Compact Reactor Bus Bar Routing Through Magnetic Core
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Solution Overview
Problem
The increasing number of coil turns and installation-related issues lead to a larger reactor size due to the need for extended bus bars, which are unstable and require significant clearance for insulation, resulting in inefficient space utilization.
Innovation Solution
A compact reactor design featuring a bus bar embedded in a resin material terminal stage that covers the reactor body protrusion, allowing for closer proximity to the coil and casing while maintaining electrical insulation, thereby reducing the reactor's size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the number of coil turns is increased or multiple single coils are connected, then the reactor's inductance or capacity is improved, but the interval between terminals increases and the reactor size becomes larger
Solution Approach 1:
The patent applies dimensionality change by routing the bus bar through the interior space of the reactor body rather than extending it externally. The bus bar passes through the magnetic core structure, utilizing the three-dimensional internal volume to reduce the external footprint and terminal interval while maintaining the required electrical connections.
Solution Approach 2:
The bus bar is nested within the reactor body structure, specifically routed through the magnetic core and housing interior. This nesting approach allows the conductor to be contained within the existing structural envelope, eliminating the need for external extensions and reducing the overall terminal interval.
2Ease of operation
If a long length bus bar is used to extend the terminal to the drawn-out location, then the terminal connection is achieved, but the required space increases and the reactor becomes large-sized
Solution Approach 1:
The bus bar is routed through the interior three-dimensional space of the reactor body, utilizing vertical and radial paths through the magnetic core rather than horizontal external extensions. This dimensional routing reduces the external volume requirement while achieving the necessary terminal connection.
Solution Approach 2:
The magnetic core and reactor housing serve as intermediaries that guide and support the bus bar through their internal structures. These components provide built-in conduits and mounting points that facilitate compact terminal routing without requiring additional external space.
3Volume of stationary object
If the bus bar is thinned for downsizing, then the reactor size is reduced, but the bus bar becomes unstable and likely to vibrate
Solution Approach 1:
The bus bar is positioned and supported in three-dimensional space within the reactor body, utilizing structural features at multiple levels. This spatial positioning provides inherent stability through geometric constraints and multi-point support, eliminating the need for increased thickness while preventing vibration.
Solution Approach 2:
The magnetic core, housing walls, and mounting brackets serve as intermediary support structures that stabilize the thin bus bar. These intermediaries provide rigid attachment points and structural reinforcement along the bus bar's length, preventing vibration without requiring the bus bar itself to be thicker.
4Reliability
If clearance is ensured from the coil and casing for electrical insulation, then safety is improved, but the required space increases
Solution Approach 1:
The housing structure serves multiple functions simultaneously: it provides mechanical support, defines the reactor envelope, and acts as the electrical insulation barrier between the coil/bus bar and external components. This merging of structural and insulating functions eliminates the need for separate insulation elements and reduces overall volume.
Solution Approach 2:
The housing is constructed from composite or multi-functional materials that combine structural strength with electrical insulation properties. This allows the same component to fulfill both mechanical support and electrical isolation requirements, maximizing space utilization while maintaining safety clearances.
Data Source
AI summary
A small size reactor that effectively utilizes a space is provided. This reactor includes: a reactor body which includes a core and a coil attached to the core, a casing which houses therein the reactor body and which has an opening where a part of the reactor body protrudes outwardly, a bus bar which is a conductive component electrically connected to the coil and which covers a part of a side of the reactor body protruding from the opening, and a terminal stage which includes an extended portion formed of a resin material where a part of the bus bar is embedded and provided along an edge of the opening, and which supports an electrical connection portion between the bus bar and an exterior.