Segmented Iron Core Reactor for High Voltage Transportation
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Solution Overview
Problem
Current single-phase iron core reactors face challenges with increased voltage and capacity, including transportation difficulties, limited creepage distance, high creepage voltage, noise, and vibration, which affect reliability and environmental protection.
Innovation Solution
The design incorporates two or more separate active parts with 'EI' shaped iron cores and coils, connected in series or parallel, housed in a double-layer oil tank with improved insulation and cooling, allowing for increased creepage distance and reduced magnetic leakage, noise, and vibration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a single-phase iron core reactor is used with increased voltage and capacity, then the reactor performance is improved, but the width and height of the reactor increase making transportation difficult
Solution Approach 1:
The patent divides the single-phase iron core reactor into three separate phases (A-phase, B-phase, C-phase), each with its own iron core and coil assembly. This segmentation allows each phase to be designed with optimized dimensions, reducing the overall size compared to a single large-phase reactor while maintaining the required power capacity through parallel operation of all three phases.
2Power
If the voltage level of the reactor increases, then the reactor performance is improved, but the creepage voltage applied on the insulating member increases creating hidden dangers
Solution Approach 1:
The patent segments the high voltage system into three separate phase units, each handling a portion of the total voltage stress. This distribution reduces the creepage voltage burden on individual insulating members compared to a single-phase design, improving insulation reliability while maintaining the required voltage level.
Solution Approach 2:
The patent introduces oil-filled insulating structures and oil-immersed busbars as intermediary elements between high voltage conductors and ground. The oil medium provides enhanced creepage distance and voltage distribution, reducing the electric field stress on solid insulating members and improving overall insulation reliability at high voltage levels.
3Device complexity
If a single iron core and single coil structure is used, then the device complexity is reduced, but the electromagnetic force and vibration are difficult to control
Solution Approach 1:
The patent divides the single large iron core into three separate phase iron cores, each with its own coil assembly. This segmentation distributes the electromagnetic forces across three smaller units, reducing the peak electromagnetic force and vibration in each unit compared to a single large core, while the overall device complexity remains manageable through modular design.
4Device complexity
If the creepage distance of the insulating member is limited, then the device complexity is reduced, but the voltage cannot increase unlimitedly in a certain insulating distance
Solution Approach 1:
The patent employs oil-filled insulating structures and oil-immersed busbars to provide enhanced creepage distance. The liquid oil medium allows for greater voltage withstand capability within limited physical space, enabling higher voltage operation without proportionally increasing the insulating structure complexity.
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 configuration enhances transportation ease, reliability, and insulating performance while reducing magnetic leakage and noise, meeting requirements for high-voltage and large-capacity reactors.
Implementation Method 1
an iron core limb is formed by lamination of a plurality of iron core cakes with central holes and a plurality of air gaps
Implementation Method 2
each of the respective active parts of the reactor comprises an 'EI' shaped iron core and a coil respectively
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
An iron core reactor includes reactor active parts. The reactor active parts include two or more separate reactor active parts. The coils in the respective active parts are connected in series or in parallel. The respective active parts are placed in a same reactor oil tank (6).