Horizontal foil-wound ferrosilicon DC reactor
By adopting a horizontal foil-wound iron-silicon DC reactor, using an iron-silicon core and copper or aluminum foil to wind the coil, combined with thermal grease and heat dissipation fins, the problems of heat dissipation difficulties and winding difficulties of traditional reactors are solved, achieving efficient heat dissipation and stable operation.
Patent Information
- Application Number
- CN202521778830.7
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-08-20
- Publication Date
- 2026-08-04
- Estimated Expiration
- 2035-08-20
AI Technical Summary
Traditional iron-core reactors have difficulty in heat dissipation. The inner layers of the coil are tightly packed, making it difficult for heat to dissipate, resulting in a high failure rate, short service life, and difficulty in winding in high-current applications, as well as low surface flatness of the coil.
A horizontal foil-wound iron-silicon DC reactor is adopted, using iron-silicon cores, copper foil or aluminum foil to wind the coils, and thermally conductive silicone grease is filled in the gaps between the coils. Heat dissipation fins and heat dissipation channels are set up, and intelligent heat dissipation management is carried out in conjunction with temperature sensors.
It achieves excellent heat dissipation performance, reduces the failure rate, extends service life, effectively suppresses harmonic current, and improves the stability and voltage withstand performance of the reactor.
Smart Images
Figure CN224595344U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of reactor technology, specifically to a horizontal foil-wound iron-silicon DC reactor. Background Technology
[0002] In industrial production, frequency converters are widely used in automation control and energy conservation and emission reduction. DC reactors, connected in series in the DC circuit of the frequency converter, suppress harmonic currents, stabilize current, improve the power factor, and ensure stable operation of the frequency converter. Furthermore, in smelting equipment such as DC electric arc furnaces and DC submerged arc furnaces, reactors are also needed to suppress inrush currents. These devices have high power ratings, with DC currents reaching tens of thousands of amperes, placing higher demands on the performance and heat dissipation capabilities of the reactors.
[0003] Traditional iron-core reactors suffer from poor heat dissipation due to their tightly packed coil layers, making it difficult for heat to dissipate during operation, leading to increased failure rates and shortened service life. Reactors wound with copper or aluminum wire are difficult to wind for high-current applications, resulting in low coil surface flatness. With the increasing demands for energy conservation, environmental protection, and quality in the reactor industry, product structure upgrades, the application of new materials, and technological innovation are imperative. Utility Model Content
[0004] The purpose of this invention is to provide a horizontal foil-wound iron-silicon DC reactor that can meet the needs of DC power transmission and industrial fields for improved reactor performance, and is also a result of addressing the shortcomings of existing technologies and adapting to industry development trends.
[0005] The technical solution of this utility model is as follows:
[0006] A horizontal foil-wound iron-silicon DC reactor includes an iron core, a first foil-wound coil, a second foil-wound coil, an input busbar, an output busbar, a left clamp, and a right clamp. The iron core includes columns A, B, C, and D. Columns A and B are arranged laterally at intervals. The left end of column A is connected to the left end of column B via column C, and the right end of column A is connected to the right end of column B via column D. The first foil-wound coil is wound on column A, and a first gap and a second gap are respectively provided between the upper and lower parts of the first foil-wound coil and column A. A first busbar groove is provided in the first gap. The input busbar is connected in the first busbar groove, and the input end of the input busbar extends from one end of the first foil-wound coil. The second foil-wound coil... The second foil-wound coil is wound around the B-pillar, and a third gap and a fourth gap are respectively provided between the upper and lower parts of the second foil-wound coil and the B-pillar. A second conductive busbar groove is provided on the fourth gap, and the output conductive busbar is connected in the second conductive busbar groove. The output end of the output conductive busbar extends from one end of the second foil-wound coil. Thermal grease is filled in the first gap, the second gap, the third gap, and the fourth gap. A first heat sink is connected between the upper part of the first foil-wound coil and the upper part of the second foil-wound coil, and a second heat sink is connected between the lower part of the first foil-wound coil and the lower part of the second foil-wound coil. The left clamp is mounted on the C-pillar, and the right clamp is mounted on the D-pillar. Mounting holes are provided on both sides of the left clamp and the right clamp.
[0007] Furthermore, the core is made of silicon iron.
[0008] Furthermore, the first foil-wound coil and the second foil-wound coil use copper foil or aluminum foil as conductive materials.
[0009] Furthermore, both the upper and lower parts of the first foil-wound coil and the second foil-wound coil are provided with heat dissipation channels.
[0010] Furthermore, the first heat sink and the second heat sink are heat dissipation fins.
[0011] Furthermore, the upper part of the left clamp is provided with a first fixing block, the upper part of the right clamp is provided with a second fixing block, the first fixing block and the second fixing block are locked together by a first bolt, the lower part of the left clamp is provided with a third fixing block, the lower part of the right clamp is provided with a fourth fixing block, the third fixing block and the fourth fixing block are locked together by a second bolt.
[0012] Furthermore, a temperature sensor corresponding to the first foil winding coil and the second foil winding coil is installed on the first fixing block.
[0013] Compared with the prior art, the beneficial effects of this utility model are as follows:
[0014] 1. In DC power transmission converter stations, smoothing reactors are needed to suppress ripple in the DC output voltage of the rectifier circuit, making the output DC close to ideal DC. At the same time, it can also form a harmonic filtering circuit with the DC filter to reduce AC pulsation components and filter out some harmonics, reduce interference to communication, prevent steep wave impacts from damaging the converter valve, reduce the inverter commutation failure rate, and limit the peak short-circuit current, etc. The horizontal foil-wound iron-silicon DC reactor provided by this utility model can well meet these functional requirements.
[0015] 2. This utility model has multiple heat dissipation structures and has good heat dissipation performance, such as: (1) thermal conductive grease is filled between the coil and the iron core, which can enhance heat conduction. The thermal conductivity of the thermal conductive grease is not less than 2.0 W / (m·K); (2) heat dissipation fins are connected between the upper and lower parts of the two coils. The heat dissipation fins can be made of materials with good thermal conductivity, such as aluminum alloy materials; (3) heat dissipation channels are provided at the upper and lower parts of the two coils to match the thermal expansion coefficients of the iron core and the coil, which can avoid insulation aging or structural loosening caused by temperature changes.
[0016] 3. This utility model is equipped with a temperature sensor (such as a thermocouple or a thermistor) to monitor the temperature of key parts of the reactor (such as coils and iron cores) in real time. The control system (such as a PLC) automatically adjusts the speed of the cooling fan or starts the cooling water pump according to the temperature change to achieve intelligent heat dissipation management. Furthermore, by setting a temperature alarm threshold, an alarm signal is issued and corresponding protection measures are taken when the temperature exceeds the threshold. Attached Figure Description
[0017] 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.
[0018] Figure 1 A schematic diagram of the structure of a horizontal foil-wound iron-silicon DC reactor provided by this utility model. Figure 1 ;
[0019] Figure 2 A schematic diagram of the structure of a horizontal foil-wound iron-silicon DC reactor provided by this utility model. Figure 2 ;
[0020] Figure 3 This invention provides an internal structural diagram of a horizontal foil-wound iron-silicon DC reactor. Detailed Implementation
[0021] 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.
[0022] To illustrate the technical solution described in this utility model, specific embodiments are described below.
[0023] Example
[0024] Please see Figures 1-3 This embodiment provides a horizontal foil-wound iron-silicon DC reactor, including an iron core 1, a first foil-wound coil 2, a second foil-wound coil 3, an input conductive bus 4, an output conductive bus 5, a left clamp 6, and a right clamp 7. The iron core 1 includes columns A, B, C, and D. Columns A and B are arranged horizontally at intervals. The left end of column A is connected to the left end of column B via column C, and the right end of column A is connected to the right end of column B via column D. The first foil-wound coil 2 is wound on column A, and a first gap 21 and a second gap 22 are respectively provided between the upper and lower parts of the first foil-wound coil 2 and column A. A first conductive bus groove is provided on the first gap 21. The input conductive bus 4 is connected in the first conductive bus groove, and the input end of the input conductive bus 4 extends from one end of the first foil-wound coil 2. The second foil-wound coil 3 is wound on column B, and a third gap 31 and a fourth gap 32 are respectively provided between the upper and lower parts of the second foil-wound coil 3 and column B. A second conductive bus groove is provided on the fourth gap 32, and the output conductive bus 5 is connected in the second conductive bus groove. The output terminal of the output conductive bus 5 extends from one end of the second foil-wound coil 3. Thermal grease is filled in the first gap 21, second gap 22, third gap 31, and fourth gap 32. Heat dissipation channels 8 are provided at the top and bottom of both the first foil-wound coil 2 and the second foil-wound coil 3. A first heat sink 9 is connected between the upper part of the first foil-wound coil 2 and the upper part of the second foil-wound coil 3. A second heat sink 10 is connected between the lower part of the first foil-wound coil 2 and the lower part of the second foil-wound coil 3. The left clamp 6... The right clamp 7 is installed on the C-pillar, and the left clamp 6 and the right clamp 7 are installed on the D-pillar. Both sides of the left clamp 6 and the right clamp 7 have mounting holes. The upper part of the left clamp 6 has a first fixing block 61, and the upper part of the right clamp 7 has a second fixing block 71. The first fixing block 61 and the second fixing block 71 are locked together by a first bolt 20. The lower part of the left clamp 6 has a third fixing block 62, and the lower part of the right clamp 7 has a fourth fixing block 72. The third fixing block 62 and the fourth fixing block 72 are locked together by a second bolt 30.
[0025] In this embodiment, the iron core 1 is an iron-silicon iron core. Based on the magnetic properties of iron-silicon materials, a reasonable iron core structure is designed to reduce iron core losses, improve magnetic permeability, and ensure the stability of the reactor under large DC current.
[0026] In this embodiment, the first foil-wound coil 2 and the second foil-wound coil 3 use copper foil or aluminum foil as conductive materials. A horizontal winding process is designed to ensure the flatness and tightness between coil layers, reduce leakage flux and eddy current loss. Combined with the characteristics of insulating materials (such as thin films and paper tubes), the coil insulation structure is optimized to improve voltage withstand performance and heat dissipation efficiency.
[0027] In this embodiment, the first heat sink 9 and the second heat sink 10 are heat dissipation fins. These heat dissipation fins can be made of materials with good thermal conductivity, such as aluminum alloy.
[0028] In this embodiment, a temperature sensor 40 corresponding to the first foil-wound coil 2 and the second foil-wound coil 3 is installed on the first fixing block 61. The temperature sensor 40 can be a thermocouple or a thermistor, and can monitor the temperature of key parts of the reactor (such as coils and iron cores) in real time.
[0029] 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 horizontal foil-wound ferrosilicon DC reactor, characterized in that: The device includes an iron core, a first foil-wound coil, a second foil-wound coil, an input conductive bus, an output conductive bus, a left clamp, and a right clamp. The iron core includes pillars A, B, C, and D. Pillars A and B are arranged laterally at intervals. The left end of pillar A is connected to the left end of pillar B via pillar C, and the right end of pillar A is connected to the right end of pillar B via pillar D. The first foil-wound coil is wound on pillar A, and a first gap and a second gap are respectively provided between the upper and lower parts of the first foil-wound coil and pillar A. A first conductive bus groove is provided in the first gap, and the input conductive bus is connected in the first conductive bus groove. The input end of the input conductive bus extends from one end of the first foil-wound coil. The second foil-wound coil is wound on pillar B. The second foil-wound coil is mounted on the column, and a third gap and a fourth gap are respectively provided between the upper and lower parts of the second foil-wound coil and the column B. A second conductive busbar groove is provided on the fourth gap. The output conductive busbar is connected in the second conductive busbar groove, and the output end of the output conductive busbar extends from one end of the second foil-wound coil. Thermal grease is filled in the first gap, the second gap, the third gap, and the fourth gap. A first heat sink is connected between the upper part of the first foil-wound coil and the upper part of the second foil-wound coil, and a second heat sink is connected between the lower part of the first foil-wound coil and the lower part of the second foil-wound coil. The left clamp is mounted on the column C, and the right clamp is mounted on the column D. Mounting holes are provided on both sides of the left clamp and the right clamp.
2. A horizontal foil-wound ferrosilicon DC reactor according to claim 1, characterized in that: The core is made of iron-silicon alloy.
3. The horizontal foil-wound ferrosilicon DC reactor according to claim 1, characterized in that: The first foil-wound coil and the second foil-wound coil use copper foil or aluminum foil as conductive materials.
4. The horizontal foil-wound ferrosilicon DC reactor according to claim 1, characterized in that: Both the first foil-wound coil and the second foil-wound coil have heat dissipation channels at their upper and lower parts.
5. The horizontal foil-wound ferrosilicon DC reactor according to claim 1, characterized in that: The first and second heat sinks are heat dissipation fins.
6. A horizontal foil-wound ferrosilicon DC reactor according to claim 1, characterized in that: The upper part of the left clamp is provided with a first fixing block, the upper part of the right clamp is provided with a second fixing block, the first fixing block and the second fixing block are locked together by a first bolt, the lower part of the left clamp is provided with a third fixing block, the lower part of the right clamp is provided with a fourth fixing block, the third fixing block and the fourth fixing block are locked together by a second bolt.
7. A horizontal foil-wound ferrosilicon DC reactor according to claim 6, characterized in that: Temperature sensors corresponding to the first foil-wound coil and the second foil-wound coil are installed on the first fixing block.