Reactor Coil Layout With Embedded Temperature Sensor Space
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Solution Overview
Problem
Existing reactors with temperature sensors face challenges in miniaturization and accurate temperature measurement, as external placement increases reactor size and internal placement affects magnetic characteristics.
Innovation Solution
A reactor design with a temperature sensor positioned between coil portions, allowing for miniaturization and accurate temperature measurement by bending the coil's outer peripheral portions to create a space for the sensor, which is also effective in measuring temperature near the inner peripheral surface where heat rise is significant.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the temperature sensor is attached to the outer peripheral surface of the coil, then the temperature measurement is simplified, but the reactor size increases
Solution Approach 1:
The temperature sensor is nested within the coil structure by creating a space between the first and second coil portions. The sensor is disposed in this internal space, allowing it to be integrated within the reactor rather than attached externally, thus reducing the overall reactor size while maintaining temperature measurement capability.
2Volume of stationary object
If the temperature sensor is provided on a gap plate in the core, then the reactor size is reduced, but the magnetic characteristics are affected
Solution Approach 1:
The temperature sensor acts as an intermediary element disposed in the space between the first and second coil portions. This positioning allows the sensor to measure coil temperature without being integrated into the magnetic core path, thereby avoiding interference with magnetic characteristics while still achieving compact reactor design.
3Volume of stationary object
If the temperature sensor is disposed between coil portions, then the reactor is miniaturized and temperature measurement accuracy is improved, but the coil structure becomes more complex
Solution Approach 1:
The coil is segmented into a first coil portion and a second coil portion that are continuously connected in the axial direction. This segmentation creates a natural space between the portions where the temperature sensor can be disposed, integrating the sensing function without requiring separate external mounting structures.
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 design enables a compact reactor that accurately measures coil temperature, improving responsiveness to temperature changes and reducing the reactor's size while maintaining desired magnetic characteristics.
Implementation Method 1
a temperature sensor for measuring a temperature of the coil, wherein the temperature sensor is disposed in a space formed between the first coil portion and the second coil portion
Implementation Method 2
a coil; a magnetic core on which the coil is disposed
Data Source
AI summary
A reactor includes a coil, a magnetic core and a temperature sensor. The coil includes a first coil portion and a second coil portion. The first coil portion includes a plurality of first turns where a flat wire is wound edgewise. Each of the plurality of first turns includes a first inner peripheral portion that constructs an inner periphery side of the first turn and a first outer peripheral portion that constructs an outer periphery side of the first turn. The first outer peripheral portion is bent with respect to the first inner peripheral portion so as to be inclined in a first direction. The second coil portion includes a plurality of second turns where the flat wire is wound edgewise.