Reactor Core-Coil Gap Structure for Vibration Isolation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The vibration of reactors increases due to the resonance of core and coil vibrations, which are transmitted through the resin component when integrated, posing a challenge in reducing vibrations, especially with the diversification of reactor applications.
Innovation Solution
A reactor design that includes a coil with a cylindrical shape and a core with legs around which the coil is wound, featuring a gap between all legs and the inner circumferential surface of the coil, preventing direct contact and thus suppressing vibration transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the core and coil are integrated via resin component, then the structural integrity and electrical insulation are improved, but the vibration transmission between core and coil increases causing resonance
Solution Approach 1:
A resin component is introduced as an intermediary material between the core and coil. This resin layer serves dual functions: providing electrical insulation to prevent short circuits while simultaneously acting as a vibration isolation barrier. The resin's viscoelastic properties allow it to absorb and dampen vibrational energy, preventing direct transmission of mechanical vibrations between the core and coil, thus reducing resonance while maintaining structural integrity.
2Ease of manufacture
If the core legs contact the coil inner circumferential surface, then the assembly simplicity is improved, but the vibration resonance is exacerbated
Solution Approach 1:
The resin component is positioned to fill the gap between the core legs and the coil inner circumferential surface. This intermediary layer eliminates direct metal-to-metal contact while maintaining the compact assembly structure. The resin's compliance allows it to conform to the mating surfaces, ensuring complete coverage and effective vibration isolation without requiring complex positioning features or additional fastening elements.
3Object-affected harmful factors
If a gap is provided between legs and coil, then the vibration transmission is suppressed, but the manufacturing precision requirement increases
Solution Approach 1:
The design specifies a controlled gap dimension between the core legs and coil inner surface, optimized to provide effective vibration isolation. By carefully selecting the gap size parameter, the design achieves sufficient vibration suppression while accommodating normal manufacturing tolerances. The resin component's thickness is designed to fill this gap completely, and the gap dimension is set large enough to ensure complete filling even with tolerance variations, thereby reducing the stringency of manufacturing precision requirements.
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 effectively suppresses the transmission of vibrations between the core and coil, reducing the overall vibration of the reactor, thereby enhancing its performance and applicability across various applications.
Implementation Method 1
The coil generates magnetic flux in accordance with a number of turns when power flows therethrough
Implementation Method 2
the core vibrates due to magnetostriction
Data Source
AI summary
A reactor that suppresses the transmission of the vibration of the core and the vibration of the coil and that reduces the vibration thereof is provided. The reactor includes a coil 3 with a cylindrical shape and a core 1 having legs 12 around which the coil 3 is wound. The core includes a core mold resin 2 which covers at least a part of the core 1, and a core holder which holds the core 1. The coil 3 includes a coil mold resin 4 which covers at least a part of the coil 3, and a coil holder which holds the coil 3. The core holder and the coil holder independently hold the core 1 and the coil 3, respectively, and a gap S1 is provided between the legs 12 and the inner circumferential surface of the coil 3.