Reactor Core Notches for Bolt Anchoring

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Solution Overview

Problem

Reactor designs with outer peripheral iron cores and metal bolts face issues of increased loss due to loop currents and size expansion when trying to reduce weight and cost, as insulating bolts are costly and eliminating through-holes in the iron core leads to larger reactors.

Innovation Solution

A reactor design featuring a core main body with an outer peripheral iron core, multiple iron cores, and coils wound around them, where radial inner end portions converge towards the center, with gaps for magnetic connectivity, and notches on the outer surface for bolts to pass through, allowing for anchoring without increasing size or loss.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If metal bolts are inserted into through-holes in the outer peripheral iron core to anchor the core main body, then the core main body can be securely anchored, but loop currents are generated between the metal bolts and the inner wall of the through-holes, causing increased loss

Engineering Contradiction:

Improveanchoring reliabilityVSAvoidenergy loss

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

An insulating structure is introduced as an intermediary between the metal bolt and the outer peripheral iron core. This insulating structure prevents direct contact between the conductive bolt and the iron core, thereby blocking the formation of loop currents while still allowing the bolt to perform its anchoring function. The insulating structure acts as a mediator that resolves the conflict between electrical isolation and mechanical fastening.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Loss of energy

If insulating material is added to the metal bolts to prevent loop currents, then energy loss is reduced, but the cost of the reactor increases

Engineering Contradiction:

Improveenergy lossVSAvoidmanufacturing cost

Core Design Contradiction:

Loss of energyVSEase of manufacture

Solution Approach 1:

The patent employs a cost-effective insulating structure that can be manufactured inexpensively, such as a resin coating or molded insulating component. This approach uses a simple, disposable-like insulating element rather than expensive complex insulation systems, thereby reducing energy loss while keeping manufacturing costs low.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Loss of energy

If through-holes are eliminated from the outer peripheral iron core and metal bolts are arranged outside, then loop current loss is avoided, but the iron core anchoring part increases in size, resulting in a larger reactor

Engineering Contradiction:

Improveenergy lossVSAvoidreactor size

Core Design Contradiction:

Loss of energyVSVolume of moving object

Solution Approach 1:

The insulating structure is nested within the existing through-hole structure of the outer peripheral iron core. Rather than eliminating the through-holes or expanding the anchoring part externally, the insulating material is placed inside the existing spatial configuration, allowing the bolt to pass through while maintaining the original reactor footprint. This nesting approach avoids increasing the overall reactor size.

Inventive Principle:

Principle #7Nested doll (Nesting)

4Volume of moving object

If notches are formed on the outer peripheral iron core to allow bolts to pass through, then the reactor size and weight are reduced, but the structural integrity of the iron core may be compromised

Engineering Contradiction:

Improvereactor sizeVSAvoidstructural strength

Core Design Contradiction:

Volume of moving objectVSStrength

Solution Approach 1:

The notches are designed with specific local characteristics: they are positioned at predetermined locations on the outer peripheral iron core, have controlled dimensions, and are arranged in patterns that minimize structural impact. The local quality of the notch geometry and positioning is optimized to provide sufficient clearance for bolts while maintaining the overall structural integrity of the iron core.

Inventive Principle:

Principle #3Local quality

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 reduces reactor size and weight, lowers material costs, and avoids increased losses by positioning bolts inside the core footprint, enabling a lightweight, cost-effective reactor without compromising magnetic properties.

Implementation Method 1

the gap being magnetically connectable

Methodology Applied

Scientific EffectMagnetic connectivity: Magnetic Field

Implementation Method 2

coils coupled to an inner surface of the outer peripheral iron core, the at least three iron core coils including at least three iron cores and coils respectively wound around the iron cores

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentUS11605491B2Core main body including outer peripheral iron core, reactor including such core main body and manufacturing method thereof

Publication Date: 2023.03.14 FANUC LTD

AI summary

A core main body includes: an outer peripheral iron core, and at least three iron cores coupled to an inner surface of the outer peripheral iron core, in which a gap is formed between adjacent iron cores among the at least three iron cores, the gap being magnetically connectable, and a plurality of notches are formed on an outer circumferential surface of the outer peripheral iron core, the plurality of notches extending in an axial direction of the outer peripheral iron core. The reactor includes such a core body.