AC Reactor Segmented Iron Core Assembly
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Solution Overview
Problem
Conventional three-phase AC reactors with peripheral iron cores face challenges in winding coils due to integral iron cores, leading to variations in inductance and magnetic saturation characteristics, especially under mechanical vibrations, causing noise and misalignment issues.
Innovation Solution
The AC reactor employs a peripheral iron core divided by multiple surfaces, with securing members to maintain tight contact and prevent gaps, allowing for easier coil winding and reducing positional misalignment through engaging portions and strategically placed securing members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the peripheral iron core is divided into partial peripheral iron cores, then coil winding becomes easier and assembly is facilitated, but gaps occur between dividing surfaces causing inductance variations and magnetic saturation issues
Solution Approach 1:
The peripheral iron core is divided into multiple partial peripheral iron cores (first, second, third partial peripheral iron cores) that can be assembled separately. This segmentation allows coils to be wound around individual iron core portions before assembly, making the manufacturing process more manageable and facilitating coil installation while maintaining the overall magnetic circuit integrity.
Solution Approach 2:
A securing member is introduced as an intermediary element to join the partial peripheral iron cores together. This securing member fills and secures the dividing surfaces between partial cores, preventing gaps from forming. The intermediary component ensures tight contact between segmented parts, thereby maintaining consistent magnetic flux paths and preventing inductance variations that would otherwise result from gaps.
2Reliability
If the peripheral iron core is secured tightly at dividing surfaces, then inductance stability is improved, but mechanical complexity increases due to additional securing members
Solution Approach 1:
The securing member is designed to perform multiple functions simultaneously: it joins the partial peripheral iron cores together, fills the dividing surfaces to prevent gaps, and provides mechanical alignment. By merging these functions into a single component, the design achieves reliable tight contact at dividing surfaces without proportionally increasing structural complexity.
Solution Approach 2:
The securing member serves as a multi-functional element that combines mechanical fastening, gap filling, and alignment functions. This universal component addresses multiple requirements (structural integrity, magnetic circuit continuity, and positional alignment) with a single element, thereby improving inductance stability without adding excessive complexity to the overall device.
3Productivity
If the iron core coils are loosely positioned on the peripheral iron core, then assembly is simpler, but misalignment occurs due to mechanical vibrations causing noise and performance degradation
Solution Approach 1:
The securing member is designed to pre-establish tight contact between partial peripheral iron cores at their dividing surfaces before the device operates. This preliminary securing action prevents misalignment from occurring during operation, accommodating mechanical vibrations and maintaining consistent positional relationships between magnetic components throughout the device's operational life.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration ensures stable inductance and magnetic saturation characteristics, minimizing noise and misalignment, while facilitating efficient assembly and secure contact between the iron core coils and the peripheral iron core.
Implementation Method 1
a coil (12a, 12b, 12c) wound around each of the iron cores (11a, 11b, 11c)... the coil (12a, 12b, 12c) wound around the iron core
Implementation Method 2
the iron core (11a, 11b, 11c) and the peripheral iron core (2)... each of the iron core coils (1a, 1b, and 1c) includes an iron core (11a, 11b, or 11c)
Implementation Method 3
a securing member (3) for securing the partial peripheral iron cores (2a, 2b, and 2c) to maintain the peripheral iron core (2) in contact at the dividing surfaces (4a, 4b, and 4c)
Data Source
AI summary
An AC reactor according to an embodiment of this disclosure includes a peripheral iron core constituted of partial peripheral iron cores divided by a plurality of dividing surfaces, for enclosing an outer periphery; at least three iron core coils contacting, connected to, or magnetically connected to an inner surface of the peripheral iron core, each of the iron core coils including an iron core and a coil wound around the iron core; and a securing member for securing the partial peripheral iron cores to maintain the peripheral iron core in contact at the dividing surfaces.