Intermediate frequency dc reactor
By using medium-frequency DC reactors with thin, wide metal foil windings and low-loss core materials, the problems of high winding losses, poor heat dissipation, and non-compact structure have been solved, enabling the application of efficient and reliable medium-frequency reactors suitable for various industrial environments.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- GUANGDONG NRE TECH CO LTD
- Filing Date
- 2025-07-25
- Publication Date
- 2026-07-07
AI Technical Summary
Existing medium-frequency DC reactors suffer from high winding losses, poor heat dissipation, non-compact structure, insufficient reliability, and poor environmental adaptability, and are difficult to meet the stable operation requirements of medium-frequency conditions.
It employs coils wound with thin, wide metal foil and low-loss microcrystalline alloy and amorphous alloy core materials, combined with optimized winding design and insulation structure, to achieve uniform current distribution and efficient heat dissipation. It also adapts to special environments through a dry structure and is equipped with intelligent monitoring functions.
It reduces winding and core losses, improves heat dissipation efficiency and mechanical strength, reduces equipment size and maintenance costs, enhances environmental adaptability and system stability, and is suitable for reactor applications under medium frequency conditions.
Smart Images
Figure CN224472308U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of DC reactor technology, specifically to a medium-frequency DC reactor. Background Technology
[0002] Systems such as medium-frequency induction heating equipment and variable frequency speed control devices play a crucial role in many fields, including metallurgy, machinery manufacturing, and mining. The stable operation of these systems relies on the precise control and optimization of the DC-side current, which is why medium-frequency dry-type foil-wound DC reactors have emerged.
[0003] Traditional medium-frequency reactors have many drawbacks in application. Early oil-immersed reactors, while meeting some power demands for a period, posed serious safety hazards, such as the risk of insulating oil leakage, which not only pollutes the environment but may also cause fires. Furthermore, their maintenance costs are high, the maintenance process is complex, and they require regular inspection and maintenance by professionals, making them unsuitable for today's efficient and convenient industrial production pace. Ordinary iron-core reactors, under medium-frequency conditions, suffer from high eddy current and hysteresis losses in the iron core, resulting in low overall efficiency. The large weight and size of the iron core also increase the difficulty of installation and the space required.
[0004] With technological advancements, dry-type reactors have gradually emerged as a viable option. Dry-type reactors eliminate the need for insulating oil, fundamentally solving the oil leakage problem of oil-immersed reactors and making them more suitable for industrial environments with high environmental requirements and limited space. However, traditional dry-type reactors typically use enameled wire windings, which exhibit significant performance limitations when facing high-current, high-frequency operating scenarios. Under high current conditions, the uneven current distribution in enameled wire windings can easily lead to localized overheating, affecting the reactor's lifespan and stability. Simultaneously, the skin effect and proximity effect at high frequencies significantly increase the AC resistance of the windings, resulting in increased energy loss.
[0005] The emergence of foil winding technology offers a new approach to solving the aforementioned problems. Foil-wound reactors use thin, wide metal foils (such as copper or aluminum foil) as the winding material, offering unique advantages over traditional enameled wire. From a current distribution perspective, foil-wound windings exhibit more uniform current distribution, effectively reducing localized overheating. During high-current transmission, the large-area conductivity of the metal foil allows current to flow more evenly through the winding, reducing the thermal effects caused by current concentration. Under high-frequency operating conditions, the skin effect of foil winding is relatively low, resulting in a smaller increase in AC resistance, thereby reducing energy loss and improving reactor efficiency. For example, in some high-frequency induction heating equipment, foil-wound reactors enable the equipment to maintain low energy consumption during long-term operation, improving overall energy utilization.
[0006] Furthermore, foil-wound reactors also exhibit excellent mechanical strength and short-circuit withstand capability. The integrity and rigidity of the metal foil make the winding structure more robust, enabling it to withstand greater electromagnetic forces when subjected to short-circuit current surges, reducing the risk of winding deformation and damage. This characteristic is particularly important in industrial power systems with extremely high reliability requirements, effectively ensuring continuous equipment operation, reducing production interruptions caused by faults, and minimizing economic losses for enterprises.
[0007] However, the application of foil winding technology in medium-frequency DC reactors still faces some challenges. In terms of winding design, further optimization of foil material selection, number of layers, winding method, and insulation structure to achieve lower losses, higher insulation performance, and better heat dissipation remains a key research focus. Regarding manufacturing processes, high-precision foil winding equipment and process control technology need further improvement to ensure the consistency and stability of reactors and meet the stringent quality requirements of different industries. With the development of industrial automation and intelligence, new demands have been placed on the intelligent monitoring and remote operation and maintenance functions of medium-frequency dry-type foil-wound DC reactors. How to effectively integrate reactors with smart grids is a challenge that future technological development needs to overcome. Utility Model Content
[0008] The purpose of this invention is to overcome the shortcomings of the prior art and provide a medium-frequency DC reactor with low winding loss, excellent heat dissipation performance, compact structure, high reliability, strong environmental adaptability, and adaptability to medium-frequency operating conditions.
[0009] The technical solution of this utility model is as follows:
[0010] A medium-frequency DC reactor includes a magnetic core, a coil, an input busbar, and an output busbar. The magnetic core has two iron pillars facing each other on the left and right. The coil has two sets and is wound around the two iron pillars of the magnetic core respectively. The coil is made of thin wide metal foil. The input busbar is located at the lower part of the medium-frequency DC reactor and is connected to the coil. The output busbar is located at the upper part of the medium-frequency DC reactor and is connected to the coil.
[0011] Furthermore, the magnetic core is made of microcrystalline alloy or amorphous alloy iron core material.
[0012] Furthermore, the coil is made of copper foil or aluminum foil.
[0013] Furthermore, a top pressure member is installed on the top of the magnetic core, and a low pressure member is installed on the bottom of the magnetic core. A first fixing seat is provided on the front and rear sides of the top pressure member, and a second fixing seat is provided on the front and rear sides of the low pressure member. The first fixing seat and the second fixing seat are connected by a screw.
[0014] Furthermore, a base is installed at the bottom of the low-pressure component, and mounting holes are provided at both the front and rear ends of the base.
[0015] Compared with the prior art, the beneficial effects of this utility model are as follows:
[0016] 1. Low winding loss: The winding is made of thin and wide metal foil (copper foil / aluminum foil), which makes the current distribution more uniform and can effectively reduce the skin effect and proximity effect (especially under medium frequency conditions), reduce the AC resistance of the winding, and reduce energy loss. 2. Low core loss: The core material is made of low loss materials such as microcrystalline alloy and amorphous alloy, which significantly reduces eddy current and hysteresis loss under medium frequency magnetic field and improves overall efficiency.
[0017] 2. Excellent heat dissipation performance: The foil winding has a large surface area and close contact with the insulating material, resulting in a short heat conduction path and high heat dissipation efficiency. It can adapt to long-term high-load operation and reduce the risk of overheating. The dry structure does not require insulating oil and can dissipate heat quickly through natural or forced air cooling, making it suitable for compact environments with limited ventilation.
[0018] 3. Compact structure and high reliability: Small size and light weight: The foil winding process enables high-density winding arrangement. Combined with optimized core design, the overall size and weight are reduced compared to traditional reactors, saving installation space. High mechanical strength: The metal foil winding has good integrity, strong short-circuit resistance, and can withstand large electromagnetic force impacts, reducing the risk of winding deformation or loosening. Stable insulation performance: High-temperature resistant insulation materials (such as polyimide film) are used. The dry structure avoids the aging problem of insulating oil in oil-immersed systems, making the insulation performance more reliable in high-temperature and humid environments, and extending service life.
[0019] 4. Strong environmental adaptability: No insulating oil is required, eliminating the risk of oil leakage and pollution. Suitable for special industrial environments such as dustproof, explosion-proof, and clean environments (e.g., food processing, pharmaceuticals). Installation and maintenance are simple, eliminating the need for regular insulating oil replacement, reducing maintenance costs and downtime.
[0020] 5. Adaptable to medium frequency operating conditions: Designed for medium frequency power supply systems (such as medium frequency induction heating and variable frequency speed control), it can effectively smooth DC side pulsation, suppress harmonics, improve system stability, and meet the high frequency response and filtering requirements of reactors in medium frequency scenarios. Attached Figure Description
[0021] To more clearly illustrate the technical solutions in the embodiments of this utility model, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.
[0022] Figure 1This is a schematic diagram of the structure of a medium-frequency DC reactor provided by this utility model. Detailed Implementation
[0023] To make the objectives, technical solutions, and advantages of this utility model clearer, the present utility model will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the present utility model and are not intended to limit the present utility model.
[0024] To illustrate the technical solution described in this utility model, specific embodiments are described below.
[0025] Example
[0026] Please see Figure 1 This embodiment provides a medium-frequency DC reactor, including a magnetic core 1, a coil 2, an input conductor 3, and an output conductor 4. The magnetic core 1 has two iron pillars facing each other on the left and right. The coil 2 has two sets and is wound on the two iron pillars of the magnetic core 1 respectively. The coil 2 is made of thin wide metal foil. The input conductor 3 is located at the lower part of the medium-frequency DC reactor and is connected to the coil 2. The output conductor 4 is located at the upper part of the medium-frequency DC reactor and is connected to the coil 2. A top pressure member 5 is installed on the top of the magnetic core 1, and a low-voltage member 6 is installed at the bottom of the magnetic core 1. A first fixing seat 7 is provided on the front and rear sides of the top pressure member 5, and a second fixing seat is provided on the front and rear sides of the low-voltage member 6. The first fixing seat 7 and the second fixing seat are connected by a screw 8. A base 9 is also installed at the bottom of the low-voltage member 6, and mounting holes 10 are opened at the front and rear ends of the base 9.
[0027] The magnetic core 1 is made of microcrystalline alloy or amorphous alloy iron core material.
[0028] The coil 2 is made of copper foil or aluminum foil.
[0029] This medium-frequency DC reactor has the following characteristics;
[0030] 1. Low winding loss: The winding is made of thin and wide metal foil (copper foil / aluminum foil), which makes the current distribution more uniform and can effectively reduce the skin effect and proximity effect (especially under medium frequency conditions), reduce the AC resistance of the winding, and reduce energy loss. 2. Low core loss: The core material is made of low loss materials such as microcrystalline alloy and amorphous alloy, which significantly reduces eddy current and hysteresis loss under medium frequency magnetic field and improves overall efficiency.
[0031] 2. Excellent heat dissipation performance: The foil winding has a large surface area and close contact with the insulating material, resulting in a short heat conduction path and high heat dissipation efficiency. It can adapt to long-term high-load operation and reduce the risk of overheating. The dry structure does not require insulating oil and can dissipate heat quickly through natural or forced air cooling, making it suitable for compact environments with limited ventilation.
[0032] 3. Compact structure and high reliability: Small size and light weight: The foil winding process enables high-density winding arrangement. Combined with optimized core design, the overall size and weight are reduced compared to traditional reactors, saving installation space. High mechanical strength: The metal foil winding has good integrity, strong short-circuit resistance, and can withstand large electromagnetic force impacts, reducing the risk of winding deformation or loosening. Stable insulation performance: High-temperature resistant insulation materials (such as polyimide film) are used. The dry structure avoids the aging problem of insulating oil in oil-immersed systems, making the insulation performance more reliable in high-temperature and humid environments, and extending service life.
[0033] 4. Strong environmental adaptability: No insulating oil is required, eliminating the risk of oil leakage and pollution. Suitable for special industrial environments such as dustproof, explosion-proof, and clean environments (e.g., food processing, pharmaceuticals). Installation and maintenance are simple, eliminating the need for regular insulating oil replacement, reducing maintenance costs and downtime.
[0034] 5. Adaptable to medium frequency operating conditions: Designed for medium frequency power supply systems (such as medium frequency induction heating and variable frequency speed control), it can effectively smooth DC side pulsation, suppress harmonics, improve system stability, and meet the high frequency response and filtering requirements of reactors in medium frequency scenarios.
[0035] The above are merely preferred embodiments of the present utility model and are not intended to limit the present utility model. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.
Claims
1. A medium-frequency DC reactor, characterized in that: The reactor includes a magnetic core, a coil, an input busbar, and an output busbar. The magnetic core has two iron pillars facing each other on the left and right. The coil has two sets and is wound around the two iron pillars of the magnetic core respectively. The coil is made of thin and wide metal foil. The input busbar is located at the lower part of the intermediate frequency DC reactor and is connected to the coil. The output busbar is located at the upper part of the intermediate frequency DC reactor and is connected to the coil.
2. The medium-frequency DC reactor according to claim 1, characterized in that: The magnetic core is made of microcrystalline alloy or amorphous alloy iron core material.
3. The medium-frequency DC reactor according to claim 1, characterized in that: The coil is made of copper foil or aluminum foil.
4. A medium-frequency DC reactor according to claim 1, characterized in that: A top pressure member is installed on the top of the magnetic core, and a low pressure member is installed on the bottom of the magnetic core. A first fixing seat is provided on the front and rear sides of the top pressure member, and a second fixing seat is provided on the front and rear sides of the low pressure member. The first fixing seat and the second fixing seat are connected by a screw.
5. A medium-frequency DC reactor according to claim 4, characterized in that: The low-pressure component is also equipped with a base at its bottom, and mounting holes are provided at both the front and rear ends of the base.