Copper bar winding and potting DC reactor

Abstract

The utility model discloses a copper bar winding and filling DC reactor, the iron core is built -in in filling insulation box, and the B column of iron core is wound with a plurality of groups first coil, and the head and tail of each first coil are respectively embedded with first conducting row and second conducting row, and the D column of iron core is wound with a plurality of groups second coil, and the head and tail of each second coil are respectively embedded with third conducting row and fourth conducting row, and there is gap between second coil and first coil, and the second conducting row of a plurality of groups first coil is connected with the first conducting row of a plurality of groups second coil through conducting row connecting block, and the fifth conducting row is connected on the first conducting row of a plurality of groups first coil, and the sixth conducting row is connected on the second conducting row of a plurality of groups second coil. The utility model discloses through structure improvement, can improve the heat dissipation efficiency, reduces the eddy current loss, improves the insulation performance and structural stability simultaneously, and is helpful to improve production efficiency and product size accuracy, is fit for mass production.

Description

Technical Field

[0001] This utility model relates to the field of reactor technology, specifically to a copper busbar wound and potted DC reactor. Background Technology

[0002] DC reactors are primarily related to the development needs of power electronic equipment. In power electronic systems of new energy fields such as photovoltaics, wind power, and energy storage, the capacity requirements for filter reactors are increasing. As a key component, DC reactors need to have characteristics such as high operating current and small size to meet the development requirements of new energy systems. The shortcomings of existing technologies are as follows:

[0003] 1. Poor heat dissipation: Traditional reactors are generally wound with copper / wire or copper / aluminum foil, which has poor heat dissipation. Prolonged operation easily leads to heat accumulation and high temperatures, affecting service life. Furthermore, the multiple repositioning of the wires in conventional winding methods also affects heat dissipation performance.

[0004] 2. Insulation performance needs improvement: Some current reactors use multi-strand glass filament wrapped flat copper wire wound on an insulating cylinder as a coil, which has the disadvantage of poor insulation performance and affects operational reliability.

[0005] 3. Complex assembly process: Traditional electric vehicle reactors mostly use a frame assembly to support the coil and steel strips to bind and fix the iron core, which requires a lot of manual assembly operations, resulting in large assembly tolerances and high costs. Utility Model Content

[0006] The purpose of this invention is to overcome the shortcomings of the prior art and provide a copper busbar wound potted DC reactor. Through structural improvements, it can improve heat dissipation efficiency, reduce eddy current losses, improve insulation performance and structural stability, and help improve production efficiency and product dimensional accuracy, making it suitable for mass production.

[0007] The technical solution of this utility model is as follows:

[0008] A copper busbar wound potted DC reactor includes a potted insulating box, an iron core, a first coil, a first conductive busbar, a second conductive busbar, a second coil, a third conductive busbar, a fourth conductive busbar, a conductive busbar connecting block, a fifth conductive busbar, and a sixth conductive busbar. The iron core is built into the potted insulating box. The iron core includes A-pillar, B-pillar, C-pillar, and D-pillar. The A-pillar and C-pillar are arranged opposite each other horizontally, and the B-pillar and D-pillar are arranged opposite each other front and back between the A-pillar and C-pillar. Several sets of first coils are wound on the B-pillar. The head and tail of each first coil are respectively embedded with a first conductive busbar and a second conductive busbar. The first coil has several sets of second coils wound on the D-pillar, corresponding to the first coil. The second coils and the first coils are wound in the same direction. The head and tail of each second coil are respectively embedded with a third conductive bar and a fourth conductive bar. There is a gap between the second coil and the first coil. The second conductive bars of the several sets of first coils are connected to the first conductive bars of the several sets of second coils through conductive bar connecting blocks. The fifth conductive bar is connected to the first conductive bar of the several sets of first coils, and the sixth conductive bar is connected to the second conductive bar of the several sets of second coils.

[0009] Furthermore, mounting holes are provided on the periphery of the potting insulation box.

[0010] Furthermore, the empty space inside the potted insulation box is potted using vacuum epoxy potting technology.

[0011] Furthermore, upper supports are provided on the upper surfaces of the A-pillar, B-pillar, C-pillar, and D-pillar, and lower supports are provided on the lower surfaces of the A-pillar, B-pillar, C-pillar, and D-pillar, and the left and right ends of the upper supports and the left and right ends of the lower supports are connected by connecting rods.

[0012] Furthermore, the first and second coils are wound using copper busbars with a large width-to-thickness ratio.

[0013] Compared with the prior art, the beneficial effects of this utility model are as follows:

[0014] 1. Significantly enhanced heat dissipation efficiency: The coil is wound with copper busbars with a large width-to-thickness ratio (such as vertical winding process), which greatly increases the contact area between the conductor and the heat dissipation medium. At the same time, the potting compound can quickly conduct heat, solving the problem of heat accumulation in traditional wire / foil wound reactors, effectively reducing the operating temperature and extending the service life.

[0015] 2. Higher insulation and structural reliability: Vacuum epoxy potting technology can completely encapsulate the coil, isolating it from the influence of external environment such as moisture and dust, and the potting compound itself has excellent insulation properties; when combined with a special fixing structure (such as threaded rods and rotating plates), it can prevent the copper busbar from shaking. Compared with traditional frame assembly and steel strip binding, the insulation performance and structural stability are greatly improved.

[0016] 3. More efficient production and assembly: The modular structure formed by potting reduces manual assembly steps and assembly tolerances, enabling standardized and mass production. At the same time, it eliminates complex operations such as multiple wire repositioning in traditional processes, significantly reducing production costs and production cycle.

[0017] 4. Adaptable to high-capacity new energy scenarios: The copper busbar winding can meet the requirements of high current flow. Combined with the compact structure after potting, it can effectively reduce the size while ensuring the capacity of the reactor, perfectly adapting to the needs of photovoltaic, wind power, energy storage and other new energy fields for large-capacity and miniaturized power electronic components. Attached Figure Description

[0018] 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.

[0019] Figure 1 A schematic diagram of a copper busbar wound and potted DC reactor provided by this utility model;

[0020] Figure 2 This is a schematic diagram of the iron core described in this utility model. 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 Figure 1 , Figure 2This embodiment provides a copper busbar wound potted DC reactor, including a potted insulating box 1, an iron core 2, a first coil 3, a first conductive busbar 4, a second conductive busbar 5, a second coil 6, a third conductive busbar 7, a fourth conductive busbar 8, a conductive busbar connecting block 9, a fifth conductive busbar 10, and a sixth conductive busbar 11. The iron core 2 is built into the potted insulating box 1. The iron core 2 includes A-pillar 201, B-pillar 202, C-pillar 203, and D-pillar 204. A-pillar 201 and C-pillar 203 are arranged opposite each other to the left and right. B-pillar 202 and D-pillar 204 are arranged opposite each other to A-pillar 201 and C-pillar 203. An upper support 205 is provided on the upper surface of A-pillar 201, B-pillar 202, C-pillar 203, and D-pillar 204. A lower support 206 is provided on the lower surface of A-pillar 201, B-pillar 202, C-pillar 203, and D-pillar 204. The left and right ends of the upper support 205 are connected to the left and right ends of the lower support 206. The ends are connected by connecting rods 207. Several sets of first coils 3 are wound on B-pillar 202. The head and tail of each first coil 3 are respectively embedded with a first conductive bar 4 and a second conductive bar 5. Several sets of second coils 6 corresponding to the first coils 3 are wound on D-pillar 204. The second coils 6 and the first coils 3 are wound in the same direction. The head and tail of each second coil 6 are respectively embedded with a third conductive bar 7 and a fourth conductive bar 8. There is a gap between the second coils 6 and the first coils 3. The empty space inside the potting insulation box 1 is potted by vacuum epoxy potting technology. The second conductive bars 5 of several sets of first coils 3 and the first conductive bars 4 of several sets of second coils 6 are connected by conductive bar connecting blocks 9. The fifth conductive bar 10 is connected to the first conductive bars 4 of several sets of first coils 3. The sixth conductive bar 11 is connected to the second conductive bars 5 of several sets of second coils 6.

[0025] The potting insulation box 1 has mounting holes 101 on its periphery.

[0026] The first coil 3 and the second coil 6 are wound using copper busbars with a large width-to-thickness ratio.

[0027] The specific structural improvements to the copper busbar-wound potted DC reactor are as follows:

[0028] 1. Optimized winding process: The coil is wound using copper busbars with a large width-to-thickness ratio, such as vertical winding process, which can increase the contact area between the coil conductor surface and the air, improve heat dissipation efficiency, and reduce eddy current loss.

[0029] 2. Improved insulation and fixing methods: By using vacuum epoxy cast coils and setting fixing structures such as threaded rods and rotating plates, the copper busbars can be effectively fixed to prevent them from shaking, thereby improving insulation performance and structural stability.

[0030] 3. Using potting technology: The coil is encapsulated with potting compound to form a modular structure, which can achieve good protection and heat dissipation, while improving production efficiency and product dimensional accuracy, making it suitable for mass production.

[0031] 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 copper busbar wound and potted DC reactor, characterized in that: The system includes a potted insulating box, an iron core, a first coil, a first conductive busbar, a second conductive busbar, a second coil, a third conductive busbar, a fourth conductive busbar, a conductive busbar connecting block, a fifth conductive busbar, and a sixth conductive busbar. The iron core is housed within the potted insulating box. The iron core includes A-pillars, B-pillars, C-pillars, and D-pillars. A-pillars and C-pillars are positioned opposite each other, while B-pillars and D-pillars are positioned opposite each other between A-pillars and C-pillars. Several sets of first coils are wound on B-pillars, with a first conductive busbar and a second conductive busbar embedded at the head and tail of each first coil, respectively. Several sets of second coils corresponding to the first coils are wound on D-pillars, with the second coils and first coils having the same winding direction. A third conductive busbar and a fourth conductive busbar are embedded at the head and tail of each second coil, and there is a gap between the second coils and the first coils. The second conductive busbars of the several sets of first coils are connected to the first conductive busbars of the several sets of second coils via conductive busbar connecting blocks. The fifth conductive busbar is connected to the first conductive busbar of the several sets of first coils, and the sixth conductive busbar is connected to the second conductive busbar of the several sets of second coils.

2. A copper busbar wound and potted DC reactor according to claim 1, characterized in that: The potting insulation box has mounting holes on its periphery.

3. A copper busbar wound and potted DC reactor according to claim 1, characterized in that: The empty space inside the potting insulation box is potted using vacuum epoxy potting technology.

4. A copper busbar wound and potted DC reactor according to claim 1, characterized in that: The upper surfaces of the A-pillar, B-pillar, C-pillar, and D-pillar are provided with upper supports, and the lower surfaces of the A-pillar, B-pillar, C-pillar, and D-pillar are provided with lower supports. The left and right ends of the upper supports and the left and right ends of the lower supports are connected by connecting rods.

5. A copper busbar wound and potted DC reactor according to claim 1, characterized in that: The first and second coils are wound using copper busbars with a large width-to-thickness ratio.

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