WO2016192092A1 - Novel high-power annular reactor and manufacturing method therefor - Google Patents

Abstract

A novel high-power annular reactor, comprising a magnetic core (1) and a coil (2). The magnetic core (1) is an annular magnetic core formed by combining two identical semi-annular magnetic cores. The diameter of the annular magnetic core is 7-20 inches, and the magnet density of the annular magnetic core is 5.5-6.2 g/cm³. The coil (2) is sheathed on the two semi-annular magnetic cores. The coil is a spiral enameled wire coil formed by vertically winding flat wires. The semi-annular magnetic cores are made by casting magnetic composite materials composed of ferromagnetic powder and high-temperature resin glue by means of a semi-annular mold. The structure of the reactor is simple, the process is simple, automated operation is easily realized, and the production cost is low. The reactor is light in weight, small in noise, low in loss, good in surface heat dissipation, long in life, high in magnetic core utilization rate, low in leakage flux and good in EMI effect.

Description

High-power circular ring type new reactor and manufacturing method thereof High-power circular ring type new reactor and manufacturing method thereof

 High-power circular ring type new reactor and manufacturing method thereof

 Technical field

 The invention relates to the technical field of an inductor component, in particular to a high-power circular ring type new reactor and a manufacturing method thereof.

 Background technique

As a means of reactive power compensation, reactors are indispensable in power systems. Reactors are used to limit the sudden change of the grid voltage and the current surge caused by the operating process voltage, smooth the spikes contained in the power supply voltage, or the voltage defects generated during the commutation of the smooth bridge rectifier circuit, effectively protecting the inverter and improving the power factor. It can not only prevent interference from the power grid, but also reduce the pollution of the grid caused by the harmonic current generated by the rectifier unit.

 The traditional silicon steel reactor has a complicated manufacturing process and high production cost. Its manufacturing process mainly includes the following contents:

 1. Coil winding: copper or aluminum foil, insulating material Nomex paper, epoxy resin strip and epoxy resin sheet, winding Materials and equipment such as molds. Copper foil and aluminum foil are used to conduct current and form a magnetic field. Nomex paper is used for internal insulation of the coil. The winding process mainly includes inner mold assembly, inner copper row welding, Nomex paper insulation and copper foil winding. , outer copper row welding and other processes. The process requires a large amount of raw materials, and the raw materials are expensive, and the copper foil winding equipment is heavily invested, the winding efficiency is low, and the cost of the mold is high, resulting in high production costs.

 2, silicon steel Iron core production: The material used in the traditional iron core is silicon steel sheet. The production process of silicon steel sheet is complicated, especially the oriented silicon steel sheet. At present, only a few large steel mills such as Baosteel and Wuhan Iron and Steel can produce and manufacture at a very high cost. The silicon steel sheet is stripped through the strip, and then subjected to slitting and cross-cutting to form a silicon steel sheet of the required specification, and finally the silicon steel sheet is stacked and fixed by the upper and lower clips. The superimposed manufacturing process of the iron core is complicated, the manufacturing requirements are high, the degree of mechanization is low, and the shearing and stacking of the silicon steel sheet is easy to cause damage to the human body due to sharp edges and burrs, increasing the accident rate of the work and restricting the production efficiency of the iron core.

 3 Assembly: The traditional silicon steel reactor needs to be assembled and fixed by the upper and lower silicon steel sheet laminations, and the middle column laminations are assembled. The center pillar core needs to distribute the air gap and adjust the thickness of the air gap to adjust the inductance. In addition, the coil and the iron core need to be insulated during the assembly process to meet the electrical performance of the inductor. Finally, the process of dipping and baking is carried out.

On the whole, the traditional silicon steel reactor has a complicated production process, a large floor space, large equipment and personnel investment, requires professional manufacturers to produce, long production cycle, low efficiency, high production cost, and restricts the development of reactors.

 In addition, the traditional silicon steel reactor is noisy and bulky, which has a great influence on the surrounding environment and installation. The heat dissipation is poor, the magnetic leakage is easy, and EMI Poor effects and the like restrict the development of reactors. Especially in the operating environment of high current (current greater than 100A) and high frequency (frequency higher than 5KHz), traditional silicon steel sheet reactors are more difficult to meet application requirements.

 In view of this, the development of a simple process, low cost, The new type of reactor with good electromagnetic performance is an urgent need for the rapid development of electronic power.

 Summary of the invention

 In order to solve the technical problems of large noise, large volume, complicated production process and high cost in the traditional reactor, especially the traditional reactor High current (current greater than 100A), high frequency (frequency above 5KHz) It is difficult to meet the application requirements. The invention provides a low noise, good inductance performance, small magnetic leakage, small volume, excellent heat dissipation performance, low loss, and suitable for large current (current greater than 100A), high frequency (high frequency 5KHz) High-power toroidal new reactor for use in the environment.

 To achieve the above object, the present invention provides the following technical solutions:

A high-power toroidal novel reactor comprising a magnetic core and a coil, the magnetic core being a toroidal core composed of two identical semicircular toroidal cores, the diameter of the toroidal core 7 to 20 inches, the magnetic core of the toroidal core has a density of 5.5 g/cm ³ to 6.2 g/cm ³ , and the coil is sleeved on two of the semicircular toroidal cores, and the coil is flat The wire is wound up to form a spiral enameled wire core, and the semicircular toroidal magnetic core is made of a magnetic composite material composed of a ferromagnetic powder and a high temperature resin glue through a semicircular mold.

Further, a center of one end surface of the semicircular magnetic core is provided with a cylindrical recess, and a center of the other end surface of the semicircular magnetic core is provided with a cylindrical boss that cooperates with the cylindrical recess.

 Further, the semi-annular magnetic core has a circular or elliptical shape or an arbitrary polygonal shape.

 Further, the two semicircular toroidal cores are fixedly connected by glue.

 The invention also provides a manufacturing method of a high-power annular new reactor, comprising the following steps:

 1) The coil of the wrapped enameled wire is spiral;

 2 7 to 80% by weight of the resin glue, 5 to 10% by weight of the coupling agent, 15 to 20% by weight of the accelerator, and uniformly stirred to obtain a high temperature resin glue;

 3 The ferromagnetic powder and the high-temperature resin glue are mixed and stirred according to ferromagnetic powder 88-94 wt%, high-temperature resin glue 6-12 wt%, to obtain a magnetic composite material;

 4 Inserting the magnetic composite material into a semi-annular mold, respectively casting two semi-circular toroidal cores, and demolding after curing at 125 to 140 ° C for 1.5 to 2.5 hours to obtain two identical semicircular toroidal cores;

 5 Inserting the spiral-shaped enameled wire coil into the two semi-circular toroidal cores, and then combining the two semi-annular cores into a large toroidal core by using glue, thereby forming the high-power circle Ring new reactor.

 Further, the resin glue is a modified epoxy silicone resin.

 Further, the coupling agent is propyl propyl methyl dimethoxy silane.

 Further, the accelerator is m-xylylenediamine.

 Further, the particle size of the ferromagnetic powder is as follows: −100 mesh to 200 mesh: 20 to 30 wt%, −200 Head - 500 mesh: 30 to 40 wt%, −500 mesh: 30 to 50 wt%.

 Further, the ferromagnetic powder is at least one of iron silicon powder, iron powder, iron silicon aluminum powder, iron nickel powder and iron silicon chromium powder.

Compared with the prior art, the invention has the advantages that the structure is simple, the production process is simplified, a large amount of equipment investment is saved, the production area is reduced, a large amount of copper foil and the like are saved, and the whole is reduced. Production of reactors; production of wound and cast cores is easy to automate, and assembly is simple, saving a lot of human resources;

 Compared with the traditional iron core reactor, the new reactor has the following performance advantages:

 1 The reactor is light in weight and is about 1/3 lighter than the traditional iron core reactor of 500A and 300μH, which is convenient for the installation and transportation process of the reactor;

 2, the appearance of the reactor is a ring-shaped magnetic core with a vertical winding coil, the surface area is large, the heat dissipation is good, and the service life of the reactor is prolonged;

 3. The magnetic core is surrounded by the vertical winding, the utilization rate is high, the magnetic leakage is small, and the EMI effect is good;

 4. The magnetic core is composed of insulated ferromagnetic powder, the insulation performance is excellent, the eddy current loss of the magnet is low, and a large amount of energy consumption is saved;

 5, the reactor is low in noise and has little pollution to the surrounding environment.

 DRAWINGS

 1 is a schematic structural view of a novel high-power toroidal reactor according to the present invention.

 detailed description

The technical solutions in the embodiments of the present invention are clearly and completely described in the following with reference to the accompanying drawings in the embodiments of the present invention. It is obvious that the described embodiments are only a part of the embodiments of the present invention, but not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative efforts are within the scope of the present invention.

 Example 1

A high-power toroidal novel reactor comprising a magnetic core 1 and a coil 2, the magnetic core 1 being a toroidal core formed by two fixed semi-circular toroidal cores fixed by glue, the half The toroidal core has a circular cross section, the toroidal core has a diameter of 20 inches, the toroidal core has a magnet density of 6.2 g/cm ³ , and the coil 2 is sleeved in two On the semicircular toroidal core, the coil 2 is an enameled wire coil which is spirally formed by a flat wire, and the semicircular toroidal magnetic core is a magnetic composite material composed of ferromagnetic powder and high temperature resin glue through a semicircular ring mold. Made by pouring.

 The above-mentioned high-power toroidal novel reactor is manufactured by the following method, and includes the following steps:

 1) Using an automatic winding machine to wind the flat wire into a spiral enameled wire coil

 2) Epoxy silicone resin, propyl propyl methyl dimethoxy silane, m-xylylene diamine 7:1:2 The weight ratio is evenly mixed and stirred to obtain a high temperature resin glue;

 3) mixing and stirring the ferromagnetic powder and the high-temperature resin glue in a weight ratio of 94:6 to obtain a magnetic composite material, wherein the ferromagnetic powder is −100 mesh – 200 mesh, −200 mesh to 500 mesh, −500 mesh, three sizes of iron-silica powder are mixed in a ratio of 2:3:5;

 4 The magnetic composite material is injected into a semi-annular mold, and two semi-circular toroidal cores are respectively cast and demolded at 130 ° C for 2 h to obtain two identical semicircular toroidal cores;

 5 Inserting the spiral-shaped enameled wire coil into the two semi-circular toroidal cores, and then combining the two semi-annular cores into a large toroidal core by using glue, thereby forming the high-power circle Ring new reactor.

 Example 2

A high-power toroidal novel reactor comprising a magnetic core 1 and a coil 2, the magnetic core 1 being a toroidal core formed by two fixed semi-circular toroidal cores fixed by glue, the half The toroidal core has a circular cross section, the toroidal core has a diameter of 15 inches, the toroidal core has a magnet density of 5.9 g/cm ³ , and the coil 2 is sleeved in two On the semicircular toroidal core, the coil 2 is an enameled wire coil which is spirally formed by a flat wire, and the semicircular toroidal magnetic core is a magnetic composite material composed of ferromagnetic powder and high temperature resin glue through a semicircular ring mold. Made by pouring.

 The above-mentioned high-power toroidal novel reactor is manufactured by the following method, and includes the following steps:

 1) Using an automatic winding machine to wind the flat wire into a spiral enameled wire coil

 2) Put epoxy silicone resin, propyl propyl methyl dimethoxy silane and m-xylylene diamine as 75:7:18 The weight ratio is evenly mixed and stirred to obtain a high temperature resin glue;

 3) mixing and stirring the ferromagnetic powder and the high-temperature resin glue in a weight ratio of 9:1 to obtain a magnetic composite material, wherein the ferromagnetic powder is −100 mesh – 200 mesh, −200 mesh to 500 mesh, −500 mesh, three sizes of iron-silica powder are mixed in a ratio of 25:35:40;

 4) injecting the magnetic composite material into a semi-annular mold, respectively casting two semicircular toroidal cores, curing at 125 ° C for 2.5 h After demolding, two identical semicircular toroidal cores are obtained;

 5 Inserting the spiral-shaped enameled wire coil into the two semi-circular toroidal cores, and then combining the two semi-annular cores into a large toroidal core by using glue, thereby forming the high-power circle Ring new reactor.

 Example 3

A high-power toroidal novel reactor comprising a magnetic core 1 and a coil 2, the magnetic core 1 being a toroidal core formed by two fixed semi-circular toroidal cores fixed by glue, the half The toroidal core has a circular cross section, the toroidal core has a diameter of 7 inches, the toroidal core has a magnet density of 5.5 g/cm ³ , and the coil 2 is sleeved in two On the semicircular toroidal core, the coil 2 is an enameled wire coil which is spirally formed by a flat wire, and the semicircular toroidal magnetic core is a magnetic composite material composed of ferromagnetic powder and high temperature resin glue through a semicircular ring mold. Made by pouring.

 The above-mentioned high-power toroidal novel reactor is manufactured by the following method, and includes the following steps:

 1) Using an automatic winding machine to wind the flat wire into a spiral enameled wire coil

 2) Epoxy silicone resin, propyl propyl methyl dimethoxy silane, m-xylylene diamine 80:5:15 The weight ratio is evenly mixed and stirred to obtain a high temperature resin glue;

 3) mixing and stirring the ferromagnetic powder and the high-temperature resin glue in a weight ratio of 88:12 to obtain a magnetic composite material, wherein the ferromagnetic powder is −100 mesh – 200 mesh, −200 mesh to 500 mesh, −500 mesh, three sizes of iron-silica powder are mixed in a ratio of 3:4:3;

 4) injecting the magnetic composite material into a semi-annular mold, respectively casting two semicircular toroidal cores, curing at 140 ° C for 1.5 h After demolding, two identical semicircular toroidal cores are obtained;

 5 Inserting the spiral-shaped enameled wire coil into the two semi-circular toroidal cores, and then combining the two semi-annular cores into a large toroidal core by using glue, thereby forming the high-power circle Ring new reactor.

 Example 4

A high-power toroidal novel reactor comprising a magnetic core 1 and a coil 2, the magnetic core 1 being a toroidal core formed by two fixed semi-circular toroidal cores fixed by glue, the half The toroidal core has a circular cross section, the toroidal core has a diameter of 7 inches, the toroidal core has a magnet density of 6.0 g/cm ³ , and the coil 2 is sleeved in two On the semicircular toroidal core, the coil 2 is an enameled wire coil which is spirally formed by a flat wire, and the semicircular toroidal magnetic core is a magnetic composite material composed of ferromagnetic powder and high temperature resin glue through a semicircular ring mold. Made by pouring.

 The above-mentioned high-power toroidal novel reactor is manufactured by the following method, and includes the following steps:

 1) Using an automatic winding machine to wind the flat wire into a spiral enameled wire coil

 2) Epoxy silicone resin, propyl propyl methyl dimethoxy silane, m-xylylene diamine 7:1:2 The weight ratio is evenly mixed and stirred to obtain a high temperature resin glue;

 3) mixing and stirring the ferromagnetic powder and the high-temperature resin glue in a weight ratio of 9:1 to obtain a magnetic composite material, wherein the ferromagnetic powder is The iron-nickel powder of −100 mesh to 200 mesh, −200 mesh to 500 mesh, and −500 mesh is mixed in a ratio of 2:3:5;

 4) The magnetic composite material is injected into a semi-annular mold, and two semicircular toroidal cores are respectively cast and cured at 130 ° C for 2 h. After demolding, two identical semicircular toroidal cores are obtained;

 5 Inserting the spiral-shaped enameled wire coil into the two semi-circular toroidal cores, and then combining the two semi-annular cores into a large toroidal core by using glue, thereby forming the high-power circle Ring new reactor.

 The reactor of the same specification is manufactured according to the methods described in Embodiments 1 to 4, and the conventional iron core reactor Conduct electrical performance comparison test and get the following data:

	Traditional iron core reactor	Example 1	Example 2	Example 3	Example 4
Number of coil turns	30	48	48	48	48
Initial sensitivity L@0A	790	880	871	866	873
Sensitivity value retained at 400A current L@400A	780	700	685	688	693
Whether to increase the air gap	Yes	no	no	no	no
Is it easy to reach saturation?	Yes	no	no	no	no

It is apparent to those skilled in the art that the present invention is not limited to the details of the above-described exemplary embodiments, and the present invention can be embodied in other specific forms without departing from the spirit or essential characteristics of the invention. Therefore, the present embodiments are to be considered as illustrative and not restrictive, and the scope of the invention is defined by the appended claims instead All changes in the meaning and scope of equivalent elements are included in the present invention. Any reference signs in the claims should not be construed as limiting the claim.

In addition, it should be understood that although the description is described in terms of embodiments, not every embodiment includes only one independent technical solution. The description of the specification is merely for the sake of clarity, and those skilled in the art should regard the specification as a whole. The technical solutions in the respective embodiments may also be combined as appropriate to form other embodiments that can be understood by those skilled in the art.

Claims (1)

1. 1. A high-power toroidal novel reactor comprising a magnetic core and a coil, wherein the magnetic core is a toroidal magnetic core composed of two identical semicircular toroidal magnetic cores, the circular ring The core has a diameter of 7 to 20 inches, the toroidal core has a magnet density of 5.5 g/cm ³ to 6.2 g/cm ³ , and the coil is sleeved on the two semicircular toroidal cores, The coil is an enameled wire coil which is spirally formed by a flat wire which is made of a magnetic composite material composed of a ferromagnetic powder and a high-temperature resin glue, which is cast by a semi-annular mold.

   2. A high-power toroidal novel reactor according to claim 1, wherein a center of one end surface of said semicircular toroidal core is provided with a cylindrical groove, and a center of the other end surface of said semicircular toroidal core A cylindrical boss that cooperates with the cylindrical recess is provided.

   3. The high-power toroidal novel reactor according to claim 1, wherein the semi-annular core has a circular or elliptical shape or an arbitrary polygonal shape.

   4. The high-power toroidal novel reactor according to claim 1, wherein the two semicircular toroidal cores are fixedly connected by glue.

   5. A method for manufacturing a high-power toroidal novel reactor, comprising the steps of: 1) spiraling an enameled wire coil; 2) applying a resin glue 70 to 80 wt%, coupling agent 5 to 10 wt%, accelerator 15 to 20 wt%, mixing and stirring uniformly to obtain high temperature resin glue; 3) ferromagnetic powder and the high temperature resin glue according to ferromagnetic powder 88 ~ 94wt%, high temperature resin glue 6 ~ 12wt% mixing and mixing evenly, to obtain magnetic composite materials; 4) The magnetic composite material is injected into a semi-annular mold, and two semicircular toroidal magnetic cores are respectively cast and demolded at 125 to 140 ° C for 1.5 to 2.5 hours to obtain two identical semicircular toroidal magnets. a core; 5) inserting the spiral-shaped enameled wire coil into the two semi-circular toroidal cores, and then combining the two semi-annular cores into a large toroidal core, High-power toroidal new reactor.

   6. The manufacturing method according to claim 5, wherein the resin paste is a modified epoxy silicone resin.

   7. The method according to claim 5, wherein the coupling agent is propylpropylmethyldimethoxysilane.

   8. The method according to claim 5, wherein the accelerator is m-xylenediamine.

   9. The manufacturing method according to claim 5, wherein the particle size of the ferromagnetic powder is as follows: −100 mesh to 200 mesh: 20 ～ 30wt%, −200 mesh to 500 mesh: 30 to 40wt%, −500 mesh: 30 to 50wt%.

   10. The manufacturing method according to claim 5, wherein the ferromagnetic powder is iron silicon powder, iron powder, At least one of iron silicon aluminum powder, iron nickel powder, and iron silicon chromium powder.