Magnetic-Core Reactor Assembly With Composite Bolt Coupling
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Solution Overview
Problem
Existing reactor designs face challenges in productivity and magnetic characteristics due to complex assembly procedures and the use of non-magnetic materials for bolt members, which affect the magnetic circuit's performance.
Innovation Solution
A reactor design featuring an integrated magnetic core with a bolt made of a composite material dispersing soft magnetic powder in resin, securely coupling the inner and outer core parts with a shaft passing through the outer core, enhancing magnetic characteristics and simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the magnetic core is divided into multiple core pieces and coupled with bolt members, then the coupling precision can be improved, but the assembly complexity and manufacturing time increase significantly
Solution Approach 1:
The patent merges multiple core pieces into a single integrated magnetic core structure that can be molded as one piece. This eliminates the need for separate coupling operations with bolt members, thereby reducing assembly complexity while maintaining the structural integrity and precision of the magnetic core assembly.
2Manufacturing precision
If the magnetic core is divided into multiple core pieces and coupled with bolt members, then the coupling precision can be improved, but the productivity decreases due to troublesome assembly tasks
Solution Approach 1:
The patent combines multiple core pieces into a single integrated magnetic core that can be manufactured in one molding operation. This eliminates the need for separate positioning, alignment, and bolting operations, thereby significantly improving productivity while maintaining coupling precision through the integrated design.
3Strength
If the bolt member is disposed in the magnetic circuit portion, then the clamping strength can be ensured, but the magnetic characteristics deteriorate due to non-magnetic material
Solution Approach 1:
The patent employs a composite material for the bolt member that combines magnetic powder with a resin or metal matrix. This composite structure provides both the mechanical clamping strength required for securing the magnetic core and the magnetic properties necessary to maintain the magnetic circuit's performance, thereby resolving the contradiction between strength and magnetic characteristics.
4Ease of manufacture
If through holes are provided in core pieces and gap member for passing bolt members, then the assembly is enabled, but the manufacturing procedure becomes complex and time-consuming
Solution Approach 1:
The patent integrates the function of through holes and gap members into the single-piece magnetic core structure during the molding process. This eliminates the need for separate hole-drilling operations and the assembly of gap members, thereby simplifying the manufacturing procedure and improving productivity while still enabling proper assembly and positioning.
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 reactor achieves excellent magnetic characteristics and simplified production with reduced risk of magnetic deterioration, thanks to the composite bolt material and integrated core structure, facilitating secure coupling and easy assembly.
Implementation Method 1
The bolt is constituted by a composite material formed by dispersing a soft magnetic powder in a resin
Implementation Method 2
soft magnetic powder
Data Source
AI summary
A reactor including a magnetic core and a coil having a wound part, the magnetic core having an inner core part disposed inside the wound part and an outer core part disposed outside the wound part, is provided with a bolt coupling the inner core part and the outer core part, the bolt being constituted by a composite material formed by dispersing a soft magnetic powder in a resin and including a shaft part passing through the outer core part, the shaft part including a tip reaching the inner core part, and the inner core part and the outer core part respectively being an integrated member having an undivided structure.