Reactor Outer Iron Core Alignment via Welded Segmentation
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Solution Overview
Problem
Reactor designs with divided outer peripheral iron core portions are prone to misalignment due to magnetostriction, leading to increased magnetic flux leakage and losses, and existing solutions like band connections or projections and recesses can result in misalignment or additional gaps.
Innovation Solution
A reactor design featuring an outer peripheral iron core composed of multiple portions connected by weld portions or connection members, with strategically placed gaps for magnetic coupling, to prevent misalignment and minimize magnetic flux leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the outer peripheral iron core is divided into multiple portions, then the reactor structure becomes more flexible and easier to manufacture, but misalignment occurs due to magnetostriction vibration
Solution Approach 1:
The outer peripheral iron core is divided into multiple portions that can be manufactured separately and then assembled together, making the overall structure easier to manufacture while maintaining alignment through connection parts
Solution Approach 2:
Connection parts are introduced as intermediary elements between the divided outer peripheral iron core portions. These connection parts act as mediators that physically link the separate portions and prevent misalignment caused by magnetostriction vibration during operation
2Reliability
If connection parts are added to connect outer peripheral iron core portions, then misalignment is prevented, but device complexity increases
Solution Approach 1:
The connection parts are designed to merge or integrate with the outer peripheral iron core portions, forming a unified structure that maintains alignment stability without adding excessive complexity to the overall device
3Reliability
If projections and recesses are provided on connection surfaces, then misalignment due to vibration is prevented, but additional gaps form when accuracy is poor
Solution Approach 1:
The connection parts are designed with built-in compensation mechanisms that beforehand cushion or accommodate potential misalignment issues. This allows the connection to remain stable even when manufacturing accuracy of the connection surfaces is not perfect, preventing additional gaps from forming
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 connection of outer peripheral iron core portions via welds or connection members effectively prevents misalignment and reduces magnetic flux leakage, maintaining desired magnetic properties and reducing reactor size, while allowing for easy assembly and disassembly.
Implementation Method 1
vibration may occur due to magnetostriction or the like
Implementation Method 2
gaps, which can be magnetically coupled, are formed between one of the at least three iron cores and another iron core adjacent thereto
Data Source
AI summary
A reactor includes an outer peripheral iron core composed of a plurality of outer peripheral iron core portions and at least three iron core coils arranged inside the outer peripheral iron core. The at least three iron core coils are composed of iron cores coupled to the plurality of outer peripheral iron core portions and coils wound onto the iron cores. Gaps, which can be magnetically coupled, are formed between adjacent iron cores. The reactor further includes connection parts for connecting the plurality of outer peripheral iron core portions to each other.