Reactor Insulating Member Integrates Magnetic Gap
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Solution Overview
Problem
Conventional reactors face challenges in productivity due to the complexity of preparing and positioning gap materials between the coil and magnetic core, particularly when using composite materials, which can be difficult to fix and may shift during the filling process.
Innovation Solution
The reactor design incorporates gap portions formed by insulating members between the coil and magnetic core, which are integrated with end surface connecting members to maintain predetermined positions, allowing for easier assembly and reduced preparation time, especially when using composite materials for the magnetic core.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If gap plates are disposed between divided cores to adjust magnetic properties, then magnetic properties can be controlled, but the assembly process becomes complex and productivity decreases
Solution Approach 1:
The gap portion is integrated into the insulating member that already exists in the reactor structure, eliminating the need for separate gap plates. The insulating member serves dual functions: electrical insulation and magnetic gap formation, thereby simplifying the assembly process while maintaining precise control over magnetic properties.
Solution Approach 2:
The insulating member is designed to perform multiple functions simultaneously: providing electrical insulation between the coil and magnetic core, and forming the gap portion to control magnetic properties. This multi-functionality reduces the total number of components and simplifies the overall assembly process.
2Ease of manufacture
If composite materials are used for magnetic core, then manufacturing flexibility improves, but positioning and fixing difficulty increases
Solution Approach 1:
The gap portion is formed in the insulating member before the magnetic core is assembled. This preliminary formation of the gap structure allows for precise positioning of the magnetic core without requiring complex fixing mechanisms during assembly, thereby maintaining manufacturing flexibility while reducing positioning and fixing difficulty.
Solution Approach 2:
The insulating member with its integrated gap portion serves as an intermediary structure between the coil and magnetic core. It provides a pre-formed interface that facilitates easy positioning and secure assembly of the magnetic core, reducing the complexity associated with handling composite magnetic materials.
3Manufacturing precision
If gap material is prepared and disposed separately, then magnetic circuit control is achieved, but preparation time and assembly time increase
Solution Approach 1:
The gap portion is combined with the insulating member as an integrated structure, eliminating the need for separate gap material preparation and placement steps. This integration maintains precise magnetic circuit control while significantly reducing the time required for gap material preparation and assembly.
Solution Approach 2:
The gap portion is pre-formed as part of the insulating member structure before assembly with the magnetic core. This preliminary formation eliminates the need for separate gap material preparation during the assembly process, thereby reducing overall preparation time while maintaining magnetic circuit control precision.
Data Source
AI summary
A reactor includes a coil having a pair of wound portions that are arranged side-by-side; a magnetic core having inner core portions that are disposed inside the wound portions and outer core portions that are exposed from the wound portions; and gap portions each constituted by a portion of respective insulating members that are disposed between the coil and the magnetic core, the gap portions dividing the outer core portions in a direction in which the wound portions are arranged side-by-side.