Reactor Coil Holding Structure for Stable Core Positioning
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Solution Overview
Problem
The existing reactors face challenges in maintaining the stability and accurate positioning of coils due to their springy nature, leading to deformation and variations in electromagnetic performance.
Innovation Solution
A reactor design that incorporates a holding member with a coupling structure, including recessed and protruding portions, to securely attach the coil to a magnetic core, stabilizing its position and improving attachment ease.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the coil is made springy for flexibility, then the coil can be easily formed and handled, but the coil becomes prone to twisting and deformation, making it difficult to attach to the core with stable positioning
Solution Approach 1:
The holding member is prepared in advance with positioning protrusions and insertion holes that will guide and constrain the coil during attachment. The terminal portions are prepared with withdrawal directions that facilitate subsequent connection to bus bars. This preliminary preparation enables easy attachment while maintaining coil stability.
Solution Approach 2:
The holding member acts as an intermediary component between the springy coil and the magnetic core. It provides rigid positioning structures (positioning protrusions, insertion holes) that constrain the flexible coil, preventing twisting and deformation while allowing the coil to maintain its springy characteristics for ease of formation.
2Ease of operation
If the coil is allowed to move freely for easy attachment, then the attachment process is simplified, but the coil position shifts relative to the core, causing variation in electromagnetic performance
Solution Approach 1:
The holding member incorporates self-aligning features where positioning protrusions automatically guide the coil into the correct position during attachment. The insertion holes are designed to receive terminal portions in specific withdrawal directions, enabling the assembly to self-position without complex alignment procedures, thus achieving both ease of attachment and position accuracy.
Solution Approach 2:
The holding member serves as a mediator that translates the flexible coil attachment into a precise, fixed position. Its rigid structure with predefined positioning features ensures that once attached, the coil cannot shift relative to the magnetic core, eliminating variations in electromagnetic performance while keeping the attachment process simple.
3Productivity
If the holding member structure is simplified for ease of attachment, then the attachment process is faster, but the connection stability and position fixation of the coil are compromised
Solution Approach 1:
The holding member is segmented into distinct functional portions: body portions for structural support, positioning protrusions for location fixation, and insertion holes for terminal connection. This segmentation allows each feature to perform its specific function efficiently, enabling quick attachment through simple insertion while maintaining high connection stability through the distributed positioning features.
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 enhances the stability and accuracy of the coil's position, reducing variations in electromagnetic performance and improving productivity by facilitating easier attachment and connection to bus bars.
Implementation Method 1
Either the first body portion or the second body portion and the first joint portion include portions of a first coupling structure that are fitted to each other. The first coupling structure includes a first recessed portion and a first protruding portion.
Implementation Method 2
a reactor, a converter, and a power converter device
Data Source
AI summary
Provided is a reactor that includes a coil, a holding member, and a magnetic core. The coil has a first terminal portion withdrawn from a first end of the coil, and a second terminal portion withdrawn from a second end of the coil. The holding member has a first holding member and a second holding member. Either the first holding member or the second holding member has a first joint portion that is disposed along a part of an outer peripheral surface of the coil and connects between the first body portion and the second body portion. Either the first body portion or the second body portion and the first joint portion include portions of a first coupling structure that are fitted to each other. The first coupling structure includes a first recessed portion and a first protruding portion.