Reactor End Plate Support for Magnetic Flux Leakage Control
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Solution Overview
Problem
Conventional reactors with E-shaped iron cores face challenges in direct coupling due to gaps, leading to noise, vibration, and magnetic flux leakage, complicating inductance control and reactor configuration.
Innovation Solution
A reactor design featuring a core body sandwiched between end plates with axis portions that penetrate or are outside the outer circumference iron core, allowing for magnetic coupling without direct contact and reducing magnetic flux leakage, using non-magnetic materials for the end plates and axis portions to minimize interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If coupling plates are used to couple the first iron core and the second iron core, then the structural stability is improved, but the device complexity increases and magnetic flux leakage occurs
Solution Approach 1:
The patent removes the coupling plates from the structure and instead uses the end plates to directly support both the first and second iron cores. This extraction of the intermediate coupling component simplifies the device structure while maintaining structural stability through the end plate support system.
Solution Approach 2:
The patent merges the functions of the coupling plates and end plates by having the end plates directly support both iron cores. This consolidation eliminates the need for separate coupling plates, reducing device complexity while maintaining the structural stability needed to hold the cores in position with proper spacing.
2Stability of the object's composition
If coupling plates are used to couple the first iron core and the second iron core, then the structural stability is improved, but magnetic flux leakage occurs
Solution Approach 1:
The patent removes the magnetic coupling plates that were causing flux leakage and replaces them with non-magnetic end plate support structures. This extraction eliminates the source of magnetic flux leakage while preserving the mechanical stability through alternative support means.
Solution Approach 2:
The patent introduces non-magnetic end plates as intermediary support structures between the iron cores, replacing the magnetic coupling plates. These end plates serve as mediators that provide structural stability without interfering with the magnetic flux paths, thereby preventing magnetic flux leakage.
3Ease of manufacture
If the first iron core and the second iron core are directly coupled, then the manufacturing simplicity is improved, but the gap cannot be maintained
Solution Approach 1:
The patent incorporates gap spacing features directly into the end plate designs during manufacturing. This preliminary action ensures that when the end plates are installed, the correct gap spacing between iron cores is automatically established, eliminating the need for complex post-assembly adjustments while maintaining manufacturing simplicity.
Solution Approach 2:
The end plates are designed with built-in gap spacing features that automatically maintain the required distance between iron cores. This self-service mechanism eliminates the need for external coupling plates or complex adjustment mechanisms, simplifying both manufacturing and assembly while ensuring precise gap control.
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 noise and vibration control, simplifies gap length management, reduces magnetic flux leakage, and maintains consistent inductance across phases, improving the reactor's structural integrity and design flexibility.
Implementation Method 1
a first end plate and a second end plate which sandwich and fasten the core body
Implementation Method 2
a plurality of axis portions disposed in the vicinity of an outer edge portion of the core body or outward of the core body and supported by the first end plate and the second end plate
Implementation Method 3
using non-magnetic materials for the end plates and axis portions to minimize interference
Data Source
AI summary
A reactor includes a core body; a first end plate and a second end plate which sandwich and fasten the core body; and a plurality of axis portions disposed in the vicinity of an outer edge portion of the core body or outward of the core body and supported by the first end plate and the second end plate.