Hybrid iron core series reactor
By using a hybrid core structure and resin casting technology, the high loss and complex assembly problems of traditional core reactors have been solved, enabling the production of reactors with high permeability and low loss, simplifying the production process and improving product quality.
Patent Information
- Application Number
- CN202520191974.6
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-02-07
- Publication Date
- 2026-01-27
- Estimated Expiration
- 2035-02-07
AI Technical Summary
Traditional iron-core reactors suffer from high losses, cumbersome production and assembly processes, and inconsistent silicon steel sheet widths make it difficult to standardize operations and achieve rapid positioning and assembly.
The system employs a hybrid core structure, using oriented silicon steel sheets as the yoke and rolled iron-based amorphous ribbon as the core, combined with air gap pads and limiting rings. The integrated fixed connection is achieved through resin casting, simplifying the production process and improving magnetic permeability.
Reduce losses, improve production efficiency, achieve standardized operations, simplify assembly steps, and ensure product quality and reliability.
Smart Images
Figure CN223842744U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of reactor technology, specifically to a hybrid iron core series reactor. Background Technology
[0002] When a conductor carries current, it generates a magnetic field within a certain space it occupies. Therefore, all current-carrying conductors have inductance in the general sense. However, the inductance of a long straight conductor carrying current is relatively small, and the magnetic field it generates is not strong. Therefore, practical reactors are made by winding wires into a solenoid, called air-core reactors. Sometimes, in order to make this solenoid have a larger inductance, an iron core is inserted into the solenoid, called an iron-core reactor.
[0003] Traditional iron-core reactors use non-oriented silicon steel sheets stacked together for the yoke and the core cake is also made of silicon steel sheets stacked together, resulting in low space utilization and high losses. At the same time, in order to splice them into a circular shape, the silicon steel sheets in the core cake need to have different widths, which brings difficulties to production (cutting of various widths cannot be standardized) and assembly (it is difficult to achieve fast and accurate positioning and assembly of too many silicon steel sheets of different sizes). Summary of the Invention
[0004] In order to overcome the problems of "high loss and complicated production and assembly steps of traditional iron-core reactors" in the above-mentioned background technology, this utility model provides a hybrid iron-core series reactor.
[0005] The technical solution adopted by this utility model to solve the above-mentioned technical problems is:
[0006] A hybrid iron-core series reactor includes a yoke, core posts, core discs, and coil windings. The yoke is horizontally positioned, with one core post at the top and one at the bottom, arranged parallel to each other. The core posts are vertically positioned, with several core posts arranged in pairs, the two core posts in a pair being coaxially arranged with an upper and lower section and a receiving gap between them. The core discs are placed within the receiving gaps. Several core discs located within the same receiving gap are coaxially arranged. Several coil windings are arranged and respectively sleeved around the outer periphery of the receiving gaps. The yoke includes several first plates fixed by through-and-through connections. The first plates are oriented silicon steel sheets. Each core disc is a single third plate rolled into a cylindrical shape. The third plate is an iron-based amorphous ribbon.
[0007] As a further optimization of this utility model, the core post and the core cake are respectively arranged coaxially.
[0008] As a further optimization of this utility model, an air gap is provided between the core post and the core cake, as well as between two core posts with adjacent end faces.
[0009] As a further optimization of this utility model, an air gap pad is provided in the air gap to support the core cake or the core column.
[0010] As a further optimization of this utility model, the air gap pad has a first limiting ring on its top surface and a second limiting ring on its bottom surface; the bottom surface of the core cake and the bottom surface of the core column located above it are respectively provided with a first ring groove that can be adapted and engaged with the first limiting ring; the top surface of the core cake and the top surface of the core column located below it are respectively provided with a second ring groove that can be adapted and engaged with the second limiting ring.
[0011] As a further optimization of this utility model, the third plate body is provided with concave portions on both sides of its edge, which are capable of being bent into the first annular groove and the second annular groove.
[0012] As a further optimization of this utility model, the core column includes a plurality of second plates arranged in a stacked manner; the top or bottom surface of the second plate is provided with an adapter slot, and the adapter slot is arranged in a ring to form the first annular groove or the second annular groove.
[0013] As a further optimization of this utility model, the inner and outer edges of the first limiting ring are both serrated to adapt to and engage with the adapter slot; the inner and outer edges of the second limiting ring are both serrated to adapt to and engage with the adapter slot.
[0014] As a further optimization of this utility model, the top and bottom ends of the outer side wall of the air gap pad are respectively provided with a first support ring and a second support ring for abutting against the second plate or the third plate.
[0015] As a further optimization of this utility model, a reinforcing rib is provided between the first support ring and the second support ring.
[0016] In summary, this utility model has at least one of the following advantages:
[0017] (1) The present invention has a simple structure and reliable function. The iron yoke made of oriented silicon steel sheet can significantly improve the magnetic permeability and reduce the loss. The iron-based amorphous ribbon is rolled into a cylindrical shape to form a core cake, which has the characteristics of high saturation magnetic induction and low loss. It can also be cut and rolled according to uniform size, which can realize standardized operation, simplify production assembly steps and improve production efficiency.
[0018] (2) The core column and core cake are fixedly connected in one piece by resin casting. The resin layer is coated on the outer surface of the core column and the outer surface of the core cake, which can achieve the fixed connection and insulation effect of the core column and core cake, and has simple and convenient processing steps, reducing the difficulty of operation.
[0019] (3) The air gap pad can be snapped between adjacent core cakes or between adjacent core cakes and core columns to achieve temporary installation. This eliminates the need for additional support structures to support it in the mold cavity, which can greatly simplify the casting process, improve production efficiency, and reduce the use of tooling equipment.
[0020] (4) The inner and outer walls of different first limiting rings are smooth arcs or sawtooth shapes, so as to fit and fit the smooth or sawtooth first ring groove / second ring groove respectively, thereby avoiding the generation of air bubbles during casting, and ultimately avoiding the generation of air bubbles in the resin layer, ensuring the coating strength of the resin layer and improving product quality.
[0021] (5) The first support ring is used to support the outer edge of the bottom surface of the core cake to avoid the problem of the multi-layered cylindrical third plate falling down. Attached Figure Description
[0022] The present application will be further explained below with reference to the accompanying drawings:
[0023] Figure 1 This is a front view schematic diagram of the overall structure of this utility model;
[0024] Figure 2 This is a top view of the overall structure of this utility model;
[0025] Figure 3 A schematic diagram of the connection structure between the core column, core cake, and air gap pad;
[0026] Figure 4 This is a schematic diagram of the cross-section of the iron yoke from top view.
[0027] Figure 5 This is a schematic diagram of the cross-section top view of the core column structure.
[0028] Figure 6 A top view of the cross-section of the core cake;
[0029] Figure 7 This is a schematic diagram showing the position and structure of the concave portion in the unfolded state of the third plate.
[0030] Figure 8 This is a front view structural diagram of the core cake and air gap pad block in a vertical section.
[0031] Figure 9 This is a front view structural diagram of the vertical section of the air gap pad block;
[0032] Figure 10 A diagram showing the top view of the slot structure;
[0033] Figure 11 A top-view cross-section of the first limiting ring, showing a sawtooth structure on its inner and outer edges.
[0034] Figure 12A top-view cross-section of the second limiting ring, showing its serrated inner and outer edges.
[0035] Figure 13 This is a front view of the vertical section of the position and structure of the first and second support rings.
[0036] Figure 14 A schematic diagram showing the location and structure of the reinforcing ribs.
[0037] Explanation of reference numerals in the attached figures:
[0038] In the picture,
[0039] 1. Yoke; 11. First plate; 110. Insertion hole; 12. Through bolt;
[0040] 2. Core post; 21. Second board; 210. Adapter slot;
[0041] 3. Core cake; 30. Air gap pad; 301. First limiting ring; 302. Second limiting ring; 303. First support ring; 304. Second support ring; 305. Reinforcing rib; 31. Third plate; 310. Concave portion;
[0042] 4. Coil winding. Detailed Implementation
[0043] Based on the above-described structural features of this application, the implementation methods of this application will be further described as follows:
[0044] Reference Figures 1-2 This embodiment provides a hybrid iron-core series reactor, including an iron yoke 1, a core column 2, a core disc 3, and a coil winding 4. The iron yoke 1 and the core column 2 are used for directional magnetization, while the core disc 3 and the coil winding 4 are used for electromagnetic induction to generate inductance, thereby realizing the basic function of the reactor.
[0045] Reference Figures 1-2 The yoke 1 is placed horizontally, with one yoke 1 at the top and one at the bottom, and they are arranged parallel to each other; one yoke 1 is located directly above the other yoke 1, which facilitates the longitudinal installation of the core column 2, core cake 3 and winding.
[0046] Reference Figures 1-2 The core column 2 is upright, and there are several core columns 2 arranged in pairs. The two core columns 2 in a pair are coaxially arranged with one above the other and a gap between them.
[0047] Reference Figures 1-2The core pillars 2 are arranged in three groups of six; two groups of core pillars 2 are located at the left and right ends of the yoke 1, and the other group of core pillars 2 is located in the middle of the yoke 1. The three groups of core pillars 2 are evenly spaced and upright; the three upper core pillars 2 and the upper yoke 1 are arranged in an inverted E-shape, and the three lower core pillars 2 and the lower yoke 1 are arranged in an upright E-shape. The core pillars 2 are vertically fixed to the corresponding yoke 1.
[0048] Reference Figure 3 The core cake 3 is placed within the receiving gap. Several core cakes 3 located within the same receiving gap are arranged coaxially.
[0049] Reference Figure 3 There are six core cakes 3, and two core cakes 3 are arranged in a single receiving gap; the two core cakes 3 in the same receiving gap are arranged coaxially in an up-down position.
[0050] Reference Figure 1 and Figure 3 The coil winding 4 has several coils, each of which is sleeved on the outer periphery of the receiving gap.
[0051] Reference Figure 1 and Figure 3 The coil winding 4 has three sections, each fitted around the outer periphery of one of the three receiving gaps. The bottom end of the upper core post 2 is inserted into the top end of the inner cavity of the corresponding coil winding 4 to be as close as possible to the core cake 3; the top end of the lower core post 2 is inserted into the bottom end of the inner cavity of the corresponding coil winding 4 to be as close as possible to the core cake 3.
[0052] Reference Figure 1 and Figure 4 The yoke 1 includes several first plates 11 fixed by through-and-through connections; the first plates 11 are oriented silicon steel sheets; the sidewalls of the several first plates 11 are sequentially bonded together to form a rod-like or beam-like structure, thereby supporting the core column 2 and achieving magnetic conduction. Compared with non-oriented silicon steel sheets, oriented silicon steel sheets have lower iron loss, strong magnetic directionality, and superior high permeability and low loss characteristics in their rolling direction, significantly improving the performance of the reactor.
[0053] Reference Figure 4 The first plate 11 is fixed together using through bolts 12. The first plate 11 is provided with insertion holes 110, the screw of the through bolt 12 is inserted into the insertion hole 110, and the head and nut of the through bolt 12 are pressed onto both sides of the outermost first plate 11.
[0054] Reference Figure 1 and Figure 6 Each core sheet 3 is a single third plate 31 rolled into a multi-layered cylindrical shape; the third plate 31 is an iron-based amorphous ribbon. Compared with traditional stacked silicon steel sheets, the rolled cylindrical iron-based amorphous ribbon has the characteristics of high saturation magnetic induction and low loss, which can greatly reduce the weight of equipment, reduce its size, and improve efficiency.
[0055] Reference Figure 1 and Figure 3 The core column 2 and the core cake 3 are coaxially arranged, that is, the three sets of core columns 2 are coaxially arranged with the core cake 3 in the corresponding accommodating gap.
[0056] Reference Figure 3 An air gap is provided between the core post 2 and the core cake 3, as well as between two adjacent core posts 2 at their end faces. An air gap pad 30 is provided in the air gap to support the core cake 3 or the core post 2.
[0057] Reference Figure 1 and Figure 3 The core column 2, core cake 3 and air gap pad 30 are integrally fixedly connected by resin casting. The resin layer is applied to the outer periphery of the core column 2, the outer periphery of the core cake 3 and the outer periphery of the air gap pad 30 and fills the air gap, thereby achieving the insulation effect.
[0058] Reference Figure 1 and Figure 3 During assembly, the user first places the coil winding 4 around the outer periphery of the lower core post 2; then, alternately places the core cake 3 and the air gap pad 30 inside the coil winding 4; next, inserts the upper core post 2 into the inner cavity of the coil winding 4; finally, a mold is placed around the outer periphery of the coil winding 4 and resin is filled into the mold cavity. After the resin cures, it not only covers the outer periphery of the core post 2, the outer periphery of the core cake 3, and the outer periphery of the air gap pad 30, but also covers the inner and outer walls of the coil winding 4, thus achieving an integrated fixed connection.
[0059] Reference Figure 1 and Figure 3 When assembling the device, the user first assembles the core post 2, core cake 3, and air gap pad 30; then, the mold is laid out and resin is filled into the mold cavity; after the resin cures, the mold is removed and the coil winding 4 is wound around the outer wall of the resin layer. The resin only covers the core post 2, core cake 3, and air gap pad 30, but not the coil winding 4. Therefore, the coil winding 4 can be cooled by air cooling or easily replaced during maintenance.
[0060] Reference Figure 3 , Figure 8 and Figure 9 The air gap pad 30 is in the shape of a flat cylinder. The top surface of the air gap pad 30 is provided with a first limiting ring 301 and the bottom surface is provided with a second limiting ring 302. The first limiting ring 301 and the air gap pad 30 are integrally fixedly connected. The second limiting ring 302 and the air gap pad 30 are integrally fixedly connected.
[0061] Reference Figure 3 and Figure 8The bottom surface of the core cake 3 and the bottom surface of the core post 2 located above are respectively provided with a first ring groove that can be adapted and engaged with the first limiting ring 301; the top surface of the core cake 3 and the top surface of the core post 2 located below are respectively provided with a second ring groove that can be adapted and engaged with the second limiting ring 302.
[0062] Reference Figure 3 and Figure 8 The first annular groove on the bottom surface of the core cake 3 is the first annular groove a. The first limiting ring 301 on the upper surface of the air gap pad 30 can be adapted to be inserted into the first annular groove a, thereby realizing the snap-fit between the core cake 3 and the air gap pad 30. The first annular groove on the bottom surface of the upper core column 2 is the first annular groove b. The first limiting ring 301 on the upper surface of the air gap pad 30 can be adapted to be inserted into the first annular groove b, thereby realizing the snap-fit between the core column 2 and the air gap pad 30.
[0063] Reference Figure 3 and Figure 8 The second annular groove on the top surface of the core cake 3 is the second annular groove a. The second limiting ring 302 on the lower surface of the air gap pad 30 can be adapted to be inserted into the second annular groove a, thereby realizing the snap-fit between the core cake 3 and the air gap pad 30. The second annular groove on the top surface of the lower core column 2 is the second annular groove b. The second limiting ring 302 on the lower surface of the air gap pad 30 can be adapted to be inserted into the second annular groove b, thereby realizing the snap-fit between the core column 2 and the air gap pad 30.
[0064] Reference Figure 7 and Figure 8 The third plate 31 has concave portions 310 on both sides of its edge, which are capable of being bent into first and second annular grooves. After the third plate 31 is bent into a cylindrical structure, the concave portions 310 are bent into annular shapes, thereby forming the first or second annular groove.
[0065] Reference Figure 1 and Figure 5 The core column 2 includes several second plates 21 arranged in a stacked manner, each second plate 21 having a straight plate structure. (Refer to...) Figure 5 and Figure 10 The second plate 21 has an adapter slot 210 on its top or bottom surface, and several adapter slots 210 are arranged in a ring to form a first ring groove or a second ring groove.
[0066] Reference Figure 8 The inner and outer edges of part of the first limiting ring 301 are arc-shaped to fit and fit the smooth second annular groove at the bottom of the core cake 3; the inner and outer edges of part of the second limiting ring 302 are arc-shaped to fit and fit the smooth first annular groove at the top of the core cake 3; thereby avoiding the formation of air cavities in the resin layer.
[0067] Reference Figures 10-12The inner and outer edges of the first limiting ring 301 are serrated to fit and attach to the fitting slot 210; the inner and outer edges of the second limiting ring 302 are serrated to fit and attach to the fitting slot 210; thereby avoiding the formation of air cavities in the resin layer.
[0068] Reference Figure 13 The outermost two ends of the outer wall of the air gap pad 30 are respectively provided with a first support ring 303 and a second support ring 304 for abutting against the second plate 21 or the third plate 31, thereby supporting the outer edge of the core column 2 and the outer edge of the core cake 3 and preventing them from sliding down.
[0069] Reference Figure 14 A reinforcing rib 305 is provided between the first support ring 303 and the second support ring 304. The top edge of the reinforcing rib 305 is fixedly connected to the first support ring 303, the bottom edge is fixedly connected to the second support ring 304, and the inner edge is fixedly connected to the air gap pad 30. The air gap pad 30, the first limiting ring 301, the second limiting ring 302, the first support ring 303, the second support ring 304, and the reinforcing rib 305 are integrally fixedly connected.
[0070] The air gap pad 30, the first limiting ring 301, the second limiting ring 302, the first support ring 303, the second support ring 304 and the reinforcing rib 305 are all made of non-magnetic materials (such as resin, ceramic, titanium alloy, aluminum alloy, etc., with a load-bearing metal cage set inside the ceramic).
[0071] The three coil windings 4 are connected in series.
[0072] A first plate 11 is fixedly connected to three second plates 21 (e.g., by integral fixed connection) to form an E-shaped plate structure; several E-shaped plate structures are stacked to form an iron yoke 1 and a core column 2 that are fixedly connected to each other.
[0073] This utility model has a simple structure and reliable function. The iron yoke 1 made of oriented silicon steel sheet can significantly improve the magnetic permeability and reduce the loss. The iron-based amorphous ribbon is rolled into a cylindrical shape to form the core cake 3, which has the characteristics of high saturation magnetic induction and low loss. It can also be cut and rolled according to uniform size, which can realize standardized operation, simplify production assembly steps, and improve production efficiency.
[0074] In the description of this utility model, it should be noted that the terms "upper", "lower", "left", "right", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model.
[0075] In the description of this utility model, it should also be noted that, unless otherwise explicitly specified and limited, the terms "set," "install," and "connect" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or a connection through an intermediate medium; and they can refer to the internal communication between two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.
[0076] In conclusion, for those skilled in the art, any changes, modifications, substitutions, or variations made to this utility model based on its guidance, without departing from its principles and spirit, shall still fall within the protection scope of this utility model.
Claims
1. A hybrid iron-core series reactor, characterized in that: It includes an iron yoke (1), a core column (2), a core disc (3), and a coil winding (4); The iron yoke (1) is placed horizontally, and there are two iron yokes (1) arranged at the top and bottom and parallel to each other; The core column (2) is erected, and there are several core columns (2) arranged in pairs. The two core columns (2) in a pair are coaxially arranged with one above the other and a receiving gap between them. The core cake (3) is placed in the receiving gap. Several core cakes (3) located in the same receiving gap are coaxially arranged. The coil winding (4) is provided in several parts and is respectively sleeved on the outer periphery of the receiving gap; The yoke (1) includes a plurality of first plates (11) fixed by through-and-through bracing; the first plates (11) are oriented silicon steel sheets; Each core cake (3) is a single third plate (31) rolled into a cylindrical shape; the third plate (31) is an iron-based amorphous ribbon.
2. The hybrid iron core series reactor according to claim 1, characterized in that: The core column (2) and the core cake (3) are respectively arranged coaxially.
3. The hybrid iron core series reactor according to claim 2, characterized in that: An air gap is provided between the core column (2) and the core cake (3) and between two core columns (2) adjacent to each other on the end face.
4. The hybrid iron core series reactor according to claim 3, characterized in that: The air gap is provided with an air gap pad (30) for supporting the core cake (3) or the core column (2).
5. The hybrid core series reactor according to claim 4, characterized in that: The air gap pad (30) has a first limiting ring (301) on its top surface and a second limiting ring (302) on its bottom surface; the bottom surface of the core cake (3) and the bottom surface of the core column (2) located above it are respectively provided with a first ring groove that can be adapted and engaged with the first limiting ring (301); the top surface of the core cake (3) and the top surface of the core column (2) located below it are respectively provided with a second ring groove that can be adapted and engaged with the second limiting ring (302).
6. The hybrid iron core series reactor according to claim 5, characterized in that: The third plate (31) has concave portions (310) on both sides of its edge that can be bent to form the first annular groove and the second annular groove.
7. The hybrid iron core series reactor according to claim 6, characterized in that: The core column (2) includes a plurality of second plates (21) arranged in a stacked manner; the top or bottom surface of the second plate (21) is provided with an adapter slot (210), and the adapter slot (210) is arranged in a ring to form the first ring groove or the second ring groove.
8. The hybrid iron core series reactor according to claim 7, characterized in that: The inner and outer edges of the first limiting ring (301) are both serrated to fit and engage with the adapter slot (210); the inner and outer edges of the second limiting ring (302) are both serrated to fit and engage with the adapter slot (210).
9. The hybrid core series reactor according to claim 8, characterized in that: The air gap pad (30) has a first support ring (303) and a second support ring (304) at the top and bottom ends of the outer side wall for abutting against the second plate (21) or the third plate (31).
10. The hybrid core series reactor according to claim 9, characterized in that: A reinforcing rib (305) is provided between the first support ring (303) and the second support ring (304).