployed 5G base stations. In the case of a short circuit, the traditional electromagnetic current transformer will cause the core to saturate due to magnetic flux, thereby affecting the secondary side output current, which may cause the protection to fail to operate, and then cause serious power system accidents. Utility Model Content

[0006] The purpose of the utility model is to provide a solution to the above-mentioned problems, optimize the performance of the current transformer, especially the response speed and accuracy in the perception of small current faults, so as to improve the intelligent monitoring and management of the base station power supply, reduce energy consumption, and enhance system reliability. A new type of semi-air gap core component based on a 5G base station embedded circuit breaker.

[0007] In order to achieve the above-mentioned purpose, the technical solution adopted by the utility model is as follows: a new type of semi-air gap core assembly based on a 5G base station embedded circuit breaker includes a bottom plate and a core body on the bottom plate, both of which are arranged horizontally;

[0008] The iron core body is a toroidal body as a whole, and is formed by staggered stacking of multiple layers of Permalloy sheets and multiple layers of resin from top to bottom;

[0009] An air gap is provided on opposite sides of the core body, penetrating the annular body, dividing the core body into an arc-shaped left half and a right half, and the outer walls of the left half and the right half are wound with coils;

[0010] A circular conductive chassis is provided inside the iron core body, the bottom of which is fixedly connected to the bottom plate and coaxially arranged with the iron core body, and an air pipe is provided at each air gap opening, one end of the air pipe is butt-jointed with the air gap opening, and the other end is arranged axially along the iron core body; a conductive wire is connected to each of the opposite sides of the outer wall of the iron core body, and the direction of the conductive wire is perpendicular to the air pipe.

[0011] As a preferred embodiment, both ends of the left half body and the right half body are designed with rounded arcs.

[0012] Preferably, the air pipe is integrally formed with the base plate.

[0013] Preferably, the size of the air gap and the thickness of the core body can be adjusted.

[0014] Compared with the prior art, the advantages of the utility model are:

[0015] (1) In the utility model, the core body is designed with multiple layers of Permalloy sheets and multiple layers of resin layers staggered and stacked, and an air gap is opened on the core body to form a semi-air gap core structure. Among them, the Permalloy sheet is a material with high magnetic permeability and low coercivity, which can minimize hysteresis loss and improve magnetic circuit efficiency, ensure excellent magnetic properties and fast response capabilities, and is crucial for achieving highly sensitive small current fault perception. The resin layer plays the role of air gap design, forming an air gap between each layer of Permalloy sheets, which can reduce the current loss between adjacent Permalloy sheets and further reduce energy loss. The semi-air gap core structure formed by the air gap improves the ability to perceive small current faults while avoiding the problems of increased magnetic resistance and excessive excitation current, thereby achieving dual optimization of energy efficiency and performance. The structure of the utility model can reduce the amount of core materials used and achieve a 20% reduction in hysteresis loss, so that faults can be accurately and quickly sensed even at low current levels, thereby improving the protection capability of the system. At the same time, the relative magnetic permeability of the new semi-airgap core structure can reach 3000, which is about 10% higher than the magnetic permeability of the traditional core. High magnetic permeability means that under the same conditions, the core can conduct magnetic flux more effectively, thereby improving the response speed and accuracy to small current faults.

[0016] (2) The utility model reduces energy consumption and extends the life of the equipment. By selecting high-performance materials and optimizing the magnetic circuit design, energy loss is reduced, specifically, the no-load loss is reduced by 15%. The reduced energy loss means that the heat generation of the core during normal operation is reduced, thereby reducing the hysteresis loss and the energy consumption of the entire system, while extending the service life of the equipment.

[0017] (3) The utility model enhances environmental adaptability: The core component is designed and material selected with adaptability to different environments in mind. The new semi-airgap core structure design can adapt to a temperature range of -40°C to 125°C, covering the ambient temperatures that most 5G base stations may encounter, ensuring high performance and stability even under harsh conditions. The core's structural design and material selection give it better resistance to electromagnetic interference, which is particularly important for places with complex electromagnetic environments such as 5G base stations.

[0018] (4) The utility model reduces the output cost. The core design adjusts the size, thickness, position and material selection of the core and the air gap. The volume of the new semi-air gap core is about 30% smaller than that of the traditional core, which reduces the weight, reduces the complexity of installation and maintenance, improves the overall economy and operability, and is more suitable for scenarios such as 5G base stations with limited space. While achieving low current sensing, it improves the cost performance of the product. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 It is a three-dimensional diagram of the utility model;

[0020] Figure 2 for Figure 1 Top view;

[0021] Figure 3 for Figure 1 AA section view of the middle left half;

[0022] Figure 4 for Figure 3 Schematic diagram after winding the coil.

[0023] In the figure: 1, bottom plate; 2, iron core; 3, air gap; 4, conductive chassis; 5, air pipe; 6, conductive wire; 7, Permalloy sheet; 8, resin layer; 9, coil. DETAILED DESCRIPTION

[0024] The utility model will be further described below in conjunction with the accompanying drawings.

[0025] Example 1: See Figures 1 to 4A novel semi-air gap core assembly based on a 5G base station embedded circuit breaker comprises a bottom plate 1 and a core body 2 on the bottom plate 1, both of which are arranged horizontally, the core body 2 is a torus as a whole, and is formed by staggered stacking of multiple layers of Permalloy sheets 7 and multiple layers of resin layers 8 from top to bottom; an air gap opening 3 penetrating the torus is respectively arranged on opposite sides of the core body 2, and the core body 2 is divided into an arc-shaped left half and a right half, and a coil 9 is wound around the outer wall of the left half and the right half; a circular conductive chassis 4 is arranged in the core body 2, the bottom of the conductive chassis 4 is fixedly connected to the bottom plate 1 and is coaxially arranged with the core body 2, and an air pipe 5 is respectively arranged at the air gap opening 3, one end of the air pipe 5 is butt-jointed with the air gap opening 3, and the other end is arranged along the axial direction of the core body 2; a conductive wire 6 is connected to each of the opposite sides of the outer wall of the core body 2, and the direction of the conductive wire 6 is perpendicular to the air pipe 5.

[0026] In this embodiment: both ends of the left half and the right half are designed with rounded arcs. The air pipe 5 is integrally formed with the bottom plate 1. The size of the air gap 3 and the thickness of the iron core 2 can be adjusted.

[0027] The working principle of the utility model is as follows: in the traditional fully enclosed core structure, the entire core is enclosed, which may cause the magnetic flux to be unevenly distributed inside the core. However, the semi-air gap design of the core body 2 in the utility model keeps a part of the core body 2 enclosed, and the other part is connected to the external space through the air tube 5, and the air tube 5 and the conductive chassis 4 are used to fix the core body 2. This design allows the magnetic flux to flow freely inside the core body 2, while guiding part of the magnetic flux to flow out through the open air gap 3, thereby improving the overall distribution of the magnetic field.

[0028] When assembling the utility model, the iron core 2 is assembled first, an air gap is set between adjacent permalloy sheets 7, and a solidified resin is poured. The solidified resin in the air gap forms a resin layer 8, which is staggered with the permalloy sheets 7. During pouring, it is ensured that the multiple layers of permalloy sheets 7 can be bonded into a whole to form a Figure 1 Then wrap the coil 9 around the left half and the right half, and then complete Figure 1 The whole assembly is finally applied to the small current fault sensing module of the embedded circuit breaker of the 5G base station to improve the accuracy of small current sensing.

[0029] Example 2: See Figures 1 to 4 Based on Example 1, we provide a parameter comparison between two existing products and the utility model, and obtain the following Table 1.

[0030] Table 1: Comparison of three product parameters

[0031] By comparison, it is found that the utility model has the following advantages:

[0032] (1) Hysteresis loss reduction: The utility model effectively reduces hysteresis loss by optimizing the size of the air gap and the thickness of the core body 2, and can accurately and quickly sense faults even at low current levels, thereby improving the protection capability of the system. Compared with the traditional core, the hysteresis loss of the new structure is reduced by 20%, and compared with the full air gap core, it is reduced by about 15%, which significantly improves energy efficiency and response speed.

[0033] (2) Improved relative magnetic permeability: The relative magnetic permeability of the utility model reaches 3000H / m, which is about 10% higher than the 2700H / m of product one and higher than the 2500H / m of product two. This improvement enables the new core to generate stronger magnetic flux under the same external magnetic field, thereby improving the sensitivity and efficiency of equipment such as sensors or transformers.

[0034] 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 and improvements made within the spirit and principles of the present invention should be included in the protection scope of the present invention.

Claims

1. A novel semi-air gap core assembly based on a 5G base station embedded circuit breaker, comprising a base plate and a core body on the base plate, both of which are arranged horizontally, characterized in that: The iron core body is a toroidal body as a whole, and is formed by staggered stacking of multiple layers of Permalloy sheets and multiple layers of resin from top to bottom; An air gap is provided on opposite sides of the core body, penetrating the annular body, dividing the core body into an arc-shaped left half and a right half, and the outer walls of the left half and the right half are wound with coils; A circular conductive chassis is provided inside the iron core body, the bottom of which is fixedly connected to the bottom plate and coaxially arranged with the iron core body, and an air pipe is provided at each air gap opening, one end of the air pipe is butt-jointed with the air gap opening, and the other end is arranged axially along the iron core body; a conductive wire is connected to each of the opposite sides of the outer wall of the iron core body, and the direction of the conductive wire is perpendicular to the air pipe.

2. According to claim 1, a novel half-air gap core assembly based on a 5G base station embedded circuit breaker is characterized in that: Both ends of the left and right halves are designed with rounded arcs.

3. According to claim 1, a novel half-air gap core assembly based on a 5G base station embedded circuit breaker is characterized in that: The air pipe is integrally formed with the bottom plate.

4. According to claim 1, a novel half-air gap core assembly based on a 5G base station embedded circuit breaker is characterized in that: The size of the air gap and the thickness of the iron core can be adjusted.

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