Reactor Terminal Base Unit Temperature Sensor Integration
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Solution Overview
Problem
Reactor designs with outer peripheral iron cores that can be divided into pieces face difficulties in attaching temperature sensors to multiple coils, increasing manufacturing complexity and time.
Innovation Solution
A reactor design featuring a core body with multiple iron cores and coils, where a gap between iron cores allows magnetic connectivity, and a terminal base unit with a surface-mounted temperature sensor for indirect heat estimation, reducing the need for individual coil sensors and simplifying manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If temperature sensors are attached to each coil for temperature protection, then temperature monitoring reliability is improved, but manufacturing complexity and time increase
Solution Approach 1:
The patent introduces a terminal base unit as an intermediary component that houses a single temperature sensor. This terminal base unit serves as a mediator between the multiple coils and the temperature monitoring system, allowing indirect temperature detection without requiring direct sensor attachment to each coil. The terminal base unit consolidates the temperature sensing function, simplifying the overall system while maintaining monitoring capability.
2Reliability
If temperature sensors are attached to each coil, then temperature protection accuracy is improved, but manufacturing time increases
Solution Approach 1:
The patent merges the temperature sensing function from multiple individual coil sensors into a single integrated temperature sensor housed in the terminal base unit. This consolidation reduces the number of sensor attachment operations from multiple (one per coil) to a single operation, significantly reducing manufacturing time while maintaining temperature protection functionality through the unified sensing approach.
3Measurement precision
If temperature sensors are attached to each coil, then temperature detection precision is improved, but ease of manufacture deteriorates
Solution Approach 1:
The terminal base unit acts as an intermediary that simplifies the manufacturing process by providing a pre-integrated housing for the temperature sensor. This intermediary structure eliminates the need for complex individual sensor attachment procedures for each coil, making the manufacturing process more straightforward and easier to automate while maintaining temperature detection precision through the centralized sensing approach.
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 hours and complexity by allowing temperature protection without increasing the number of manufacturing steps, while enabling efficient automation and cost reduction.
Implementation Method 1
A gap is 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 that includes an outer peripheral iron core composed of a plurality of outer peripheral iron core portions, at least three iron cores coupled to the outer peripheral iron core portions, and coils wound on the iron cores. A gap is 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. The reactor includes a terminal base unit for electrically connecting the coils to an external device, and a temperature sensor attached to a surface of the terminal base unit, the surface being opposite the coils.