Reactor Terminal Block Stacking for Compact Coil Wiring
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The increasing rated current in air conditioning devices necessitates larger wire diameters for reactor coils, making it difficult to bend conductor wires and resulting in a larger reactor size due to increased distance between the coil and terminal block.
Innovation Solution
The reactor design features input-side and output-side terminal blocks positioned on different levels in the winding core direction, allowing for reduced bending of conductor wires and closer placement to the coil, with direct connection of wires to terminal plates via caulking, eliminating the need for crimp terminals and enabling efficient component connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the wire diameter of the coil becomes larger to handle increased rated current, then the current carrying capacity is improved, but the conductor wires cannot be bent at large curvature and the distance from the coil to the terminal block becomes larger
Solution Approach 1:
The patent transitions from a planar arrangement to a three-dimensional stacked arrangement where terminal blocks are positioned at different heights (upper and lower levels) relative to the coil. This vertical dimensionality allows conductor wires to connect directly without excessive bending, solving the contradiction between handling large currents with thick wires and maintaining compact dimensions.
Solution Approach 2:
The terminal block is segmented into multiple independent terminal blocks positioned at different heights. Each terminal block handles specific conductor wires independently, allowing optimized routing for each wire without interference from others, thus reducing overall distance while accommodating thick, difficult-to-bend wires.
2Ease of manufacture
If the distance from the coil to the terminal block becomes larger due to bending constraints, then the conductor wires can be properly connected, but the size of the reactor increases
Solution Approach 1:
By utilizing the vertical dimension with upper and lower terminal blocks positioned at different heights, the patent enables direct connection of conductor wires to terminal blocks without requiring long horizontal runs or sharp bends. This reduces the overall reactor volume while maintaining ease of conductor wire connection.
Solution Approach 2:
The terminal blocks are pre-positioned at optimal heights relative to the coil winding structure, allowing conductor wires to be directly connected at the point of emergence from the coil. This preliminary positioning eliminates the need for complex bending operations and reduces the space required for wire routing.
Data Source
AI summary
A reactor is provided. The reactor includes a coil and a terminal block that is fixed to conductor wires that led out from both ends in a winding core direction of the coil. The terminal block includes an input-side terminal block that is fixed to an input-side conductor wire that leads out from one end of the coil, and an output-side terminal block that is fixed to an output-side conductor wire that leads out from another end portion of the coil. The input-side terminal block and the output-side terminal block are disposed on different levels in the winding core direction based on lead-out positions in the winding core direction of the input-side conductor wire and the output-side conductor wire.