An electric reactor assembling tool

Abstract

This utility model relates to the technical field of reactor production equipment, and in particular to a reactor assembly fixture, including a coil positioning component and a yoke positioning frame. The coil positioning component is located inside the yoke positioning frame. The coil positioning component includes a base plate, a front side plate, and a rear side plate. The front side plate is located at the front end of the base plate, and the rear side plate is located at the rear end of the base plate. Three sets of U-shaped grooves corresponding to each other are respectively opened on the front and rear side plates. The U-shaped grooves are arranged at intervals along the length direction of the base plate, and the horizontal height of the bottom of the U-shaped grooves is higher than that of the base plate. The yoke positioning frame includes a front clamp and a rear clamp arranged opposite to each other, and several tie bolts connecting the front clamp and the rear clamp. The front side plate corresponds to the position of the front clamp, and the rear side plate corresponds to the position of the rear clamp. This utility model can improve the assembly efficiency of three-phase iron-core reactors and improve the consistency of product performance.

Description

Technical Field

[0001] This utility model relates to the technical field of reactor production equipment, specifically to a reactor assembly fixture. Background Technology

[0002] Three-phase core reactors are key components of the three-phase, three-branch PWM filter in three-phase IGBT inverters, and their performance directly affects the system's filtering effect and operational stability. These reactors typically employ a closed core structure made of laminated silicon steel sheets, with symmetrical windings wound on the three core columns. They must meet stringent design requirements such as low flux leakage, low eddy current loss, high linearity, excellent heat dissipation, and good electromagnetic symmetry under high-frequency PWM pulses. In traditional assembly processes, due to the lack of specialized tooling, manual adjustment of the relative positions of the core and coils is often necessary, requiring auxiliary tools to temporarily fix the upper and lower yokes. This results in low assembly efficiency, difficulty in ensuring positioning accuracy, and a tendency to cause problems such as winding asymmetry and magnetic circuit imbalance, affecting product performance consistency. Furthermore, repeated adjustments increase the risk of component damage, hindering improvements in production quality and efficiency. Utility Model Content

[0003] To address the shortcomings of existing technologies, the purpose of this utility model is to provide a reactor assembly fixture that can improve the assembly efficiency of three-phase iron-core reactors and enhance product performance consistency.

[0004] To achieve the above objectives, this utility model provides the following technical solution: a reactor assembly fixture, comprising a coil positioning component and a yoke positioning frame, wherein the coil positioning component is disposed inside the yoke positioning frame; the coil positioning component comprises a base plate, a front side plate, and a rear side plate, wherein the front side plate is disposed at the front end of the base plate, and the rear side plate is disposed at the rear end of the base plate; three sets of U-shaped grooves corresponding to each other are respectively opened on the front side plate and the rear side plate, the U-shaped grooves are arranged at intervals along the length direction of the base plate, and the horizontal height of the bottom of the U-shaped groove is higher than that of the base plate; the yoke positioning frame comprises a front clamp and a rear clamp arranged opposite to each other, and a plurality of tie bolts connecting the front clamp and the rear clamp; the front side plate corresponds to the position of the front clamp, and the rear side plate corresponds to the position of the rear clamp.

[0005] Preferably, both the front and rear side plates are fixedly connected to the base plate.

[0006] Preferably, it also includes multiple partitions, which are fixedly installed between the front side plate and the rear side plate and are arranged alternately with multiple sets of U-shaped grooves; the partitions are located above the bottom plate.

[0007] Preferably, the upper edge of the partition is flush with the upper edges of the front and rear side panels.

[0008] Preferably, the bottom plate has a through hole in the middle.

[0009] Preferably, the main end faces of the front side plate and the rear side plate are both perpendicular to the main end face of the bottom plate.

[0010] Preferably, both the front and rear side panels are detachably connected to the bottom plate.

[0011] Preferably, the number of partitions is four.

[0012] Preferably, the through hole has a square structure.

[0013] Preferably, the front clamp and the rear clamp have the same structure; the front clamp includes two clamping plates, a fixing plate and a positioning bolt; the two clamping plates are fixed together by the fixing plate and the positioning bolt.

[0014] Compared with the prior art, the beneficial effects of this utility model are as follows: This utility model achieves rapid and accurate horizontal positioning of the iron core through three sets of corresponding U-shaped groove structures in the coil positioning component, ensuring that the axes of the three are parallel and the spacing is consistent, effectively avoiding repeated manual adjustments and significantly improving assembly accuracy and efficiency; the partition design not only enhances the overall rigidity of the tooling, but also isolates adjacent coil leads to prevent interference, further ensuring electromagnetic symmetry; the square through hole in the middle of the base plate reduces weight and cost, while providing an observation and operation window, facilitating visual confirmation and fine-tuning during installation, and enhancing the controllability of the assembly process; the iron yoke positioning frame forms a rigid positioning space through the combination of front and rear clamps and tie bolts, enabling the upper and lower iron yokes to be stably at the same horizontal height and accurately aligned with the iron core ends, providing reliable positioning for welding and ensuring the consistency of magnetic circuit closure; the overall tooling supports horizontal assembly and overall flipping and removal, simplifying the operation process, reducing the number of hoisting operations, reducing labor intensity and the risk of component collisions, while also taking into account the heat dissipation space and welding process adaptability, comprehensively improving the assembly quality, consistency and production efficiency of the reactor. Attached Figure Description

[0015] Figure 1 This is a top view of the assembly tooling of this utility model; Figure 2 This is a coil positioning component of the present invention; Figure 3 This is a front view of the coil positioning component of this utility model; Figure 4 This is a schematic diagram of the front clamp of this utility model.

[0016] In the diagram: 1. Base plate, 2. Front side plate, 3. Rear side plate, 4. Partition plate, 5. U-shaped groove, 6. Front clamp, 7. Rear clamp, 8. Tie bolt, 11. Square hole, 61. Clamping plate, 62. Fixing plate, 63. Positioning bolt. Detailed Implementation

[0017] The specific embodiments of this utility model are described in detail below with reference to the accompanying drawings, so that those skilled in the art can more clearly understand how to practice this utility model. Although this utility model has been described in conjunction with its preferred embodiments, these embodiments are merely illustrative and not intended to limit the scope of this utility model.

[0018] See Figure 1-4 In one embodiment of this utility model, a reactor assembly fixture includes a coil positioning component and a yoke positioning frame. The coil positioning component is located inside the yoke positioning frame. The coil positioning component is used to accurately position three sets of wound iron cores and coils, while the yoke positioning frame is used to position the upper and lower yokes, so that the upper and lower yokes can be assembled with the three sets of wound iron cores and coils by welding.

[0019] See Figure 2 and Figure 3 The coil positioning component includes a main body and four partitions 4 disposed on the top of the main body. The main body has a box-shaped structure with an open design on the top and left and right sides, giving the main body an overall U-shaped structure. The main body is specifically composed of a base plate 1, a front side plate 2, and a rear side plate 3, wherein the front side plate 2 and the rear side plate 3 are respectively vertically fixed to the front and rear ends of the base plate 1. It can be understood that the main body is an integral structure formed by bending a single metal plate. Three sets of corresponding U-shaped grooves 5 are respectively opened on the front side plate 2 and the rear side plate 3. These U-shaped grooves 5 are arranged at intervals along the length of the base plate 1, and the horizontal height of the bottom of the U-shaped grooves 5 is higher than that of the base plate 1, thereby forming three placement spaces for placing the iron core.

[0020] After the coil core is wound, it can be placed horizontally in the corresponding U-shaped grooves 5, with both ends supported at the bottom of the grooves and extending outwards from the outside of the fixture. At this time, the coil is suspended above the base plate 1. Through the limiting effect of the three sets of U-shaped grooves 5, the position of the core is accurately positioned, effectively avoiding the problems of repeated size adjustments and the use of auxiliary tools in traditional assembly.

[0021] In this embodiment, four partitions 4 are fixedly installed between the front side plate 2 and the rear side plate 3. The four partitions 4 and the three sets of U-shaped grooves 5 are arranged alternately, and the upper edge of the partitions 4 is flush with the upper edges of the front side plate 2 and the rear side plate 3. The partitions 4 not only clearly distinguish the various placement areas, but also help to enhance the overall structural rigidity of the fixture. During assembly, the partitions 4 can isolate the leads of adjacent coils, prevent mutual interference, and further improve assembly accuracy.

[0022] Furthermore, a through square hole 11 is provided in the middle of the base plate 1. This square hole 11 serves as a through hole, which on the one hand helps to reduce the overall weight of the tooling, reduce material costs, and facilitate operation and handling; on the other hand, it makes the tooling present a more hollow structure, thereby providing an observation and operation window for operators during the assembly process, facilitating visual confirmation and fine-tuning of the installation position of the internal components of the reactor, and effectively improving the flexibility and controllability of the assembly process.

[0023] The iron yoke positioning frame includes a front clamp 6, a rear clamp 7, and several tie bolts 8. The front clamp 6 and the rear clamp 7 have the same structure. The front clamp 6 includes two clamping plates 61, a fixing plate 62, and positioning bolts 63. The two clamping plates 61 are arranged vertically and are fixed together by the fixing plate 62 and the positioning bolts 63 to form a frame structure. The front clamp 6 and the rear clamp 7 are fixed together by tie bolts 8, forming a positioning space between the front clamp 6 and the rear clamp 7.

[0024] Instructions for use: When assembling the reactor, a horizontal assembly method is adopted. The reactor core is arranged horizontally front to back, and the upper and lower yokes are at the same horizontal height. The specific steps are as follows: First, place the coil positioning piece and the yoke positioning frame on the workbench at the same time. Place the coil positioning piece inside the yoke positioning frame, and make the two clamps correspond to the front and rear side plates respectively, that is, the front clamp 6 corresponds to the front side plate 2, and the rear clamp 7 corresponds to the rear side plate 3. After completion, place the wound coil and the core in the three placement spaces in sequence. Next, place the upper yoke between the front clamp 6 and the front side plate 2, and the lower yoke between the rear clamp 7 and the rear side plate 3. Finally, complete the connection between the core, yoke and clamps by welding. After welding, the fixture can be pulled out from the formed reactor by flipping the whole unit.

[0025] In summary, this reactor assembly fixture achieves rapid and precise horizontal positioning of the iron core through three sets of corresponding U-shaped groove structures in the coil positioning components, ensuring that the axes of the three components are parallel and the spacing is consistent, effectively avoiding repeated manual adjustments and significantly improving assembly accuracy and efficiency. The partition design not only enhances the overall rigidity of the fixture but also isolates adjacent coil leads to prevent interference, further ensuring electromagnetic symmetry. The square through-hole in the middle of the base plate reduces weight and cost while providing an observation and operation window, facilitating visual confirmation and fine-tuning during installation and enhancing the controllability of the assembly process. The yoke positioning frame forms a rigid positioning space through the combination of front and rear clamps and tie bolts, ensuring that the upper and lower yokes are stably at the same horizontal level and precisely aligned with the ends of the iron core, providing reliable positioning for welding and ensuring consistent magnetic circuit closure. The overall fixture supports horizontal assembly and overall flipping and removal, simplifying the operation process, reducing the number of hoisting operations, reducing labor intensity and the risk of component collisions, while also taking into account heat dissipation space and welding process adaptability, comprehensively improving the reactor assembly quality, consistency, and production efficiency.

[0026] In the above embodiments, although the distance between the front clamp 6 and the rear clamp 7 can be adjusted by tie bolts, the coil positioning component, being an integral structure, is generally only applicable to reactor products of specific specifications. However, in actual production, the dimensional parameters of different reactor models—especially the length of the iron core—often vary significantly. To improve the versatility of the tooling and reduce tooling costs in multi-specification production, in a preferred embodiment of this invention, the front side plate 2 and the rear side plate 3 are detachably connected to the base plate 1, eliminating the need for the partition plate 4 structure. By simply replacing the base plate 1 with different widths, the width of the coil positioning component can be quickly adjusted to accommodate the assembly requirements of iron cores of different lengths. This modular design significantly enhances the applicability of the tooling, effectively enabling tooling reuse and reducing the cost of manufacturing additional dedicated tooling due to product model changes.

[0027] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this utility model and are not intended to limit it. Although this utility model has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of this utility model without departing from the spirit and scope of the technical solutions of this utility model, and all such modifications or substitutions should be covered within the scope of the claims of this utility model.

Claims

1. A reactor assembly fixture, characterized in that: The device includes a coil positioning component and a yoke positioning frame. The coil positioning component is located inside the yoke positioning frame. The coil positioning component includes a base plate (1), a front side plate (2), and a rear side plate (3). The front side plate (2) is located at the front end of the base plate (1), and the rear side plate (3) is located at the rear end of the base plate (1). Three sets of U-shaped grooves (5) corresponding to each other are respectively opened on the front side plate (2) and the rear side plate (3). The U-shaped grooves (5) are arranged at intervals along the length direction of the base plate (1), and the horizontal height of the bottom of the U-shaped grooves (5) is higher than that of the base plate (1). The yoke positioning frame includes a front clamp and a rear clamp arranged opposite to each other, and several tie bolts connecting the front clamp and the rear clamp. The front side plate (2) corresponds to the position of the front clamp, and the rear side plate (3) corresponds to the position of the rear clamp.

2. The reactor assembly fixture according to claim 1, characterized in that: Both the front side plate (2) and the rear side plate (3) are fixedly connected to the bottom plate (1).

3. The reactor assembly fixture according to claim 1, characterized in that: It also includes multiple partitions (4), which are fixedly installed between the front side plate (2) and the rear side plate (3) and are arranged alternately with multiple sets of U-shaped grooves (5); the partitions (4) are located above the bottom plate (1).

4. The reactor assembly fixture according to claim 3, characterized in that: The upper edge of the partition (4) is flush with the upper edges of the front side plate (2) and the rear side plate (3).

5. The reactor assembly fixture according to claim 1, characterized in that: The bottom plate (1) has a through hole in the middle.

6. The reactor assembly fixture according to claim 1, characterized in that: The main end faces of the front side plate (2) and the rear side plate (3) are perpendicular to the main end face of the bottom plate (1).

7. The reactor assembly fixture according to claim 1, characterized in that: Both the front side plate (2) and the rear side plate (3) are detachably connected to the bottom plate (1).

8. The reactor assembly fixture according to claim 3, characterized in that: The number of partitions (4) is four.

9. A reactor assembly fixture according to claim 5, characterized in that: The through hole has a square structure.

10. A reactor assembly fixture according to claim 1, characterized in that: The front clamp and the rear clamp have the same structure; the front clamp includes two clamping plates, a fixing plate and a positioning bolt; the two clamping plates are fixed together by the fixing plate and the positioning bolt.

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