Amorphous Core Reactor for Solar Power Loss Reduction
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Solution Overview
Problem
Existing reactor devices for solar power generation systems face challenges in reducing loss and size when converting DC power to AC power, particularly due to inefficiencies in the iron core materials used in three-phase reactor devices.
Innovation Solution
A reactor device employing an amorphous core with a fan-like magnetic leg core configuration and zero-phase cores, where the magnetic leg cores and coils are precisely positioned and fixed to minimize overlap and loss, and the use of amorphous material for the iron cores to reduce eddy-current loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional crystalline iron cores are used in three-phase reactor devices, then the device structure is simple and easy to manufacture, but the iron loss and device size are large
Solution Approach 1:
The patent changes the material parameter from conventional crystalline iron to amorphous metal, fundamentally altering the magnetic properties and reducing iron loss by approximately 70% compared to conventional cores, while accepting increased manufacturing complexity
Solution Approach 2:
The patent employs composite construction by stacking multiple thin amorphous metal sheets (0.02-0.05mm thickness) to form the core, combining the advantages of amorphous material low-loss properties with manageable manufacturing through lamination
2Loss of energy
If amorphous metal cores are used to reduce loss, then the iron loss decreases significantly, but the manufacturing precision and positioning accuracy become more critical
Solution Approach 1:
The patent divides the core into multiple thin amorphous sheets stacked together, which not only reduces eddy-current loss through insulation between layers but also allows for better positioning control of each individual sheet, achieving precise magnetic path alignment
Solution Approach 2:
The patent introduces insulating coatings and bonding materials as intermediaries between amorphous sheets, facilitating precise positioning and fixation while maintaining the low-loss characteristics of the amorphous material structure
3Weight of moving object
If the reactor device size is reduced using amorphous cores, then the mass and volume decrease, but the coil positioning and balancing of three legs become more difficult
Solution Approach 1:
The patent designs a standardized modular amorphous core structure that can be universally applied to all three phases, with uniform dimensions and magnetic path lengths, simplifying coil positioning and ensuring balanced electrical characteristics across all legs despite reduced overall size
Solution Approach 2:
The patent ensures equal magnetic path lengths and symmetric arrangement of the three amorphous core legs, creating equipotential magnetic conditions that facilitate uniform coil positioning and balanced performance across all phases
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
The solution achieves a decrease in loss and size reduction of the reactor device while ensuring electrical symmetry and efficient magnetic flux flow, leading to improved performance and reduced mass.
Implementation Method 1
the use of amorphous material for the iron cores to reduce eddy-current loss
Implementation Method 2
efficient magnetic flux flow
Data Source
Figure 1
Figure 2A~2B
Figure 2C~2D
AI summary
Provided is a device that reduces loss by means of a large-capacity, three-phase reactor device that eliminates high-frequency components arising in a power controller system used in solar power generation and the like. The present invention is provided with: a yoke core that uses an amorphous ribbon; magnetic leg cores formed into a fan shape using an amorphous ribbon; and a coil wound around the magnetic leg cores. The yoke core is disposed in an approximately hexagonal bottom fastening fixture, the magnetic leg cores are disposed stacked at three equally spaced locations on the inner peripheral surface of the yoke core, the coil is inserted and disposed at the stacked magnetic leg cores, the yoke core is disposed above the magnetic leg cores, the yoke core is covered by an approximately hexagonal top fastening fixture, studs are disposed at the center of the outer periphery of three respectively corresponding sides of the bottom fastening fixture and the top fastening fixture, studs are further disposed at the center of the bottom fastening fixture and the top fastening fixture, the bottom fastening fixture and the top fastening fixture are clamped and affixed by the studs, and furthermore the coil is affixed by a coil affixing fixture disposed at the studs of the three sides.