CN1076509C - Reactor and method of production thereof - Google Patents

Abstract

This invention relates to a reactor for electric/electronic appliances, comprising a rectangular magnetic path formed of at least one iron core, a main magnetic leg core insulated inside the rectangular magnetic path, and a coil wound round the main magnetic leg core. According to this construction, the main magnetic leg core is completely isolated from other cores and the ground, and no electric insulation is required between the coil and the main magnetic leg core in it. Therefore, the coil can be directly wound round the main magnetic leg core, the quantity of wirer used for the coil can be drastically reduced, and an economical reactor can be obtained.

Description

Reactance coil and manufacture method thereof

Technical field

The present invention relates to the employed reactance coil of power electronic equipment.

Background technology

Existing reactance coil is general as Figure 21, Figure 22, shown in Figure 23, be on E shape iron core 101, to form iron core air-gap pad 104 in advance by the stacked iron core 101 of E shape electromagnetic steel plate, by I shape electromagnetic steel plate stacked iron core 102 and 1 structure that coil 103 assembles in the middle of them.

In order to also to be fixed on the iron core 101 by welding to the mounting panel of installing on the miscellaneous equipment 105.At this moment, because of iron core 101,102 all passes through mounting panel 105 ground connection, so utilize insulating paper 106 with coil 103 insulation.

But such structure is because coil that will wind in advance 103 inserts iron cores to be assembled, so must make the width dimensions W1 of main magnetic post of the relative iron core 101 of internal diameter size W2 of coil leave sufficient size surplus.

And, in order to ensure the insulation distance between each face of deciding space, have to make internal coil diameter size L2 to be far longer than the laminated thickness size L1 of iron core 101,102.

This shows that the internal diameter size W2 of coil 103 and L2 are enough big owing to making, so it is winding length increases, causes that the electric wire consumption increases, totally unfavorable on cost.

And winding length increases the temperature rising when causing wire resistor increase, copper loss increase and reactance coil work etc., thereby influences the performance of reactance coil.Avoid this point, must add thick line footpath, thus more increase electric wire consumption, make the unfavorable multiplication on the cost.

In addition,, produce fierce magnetic vibration during work,, thereby become the reason of generation abnormal vibrations and sound because of the reason and the installed device of installing produces resonance in the relative part of the iron core air-gap pad 104 of iron core 101 and iron core 102.

The 2nd prior art of reactance coil is shown in Figure 24.

Make the 1st stacked iron core 201 of 2 electromagnetic steel plates that will run through and insert coil 202 separately arranged side by side, the iron core air-gap pad of using by the double as insulating paper 203 docks the magnetic circuit that form square shape with other 2 by the 2nd stacked iron core 204 of electromagnetic steel plate with them.

The 205th, fixedly the part of usefulness is fixed on them on the 2nd iron core 204 by methods such as welding.

In this structure, the 1st iron core 201 is that electricity is isolated and insulated fully with part 205 and the 2nd iron core 204 that is connected therewith.

Therefore, do not need electric insulation between coil 202 and the 1st iron core 201, coil 202 can be directly on the 1st iron core 201.

In the 2nd prior art, for having coil and the structure that runs through and insert the iron core of this coil, be the same with the situation that begins described prior art, also exist the same problem that should solve.

Disclosure of an invention

The present invention proposes in order to solve so in the past problem, and its purpose is to provide a kind of not only economy but also easily produces and the reactance coil of superior performance.

In order to achieve the above object, reactance coil of the present invention comprises square shape magnetic circuit that the iron core that uses more than 1 forms, is provided in the main magnetic column iron core of above-mentioned square shape magnetic circuit inboard and is provided in coil around the above-mentioned main magnetic column iron core through insulating element.

At least a portion of insulating element has elasticity.

Make it fixing by the part dipping lacquer that square shape magnetic circuit, insulating element and main magnetic column iron core are contacted with each other.

Insulating element is made of porous material or fibrous material.

In addition, reactance coil of the present invention comprises that the square shape magnetic circuit of the iron core formation of using more than 1, the main magnetic column iron core that is provided in above-mentioned square shape magnetic circuit inboard and process insulating element are provided in above-mentioned main magnetic column iron core coil on every side.

Main magnetic column iron core has the curved rectangle magnetic circuit cross section of circle or signet shape or bight.

At least a portion is resin-cast moulding or resin moulded.

Be lined with the buffer unit of コ font in the bight of main magnetic column iron core, direct winding around thereon with square-section.

Bight to main magnetic column iron core with square-section applies R processing, without any need for buffer unit, and direct winding around thereon.

At the both side ends installation end mask of at least one pair of opposite side of main magnetic column iron core the parts of R are arranged, thereon direct winding around with square-section.

Main magnetic column iron core is stacked by electromagnetic steel plate, utilizes projection welding to be fixed.

Only one of main magnetic column iron core is located to apply projection welding.

Many places at main magnetic column iron core flow direction apply projection welding.

At least one place that the manufacture method of reactance coil of the present invention is included in electromagnetic steel plate be provided with projection the 1st step, the 2nd step that the above-mentioned electromagnetic steel plate of multi-disc is stacked, apply projection welding with fixing the 4th step that forms the 3rd step of iron core and coil is set of the above-mentioned electromagnetic steel plate of multi-disc around above-mentioned iron core.

In addition, the manufacture method of reactance coil of the present invention by at least one place at electromagnetic steel plate be provided with projection the 1st step, the 2nd step that the above-mentioned electromagnetic steel plate of multi-disc is stacked, apply projection welding and form the 3rd step of iron core and form the above-mentioned electromagnetic steel plate of multi-disc is fixing in the 4th step that coil is set on every side of above-mentioned iron core.

Reactance coil of the present invention is to make the 1st stacked iron core of 2 electromagnetic steel plates that will run through and insert coil separately side by side, by iron core air-gap pad they are docked in the 2nd prior art of the magnetic circuit that forms square shape with other 2 the 2nd iron cores stacked by electromagnetic steel plate, coil directly is being wrapped in the bight of above-mentioned the 1st iron core with square-section by the buffer unit of コ font.

Reactance coil of the present invention is to make the 1st stacked iron core of 2 electromagnetic steel plates that will run through and insert coil separately side by side, by iron core air-gap pad they are docked in the 2nd prior art of the magnetic circuit that forms square shape with other 2 the 2nd iron cores stacked by electromagnetic steel plate, bight to above-mentioned the 1st iron core with square-section applies R processing, thereon direct winding around.

Reactance coil of the present invention is to make the 1st stacked iron core of 2 electromagnetic steel plates that will run through and insert coil separately side by side, by iron core air-gap pad they are docked in the 2nd prior art of the magnetic circuit that forms square shape with other 2 the 2nd iron cores stacked by electromagnetic steel plate, at the both side ends installation end mask of at least one pair of opposite side of above-mentioned the 1st iron core the parts of R are arranged, thereon direct winding around with square-section.

In addition, in the 2nd prior art that has illustrated in front, at least the 1 iron core is stacked and utilize projection welding to be fixed with electromagnetic steel plate.

In the 2nd prior art, one of the 1st iron core is located to apply projection welding.

In the 2nd prior art, apply projection welding in the many places of the 1st iron core flow direction.

In the 2nd prior art, the 2nd iron core has the limit of will dock with the 1st iron core as the trapezoid cross section of going to the bottom, and applies projection welding in the bight of being made up of upper base and hypotenuse simultaneously.

According to said structure, reactance coil of the present invention can be treated main magnetic column iron core as the parts of separating with the iron core that constitutes the square shape magnetic circuit, thereby can be with main magnetic column iron core and the close configuration of coil, and then, by making the insulation of main magnetic column iron core and square shape magnetic circuit, needn't carry out between main magnetic column iron core and coil insulation, just coil is twined near main magnetic column iron core, so can reduce the consumption of coil-winding.

Because at least a portion of insulating element has elasticity, thus can push insulating element and be fixed by means of main magnetic column iron core and square shape magnetic circuit, thus can suppress contingent magnetic noise and magnetic vibration sound therebetween.

Make it fixing by the part dipping lacquer that square shape magnetic circuit, insulating element and main magnetic column iron core are contacted with each other, thereby fixing effect firm, that suppress magnetic noise and magnetic vibration sound is better.

Because insulating element is porous material or fibrous material, so can carry out dipping lacquer more reliably.

The main magnetic column iron core of the inboard that have square shape magnetic circuit that the iron core that uses more than 1 forms, is provided in above-mentioned square shape magnetic circuit and through insulating element be provided in above-mentioned main magnetic column iron core around the reactance coil of coil, main magnetic column iron core can be treated as the parts of separating with the iron core that constitutes the square shape magnetic circuit, thereby main magnetic column iron core and the close configuration of coil still can be able to be sought to reduce the consumption of coiling.

Because main magnetic column iron core has the curved rectangle magnetic circuit cross section of circle or signet shape or bight, so can prevent to cause the damage of coiling because of the tension force that winds the line.

By making a part at least is resin-cast moulding or resin moulded, and the reactance coil that fixing of each several part is reliable, avoid excellent performances such as outside air intrusion and water proofing property can be provided.

By means of by at the コ font buffer unit that has on the main magnetic column iron core bight of square-section, coil surely not directly be subjected to main magnetic post the square-section the bight extruding and damage, and the straight line portion coil beyond the bight of main magnetic column iron core also can not be subjected to the extruding of iron core and bending, so, the coil scar that causes can not appear twining, thereby can not need buffer at the straight line portion of main magnetic column iron core (that is the part beyond the bight).

In addition, foregoing invention is equally applicable to the 1st iron core and the coil of above-mentioned the 2nd prior art.

Thus, can reduce the material usage of buffer unit and twine man-hour greatly.

And, the more important thing is, owing to do not need the whole peripheral of iron core twined padded coaming, so can prevent the expansion of expansion that padded coaming is reeled and the coiling that causes thus.

By being applied projection welding, the main magnetic column iron core of separating with other iron core fixes, the short-circuit loop of formation in the iron core and projecting section's area that the magnetic flux quadrature is produced have been reduced, therefore can reduce the wastage, simultaneously because be projection welding so can shorten weld time, thereby the thermal diffusion when having reduced welding, improved operability.

In addition, foregoing invention can be applicable to the 1st iron core of above-mentioned the 2nd prior art too.

Only just can obtain with in the past the same intensity,, can shorten weld time simultaneously, can seek to improve operability because of the projecting section's area with the magnetic flux quadrature reduces so loss reduces by only 1 place being applied welding with projection welding.

Apply projection welding by many places intensity is improved at flow direction, simultaneously, increase that can suppression loss.

In addition, at least one place that the manufacture method of reactance coil of the present invention is included in electromagnetic steel plate be provided with projection the 1st step, the 2nd step that the above-mentioned electromagnetic steel plate of multi-disc is stacked, apply projection welding with fixing the 4th step that forms the 3rd step of iron core and coil is set of the above-mentioned electromagnetic steel plate of multi-disc around above-mentioned iron core, therefore, weld time can be shortened, thereby the thermal diffusion when having reduced welding, improved operability, the projecting section's area that hinders magnetic flux simultaneously reduces, thereby can produce low-loss reactance coil.

The simple declaration of accompanying drawing

Fig. 1 is the sectional view of the 1st embodiment reactance coil of the present invention; Fig. 2 is the 1st outline drawing of the main magnetic column iron core of above-mentioned reactance coil; Fig. 3 is the 2nd outline drawing of the main magnetic column iron core of above-mentioned reactance coil; Fig. 4 is the 3rd outline drawing of the main magnetic column iron core of above-mentioned reactance coil; Fig. 5 is the sectional view of the reactance coil of the 2nd embodiment of the present invention; Fig. 6 (a) is the structure chart of the reactance coil of the 3rd embodiment of the present invention; Fig. 6 (b) is the structure chart of the reactance coil of the 3rd embodiment of the present invention; Fig. 7 is the structure chart of the reactance coil of the 4th embodiment of the present invention; Fig. 8 is the structure chart of the reactance coil of the 5th embodiment of the present invention; Fig. 9 is the structure chart of the reactance coil of the 6th embodiment of the present invention; Figure 10 is the structure chart of the reactance coil of the 7th embodiment of the present invention; Figure 11 is the 1st structure chart of the reactance coil of the 8th embodiment of the present invention; Figure 12 is the 2nd structure chart of the reactance coil of the 8th embodiment of the present invention; Figure 13 is the structure key diagram of the main magnetic column iron core of reactance coil among the 9th embodiment of the present invention; Figure 14 is the structure chart of electromagnetic steel plate that constitutes the main magnetic column iron core of above-mentioned reactance coil; Figure 15 is the sectional view of above-mentioned electromagnetic steel plate; Figure 16 (a) is the stacked sectional view of above-mentioned electromagnetic steel plate; Figure 16 (b) is the sectional view of welding back electromagnetic steel plate; Figure 17 is the structure chart of projection welding machine used among the 9th embodiment of the present invention; Figure 18 is the enlarged drawing of the major part of above-mentioned projection welding machine; Figure 19 is the figure of another form of the electromagnetic steel plate of the main magnetic column iron core of formation reactance coil among expression the 9th embodiment of the present invention; Figure 20 is the comparison diagram of core loss value; Figure 21 is the outline drawing of existing reactance coil; Figure 22 is the sectional view of above-mentioned reactance coil; Figure 23 is the vertical view of above-mentioned reactance coil; Figure 24 is the outline drawing of another existing reactance coil; Figure 25 is that the iron core of existing reactance coil directly twines the coiling key diagram with padded coaming; Figure 26 is the figure that reels and expand about the padded coaming of existing reactance coil; Figure 27 is the key diagram of the coiling anchor clamps (side plate) of existing reactance coil; Figure 28 is the key diagram of the method for winding of existing reactance coil; Figure 29 is existing structure key diagram with the fixing main magnetic column iron core of TIG welding; Figure 30 is the plane graph (welding position key diagram) of above-mentioned main magnetic column iron core; The front view of the above-mentioned main magnetic column iron core of Figure 31.

The optimal morphology that carries out an invention

(embodiment 1)

Below, the reactance coil of the present invention the 1st embodiment is described with reference to Fig. 1.

Present embodiment describes with regard to reactance coil, but the present invention is not limited to reactance coil, can certainly be widely used in electromagnetic equipments such as transformer and motor.

Omit its explanation for point same as the prior art.In Fig. 1, the 1, the 2nd, respectively that the electromagnetic steel plate of I shape, C shape is stacked and make it the iron core of blocking with welding, extension crimping, method such as bonding.

3 is different with above-mentioned iron core 1,2, are the main magnetic column iron cores with the stacked formation of electromagnetic steel plate of rectangle, and directly winding around 4.5 is iron core air-gap pads of double as insulating paper thereon.

Assembling sequence is that the iron core air-gap pad 5 of two place's double as insulating papers about main magnetic column iron core 3 processes of directly having twined coil 4 is included within the iron core 2 of C shape, then, it is pushed down and it is fixed from top with the iron core 1 of I shape in the welding of the docking section of iron core 1,26 usefulness.

In order to the mounting panel 7 that is installed to miscellaneous equipment also by being weldingly fixed on the iron core 2 thereafter.After the assembling, the reactance coil dipping lacquer is handled.Make it form the square shape magnetic circuit like this.

According to above structure, by the stacked main magnetic column iron core 3 that forms of rectangle electromagnetic steel plate by the double as insulating paper use iron core air-gap pad and other iron core 1,2 separate fully with ground and insulate.Thereby, do not need the insulation between coil 4 and the main magnetic column iron core 3 basically.

Therefore, can be with the main magnetic column iron core 3 that separated fully as the direct coiling 4 of skeleton, can make the internal diameter minimum of coil, can seek to reduce significantly electric wire material, simultaneously, do not need can also seek the skeleton mold, can reduce because of the detached job of coil after not needing to wind the line and skeleton mold and make man-hour, or the like.

And then the docking section of the docking section of main magnetic column iron core 3 and iron core 1 and main magnetic column iron core 3 and iron core 2, to be the iron core air-gap be set at about 3mm usually according to the requirement to the reactance coil characteristic.

There is magnetic vibration and magnetic noise and the abnormal vibrations that equipment produced that is assembled into and the problem of abnormal sound that causes because of this iron core air-gap portion mostly in general reactance coil.

To this, the structure of present embodiment at least at the iron core air-gap pad 5 of thickness direction rubber-like double as insulating paper, makes with iron core air-gap portion relative iron core 1 and main magnetic column iron core 3, main magnetic column iron core 3 and iron core 2 etc. mechanically fix and anchor at together by handling at the after-applied dipping lacquer of assembling in the iron core air-gap portion insertion that this problem occurs.

Therefore, can reduce magnetic vibration and the magnetic noise that the iron core air-gap produces significantly.

In addition,, when dipping lacquer, can soak japanning more securely if use the iron core air-gap pad 5 of the insulating material of porous material or fibrous material as the double as insulating paper, effective.

Because main magnetic column iron core 3 is the other iron cores that separate with iron core 1,2,, also be very effective from the operability that winds the line if make shapes such as signet shape, circle or rectangle with Magnaglo press-powder moulding integrally and with the shape in magnetic circuit cross section.That is,, can wind the line smoothly, can prevent that tension force because of coiling from causing the damage of electric wire enamel-cover coating being under the circular situation as shown in Figure 2 as the cross sectional shape of the main magnetic column iron core 3 of skeleton.

In addition, thus the expansion that can also prevent so-called coil can make the electric wire minimized.According to design, signet shape shown in Figure 3, the rectangle situation with fillet R shown in Figure 4 also are useful.

By the part of the reactance coil of present embodiment is carried out mold pressing with resin, iron core 1,2, main magnetic column iron core 3 and coil 4 are fixed together reliably, the installation portion that can easily make it possess the terminal fixed part and on other equipment, install simultaneously, therefore, in the time that worker can being reduced, and can be designed to the structure that is suitable for producing in batches.

By reactance coil integral body is carried out mold pressing with resin; iron core 1,2, main magnetic column iron core 3 and coil 4 are fixed together by resin-molded layer fully; simultaneously; can isolate outside air is protected it; therefore; water resistance is good especially, and can obtain to suppress the noise that reactance coil produces and the reactance coil structure of vibration.

And can easily make it terminal fixed part that possesses fixed terminal and the installation portion of on miscellaneous equipment, installing, can be designed to the structure that is very suitable for producing in batches.

As seen from the above description, the main magnetic column iron core 3 of the reactance coil of present embodiment separates fully with ground and insulate, therefore, coil 4 can not need the insulation and directly on main magnetic column iron core 3.Thus, the electric wire consumption can reduce significantly, does not simultaneously need the skeleton mold, because so the detached job of coil 4 after not needing to wind the line and skeleton mold is can seek to reduce worker the time etc.

And then, the iron core air-gap pad 5 of the double as insulating paper by inserting iron core air-gap portion is fixing and anchor at together with the iron core air-gap pad 5 of the iron core 1,2 of iron core air-gap portion, main magnetic column iron core 3 and double as insulating paper, can reduce magnetic vibration and magnetic noise that iron core air-gap portion produces significantly.

(embodiment 2)

Below, describe with regard to the 2nd embodiment of the present invention.

Fig. 5 is the sectional view of the 2nd reactance coil of the present invention.Present embodiment and embodiment 1 difference are that the square shape magnetic circuit and the main magnetic column iron core 3 that are formed by iron core 1,2 are direct-connected at an end of main magnetic column iron core 3, connect by iron core air-gap pad 9 at the other end; And, dispose insulating trip 8 between main magnetic column iron core 3 and the coil 4.

Therefore, even without all effects of embodiment 1, still, can after coil 4 winds, be assembled on the main magnetic column iron core 3 as reactance coil, thus, not need to consider as before the internal coil diameter size is left surplus by insulating trip 8, so, can seek to reduce the consumption of coiling.

When coil 4 was directly on main magnetic column iron core 3, in fact in the bight of the main magnetic column iron core 3 with square-section, the enamelled wire of the coil 4 of the direct coiling of tension force during because of winding was injured easily, might form the short circuit between interior circle of coil and the circle.

In order to prevent this situation, take usually as shown in figure 25 like that to place the suitable padded coaming 10 of winding, the method for winding around 4 thereon again at the square-section of main magnetic column iron core 3 whole outer.At this moment, be necessary the whole peripheral padded coaming 10 that twines to main magnetic column iron core 3, the increase that this can bring the fee of material of this padded coaming 10 and twine workload is disadvantageous on mass production cost.

In fact, padded coaming 10 can be subjected to the extruding in main magnetic column iron core 3 bights because of sizable winding tension, and therefore, in order to bear this pressure, the material of padded coaming 10 must have suitable mechanical strength.

Because mechanical strength is strong, be that the padded coaming of general hard rigid material is difficult to twine, the crack appears in bight easily, so in fact will be with hard and thin padded coaming around first-class multilayer, the result, the operability of winding greatly reduces.

In addition, in the time of on padded coaming 10 being wrapped in the rectangular main magnetic column iron core 3 in bight, padded coaming 10 is expanded into cydariform easily as shown in Figure 26, along with its degree of increase of thickness, intensity and the winding number of plies of padded coaming 10 is severe more.On the other hand, when winding around 4 on main magnetic column iron core 3, the main magnetic column iron core 3 that has been wrapped with padded coaming 10 is in advance also fixed as Figure 27 and Embedded Division 14 shown in Figure 28, as to embed coiling anchor clamps (side plate) 13.Therefore, the size of this Embedded Division 14 must be at least than comprising of Figure 26 the size W and the big size W ' and the L ' of L of dilation.But, since when twining strong winding tension master magnetic column iron core 3 will be in the Embedded Division 14 of coiling anchor clamps 13 when being equivalent to these padded coaming 10 windings just the amplitude of dilation dimension rock, can not carry out level and smooth coiling.Under opposite extreme situations, can not wind the line at all.

And then also have, even if can wind the line, coil 4 also can be expanded into cydariform along with the expansion of padded coaming 10, the occupation efficiency of coiling is low, can bring the problem because of the increase cost rising of electric wire consumption etc.Therefore, must try one's best the coiling of padded coaming 10 expanded and be suppressed to Min..

(embodiment 3)

Below, just the reactance coil for the 3rd embodiment of the present invention that addresses this problem describes.

Fig. 6 (a) (b) in, mountain font electromagnetic steel plate is stacked and make its blocking with welding, extension crimping and bonding etc. method, stick the padded coaming 10 of コ font with methods such as stickups in the periphery of the main magnetic column iron core 3 that forms the square-section, direct winding around 4 thereon.

At the straight line portion (part beyond the bight) of main magnetic column iron core 3 peripheries, the coiling of coil can only contact the flat of main magnetic column iron core 3 at the most during coiling, can be not injured because of the winding of coil 4, do not need padded coaming in this section.

Therefore, cover, just can prevent the damage of the coiling that the winding because of coil produces effectively if most possibly give the bight 11 of the main magnetic column iron core that coil 4 damages because of winding tension only will wind the line the time.

In addition,, require its softness, when on having the main magnetic column iron core 3 of square-section, twining, particularly twine easily along the bight 11 of rectangular main magnetic column iron core with box lunch as the material of padded coaming 10; Require it to have viscosity, so that after winding, can not produce crack and breakage in winding place in the bight 11 of rectangular main magnetic column iron core; And then also require it to have enough mechanical strengths, even also can be damaged so that be subjected to the extruding in bight 11 of the rectangular main magnetic column iron core of main magnetic column iron core 3 because of coiling in when coiling.

When the operability of the economy of considering material and winding, the length of the fiber of those padded coamings 10 be suitable to the consistent fibrous material of the direction of main magnetic column iron core 3 windings, present embodiment has adopted the brown paper of high density type.

Because of the tension force that winds the line directly changes with the line that winds the line, so the power that is added on the padded coaming also changes with it.The thickness of padded coaming 10 is selected with need also waiting according to the operability of these actual added power and winding around which floor.

By adopting such structure can make the consumption of padded coaming 10 be reduced to the practical essential Min. that, simultaneously, its sticking operation amount also reduces thereupon.

By the coiling that suppresses padded coaming 10 the expand operability that to improve winding, the consumption of seeking to reduce electric wire.

Fibrous material as padded coaming 10 uses, the tensile failure intensity of its scrolling direction is that they are more than 3 times with comparing perpendicular to the tensile failure intensity of scrolling direction, is folded use of material double-layer more than the 0.05mm as padded coaming 10 with 2 above thickness, use the magnetic wire of diameter in 0.5～3mm scope as the electric wire that constitutes coil 4, this also is useful.

(embodiment 4)

Fig. 7 illustrates the 4th embodiment.

The structure that the padded coaming 10 of 4 L fonts is installed respectively on 4 bights 11 of main magnetic column iron core 3 also is useful as the means that further reduce the padded coaming consumption.If the operability of taking into account when main magnetic column iron core 3 is pasted is selected good.

(embodiment 5)

With Fig. 8 the 5th embodiment is described.

Its structure is to process by carrying out R in methods such as 11 usefulness grindings of the bight of main magnetic column iron core 3 or welding torch fusings as shown in the figure, and needn't use the structure of padded coaming 10.

The size of the winding tension that adopts during the kind of the line footpath of the electric wire that uses according to reality of the size of R, coat of paint, rerum natura, coiling here etc. decides.

By adopting such structure, when winding around 4 on main magnetic column iron core 3, because coiling is to twine along the R in main magnetic column iron core bight 11, so also can not be created in winding scar on the bight 11 of main magnetic column iron core basically even without padded coaming 10.Just; in fact owing to the quality condition of the precision of R processing and grinding skin even abrasive dust and foreign matter might produce the coiling scar attached to the reasons such as surface of R portion; so; in order also to prevent this situation, the polyester belt that can stick tens μ m left and right thicknesses in the bight 11 of main magnetic column iron core is as ten thousand protection usefulness for the moment.

(embodiment 6)

With Fig. 9 the 6th embodiment is described.

Though be not R completely, resembling will be stacked at the electromagnetic steel plate that the bight of main magnetic column iron core 3 11 director's degree a little a bit change Fig. 9, make angle R be approximately stairstepping, and such structure is also useful.

(embodiment 7)

As the 7th embodiment, as shown in figure 10, thereby R is set by using on curling electromagnetic steel plate in end or the bight 11 of iron plate at main magnetic column iron core 3 at the two ends of stacked iron core, this also is useful.

(embodiment 8)

Below, the reactance coil of the 8th embodiment of the present invention is described with Figure 11 and Figure 12.

In Figure 11, in the side end of main magnetic column iron core 3 end face is set respectively and has R, be the parts 12 of half cone-shaped, thereon direct winding around 4.As the material of the parts 12 of half cone-shaped, generally can use plastics class with insulating properties, still,, also can use iron plate, aluminium, stainless steel and other metal materials if do some sacrifice, how much reduce some magnetic characteristics.

As shown in figure 12, for the opposite side different, can adopt same structure with Figure 11.

Even use both ends to apply the parts that R processes, also can obtain the structure same with Figure 10 to the outermost electromagnetic steel plate itself that constitutes main magnetic column iron core 3.

(embodiment 9)

And then, use description of drawings the 9th embodiment of the present invention.

Have again, to enclosing same symbol and omit its explanation with same structure of past.

Figure 13 is the structure key diagram of the main magnetic column iron core 3 of reactance coil in one embodiment of the invention.In the drawings, the 15th, the columned welding body that forms by projection welding.

With stacked electromagnetic steel plate (for example silicon steel sheet) 16 sets, make main magnetic column iron core 3 with so cylindric welding body 15.

As constitute structure chart shown in Figure 14 of an electromagnetic steel plate 16 of above-mentioned main magnetic column iron core 3, be provided with projection 17 on the surface of each electromagnetic steel plate 16.The thickness of slab of electromagnetic steel plate 16 is 0.5mm, long 49.5mm, wide 27.4mm.

Figure 15 is the sectional view of above-mentioned electromagnetic steel plate 16, but has made 3 kinds that the diameter D of projection 17 and the height H of projection 17 (with the size Expressing of size * H of D) are respectively 1.5 * 0.7,2.0 * 0.9,2.5 * 1.1 (mm of unit) in the present embodiment.Figure 16 (a) is the figure that electromagnetic steel plate has been piled up after (stacked), carries out projection welding after such electromagnetic steel plate 16 is piled up, and forms main magnetic column iron core 3 like that shown in cross section Figure 16 (b) of the electromagnetic steel plate after the welding.

So-called projection welding method is in the projection of any local press molding hemisphere face on tabular welded article surface or circular cone shape, makes welding current concentrate on the resistance welding method that this high spot welds.

When forming above-mentioned main magnetic column iron core 3, use 21 pairs of resistance welders having upper electrode 18, lower electrode 19 and posting 20 in the projection welding machine of the used Figure 17 of the 9th embodiment of the present invention to pile up the iron core that forms and carry out projection welding, resemble the whole welding bodies 15 that couple together that generate Figure 16 (b) stacked electromagnetic steel plate 16 thus being located at projection alignment back on every electromagnetic steel plate.

Figure 18 is the major part enlarged drawing of above-mentioned projection welding machine, the upper electrode 18 of above-mentioned resistance welding machine 21, lower electrode 19, posting 20 and electromagnetic steel plate 16 is amplified illustrate.Posting 20 be because projection when projection welding because of each electromagnetic steel plate of resistance heat fusion 16 sinks to moving and will be with the squareness regulation of the piece after the welding in ± 0.1mm to bonding position respectively easily, clearance size C is decided to be 0.03～0.05mm.

In the past, when the such main magnetic column iron core 3 of set, also considered bonding or method such as extension crimping, but, generally adopted the TIG welding from the reliability of set.Under the TIG welding manner, can produce the shortcoming that the reactance coil iron loss increases.

With figure the reason that this iron loss increases is described.Figure 29 is the structure key diagram when being the TIG mode with main magnetic column iron core set with existing welding method.In addition, Figure 30 is that the same plane graph, Figure 31 is the same front view.

As shown in the figure, in order to keep common set intensity, carry out the TIG welding at 2 places of a-b and c-d.At this moment, discrete can not make this position of welding bead 22,23 is in full accord up and down because of structural, a size A causes staggering.

At this moment, in reactance coil when work,, main magnetic column iron core 3 shortens 1 circle through the path of a-b-c-d, in short circuit paths a-b-c-d, produce with and the proportional current potential of magnetic flux of magnetic flux cross section A * B interlinkage by main magnetic column iron core 3.And, flow through this short circuit paths by the short circuit current of the resistance value of this current potential and short circuit paths a-b-c-d decision, increased loss.

Here, sectional area A * B is long-pending with the projecting section along the vertical interlinkage of magnetic flux of short circuit paths a-b-c-d.

The caloric value of reactance coil increases because of the increase of above-mentioned loss, can surpass the allowable temperature higher limit, can become the reason of overheat accident under opposite extreme situations.If want to suppress this situation, must use the low-loss iron core of high price, the increase of cost is caused, the unfavorable factor of bringing overall dimension to increase in the line footpath of the overstriking coil 4 of having to.

To this, the present invention applies the projection welding that connects electromagnetic steel plate 16 along stacked direction to 1 place of main magnetic column iron core 3 as shown in figure 13, by only with 1 cylindric welding body 15 as fixture, can not form the path of 1 circle short circuit.

Thus, the increase of the iron loss that caused by fixing apparatus and take place can be suppressed to minimum.

In existing TIG welding manner, because be that the both sides of the stacked end face of iron core are welded along whole length, it is long to pretend the industry time.To this, as the present invention,, needn't move along welding electrode, and thermal diffusion is few if introduce the projection welding mode, so, can shorten the weld job time significantly by welding current being concentrated being waited, can obtain stable weldability simultaneously.

In addition, in above-mentioned main magnetic column iron core 3, only carry out the projection welding of 1 point, columned welding body 15 is 1, but also can carry out projection welding on a plurality of points.

That is, Figure 19 is the figure of other form of the electromagnetic steel plate of the expression main magnetic column iron core 3 that constitutes the reactance coil among the present invention the 9th embodiment, but with the interval of 6～7mm 2 embodiment with the same projection 17 of 1 projection welding situation is set.

Figure 20 is the comparison diagram of core loss value.During projection welding, the diameter of projection place big more, welding is many more, and iron loss is big more.

According to the result of experimental verification, if the diameter of projection is 2mm, then the set intensity of practical upper core is just enough.Projection diameter is that the core loss value of the reactance coil of 2mm is compared with the core loss (IronLoss) of the reactance coil made from prior art (TIG welding), only low 1.5W (18%).

Like this, substituting in the past general used TIG welding, introduce the stacked electromagnetic steel plate of projection welding method set reactance coil, is effectively to reducing iron loss.

Have again, be the iron core perforation that 2～3 stacked electromagnetic steel plates are folded layer by layer and weld with the very similar so-called resistance spot welding method of projection welding method, known that this is limited, it is impossible resembling the present invention 38～113 stacked welding of electromagnetic steel plate.

So, as present embodiment,, can therefore not produce loss if the projection welding of carrying out 1 point then can not constitute above-mentioned 1 circle short circuit paths iron core is fixing.In addition, even apply the projection welding of 2 points, because the position of projection 17 is by the part location, so can make 2 mutual alignment depart from very little (usually in 0.3mm), loss can be suppressed to roughly close degree, compare with existing welding and can seek significantly low-lossization with the projection welding of 1 point.

By adopting its speed of welding of projection welding method faster than the TIG welding, the diffusion of sweating heat is few, so operability has improved.

In the time of on reactance coil of the present invention being used for power electronic equipments such as air-conditioning, can reduce above-mentioned iron loss, reduce power consumption, so, can access very big energy-saving effect.

In addition, similarly adopting described so far the 1st～the 9th embodiment in other reactance coil (shown in Figure 24) in the past also is of great use.Because of content is identical substantially, its detailed description of Therefore, omited.

The possibility of industrial utilization

By above explanation as can be known, reactance coil of the present invention can reduce the use of coil-winding Amount.

The magnetic noise that between the main magnetic column iron core of inhibition and square shape magnetic circuit, takes place, magnetic vibration sound Simultaneously, make the set of main magnetic column iron core, insulating element and square shape magnetic circuit firmer, and then can Process to carry out more reliably dipping lacquer.

Can prevent that the coiling that causes because of winding tension from damaging.

Can provide each several part the fixing excellences such as outside air affects, water resistance that reliably, are not subjected to Reactance coil.

The padded coaming that uses the コ font only in fact necessary place, be the angle, right angle of iron core Section covers, and is prevented thus the direct injured structure of coil on iron core, can The consumption of decrease padded coaming.

Padded coaming is to the man-hour that iron core is pasted and the situation of twining in whole periphery like that in the past Compare and to improve significantly. And then can also prevent that the padded coaming coiling from expanding, and can get To the effect that improves prehensile, reduction use electric wire amount etc.

Directly be processed to form R by the right-angled corners at iron core, even do not use slow fully Rush material and also can obtain the not injured reactance coil of coiling when coil is directly on the iron core Structure can reduce the cost that reactance coil uses material. And then, because padded coaming is to iron The operation that core is pasted has not had yet, so can reduce the making man-hour of reactance coil.

As the fixing method of iron core, become the projection welding method from existing TIG welding, thereby, Long-pending the minimizing of projecting section that the interior short-circuit loop that forms of iron core and magnetic flux quadrature are produced, from And can decrease and the loss of the long-pending proportional increase of above-mentioned projecting section.

In existing TIG welding manner, to the stacked end face (2 face) of iron core across whole Stack length is welded, so the activity duration is long. In contrast, draw the present invention if resemble Enter projection welding, so the weld job time can be shortened significantly because not needing that welding electrode is moved.

Because thermal diffusion is few, so by making concentrated the flowing of welding current can obtain stable welding The property.

By being increased in the number of pad on the flow direction, can regulate set intensity.

Claims (14)

1, a kind of reactance coil, comprise square shape magnetic circuit that the iron core that uses more than 1 forms, be provided in the main magnetic column iron core of above-mentioned square shape magnetic circuit inboard and be provided in coil around the above-mentioned main magnetic column iron core, it is characterized in that, between the both ends of above-mentioned magnetic circuit and the described main magnetic column iron core relative with it, and the both ends of the surface of described coil and described magnetic circuit between get involved seal.

2, the reactance coil of claim 1 record is characterized in that at least a portion of insulating element has elasticity.

3, the reactance coil of claim 1 record is characterized in that insulating element is made of porous material or fibrous material.

4, the reactance coil of claim 2 record is characterized in that insulating element is made of porous material or fibrous material.

5, reactance coil as claimed in claim 1 is characterized in that, above-mentioned main magnetic column iron core has curved rectangle magnetic circuit cross section, bight.

6, the reactance coil of claim 1 record is characterized in that at least a portion is resin-cast moulding or resin moulded.

7, reactance coil as claimed in claim 1 is characterized in that, main magnetic column iron core on the bight of the described main magnetic column iron core of square-section through the direct winding around of the buffer unit of コ font.

8, reactance coil as claimed in claim 1 is characterized in that, main magnetic column iron core applies R processing and direct winding around thereon in the bight of the main magnetic column iron core of square-section.

9, reactance coil as claimed in claim 1 is characterized in that, main magnetic column iron core has the parts of R and direct winding around thereon at the both side ends installation end mask of at least one pair of opposite side of square-section.

10, reactance coil as claimed in claim 1 is characterized in that, main magnetic column iron core is stacked by electromagnetic steel plate, utilizes projection welding with its set.

11, the reactance coil of claim 10 record is characterized in that, one of main magnetic post is located to apply projection welding.

12, the reactance coil of claim 10 record is characterized in that, the many places of main magnetic post flow direction are applied projection welding.

13, a kind of manufacture method of reactance coil, it is characterized in that, at least one place that is included in electromagnetic steel plate be provided with projection the 1st step, the 2nd step that the above-mentioned electromagnetic steel plate of multi-disc is stacked, apply projection welding with fixing the 4th step that forms the 3rd step of iron core and coil is set of the above-mentioned electromagnetic steel plate of multi-disc around above-mentioned iron core.

As each the described reactance coil in the claim 1,2,3,4,5～12, it is characterized in that 14, magnetic circuit and seal and main magnetic column iron core are in contact with one another part makes it fixing with dipping lacquer.

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