Reactor device and method for manufacturing reactor device

Abstract

A reactor device (1) is provided with a plurality of winding cores (11), a plurality of disk coils (12), a maintenance member, and a pair of frames (16). The disk coils (12) are provided for each winding core (11) and are arranged in an extension direction of a central axis (AX1). The maintenance member maintains a relative positional relationship between the plurality of disk coils (12). The pair of frames (16) sandwich the plurality of winding cores (11), the plurality of disk coils (12), and the maintenance member in the extension direction of the central axis (AX1). Adjacent disk coils (12) are positioned across a gap (13). Each of the disk coils (12) is formed of windings (12a) wound around the corresponding winding core (11) in a plurality of winding positions (11a, 11b) arranged in the extension direction of the central axis (AX1). The adjacent winding positions (11a, 11b) are separated from each other in the extension direction of the central axis (AX1) at an interval greater than the width of the windings (12a).

Description

Reactor device and method for manufacturing the same

[0001] The present disclosure relates to a reactor device and a method for manufacturing a reactor device.

[0002] A reactor device is provided to suppress sudden fluctuations in the current flowing through an electronic device. Some reactor devices have multiple coils wound in multiple rows to reduce high-frequency loss. An example of this type of coil is disclosed in Patent Document 1. The alpha winding coil disclosed in Patent Document 1 is a disk coil wound in multiple rows.

[0003] JP 2010-093145 A

[0004] As reactor devices become larger in capacity and higher in frequency, the amount of heat generated by the coils of the reactor devices increases, resulting in a rise in the coil temperature. Because the first and second layers of the alpha winding coil disclosed in Patent Document 1 abut against each other, it is difficult to dissipate heat from the abutting points between the first and second layers. Therefore, the alpha winding coil experiences a larger rise in coil temperature than a single-row disc coil or a continuous-winding coil. The rise in coil temperature can result in damage to the coil.

[0005] The present disclosure has been made in consideration of the above circumstances, and aims to provide a reactor device with high cooling performance and a method for manufacturing a reactor device.

[0006] In order to achieve the above object, the reactor device of the present disclosure includes a plurality of winding cores, a plurality of disc coils, a retaining member, and a pair of frames. The plurality of winding cores have a columnar or tubular shape and are aligned in the extension direction of the central axis. A plurality of disc coils are provided for each winding core and aligned in the extension direction. The retaining member maintains the relative positional relationship of the plurality of disc coils to each other. The pair of frames sandwich the plurality of winding cores, the plurality of disc coils, and the retaining member in the extension direction. Adjacent disc coils are positioned with a gap between them. Each disc coil is formed by a winding wound around a corresponding winding core at a plurality of winding positions aligned in the extension direction. Adjacent winding positions are separated from each other by a distance in the extension direction that is greater than the width of the winding.

[0007] The reactor device according to the present disclosure includes a plurality of disc coils, each provided on a winding core, with a gap between adjacent disc coils. Each disc coil is formed by a winding wound around a corresponding winding core at a plurality of winding positions aligned in the direction of the central axis. Adjacent winding positions are spaced apart in the direction of the central axis by a distance greater than the width of the winding. This allows air to flow through the gaps between the disc coils and inside each disc coil, resulting in a reactor device with high cooling performance.

[0008] FIG. 14 is a front view of a reactor device according to a first embodiment; FIG. 15 is a cross-sectional view taken along line II-II in FIG. 1 of a reactor device according to a first embodiment; FIG. 16 is a cross-sectional view taken along line III-III in FIG. 1 of a reactor device according to a first embodiment; FIG. 17 is a cross-sectional view taken along line IV-IV in FIG. 2 of a reactor device according to a first embodiment; FIG. 18 is a cross-sectional view of a reactor device according to a first embodiment; FIG. 19 is a cross-sectional view of a first modified example of a reactor device according to an embodiment; FIG. 20 is a cross-sectional view of a reactor device according to a first embodiment;

[0009] Hereinafter, reactor devices according to embodiments of the present disclosure will be described in detail with reference to the drawings, in which the same or equivalent parts are designated by the same reference numerals.

[0010] (First Embodiment) Some reactor devices are mounted on railway vehicles to suppress sudden fluctuations in current flowing in electronic devices, such as power conversion devices. Of these types of reactor devices, a reactor device mounted under the floor of a railway vehicle will be used as an example to describe a reactor device according to a first embodiment.

[0011] The reactor device 1 shown in FIG. 1, FIG. 2 which is a cross-sectional view taken along line II-II in FIG. 1, FIG. 3 which is a cross-sectional view taken along line III-III in FIG. 1, and FIG. 4 which is a cross-sectional view taken along line IV-IV in FIG. 2 has a columnar or cylindrical shape and includes a plurality of winding cores 11 arranged in the extension direction of a central axis AX1, and a plurality of disc coils 12 provided for each winding core 11.

[0012] The reactor device 1 includes a maintaining member that maintains the relative positional relationship between the plurality of disc coils 12. The maintaining members of the reactor device 1 include at least one first spacer 14 provided in the gap 13 between the disc coils 12 and a plurality of second spacers 15 provided for each winding core 11. In the first embodiment, the reactor device 1 includes a plurality of first spacers 14 provided in the gap 13 between the disc coils 12.

[0013] The reactor device 1 includes a pair of frames 16 that sandwich a plurality of winding cores 11, a plurality of disc coils 12, and a plurality of first spacers 14 and a plurality of second spacers 15, which are maintaining members, in the direction of extension of the central axis AX1.

[0014] The reactor device 1 includes a plurality of first bolts 17 that penetrate the first spacer 14 and the second spacer 15 in the direction of extension of the central axis AX1 and are fixed to the pair of frames 16. The first bolts 17 are fixed to the pair of frames 16 by fastening first fastening members 18.

[0015] The reactor device 1 further includes a pair of end spacers 19, each of which is positioned between the disc coil 12 and the frame 16. The end spacers 19 are provided between the disc coils 12 and the frame 16 that are positioned at the ends in the arrangement direction.

[0016] 1 to 4, the X-axis is defined as an axis parallel to the extension direction of the central axis AX1 of the winding core 11. When the reactor device 1 is installed with the central axis AX1 extending horizontally, the Z-axis is defined as an axis indicating the vertical direction. The Y-axis is defined as an axis perpendicular to both the X-axis and the Z-axis. This also applies to the subsequent figures. The reactor device 1 is mounted, for example, under the floor of the car body of the railway vehicle with the X-axis oriented to coincide with the width direction of the railway vehicle. At this time, the railway vehicle travels in the Y-axis positive direction or the Y-axis negative direction.

[0017] Each part of the reactor device 1 having the above configuration will be described below. The winding core 11 has a cylindrical shape. The central axis AX1 of the cylindrical shape is indicated by a dashed line in FIGS. 1 to 4. In the first embodiment, as shown in FIGS. 2 and 3, the winding core 11 has a cylindrical shape. The winding core 11 is formed of an insulating material such as resin or ceramic. As shown in FIG. 4, in the first embodiment, the reactor device 1 includes four winding cores 11. The four winding cores 11 are arranged in contact with each other and aligned in the X-axis direction.

[0018] As shown in FIG. 4, the length L1 of the winding core 11 in the direction in which the central axis AX1 extends is longer than the length L2 of the disc coil 12 in the direction in which the central axis AX1 extends.

[0019] The disc coils 12 are provided for each winding core 11 and are aligned in the direction in which the central axis AX1 extends. Adjacent disc coils 12 are positioned across a gap 13. In the first embodiment, four disc coils 12 are aligned in the direction in which the central axis AX1 extends, and adjacent disc coils 12 are positioned across a gap 13.

[0020] Each disc coil 12 is a multi-row coil. Specifically, as shown in FIG. 4 , each disc coil 12 is formed by a single winding 12a wound around multiple winding positions, specifically, two winding positions 11a and 11b, arranged on the winding core 11 in the extension direction of the central axis AX1, with the portions wound around the different winding positions 11a and 11b being separated from each other. In other words, although the disc coil 12 is a multi-row coil, it does not have connection points between the windings located radially inward. Forming the disc coil 12, which is a multi-row coil, with a single continuous winding 12a without connection points simplifies the manufacturing process and reduces the risk of connection failure. Reducing the risk of connection failure results in improved quality of the reactor device 1 and an extended product life.

[0021] As shown in Fig. 4 and Fig. 5, in which the winding core 11 is omitted from Fig. 4, a disc coil 12 is formed by winding one winding 12a around winding positions 11a and 11b. Adjacent winding positions 11a and 11b on the outer circumferential surface of the winding core 11 are spaced apart by a distance greater than the width of the winding 12a. That is, as shown in Fig. 4, the distance D1 between the winding positions 11a and 11b is greater than the width W1 of the winding 12a in the extension direction of the central axis AX1. It is preferable that the distance D1 be greater than twice the width W1.

[0022] As a result, in each of the disc coils 12, a portion of the disc coil 12 wound around the winding position 11a and another portion of the disc coil wound around the other winding position, i.e., the winding position 11b, are spaced apart in the direction of extension of the central axis AX1. In other words, a gap 12b is formed between the portion of the winding 12a wound around the winding position 11a and the portion of the winding 12a wound around the winding position 11b.

[0023] Adjacent disc coils 12 are electrically connected. Specifically, the winding start of one of the adjacent disc coils 12 is electrically connected to the winding end of the other. For example, one end of the winding 12a forming each disc coil 12 on the positive side of the X-axis is the winding start, and the other end of the winding 12a is the winding end. For two adjacent disc coils 12, the winding start of one disc coil 12 located on the negative side of the X-axis is electrically connected to the winding end of the other disc coil 12.

[0024] The winding 12a is formed of a wire 61 shown in Fig. 6. The wire 61 has a conductor 62 made of a conductive material such as copper or aluminum, and an insulating covering member 63 made of an insulating material such as vinyl or resin that covers the conductor 62.

[0025] In the first embodiment, the winding 12a is formed from a plurality of wires 61, as shown in Fig. 7. The winding 12a is formed by overlapping the plurality of wires 61, for example, three wires 61, and winding an insulating tape 64 made of, for example, enamel around the three overlapping wires 61. The winding 12a formed as described above is wound around the winding core 11 in a flatwise manner to form the disc coil 12.

[0026] As shown in FIG. 1 , each first spacer 14 is disposed in a gap 13 and abuts against two disc coils 12 that sandwich the gap 13. The first spacers 14 are formed of an insulating material such as resin or ceramic. The first spacers 14 are preferably formed of an elastically deformable insulating material, such as fiber-reinforced plastic (FRP). In the first embodiment, the first spacers 14 are plate-shaped members extending in the Z-axis direction, as shown in FIG. 2 . In other words, the first spacers 14 have a rectangular cross section in the YZ plane, and are disposed so that their longitudinal directions coincide with the Z-axis direction and abut against two adjacent disc coils 12. Both ends of the first spacer 14 in the Z-axis direction are located radially outward from the outer circumferential surfaces of the disc coils 12. The radial direction refers to a direction perpendicular to the central axis AX1.

[0027] The first spacer 14 abuts against the disk coils 12, thereby maintaining the relative positional relationship between the disk coils 12. Because the disk coils 12 are spaced apart from each other by the gap 13, air flows in the positive direction of the Z axis between adjacent disk coils 12, allowing the disk coils 12 to be cooled.

[0028] As shown in FIG. 4 , each second spacer 15 is located between two winding positions 11a and 11b of the winding core 11 in the extension direction of the central axis AX1 and abuts against the winding 12a wound around the winding core 11. The second spacer 15 is formed of an insulating material such as resin or ceramic. The second spacer 15 is preferably formed of an elastically deformable insulating material, for example, FRP. In the first embodiment, the second spacer 15 is a plate-shaped member extending in the Z-axis direction as shown in FIG. 3 . Both ends of the second spacer 15 in the Z-axis direction are located radially outward from the outer circumferential surface of the disk coil 12.

[0029] The second spacer 15 is positioned between the two winding positions 11a and 11b and abuts against the winding 12a, thereby maintaining the relative positional relationship between the part of the winding 12a wound at the winding position 11a and the other part of the winding 12a wound at the winding position 11b. The provision of the second spacer 15 ensures a gap 12b between the part of the winding 12a wound at the winding position 11a and the other part of the winding 12a wound at the winding position 11b. This allows air to flow through the gap 12b between the winding positions 11a and 11b in the positive direction of the Z axis, thereby cooling the disk coil 12.

[0030] The frame 16 is firmly attached to the underfloor of the car body so that the relative positional relationship between the car body and the reactor device 1 will not be displaced by vibrations from the railcar while the railcar is traveling. For example, the frame 16 is attached to the underfloor of the car body by fastening members (not shown). The frame 16 is preferably formed from a member having a rigidity sufficient to prevent deformation due to vibrations from the railcar while the railcar is traveling, such as a metal such as iron or aluminum.

[0031] The pair of frames 16 are arranged in a state in which the plurality of winding cores 11, the plurality of disc coils 12, the plurality of first spacers 14, the plurality of second spacers 15, and the pair of end spacers 19 are sandwiched between them in the direction of extension of the central axis AX1. The pair of frames 16 hold the plurality of disc coils 12 by sandwiching the plurality of disc coils 12 between them via the plurality of first spacers 14, the plurality of second spacers 15, and the pair of end spacers 19.

[0032] The end spacer 19 is provided between the disc coil 12 located at the end in the extension direction of the central axis AX1 and the frame 16. The end spacer 19 abuts against the disc coil 12 located at the end and the frame 16. The end spacer 19 is made of an insulating material such as resin or ceramic. In the first embodiment, the end spacer 19 is a plate-shaped member extending in the Z-axis direction, similar to the first spacer 14 and the second spacer 15.

[0033] 1 , the first bolt 17 passes through the first spacer 14, the second spacer 15, and the end spacer 19, and is fixed to the pair of frames 16 by the first fastening member 18. The first bolt 17 is preferably made of a material having a rigidity sufficient to prevent deformation when fastened by the first fastening member 18, such as an insulated metal such as iron or aluminum. By fixing the multiple first bolts 17 to the pair of frames 16, the relative positions of the multiple disk coils 12 with respect to the pair of frames 16 are fixed.

[0034] In the reactor device 1 having the above configuration, the multiple disk coils 12 are arranged with gaps 13 between them. Furthermore, in each disk coil 12, a gap 12b is provided between the winding 12a wound at the winding position 11a and the winding 12a wound at the winding position 11b. Therefore, air flows in the positive direction of the Z axis due to natural convection through the gaps 13 between adjacent disk coils 12 and the gaps 12b inside each disk coil 12. Heat is transferred from the disk coils 12 to this air, thereby cooling the disk coils 12.

[0035] The reactor device 1 having the above configuration is manufactured by the manufacturing method shown in Fig. 8. First, a winding step is performed in which the winding 12a is wound around the winding core 11 to produce the disc coil 12 (step S11).

[0036] An apparatus for performing the winding process is shown in Fig. 9. The winding table 51 is a table that can rotate around a rotation axis AX2 extending in the vertical direction. The winding core 11 is attached to a recess in the center of the winding table 51 with its central axis AX1 aligned with the rotation axis AX2 of the winding table 51.

[0037] The first winding drum 52 and the second winding drum 53 are pre-wound with the winding 12a to be wound around the winding core 11. The first winding drum 52 is rotatable about a rotation axis AX3 extending horizontally. The second winding drum 53 is rotatable about a rotation axis AX2.

[0038] One portion of the winding 12a is wound around one end of the winding 12a on the first winding drum 52, and the other portion is wound around the other end of the winding 12a on the second winding drum 53. Reference positions of the winding 12a, which are spaced apart from both ends of the winding 12a, are located adjacent to the winding core 11. In the first embodiment, the intermediate portion of the winding 12a, including the center thereof, is set as the reference position located adjacent to the winding core 11.

[0039] When the winding table 51 rotates around the rotation axis AX2 in the state shown in Figure 9, the winding 12a, which has already been wound around the first winding drum 52, is wound around the winding position 11a of the winding core 11, as shown in Figure 10. When the winding table 51 rotates, the winding 12a is pulled from the first winding drum 52 toward the winding table 51, causing the first winding drum 52 to rotate counterclockwise around the rotation axis AX3. At this time, the second winding drum 53 rotates together with the winding table 51. Therefore, the relative positional relationship between the second winding drum 53 and the winding table 51 is maintained.

[0040] Once the winding 12a has been wound around the winding position 11a, a removable jig 54 is installed vertically above the winding 12a wound around the winding position 11a, as shown in Fig. 11. The jig 54 has a structure that allows the winding 12a to be inserted therethrough and that allows it to be removed from the disk coil 12 after the winding 12a has been wound around the winding position 11b. In the first embodiment, the jig 54 has semicircular ring members 54a and 54b, as shown in Fig. 12. Fig. 12 is a vertical view of the jig 54 installed as shown in Fig. 11.

[0041] 11, when the winding table 51 rotates about the rotation axis AX2 while the second winding drum 53 is stopped, the winding table 51 rotates relative to the second winding drum 53. As a result, the winding 12a that has been wound around the second winding drum 53 in advance is pulled from the second winding drum 53 toward the winding table 51 and is wound around the winding position 11b of the winding core 11, as shown in FIG.

[0042] When the winding 12a is completely wound around the winding position 11b, the winding 12a is separated from the first winding drum 52 and the second winding drum 53, and the disk coil 12 is formed.

[0043] 8, a removal step is performed to remove the jig 54 from the disk coil 12 (step S12). In detail, by moving the jig 54 horizontally in the state shown in FIG. 13, the jig 54 sandwiched between the winding 12a wound at the winding position 11a and the winding 12a wound at the winding position 11b can be removed.

[0044] Next, as shown in Figure 8, an arrangement process is performed in which multiple disk coils 12 wound around corresponding winding cores 11 and maintaining members that abut against the multiple disk coils 12 to maintain the relative positional relationship of the multiple disk coils 12 are arranged (step S13).

[0045] Specifically, instead of the jig 54 removed in step S12, second spacers 15 are sandwiched between the windings 12a. The first spacers 14 are provided between the disk coils 12 by alternately arranging the disk coils 12 sandwiched between the second spacers 15 and the first spacers 14.

[0046] Next, a fixing process is performed in which the multiple disk coils 12, multiple first spacers 14, and multiple second spacers 15 arranged as described above are sandwiched between a pair of frames 16, and multiple first bolts 17 supporting the multiple disk coils 12 are fixed to the pair of frames 16 (step S14).

[0047] In detail, the plurality of disc coils 12, the plurality of first spacers 14, and the plurality of second spacers 15 are sandwiched between a pair of frames 16 via a pair of end spacers 19. First bolts 17 are inserted into two through holes formed in each of the plurality of first spacers 14, the plurality of second spacers 15, the pair of end spacers 19, and the pair of frames 16. Each first bolt 17 is fixed to the respective frame 16 by fastening a first fastening member 18.

[0048] When the process of step S14 is completed, the reactor device 1 is assembled. The assembled reactor device 1 is subjected to an insulating treatment, for example, by impregnating with varnish.

[0049] As described above, the disc coil 12 included in the reactor device 1 according to the first embodiment is formed by the winding 12a wound around two winding positions 11a and 11b spaced apart from each other on the winding core 11. The portion of the winding 12a wound around the winding position 11a and the portion of the winding 12a wound around the winding position 11b are spaced apart from each other. This allows air to flow through the gap 12b inside the disc coil 12, which is made up of multiple rows of coils. Therefore, the cooling performance of the reactor device 1 is higher than that of a reactor device having multiple rows of coils that abut against each other. The improved cooling performance of the reactor device 1 enables the reactor device 1 to have a larger capacity or be smaller in size.

[0050] Although the disc coil 12 is a coil with multiple rows, it is formed of a single winding 12a, and there is no need to connect the multiple rows of coils on the radially inner side. Furthermore, both ends of the winding 12a are located on the radially outer side. Therefore, the manufacturing process of the reactor device 1 is simpler than a manufacturing process that includes a process of connecting the multiple rows of coils on the radially inner side.

[0051] Second Embodiment The structure and shape of the reactor device 1 are not limited to the above-described example. A reactor device having a structure and shape different from the reactor device 1 according to the first embodiment will be described in a second embodiment, focusing on the differences from the first embodiment.

[0052] As shown in Figure 14 and Figure 15, which is a cross-sectional view taken along line XV-XV in Figure 14, reactor device 2 according to embodiment 2 includes four winding cores 21 arranged in the direction in which central axis AX1 extends. Adjacent winding cores 21 abut against each other. The method of manufacturing reactor device 2 is the same as that of embodiment 1.

[0053] The winding core 21, which is located at an end in the extension direction of the central axis AX1, abuts against the frame 16. The winding core 21 has a cylindrical shape. In a cross section perpendicular to the central axis AX1, the cross-sectional area of ​​the winding core 21 is larger than the cross-sectional area of ​​the winding core 11 in the first embodiment. In other words, the winding core 21 is a cylinder that is thicker than the winding core 11. The winding core 21 is formed of an insulating material such as resin or ceramic.

[0054] The reactor device 2 includes suppression members 22 that suppress movement of the plurality of disc coils 12 in the direction of extension of the central axis AX1, as maintaining members that maintain the relative positional relationship between the plurality of disc coils 12. In the second embodiment, the reactor device 2 includes a pair of suppression members 22 that sandwich the plurality of disc coils 12 in a radial direction perpendicular to the central axis AX1.

[0055] The suppressing member 22 extends in the extension direction of the central axis AX1 and abuts against the plurality of disc coils 12, thereby suppressing misalignment of the disc coils 12 in the extension direction of the central axis AX1. The surface of the suppressing member 22 facing the plurality of disc coils 12 is curved. The suppressing member 22 abuts against the plurality of disc coils 12 at this curved surface. The suppressing member 22 may be attached to the disc coils 12, for example, by a string-like attachment member 22a inserted between the wound windings 12a. The suppressing member 22 and the attachment member 22a are formed of an insulating material such as resin or ceramic. The attachment member 22a is, for example, a cable tie. When winding the winding 12a around the winding core 21 in the winding process shown in FIG. 8 , a removable piece is sandwiched between the windings 12a to form a gap for inserting the attachment member 22a.

[0056] The reactor device 2 includes a plurality of second bolts 23 that penetrate the winding core 21 in the X-axis direction and are fixed to the pair of frames 16. The second bolts 23 are fixed to the frames 16 by fastening second fastening members 24.

[0057] Adjacent winding cores 21 abut against each other, and the winding cores 21 located at both ends abut against the frame 16. A second bolt 23 passing through the plurality of winding cores 21 is fixed to the frame 16, whereby the relative position of the disc coil 12 wound around the winding cores 21 to the frame 16 is fixed.

[0058] As described above, the reactor device 2 according to the second embodiment maintains the relative positional relationship between the multiple disc coils 12 by the suppression member 22. The reactor device 2 does not have the first spacer 14 and the second spacer 15 that the reactor device 1 has. This allows more air to flow through the gaps 13 between the disc coils 12 and the gaps 12b in each disc coil 12. Therefore, the reactor device 2 has higher cooling performance than the reactor device 1.

[0059] Third Embodiment The structure of the winding core is not limited to the above-described example. A reactor device including a solid winding core will be described in a third embodiment, focusing on the differences from the second embodiment.

[0060] The configuration of the reactor device according to embodiment 3 is the same as that of embodiment 2, except for the structure of the winding core. The manufacturing method of reactor device 3 is the same as that of embodiment 1. Winding core 31 provided in reactor device 3 shown in Fig. 16 has a cylindrical magnetic body 32 extending in the extension direction of central axis AX1, and a first insulating member 33 covering the outer peripheral surface of magnetic body 32 around central axis AX1.

[0061] The magnetic body 32 is a ferromagnetic body, for example, ferrite. The magnetic body 32 has a cylindrical shape. The second bolt 23 is inserted into the magnetic body 32. As shown in FIG. 17 , in which the second bolt 23 is omitted from FIG. 16 , the magnetic body 32 is formed with a first through-hole 32 a through which the second bolt 23 is inserted.

[0062] The reactor device 3 further includes a second insulating member 34 that covers the wall surface of the first through hole 32 a of the magnetic body 32. The second insulating member 34 is, for example, a resin that is applied to the wall surface of the first through hole 32 a. The second insulating member 34 insulates the magnetic body 32 from the second bolt 23 that is inserted into the first through hole 32 a.

[0063] The first insulating member 33 is, for example, a resin applied to the outer peripheral surface of the magnetic body 32. The first insulating member 33 insulates the magnetic body 32 from the disk coil 12 wound around the winding core 31.

[0064] By including the winding core 31 having the magnetic body 32 inside, the reactor device 3 exhibits characteristics similar to a reactor including a coil with an iron core. The reactance L of the reactor is expressed by the following formula (1). In the following formula (1), N is the number of turns of the coil, φ is the flux linkage of the coil, and I is the current flowing through the coil. L=Nφ / I (1)

[0065] The flux linkage φ of a coil changes depending on whether or not the coil has an iron core. ０ is expressed by the following formula (2), and the interlinkage magnetic flux φ of the iron-core coil is ｓ is expressed by the following equation (3): k is a proportionality constant, and μ ０ is the permeability of a vacuum, and μ ｓ is the relative permeability of the iron core. ０ =k・μ0...(2) φ ｓ = k μ 0 μ ｓ ...(3)

[0066] Relative permeability μ of the iron core ｓ is sufficiently larger than 1, the reactance of the reactor device 3, which exhibits characteristics similar to those of a reactor having an iron-core coil, is larger than those of the reactor devices 1 and 2.

[0067] As described above, the reactor device 3 according to the third embodiment includes the winding core 31 having the magnetic body 32. Therefore, the winding core 31 serves as an iron core, and the reactance of the reactor device 3 is increased compared to the reactor devices 1 and 2. By using the reactor device 3 with increased reactance, it is possible to reduce the size and weight of the device.

[0068] The present disclosure is not limited to the above-described exemplary embodiments. Any combination of the above-described exemplary embodiments is possible. For example, the reactor devices 2 and 3 may include at least one of the first spacer 14 and the second spacer 15 included in the reactor device 1.

[0069] The structure of the winding core is not limited to the above example. As an example, the winding core 11 provided in the reactor device 1 may be formed with second through holes 11c penetrating in the radial direction, as shown in Fig. 18. By forming the second through holes 11c, more air can flow between the disc coils 12, and the cooling performance of the reactor device 1 can be improved.

[0070] As another example, the winding cores 11, 21 may be in the shape of a square tube, and the winding core 31 may be in the shape of a square pillar. The number of winding cores 11, 21, 31 is not limited to the above example, and may be any number equal to or greater than two.

[0071] As another example, the winding core 31 may be formed by fitting a columnar magnetic body 32 into a cylindrical first insulating member 33. As another example, the winding core 31 may be formed by bonding an insulating member in the form of a sheet to the outer circumferential surface of the columnar magnetic body 32, so that the first insulating member 33 is formed.

[0072] The structure and winding method of the winding 12a are not limited to the above example. As one example, the winding 12a may be formed from a single wire 61, or may be formed by combining any number of wires 61 and covering them with insulating tape 64. As another example, the winding 12a may be wound around the winding cores 11, 21, and 31 edgewise.

[0073] The first spacer 14 is not limited to the above example, but may be formed from any material that can reduce the thermal stress acting on the disk coil 12 by being pushed and deformed by the disk coil 12 that expands when current is applied.

[0074] The shape and arrangement of the first spacers 14 are not limited to the above example and may be any shape and arrangement as long as they can abut two adjacent disc coils 12 and guide air in the positive direction of the Z axis. As one example, four first spacers 14, which are plate-like members extending in the radial direction, may be provided in each gap 13. As another example, the thickness of the first spacers 14 in the extension direction of the central axis AX1 may vary depending on the position of the first spacers 14 in the extension direction of the central axis AX1. For example, the thickness of the first spacers 14 located at the center in the extension direction of the central axis AX1 may be greater than the thickness of the first spacers 14 located at the ends in the extension direction of the central axis AX1.

[0075] The second spacer 15 is not limited to the above example, but may be formed from any material that can reduce the thermal stress acting on the disk coil 12 by being pushed and deformed by the disk coil 12 that expands when current is applied.

[0076] The shape and arrangement of the second spacers 15 are not limited to the above example, and may be any shape and arrangement as long as they can contact the windings 12a wound around the winding positions 11a and 11b of the winding core 11 and guide air in the positive direction of the Z axis. As an example, four second spacers 15, which are plate-like members extending in the radial direction, may be provided in each gap 12b.

[0077] The number and positions of the first bolts 17 are not limited to the above example. As an example, the reactor device 1 may include eight first bolts 17 that penetrate the plurality of first spacers 14, the plurality of second spacers 15, and the pair of end spacers 19.

[0078] The method of attaching the first bolts 17 to the pair of frames 16 is not limited to fastening with the first fastening members 18, but may be other attachment methods such as bonding with an adhesive or welding.

[0079] The number and positions of the second bolts 23 are not limited to the above example. As an example, the reactor device 3 may include three second bolts 23 that penetrate the winding core 31.

[0080] The method of attaching the second bolts 23 to the pair of frames 16 is not limited to fastening with the second fastening members 24, but may be an attachment method such as bonding with an adhesive or welding.

[0081] The reactor device 1 does not need to include the end spacers 19. In this case, it is sufficient that the winding core 11 located at the end in the extension direction of the central axis AX1 abuts against the frame 16. When the winding core 11 abuts against the frame 16, a gap is formed between the disc coil 12 located at the end and the frame 16. In this case, it is preferable that the width of the gap between the disc coil 12 and the frame 16 is longer than the insulation distance required to insulate the disc coil 12 from the frame 16.

[0082] The number of winding cores 11 included in the reactor device 1 is any number equal to or greater than two. Adjacent winding cores 11 may be spaced apart from each other. The number of winding cores 21 and 31 included in the reactor devices 2 and 3, respectively, is any number equal to or greater than two.

[0083] The structure and mounting method of the suppressing member 22 are not limited to the above example and are arbitrary. As one example, as shown in FIG. 19 , both ends of the suppressing member 22 may abut against the frame 16. As another example, the suppressing member 22 may be bonded to the plurality of disc coils 12. As another example, the shape of a cross section of the suppressing member 22 perpendicular to the central axis AX1 may be rectangular. As another example, the surface of the suppressing member 22 facing the plurality of disc coils 12 may be formed with alternating convex portions that protrude into the gap 13 and concave portions into which the disc coils 12 fit.

[0084] The shape, structure, and mounting position of the mounting member 22a are arbitrary as long as the suppression member 22 can be mounted firmly enough to suppress movement of each disc coil 12 in the extension direction of the central axis AX1. As an example, the suppression member 22 may be mounted to the disc coil 12 by a mounting member 22a provided for each disc coil 12.

[0085] The manufacturing method of the reactor device 1-3 is not limited to the above example. As one example, varnish impregnation may be performed on each of the disc coils 12 wound around the winding cores 11, 21, and 31. As another example, the structure and shape of the jig 54 are not limited to the above example, and any structure and shape may be used as long as the jig 54 can have the winding 12a inserted therethrough and can be removed after the winding 12a has been wound around the winding positions 11a and 11b.

[0086] The orientation in which the reactor device 1-3 is attached under the floor of the car body of the railway vehicle is not limited to the above example. As an example, the reactor device 1-3 may be attached under the floor of the car body with the Y axis oriented in the width direction of the railway vehicle. The reactor device 1-3 is not limited to being attached under the floor of the car body, and can be attached at any position on the railway vehicle. The reactor device 1-3 is not limited to being mounted on a railway vehicle, and can be mounted on any moving body such as a trolleybus or a tram. The reactor device 1-3 is not limited to being mounted on a moving body, and can be installed at any indoor or outdoor location.

[0087] The present disclosure allows various embodiments and modifications without departing from the broad spirit and scope of the present disclosure. Furthermore, the above-described embodiments are intended to illustrate the present disclosure and do not limit the scope of the present disclosure. That is, the scope of the present disclosure is defined by the claims, not the embodiments. Various modifications made within the scope of the claims and the meaning of equivalent disclosures are considered to be within the scope of the present disclosure.

[0088] 1, 2, 3 Reactor device, 11, 21, 31 Winding core, 11a, 11b Winding position, 11c Second through hole, 12 Disk coil, 12a Winding, 12b, 13 Air gap, 14 First spacer, 15 Second spacer, 16 Frame, 17 First bolt, 18 First fastening member, 19 End spacer, 22 Suppression member, 22a Mounting member, 23 Second bolt, 24 Second fastening member, 32 Magnetic body, 32a First through hole, 33 First insulating member, 34 Second insulating member, 51 Winding base, 52 First winding drum, 53 Second winding drum, 54 Jig, 54a, 54b Semicircular member, 61 Wire, 62 Conductor, 63 Insulating coating member, 64 Insulating tape, AX1 Central axis, AX2, AX3 Rotating axis, D1 Spacing, L1, L2 lengths, W1 width.

Claims

1. A reactor device comprising: a plurality of winding cores having a columnar or tubular shape and aligned in an extension direction of a central axis; a plurality of disc coils provided for each of the winding cores and aligned in the extension direction; a maintaining member that maintains the relative positional relationship of the plurality of disc coils to each other; and a pair of frames that sandwich the plurality of winding cores, the plurality of disc coils, and the maintaining member in the extension direction, wherein adjacent disc coils are located with a gap between them, and each of the disc coils is formed by a winding wound around a plurality of winding positions aligned in the extension direction on the corresponding winding core, and adjacent winding positions are separated from each other by a distance in the extension direction that is greater than the width of the winding.

2. The reactor device according to claim 1, wherein the length of the winding core in the extension direction is longer than the length of the disk coil in the extension direction.

3. A reactor device according to claim 1 or 2, wherein the retaining member includes at least one insulating first spacer that is provided in the gap between adjacent disc coils and abuts against the two disc coils that sandwich the gap.

4. A reactor device as described in claim 3, wherein the maintaining member includes a plurality of insulating second spacers provided for each of the winding cores, positioned between adjacent winding positions of the winding core in the extension direction, and abutting a portion of the winding core wound around one of the two winding positions and another portion of the winding wound around the other of the two winding positions.

5. A reactor device according to any one of claims 1 to 4, wherein the retaining member includes at least one suppressing member extending in the extension direction and abutting against the plurality of disc coils to suppress misalignment of the disc coils in the extension direction.

6. The reactor device according to claim 5, wherein the retaining member includes at least a pair of the suppressing members, and the pair of suppressing members sandwich the plurality of disk coils in a radial direction perpendicular to the central axis.

7. The reactor device according to claim 3, further comprising a plurality of first bolts that penetrate the first spacer in the extension direction and are fixed to the pair of frames.

8. The reactor device according to claim 4, further comprising a plurality of first bolts that penetrate the first spacer and the plurality of second spacers in the extension direction and are fixed to the pair of frames.

9. A reactor device according to any one of claims 1 to 8, wherein the columnar winding core has a magnetic body extending in the extension direction and a first insulating member covering an outer circumferential surface of the magnetic body.

10. The reactor device according to any one of claims 1 to 8, further comprising a plurality of second bolts that penetrate the winding core in the extension direction and are fixed to the pair of frames.

11. A reactor device as described in claim 9, further comprising a plurality of second bolts that penetrate the winding core in the extension direction and are fixed to the pair of frames, wherein first through holes are formed in the winding core, and each of the second bolts is inserted therethrough, and the winding core further has a second insulating member that covers a wall surface of the first through hole.

12. The reactor device according to any one of claims 1 to 11, wherein at least one second through hole is formed in the winding core, the second through hole extending in a radial direction perpendicular to the central axis.

13. A method for manufacturing a reactor device comprising: a winding step of winding a reference position away from both ends of a winding adjacent to a winding core, winding the winding from the reference position toward one end to one of two winding positions that are separated from each other in an extension direction of a central axis of the winding core, and then, with a removable jig sandwiched between the wound winding, winding the winding from the reference position toward the other end to form a disk coil; a removal step of removing the jig sandwiched between the winding; an arrangement step of arranging a plurality of the disk coils wound around a plurality of the windings and a maintaining member that abuts against the plurality of the disk coils to maintain the relative positional relationship of the plurality of the disk coils to each other; and a fixing step of sandwiching the plurality of the disk coils wound around a plurality of the windings and the maintaining member between a pair of frames in the extension direction, and fixing the plurality of the disk coils to the pair of frames.

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