Reactor Covering Portions With Fitting Parts For Assembly
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Solution Overview
Problem
The assembly of iron core coils in reactors is prone to position deviation due to the attachment of coils within casings, leading to increased manufacturing time and difficulty in automation.
Innovation Solution
A reactor design featuring a core body with peripheral iron core portions and coils, where gaps between iron cores allow magnetic connectivity, and covering portions with fitting parts that can be circumferentially fitted to each other, reducing assembly complexity and improving automation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If coils are attached to iron cores in a state of being contained in casings, then the coils are protected and organized, but assembly position deviation occurs leading to increased manufacturing time and difficulty in automation
Solution Approach 1:
The reactor is divided into modular units with standardized covering portions that can be independently assembled. Each covering portion with its fitted parts creates a self-contained module, allowing parallel assembly operations and reducing overall manufacturing time while maintaining coil protection.
Solution Approach 2:
The invention changes the geometric parameters of the covering portions by adding fitting parts (protrusions and recesses) that enable precise positioning. This parameter modification eliminates assembly position deviation without compromising the protective function of the casings.
2Reliability
If coils are attached to iron cores in a state of being contained in casings, then the coils are protected and organized, but assembly complexity increases making automation difficult
Solution Approach 1:
The assembly process is segmented into simple, repeatable steps: placing the coil in the covering portion, engaging the fitting parts, and attaching to the iron core. This segmentation reduces assembly complexity by breaking down the complex task into standardized operations suitable for automation.
Solution Approach 2:
The fitting parts (protrusions and recesses) enable self-aligning and self-positioning during assembly. The components guide themselves into the correct positions through the interlocking fitting parts, eliminating the need for complex alignment procedures and manual adjustment.
3Ease of manufacture
If covering portions are designed without fitting parts, then manufacturing is simpler, but assembly position deviation occurs
Solution Approach 1:
The fitting parts introduce asymmetric features (protrusions and recesses) to otherwise symmetric covering portions. This asymmetry provides unique positioning information and physical constraints that prevent position deviation during assembly, while the overall manufacturing process remains simple through standardized production methods.
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 manufacturing time and complexity by enabling precise assembly of iron core coils and improves the mechanical stability of the reactor, minimizing magnetic vibration and noise.
Implementation Method 1
Gaps are formed between one of the iron cores and another of the iron cores adjacent to the one of the iron cores, so as to be magnetically connectable through the gap
Data Source
AI summary
A reactor according to an embodiment of the present disclosure includes a core body. The core body includes a peripheral iron core composed of a plurality of peripheral iron core portions, at least three iron cores coupled to the peripheral iron core portions, and coils wound on the iron cores. Gaps are formed between one of the iron cores and another iron core adjacent thereto, so as to be magnetically connectable through the gaps. The reactor further includes a plurality of covering portions each for covering each of the coils. The covering portions adjacent in a circumferential direction can be fitted to each other.