Planar Reactor Pillar Geometry for Coil Loss Reduction
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Solution Overview
Problem
The challenge is to reduce coil loss in flat reactors used in variable-frequency drives and inverters while maintaining the core's saturation current requirements, as the flattening process increases the ratio of the core's length to width, leading to increased coil winding circumference and loss.
Innovation Solution
A planar reactor design where the pillar and at least one of the upper or lower boards are coplanar at one side, allowing the pillar to be sunk into the winding space from the opposite side, thereby increasing the pillar's width and decreasing its length while maintaining a constant cross-sectional area, which reduces the coil's winding circumference and loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If the reactor is flattened to reduce thickness, then the thickness of upper/lower board decreases, but the ratio of length to width of the pillar increases, leading to increased coil loss
Solution Approach 1:
The pillar is sunk into the winding space from the second side, creating a stepped structure that changes the dimensional distribution of the core. This allows the pillar to have different effective dimensions in different regions, optimizing the magnetic flux path while maintaining a compact overall footprint and reducing coil loss without further reducing board thickness.
2Reliability
If the pillar dimensions are adjusted to maintain saturation current, then the cross-sectional area must be maintained, but this increases the winding circumference and coil loss
Solution Approach 1:
The pillar is designed with different dimensions in different regions: wider at the base and narrower at the top. This local variation in geometry allows the core to maintain sufficient cross-sectional area where needed for saturation current requirements while reducing the winding circumference in regions where the coil is wrapped, thereby reducing coil loss.
3Volume of moving object
If the coil is fully contained in the winding space, then the reactor becomes more compact, but the coil may not have sufficient space for proper winding
Solution Approach 1:
The winding space is segmented into different regions: a first winding space above the pillar and a second winding space below the pillar. This segmentation allows the coil to be properly wound around the pillar with adequate space, while the overall reactor remains compact due to the efficient use of vertical space and the stepped pillar structure.
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 design effectively reduces coil loss and prevents the coil from protruding, allowing for a more compact and efficient reactor that meets saturation current requirements.
Implementation Method 1
a reactor comprises a core and a coil. The core comprises an upper board, a lower board and a pillar. The pillar is located between the upper board and the lower board. A winding space is located among the upper board, the lower board and the pillar. The coil is wound around the pillar and located in the winding space
Data Source
AI summary
A planar reactor includes a core and a coil. The core includes an upper board, a lower board and a pillar. The pillar is located between the upper board and the lower board. A winding space is located among the upper board, the lower board and the pillar. The coil is wound around the pillar and located in the winding space. The pillar and at least one of the upper board and the lower board are coplanar at a first side of the planar reactor. The pillar is sunk into the winding space from a second side of the planar reactor, wherein the first side is opposite to the second side. A first end of the coil is exposed from the first side of the planar reactor. A second end of the coil is hidden in the winding space partially or wholly at the second side of the planar reactor.