Annular water-cooled reactor

Abstract

The utility model relates to the technical field of electric reactors, and discloses an annular water-cooled electric reactor which comprises a coil assembly, a filling ring, an insulating tube and a potting colloid. The coil assembly comprises a conducting bar, a water joint and a coil body; the coil body is a hollow pipe which is hollow inside, the hollow pipe is wound on the filling ring to form a plurality of groups of coils, and water joints are arranged at two ends of the coil body; an insulating tube is arranged at the rotation center of the filling ring; and the coil assembly, the filling ring and the insulating tube are externally filled with a potting colloid. According to the utility model, the coil assembly, the filling ring, the potting colloid and the coil are integrally welded and formed, and the potting colloid structure is matched, so that the mechanical strength is high, the capacity of the reactor for bearing instantaneous pulse large current is strong, the partial discharge phenomenon is reduced, and the process execution difficulty and cost are reduced under the condition of improving the strength and quality of the reactor; the light weight of the annular water-cooled reactor is achieved, and the anti-cracking capacity of the rubber layer during internal cooling and heating alternation is systematically improved through raw materials, structural design and the like.

Description

Technical Field

[0001] This utility model relates to the field of reactor technology, and in particular to a toroidal water-cooled reactor. Background Technology

[0002] Toroidal water-cooled reactors are DC reactors primarily used in the output filtering circuits of rectifier circuits. Their main functions are to limit the rate of current change, reduce harmonic interference, improve the power factor, and refine the input current waveform. They also protect the frequency converter in the rectifier circuit. However, current reactors share the same cooling water circuit as the main converter circuit, leading to significant water temperature variations and making the coils and potting compound prone to cracking and delamination. Furthermore, most similar water-cooled reactors in related technologies suffer from large internal cavities, partial discharge phenomena, easy cracking of the potting compound, and low mechanical strength, and are also heavy, hindering weight reduction.

[0003] Therefore, there is an urgent need to provide a toroidal water-cooled reactor to solve the problems existing in the prior art. Utility Model Content

[0004] The purpose of this utility model is to provide a toroidal water-cooled reactor with good performance and long lifespan. The specific technical solution is as follows:

[0005] A toroidal water-cooled reactor includes a coil assembly, a filler ring, an insulating tube, and a potting compound;

[0006] The coil assembly includes a conductive busbar, a water connector, and a coil body; the coil body is a hollow tube with an internal hollow structure, and the hollow tube is wound around a filler ring to form multiple coils. Water connectors are provided at both ends of the coil body, and the water connectors are all fixedly installed on the conductive busbar.

[0007] An insulating tube is provided at the center of rotation of the filling ring, and the insulating tube is arranged perpendicular to the plane where the filling ring is located;

[0008] The coil assembly, filling ring, and insulating tube are externally filled with potting compound, and a portion of the conductive busbar and water connector are exposed outside the potting compound.

[0009] Preferably, the coil body is made of aluminum alloy profile, the aluminum alloy profile is made of 6 series hard state aluminum alloy, and the conductive busbar, water connector and coil body are connected by weld.

[0010] The outer contour of the cross-section of the hollow tube of the coil body is square, and the four corners of the square are rounded.

[0011] Preferably, the conductive busbar is provided with multiple through holes, some of which are used to install an insulating plate, and the remaining through holes are used to connect to an external power source;

[0012] The insulating board is made of epoxy glass cloth and is used for positioning and fixing the conductive bar.

[0013] Preferably, the thickness of the conductive busbar is consistent with the outer diameter of the hollow tube of the coil body, and the width of the conductive busbar is one-third of the total height of the coil body.

[0014] Preferably, the filling ring is composed of four quarter-circular rings connected to each other, and its material is a foaming material with the same coefficient of thermal expansion as the potting compound.

[0015] Preferably, it also includes insulating paper disposed between the coils of the coil body to provide insulation, the insulating paper comprising multiple layers of whole sheets of NOMEX insulating paper.

[0016] Preferably, it also includes a binding tape for binding the insulating paper and the coil body, said binding tape being an alkali-free glass fiber tape.

[0017] Preferably, it also includes a mesh cloth covering the coil body, wherein the mesh cloth is a mesh-shaped epoxy resin glass fiber cloth;

[0018] The mesh fabric is fixed to the coil body by glass fiber ribbon and single-sided adhesive glass fiber tape.

[0019] Preferably, the insulating tube is made of epoxy glass cloth tube, and the space between the insulating tube and the bound coil body is filled with potting compound.

[0020] Preferably, the potting compound is made of polyurethane, and the potting compound includes a positioning hole, an mounting plane, an arc surface, an outer transition surface, and a conical surface integrally cast; the positioning hole, mounting plane, arc surface, outer transition surface, and conical surface together form the outer surface of the potting compound;

[0021] The positioning holes are set on the mounting plane for positioning the reactor in the circumferential direction and fixing the clamping iron plate on the reactor; the outer transition surface is used to transition between the arc surface and the conical surface; the conical surface is used to facilitate demolding of the casting mold after potting, and the transition between the two conical surfaces is smooth without stress concentration.

[0022] The application of the technical solution of this utility model has the following beneficial effects:

[0023] A toroidal water-cooled reactor includes a coil assembly, a filler ring, an insulating tube, and a potting compound. The coil assembly includes a busbar, a water connector, and a coil body. The coil body is a hollow tube with an internal cavity, and the hollow tube is wound around the filler ring to form multiple coils. Water connectors are provided at both ends of the coil body, and the water connectors are all fixedly mounted on the busbar. An insulating tube is provided at the center of rotation of the filler ring, and the insulating tube is perpendicular to the plane where the filler ring is located. The coil assembly, the filler ring, and the insulating tube are filled with potting compound, and a portion of the busbar and the water connector are exposed outside the potting compound. This utility model's toroidal water-cooled reactor utilizes a molded and welded coil assembly, a filler ring, and an optimized potting compound structure. The coil is integrally welded, and the potting compound structure provides high mechanical strength, enabling the reactor to withstand instantaneous high-current pulses and reducing partial discharge. This improves the reactor's mechanical strength and quality while reducing manufacturing difficulty and cost. It also achieves lightweight design of the toroidal water-cooled reactor. Furthermore, through material selection and structural design, the reactor systematically enhances the crack resistance of the internal adhesive layer under alternating hot and cold conditions.

[0024] In addition to the objectives, features, and advantages described above, this utility model has other objectives, features, and advantages. The present utility model will now be described in further detail with reference to the figures. Attached Figure Description

[0025] The accompanying drawings, which form part of this utility model, are used to provide a further understanding of the utility model. The illustrative embodiments of the utility model and their descriptions are used to explain the utility model and do not constitute an undue limitation of the utility model. In the drawings:

[0026] Figure 1 This is a schematic diagram of the overall structure of a toroidal water-cooled reactor according to the present invention;

[0027] Figure 2 for Figure 1 A schematic diagram of the assembly structure of the coil assembly, filling ring, and insulating tube of a medium-sized toroidal water-cooled reactor;

[0028] Figure 3 for Figure 1 A schematic diagram of the structure after removing the external potting compound;

[0029] Figure 4 This is a schematic diagram of the filling ring structure.

[0030] In the diagram: 1. Coil assembly, 1.1. Conductor bar, 1.2. Water connector, 1.3. Coil body; 2. Filler ring, 2.1. Quarter ring; 3. Insulating tube; 4. Encapsulating colloid, 4.1. Positioning hole, 4.2. Mounting plane, 4.3. Arc surface, 4.4. External transition surface, 4.5. Conical surface; 5. Insulating paper; 6. Binding tape; 7. Mesh cloth; 8. Fiberglass tape; 9. Fiberglass tape; 10. Insulating board. Detailed Implementation

[0031] The embodiments of the present invention will be described in detail below with reference to the accompanying drawings. However, the present invention can be implemented in many different ways as defined and covered by the claims.

[0032] refer to Figure 1 A toroidal water-cooled reactor includes a coil assembly 1, a filling ring 2, an insulating tube 3, and a potting compound 4. The coil assembly 1 includes a conductive busbar 1.1, a water connector 1.2, and a coil body 1.3. The coil body 1.3 is a hollow tube with an internal cavity, and the hollow tube is wound around the filling ring 2 to form multiple coils. Water connectors 1.2 are provided at both ends of the coil body 1.3, and the water connectors 1.2 are all fixedly mounted on the conductive busbar 1.1. The insulating tube 3 is provided at the center of rotation of the filling ring 2, and the insulating tube 3 is arranged perpendicular to the plane where the filling ring 2 is located. The coil assembly 1, the filling ring 2, and the insulating tube 3 are filled with potting compound 4, and a portion of the conductive busbar 1.1 and the water connector 1.2 are exposed outside the potting compound 4.

[0033] The toroidal water-cooled reactor of this embodiment features a structure consisting of a molded and welded coil assembly, a filler ring, and an optimized potting compound. The coil assembly is integrally welded, resulting in high mechanical strength and enabling the reactor to withstand instantaneous high-current pulses while reducing partial discharge. By combining this with the potting compound structure, the reactor's mechanical strength and quality are improved while reducing the difficulty and cost of the manufacturing process. This also achieves a lightweight design for the toroidal water-cooled reactor. Furthermore, through the selection of raw materials and structural design, the crack resistance of the internal adhesive layer under alternating hot and cold conditions is systematically improved.

[0034] refer to Figure 2 The coil body 1.3 is made of aluminum alloy profile, and the aluminum alloy profile is selected as 6 series hard state aluminum alloy. The conductive busbar 1.1, water connector 1.2 and coil body 1.3 are connected by weld. The outer contour of the cross-section of the hollow tube of the coil body 1.3 is square, and the four corners of the square are rounded.

[0035] The conductive busbar 1.1 has multiple through holes, some of which are used to install the insulating plate 10, while the remaining through holes are used to connect to an external power source. The insulating plate 10 is made of epoxy glass cloth and is used to position and fix the conductive busbar 1.1, thereby improving its ability to withstand instantaneous high-current pulses.

[0036] The thickness of the conductive busbar 1.1 is consistent with the outer diameter of the hollow tube of the coil body 1.3, and the width of the conductive busbar 1.1 is one-third of the total height of the coil body 1.3.

[0037] The inner hole of the water connector communicates with the inner hole of the coil body and is connected to the external water circuit via an internal thread. External cooling deionized water enters the coil body through the water connector and exits through the water connector, forming a cooling circuit. The coil body does not require insulation treatment, the coil manufacturing process is simple, and there are no safety or quality risks caused by insulation layer peeling. When the reactor is energized, the cooling water continuously carries away internal heat, playing a role in water cooling and heat dissipation. The coil body is made of drawn aluminum alloy with a hole in the center of the cross-section for cooling water circulation. The cross-section is rounded, which optimizes the electric field distribution, reduces electric field concentration and partial discharge phenomena caused by sharp corners, reduces heat accumulation at sharp corners, and reduces damage to the potting compound structure from sharp corners, thereby improving the overall mechanical strength. The coil body manufacturing process is as follows: After drawing, the wire undergoes heat softening treatment, first wound into a multi-turn hollow coil, and then bent into a ring. This reduces damage to the surface of the aluminum alloy profile by the tooling mold during the forming process and avoids micro-cracks in the internal cavity. After bending, the coil is welded into a whole, and then subjected to heat treatment to make the coil as a whole harden. Its ring structure and conductor busbar have good strength and strong ability to withstand instantaneous pulsed large current.

[0038] refer to Figure 3 The filling ring 2 is composed of four quarter-circular rings 2.1 connected together to form a single ring. This modular design facilitates installation and disassembly. Its material is a foaming material with the same coefficient of expansion as the potting compound 4. Its cross-sectional shape matches the inner cavity of the coil body. During use, the two conductive pads are staggered, and the quarter-circular filling rings are sequentially inserted into the inner cavity of the coil assembly. This serves to fill and support the coil assembly and the potting compound, minimizing damage to the potting compound structure. Its low density results in a lightweight product. During expansion and contraction of the coil assembly and the potting compound, the foaming material releases internal stress, preventing cracking of the compound layer. Furthermore, by significantly reducing the amount of potting compound used, it reduces quality issues such as large shrinkage rates and numerous internal cavities caused by excessive potting compound usage, minimizes partial discharge, and lowers the difficulty and cost of the manufacturing process.

[0039] It also includes insulating paper 5 disposed between the coils of the coil body to provide insulation, the insulating paper 5 comprising multiple layers of whole sheets of NOMEX insulating paper.

[0040] It also includes a binding tape 6 for binding the insulating paper 5 and the coil body 1.3, the binding tape 6 being an alkali-free glass fiber tape.

[0041] It also includes a mesh cloth 7 covering the coil body 1.3. The mesh cloth 7 is a mesh-shaped epoxy resin glass fiber cloth. The mesh cloth 7 is fixed to the outside of the coil body 1.3 by glass fiber tape 8 and single-sided adhesive glass fiber tape 9. The mesh cloth is made of epoxy resin impregnated glass fiber cloth, has a mesh shape, and has good toughness and strength. By passing through the outer diameter and inner hole of the coil assembly, it plays a role in binding and fixing the coil assembly, providing support for the potting compound, thereby strengthening the mechanical structure.

[0042] The insulating tube 3 is made of epoxy glass cloth tube, and the space between the insulating tube 3 and the bound coil body 1.3 is filled with potting compound 4.

[0043] The inner hole of the insulating tube serves as the mounting hole for the reactor. Its wall thickness is moderate, and there is sufficient distance and space between the outer ring and the inner hole of the bound coil body for filling with potting compound. The compound layer is sufficiently thick, resulting in high local and overall mechanical strength, and the surface quality of the mounting hole's inner hole is good. During molding, the insulating tube is installed on the casting mold, and the reactor is integrally potted. During potting, the insulating tube also serves to seal the liquid potting compound. Pouring into the inner hole is difficult and prone to defects. Thickened insulating tubes or rods result in a thinner compound layer; therefore, the insulating tube is used as the inner hole's positioning element.

[0044] refer to Figure 4 The potting compound 4 is made of polyurethane, which has good flexibility. The potting compound 4 includes a positioning hole 4.1, a mounting plane 4.2, an arc surface 4.3, an outer transition surface 4.4, and a conical surface 4.5, which are integrally cast. The positioning hole 4.1, the mounting plane 4.2, the arc surface 4.3, the outer transition surface 4.4, and the conical surface 4.5 together form the outer surface of the potting compound 4. The positioning hole 4.1 is set on the mounting plane 4.2 and is used to position the reactor in the circumferential direction and to fix the clamping iron plate on the reactor. The outer transition surface 4.4 is used to transition and connect the arc surface 4.3 and the conical surface 4.5. The conical surface 4.5 is used to facilitate demolding of the casting mold after potting, and the transition between the two conical surfaces 4.5 is smooth and stress-free.

[0045] The material of the potting compound is suitable for conditions with large temperature differences and thermal expansion / contraction between the coil assembly and the potting compound when the reactor is energized and internally cooled by water. The compound layer is less prone to cracking, and the coil and potting compound are less likely to delaminate, reducing partial discharge phenomena. Positioning holes are cast into the mold in one step for circumferential positioning of the reactor. The mounting plane is used to install two clamping plates to secure the reactor to the external frame without rotation. During energized and water-cooled operation, and when the coil assembly and other internal components experience alternating hot and cold temperatures, the clamping plates prevent deformation in the thickness direction of the reactor and avoid cracking of the potting compound. The arc surface shape and distance are basically consistent with the coil assembly shape, and the potting compound layer thickness is basically consistent, eliminating stress concentration and cracking caused by uneven thickness, and facilitating demolding after casting. The external transition surface is used to connect the arc surface and the conical surface, aiming to eliminate stress concentration in the potting compound and prevent cracking. The conical surface facilitates demolding after filling and the two conical surfaces transition smoothly without stress concentration.

[0046] The above description is merely a preferred embodiment of this utility model and is not intended to limit the utility model. Various modifications and variations can be made to this utility model by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this utility model should be included within the protection scope of this utility model.

Claims

1. A toroidal water-cooled reactor, characterized in that, It includes a coil assembly (1), a filler ring (2), an insulating tube (3), and a potting compound (4); The coil assembly (1) includes a conductive busbar (1.1), a water connector (1.2), and a coil body (1.3); the coil body (1.3) is a hollow tube with an internal hollow structure, and the hollow tube is wound around a filling ring (2) to form multiple coils. Water connectors (1.2) are provided at both ends of the coil body (1.3), and the water connectors (1.2) are all fixedly installed on the conductive busbar (1.1); An insulating tube (3) is provided at the rotation center of the filling ring (2), and the insulating tube (3) is arranged perpendicular to the plane where the filling ring (2) is located; The coil assembly (1), the filling ring (2) and the insulating tube (3) are externally filled with potting compound (4), and a portion of the conductive bus (1.1) and the water connector (1.2) are exposed outside the potting compound (4).

2. The ring-shaped water-cooled reactor according to claim 1, characterized in that The coil body (1.3) is made of aluminum alloy profile, which is 6 series hard aluminum alloy. The conductive busbar (1.1), water connector (1.2) and coil body (1.3) are connected by weld. The outer contour of the cross-section of the hollow tube of the coil body (1.3) is square, and the four corners of the square are rounded.

3. The ring-shaped water-cooled reactor according to claim 1, characterized in that The conductive bus (1.1) is provided with multiple through holes, some of which are used to install the insulating plate (10), and the remaining through holes are used to connect to an external power source; The insulating board (10) is made of epoxy glass cloth and is used to position and fix the conductive bar (1.1).

4. The ring-shaped water-cooled reactor according to claim 1, characterized in that, The thickness of the conductive busbar (1.1) is consistent with the outer diameter of the hollow tube of the coil body (1.3), and the width of the conductive busbar (1.1) is one-third of the total height of the coil body (1.3).

5. The ring-shaped water-cooled reactor according to claim 1, characterized in that, The filling ring (2) is composed of four quarter-circular rings (2.1) connected to each other, and its material is a foaming material with the same coefficient of expansion as the potting compound (4).

6. The ring-shaped water-cooled reactor of any one of claims 1-5, characterized in that It also includes insulating paper (5) disposed between the coils of the coil body to provide insulation, the insulating paper (5) comprising multiple layers of whole sheets of NOMEX insulating paper.

7. The ring-shaped water-cooled reactor according to claim 6, characterized in that It also includes a binding tape (6) for binding the insulating paper (5) and the coil body (1.3), said binding tape (6) being an alkali-free glass fiber tape.

8. The ring-shaped water-cooled reactor according to claim 7, characterized in that It also includes a mesh cloth (7) covering the coil body (1.3), wherein the mesh cloth (7) is a mesh-shaped epoxy resin glass fiber cloth; The mesh fabric (7) is fixed to the outside of the coil body (1.3) by glass silk ribbon (8) and single-sided adhesive glass silk tape (9).

9. The ring-shaped water-cooled reactor according to claim 1, characterized in that The insulating tube (3) is made of epoxy glass cloth tube, and the space between the insulating tube (3) and the bundled coil body (1.3) is filled with potting compound (4).

10. The ring-shaped water-cooled reactor according to claim 9, characterized in that The potting compound (4) is made of polyurethane. The potting compound (4) includes a positioning hole (4.1), a mounting plane (4.2), an arc surface (4.3), an outer transition surface (4.4), and a conical surface (4.5) formed by integral casting. The positioning hole (4.1), the mounting plane (4.2), the arc surface (4.3), the outer transition surface (4.4), and the conical surface (4.5) together form the outer surface of the potting compound (4). The positioning hole (4.1) is set on the mounting plane (4.2) for positioning the reactor in the circumferential direction and fixing the clamping iron plate on the reactor; the outer transition surface (4.4) is used to transition and connect the arc surface (4.3) and the conical surface (4.5); the conical surface (4.5) is used to facilitate demolding of the casting mold after potting, and the transition between the two conical surfaces (4.5) is smooth and stress-free.

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