Dielectric Composite Cradle for AC Air Core Reactors
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Solution Overview
Problem
Air core reactors, particularly AC types, face challenges with ferrous cradle materials heating up due to strong magnetic fields, leading to energy wastage and structural instability, while existing solutions for DC reactors are not effectively adaptable for AC systems.
Innovation Solution
A cradle configured in a star or wheel form, at least partially made from dielectric materials, such as fiberglass composite or porcelain, to eliminate eddy current paths and mitigate electromagnetic heating, using non-ferrous materials for structural support and thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If ferrous material is used for the cradle to provide structural support, then the cradle can support the heavy coil, but the magnetic field causes the ferrous material to heat up due to eddy currents
Solution Approach 1:
The patent applies composite materials by combining non-ferrous structural members (for mechanical strength) with dielectric material members (for electrical insulation and eddy current elimination). This composite structure provides both the required structural support and the electrical properties to prevent eddy current heating in the magnetic field environment.
Solution Approach 2:
The patent applies local quality by using different materials for different parts of the cradle structure. Non-ferrous materials are used in regions requiring structural support, while dielectric materials are used in regions where electrical insulation and eddy current prevention are critical. This localized material selection optimizes both mechanical and electrical performance.
2Strength
If ferrous material is used for the cradle, then structural strength is provided, but electromagnetic heating occurs making the solution unacceptable for AC reactors
Solution Approach 1:
The patent uses composite materials combining non-ferrous structural members with dielectric material members. The non-ferrous materials provide structural strength while the dielectric materials prevent electromagnetic heating by blocking eddy current paths, thus solving both the strength and temperature issues simultaneously.
Solution Approach 2:
The dielectric material members act as intermediaries between the magnetic field and the structural members. These intermediate elements prevent direct interaction between the magnetic field and ferrous materials, thereby eliminating induction heating while maintaining structural integrity.
3Adaptability or versatility
If DC reactor solutions are applied to AC reactors, then mounting capability is provided, but eddy current paths are created causing heating
Solution Approach 1:
The patent adapts the DC reactor mounting solution for AC reactors by using composite materials. The cradle combines non-ferrous structural members with dielectric material members, creating a structure that can be mounted on insulators like DC reactors while preventing eddy current paths that would cause heating in AC magnetic fields.
Solution Approach 2:
The patent changes the material parameters of the cradle from purely ferrous to a composite of non-ferrous and dielectric materials. This parameter change in material composition eliminates eddy current paths while maintaining the mounting capability required for AC reactor applications.
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 dielectric cradle design effectively reduces energy wastage and structural instability by minimizing eddy currents and induction heating, ensuring efficient load transmission and long-term durability in AC air core reactors.
Implementation Method 1
The plurality of outer members are formed from a dielectric material... to eliminate eddy current paths and/or mitigate electromagnetic heating
Implementation Method 2
This magnetic field causes the ferrous material of the cradle to heat up. The energy used in heating the cradle is wasted
Data Source
Figure 1A~1B
Figure 2~3
Figure 4
AI summary
A cradle (200) to mount a coil (405) of an electric power line reactor (400) is provided. The cradle (200) includes a plurality of a pair of opposing arms (215(1-4)). Each arm 215 has a free end (225(1-4)) and an end coupled to a hub (220). The free end (225) of each arm (215) is configured to be coupled to a bearing assembly. The cradle (200) further includes a plurality of outer members (235(1-4)). The free ends of each pair of adjacent arms (215(1-2)) of the plurality of a pair of opposing arms (215(1-4)) are coupled to a corresponding outer member (235) of the plurality of outer members (235(1- 4)). At least one outer member (235) of the plurality of outer members (235(1-4)) is formed from a dielectric material and the plurality of a pair of opposing arms (215(1-4)) being formed from a material that enables the cradle (200) to support weight of the coil (405).