Three-Phase Reactor Air Gaps Alloy Powder Core Flux
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Solution Overview
Problem
Traditional silicon steel sheet reactors experience significant losses at high switching frequencies, and existing alloy powder core reactors suffer from eddy current losses due to non-uniform magnetic flux distribution and low relative permeability, making them unsuitable for high-power, high-frequency applications.
Innovation Solution
A three-phase reactor design is proposed, where the yokes are made of high permeability material and the core columns are made of alloy powder block core with air gaps, allowing for reduced eddy current losses by varying the relative permeability and positioning air gaps to manage magnetic flux effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If traditional silicon steel sheet is used in reactors, then the reactor can operate at low frequencies, but the loss increases sharply at high switching frequencies up to thousands of Hertz
Solution Approach 1:
The patent changes the fundamental material parameter from crystalline silicon steel sheet to non-crystalline alloy powder core material. This material parameter change enables the reactor to operate efficiently at high switching frequencies (thousands of Hertz) by eliminating the sharp loss increase that occurs with traditional silicon steel sheet at high frequencies.
Solution Approach 2:
The patent uses composite construction by stacking multiple alloy powder block cores to form the magnetic circuit. This composite approach combines the advantages of powder core material (low high-frequency loss) with a structured stacked configuration that maintains magnetic circuit integrity while enabling high-frequency operation.
2Adaptability or versatility
If alloy powder block cores are stacked to form a magnetic circuit, then the reactor can operate at high frequencies, but eddy current losses occur due to non-uniform magnetic flux distribution
Solution Approach 1:
The patent applies local quality by making different parts of the magnetic circuit have different properties. Specifically, air gaps are introduced at specific locations (in the core columns) to locally modify the magnetic flux distribution. This local modification ensures uniform magnetic flux throughout the magnetic circuit, preventing eddy current losses in the windings while maintaining high-frequency operation capability.
Solution Approach 2:
The air gaps serve as intermediary elements that mediate the magnetic flux distribution. By introducing these air gaps into the core columns, the patent creates a controlled magnetic path that distributes flux uniformly, preventing the concentration of magnetic motive force that would otherwise cause eddy current losses in the windings.
3Device complexity
If windings are wound around only two parallel columns of stacked alloy powder block cores, then the structure is simple, but magnetic motive force is not distributed uniformly along the magnetic circuit
Solution Approach 1:
The patent applies local quality by introducing air gaps at specific locations in the core columns where windings are present. This local modification ensures that the magnetic motive force generated by the windings is distributed uniformly along the entire magnetic circuit, including the yokes and core columns, preventing magnetic motive force concentration and associated losses.
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 significantly reduces eddy current losses and meets high-power requirements by optimizing the distribution of magnetic flux, ensuring balanced electric inductances across phases and minimizing size while maintaining performance.
Implementation Method 1
the magnetic core and the super silicon steel both are continuous flat conductor or curved conductor, which causes a huge eddy current loss once there is an alternating magnetic flux in the same or similar direction with the normal direction of the flat surface or the curved surface of the conductor
Implementation Method 2
the distributions of the magnetic motive force in a magnetic circuit are in direct proportion to the resistance of this magnetic circuit
Implementation Method 3
the relative permeability of the first material is greater than that of the second material, and at least one air gap is positioned in each of the first core columns
Data Source
AI summary
The present application discloses a three-phase reactor, including: an upper yoke and a lower yoke, the upper yoke and the lower yoke containing a first material; and at least three first core columns, the first core columns containing a second material, and the both ends of each of the first core columns being connected with the upper yoke and the lower yoke, respectively, wherein, the relative permeability of the first material is greater than that of the second material, and at least one air gap is positioned in each of the first core columns. In the three-phase reactor proposed by the present disclosure, the yokes are made of a material different from that of the core columns, and air gaps are positioned in the core columns, so that the eddy current losses may be reduced significantly and the requirement for the use of high power may be satisfied.