Magnetically Coupled Reactor Core Segmentation
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Solution Overview
Problem
The magnetically coupled reactor experiences magnetic flux leakage at the junction of its reactor core, leading to eddy currents in winding wires, which causes current density deviations and temperature rises, necessitating an increase in reactor size to mitigate these issues.
Innovation Solution
A magnetically coupled reactor design featuring a closed magnetic circuit with split coil portions wound around intermediate core portions, positioned to minimize leakage magnetic flux interlinking, utilizing a configuration of first and second outer core portions and intermediate core portions to cancel magnetic flux and reduce eddy currents without increasing size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the reactor core uses butted together U-shaped split cores to form a closed magnetic circuit, then the magnetic circuit is closed, but magnetic flux leaks from the junction portion causing eddy currents in winding wires
Solution Approach 1:
The reactor core is divided into multiple segmented cores (first reactor core and second reactor core) that are arranged side by side. Each core has its own coil portions wound therearound, creating separate magnetic circuits that reduce flux leakage at junctions while maintaining closed magnetic paths.
Solution Approach 2:
Insulating films are introduced as intermediary layers at the junction portions where reactor cores are connected. These insulating films prevent direct magnetic coupling between adjacent cores at the junction, thereby reducing magnetic flux leakage and eddy current generation in the winding wires.
2Loss of energy
If multi-phase coils are wound around one reactor core to cancel DC magnetic flux, then DC magnetic flux is canceled, but leakage magnetic flux still interlinks with winding wires causing temperature rise
Solution Approach 1:
The coil system is segmented into first coil portions and second coil portions wound around different reactor cores. The first coil portions are wound in a first direction while the second coil portions are wound in a second direction (opposite to the first direction), creating opposing magnetic fluxes that cancel DC components while reducing leakage flux interlinking.
Solution Approach 2:
The coil portions are asymmetrically arranged with different winding directions on different cores. This asymmetric configuration optimizes the cancellation of DC magnetic flux while minimizing the interlinking of leakage flux with winding wires, thereby reducing eddy currents and temperature rise.
3Object-generated harmful factors
If the size of the magnetically coupled reactor is increased to reduce eddy currents, then eddy currents are reduced, but the reactor size increases
Solution Approach 1:
Instead of increasing the size of a single reactor core, the system uses multiple smaller reactor cores arranged side by side. This segmented approach reduces eddy currents by eliminating large junction portions while maintaining a compact overall reactor size.
Solution Approach 2:
The reactor cores are arranged in a lateral dimension (side by side) rather than increasing the size in the vertical or depth direction. This dimensional arrangement reduces eddy currents without significantly increasing the overall reactor footprint, maintaining installation flexibility.
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 effectively reduces leakage magnetic flux interlinking with winding wires, suppressing temperature rises and maintaining a compact reactor size, thus enhancing the reactor's performance and installation flexibility.
Implementation Method 1
a reactor core forming a closed magnetic circuit
Implementation Method 2
a first coil portion wound around the reactor core in a split manner, and a second coil portion wound in a split manner
Implementation Method 3
multi-phase coils are wound around one reactor core to cancel out the DC magnetic flux by reversing the directions of the magnetic flux from each other
Data Source
AI summary
A reactor core of the magnetically coupled reactor includes a first outer core portion including two first leg portions extending in a first direction and a first base portion linking the two first leg portions, a second outer core portion including two second leg portions extending in the first direction and a second base portion linking the two second leg portions, and an intermediate core portion integrally extending continuously in the first direction and connecting the first leg portions and the second leg portions, in which a first connection portion, to which the first leg portions and the intermediate core portion are connected, is positioned in an area in which a first coil portion is wound in the first direction, and a second connection portion, to which the second leg portions and the intermediate core portion are connected, is positioned in an area in which the second coil portion is wound in the first direction.