CN112992490A - Four-quadrant low-noise reactor and manufacturing method thereof - Google Patents

Abstract

The invention provides a four-quadrant low-noise reactor which comprises three iron-silicon magnetic cores, epoxy plates, enameled aluminum wires, temperature sensors and connecting terminals, wherein the three iron-silicon magnetic cores are bonded on the epoxy plates in parallel through adhesives, the enameled aluminum wires are wound on the peripheries of the iron-silicon magnetic cores, two end parts of the enameled aluminum wires on each iron-silicon magnetic core are connected with the connecting terminals through high-temperature silica gel cables, and the iron-silicon magnetic core in the middle is connected with the temperature sensors through the high-temperature silica gel cables. The magnetic ring reactor has the advantages of uniform air gap distribution, small magnetostriction, low noise, small iron loss and easy heat dissipation due to the annular shape, and compared with a silicon steel sheet reactor, the magnetic ring reactor has the same inductance, lighter weight and more economical and practical price.

Description

Four-quadrant low-noise reactor and manufacturing method thereof

Technical Field

The invention relates to the technical field of reactors, in particular to a four-quadrant low-noise reactor and a manufacturing method thereof.

Background

Conventional silicon steel sheet reactor is because air gap distribution is inhomogeneous, and the iron loss is big, can lead to local heating, can cause the noise of reactor itself simultaneously big, influences user experience. And the reactor with the same inductance is manufactured, the overall cost of the silicon steel sheet is higher, and the weight is heavier.

Disclosure of Invention

Therefore, it is necessary to provide a four-quadrant low-noise reactor and a manufacturing method thereof to solve the problems of high noise and high cost of the existing reactor.

The utility model provides a four-quadrant low noise reactor, includes indisputable silicon magnetic core, epoxy board, enameled aluminum wire, temperature sensor and binding post, indisputable silicon magnetic core is three, and bonds on the epoxy board side by side through the bonding agent, the enameled aluminum wire winding is peripheral at indisputable silicon magnetic core, and two tip of the enameled aluminum wire on every indisputable silicon magnetic core all have binding post through high temperature silica gel cable junction, are connected with temperature sensor through the wire on the indisputable silicon magnetic core that wherein is located the middle part.

Preferably, the cable also comprises a nylon cable tie for binding the high-temperature silica gel cable.

Preferably, the terminal is an ENY4012 tube terminal.

Preferably, the adhesive is black glue.

The invention also provides a manufacturing method of the four-quadrant low-noise reactor, which comprises the following steps:

the method comprises the following steps: and (3) a group of iron-silicon magnetic cores are arranged on a clamping table of the annular winding machine, and the positions of rubber wheels of the clamping table are adjusted to clamp the iron-silicon magnetic cores.

Step two: cutting the silica gel sleeve, and cutting the white silica gel sleeve with the diameter of 2.0mm to the length of 200mm for later use.

Step three: and selecting a winding machine, winding the enameled aluminum wire on the iron-silicon magnetic core, and using 7-16 wire loops.

Step four: a QZY (XY) L-2, phi 2.20mm enameled aluminum wire storage wire 12TS winding 108TS is used, a phi 2.0mm white silicone tube is sleeved at the head and tail of the wire, and the silicone tube is sleeved with at least 1 TS.

Step five: connecting a connecting terminal at the free end of the enameled aluminum wire through a high-temperature silica gel cable, and connecting a temperature sensor on the middle iron-silicon magnetic core through the high-temperature silica gel cable to obtain a finished product;

step six: performing an environment test on a finished product, namely sequentially performing a heat resistance test, a damp-heat test and a temperature cycle test;

step seven: and performing total number check and extraction check.

Preferably, the environmental test method in the sixth step is as follows:

heat resistance test: and (3) placing the material in an environment at the temperature of 155 +/-3 ℃ for 24 hours, taking out the material, placing the material for 5 minutes, and testing to meet the requirements of insulation resistance and voltage resistance tests.

And (3) moisture and heat property test: and (3) placing the test product in a constant temperature and humidity test box with the temperature of 40 +/-2 ℃ and the relative humidity of 90-95% R H for 48 hours, taking out the test product, sufficiently removing water drops, and testing after 1 minute to meet the requirements of insulation resistance and voltage resistance tests.

Temperature cycle test: the temperature of 70 plus or minus 3 ℃ for 24 hours, the room temperature for 1 hour, the temperature of minus 20 ℃ for 5 hours, and the room temperature for 5 hours, the test accords with the requirements of the insulation resistance and the voltage resistance test.

The invention has the beneficial effects that:

the inductance is designed according to the internal parameters of the frequency converter of D03, which is reached by customers in new time, and the inductance, the size, the material, the number of turns, the wire diameter and the like are verified through continuous tests. The magnetic ring reactor has the advantages of uniform air gap distribution, small magnetostriction, low noise, small iron loss and easy heat dissipation due to the annular shape, and compared with a silicon steel sheet reactor, the magnetic ring reactor has the same inductance, lighter weight and more economical and practical price.

Drawings

FIG. 1 is a schematic structural view of the present invention;

FIG. 2 is a top view of FIG. 1;

FIG. 3 is a left side view of FIG. 1;

FIG. 4 is a cross-sectional view of the iron-silicon magnetic core after being wound with an enameled aluminum wire;

FIG. 5 is a schematic circuit diagram;

in the figure, 1-iron silicon magnetic core, 2-epoxy board, 3-enameled aluminum wire, 4-temperature sensor, 5-nylon ribbon, 6-connecting terminal, 7-high temperature silica gel cable, 8-viscose.

Detailed Description

The following detailed description of the preferred embodiments of the present invention, taken in conjunction with the accompanying drawings, will make the advantages and features of the invention easier to understand by those skilled in the art, and thus will clearly and clearly define the scope of the invention.

Referring to fig. 1-5, a four-quadrant low-noise reactor includes a ferrite core 1, an epoxy board 2, an enameled aluminum wire 3, a temperature sensor 4, a nylon band 5, and a connection terminal 6.

The utility model discloses a binding post, including epoxy board 2, iron silicon magnetic core 1, including iron silicon magnetic core 1, two tip that the iron silicon magnetic core 1 is three, and iron silicon magnetic core 1 bonds side by side on epoxy board 2 through viscose 8, the winding of enameled aluminum wire 3 is in 1 periphery of iron silicon magnetic core, and two tip of enameled aluminum wire 3 on every iron silicon magnetic core 1 all are connected with binding post 6 through high temperature silica gel cable 7, and wherein lie in and be connected with temperature sensor 4 through the wire on the iron silicon magnetic core 1 at middle part, and nylon ribbon 5 is used for binding high.

Preferably, the ferrosilicon core 1 is 78912a7 type magnetic core available from magnetic corporation.

Preferably, the enameled aluminum wire 3 is a Q (ZY/XY) L-2 phi 2.2 enameled wire of Tonglingjinsu special enameled wire, Inc.

Preferably, the terminal 6 is a ENY4012 tube type terminal available from siemens electric and electronics limited.

Preferably, the high-temperature silica gel cable 7 is 4mm of a silicon rubber product factory of Xingyu province of China²An electrical cable.

Preferably, 3300A/B epoxy resin available from Suzhou force electronics materials Co.

As a priority, the epoxy board 2 was a 5mm thick FR4 insulating board by east space electronics limited, jing jiang.

The invention also provides a manufacturing method of the four-quadrant low-noise reactor, which comprises the following steps:

the method comprises the following steps: and (3) a group of iron-silicon magnetic cores are arranged on a clamping table of the annular winding machine, and the positions of rubber wheels of the clamping table are adjusted to clamp the iron-silicon magnetic cores.

Step two: cutting the silica gel sleeve, and cutting the white silica gel sleeve with the diameter of 2.0mm to the length of 200mm for later use.

Step three: and selecting a winding machine, winding the enameled aluminum wire on the iron-silicon magnetic core, and using 7-16 wire loops.

Step four: a QZY (XY) L-2, phi 2.20mm enameled aluminum wire storage wire 12TS winding 108TS is used, a phi 2.0mm white silicone tube is sleeved at the head and tail of the wire, and the silicone tube is sleeved with at least 1 TS.

Step five: connecting a connecting terminal at the free end of the enameled aluminum wire through a high-temperature silica gel cable, and connecting a temperature sensor on the middle iron-silicon magnetic core through the high-temperature silica gel cable to obtain a finished product;

step six: performing an environment test on a finished product, namely sequentially performing a heat resistance test, a damp-heat test and a temperature cycle test; the test methods are shown in table 1:

table 1 shows the environmental tests and methods of the present invention

Step seven: and performing total number check and extraction check. During the inspection, the inspection is performed according to the electrical parameter table of table 2.

Table 2 is an electrical parameter table

All examination items: static inductance, withstand voltage, appearance.

Extracting inspection items: temperature rise, insulation resistance, size inspection and terminal strength are performed according to the specification of n-5 pieces/batch, the temperature rise inspection is performed according to the specification of n-l pieces/batch, and other items are extracted according to the S-3 standard.

The above-mentioned embodiments only express several embodiments of the present invention, and the description thereof is more specific and detailed, but not construed as limiting the scope of the present invention. It should be noted that, for a person skilled in the art, several variations and modifications can be made without departing from the inventive concept, which falls within the scope of the present invention. Therefore, the protection scope of the present patent shall be subject to the appended claims.

Claims (6)

1. The utility model provides a four-quadrant low noise reactor, its characterized in that includes indisputable silica magnetic core, epoxy board, enameled aluminum wire, temperature sensor and binding post, indisputable silica magnetic core is three, and bonds on the epoxy board side by side through the adhesive, the enameled aluminum wire winding is peripheral at indisputable silica magnetic core, and two tip of the enameled aluminum wire on every indisputable silica magnetic core all have binding post through high temperature silica gel cable connection, are connected with temperature sensor through the wire on the indisputable silica magnetic core that wherein is located the middle part.

2. The four-quadrant low-noise reactor according to claim 1, further comprising nylon ties for binding the high-temperature silicone cables.

3. The four-quadrant low noise reactor according to claim 2, wherein the terminal is a ENY4012 tubular terminal.

4. The four-quadrant low-noise reactor according to claim 3, wherein the adhesive is black glue.

5. The method for manufacturing a four-quadrant low-noise reactor according to claim 4, comprising the steps of:

the method comprises the following steps: a group of iron-silicon magnetic cores are arranged on a clamping table of an annular winding machine, the position of a rubber wheel of the clamping table is adjusted, and the iron-silicon magnetic cores are clamped tightly;

step two: cutting the silica gel sleeve, and cutting the white silica gel sleeve with the diameter of 2.0mm to the length of 200mm for later use;

step three: selecting a winding machine, winding the enameled aluminum wire on a ferro-silicon magnetic core, and using a 7-16 wire ring;

step four: winding 108TS by using a QZY (XY) L-2, phi 2.20mm enameled aluminum wire storage wire 12TS, sleeving a phi 2.0mm white silicone tube at the head and tail of the wire, and sleeving at least 1TS by using the silicone tube;

step five: connecting a connecting terminal at the free end of the enameled aluminum wire through a high-temperature silica gel cable, and connecting a temperature sensor on the middle iron-silicon magnetic core through the high-temperature silica gel cable to obtain a finished product;

step six: performing an environment test on a finished product, namely sequentially performing a heat resistance test, a damp-heat test and a temperature cycle test;

step seven: and performing total number check and extraction check.

6. The manufacturing method of the four-quadrant low-noise reactor according to claim 5, wherein the environmental test method in the sixth step is as follows:

heat resistance test: the insulation resistance and voltage resistance testing device is placed in an environment at the temperature of 155 +/-3 ℃ for 24 hours, then is taken out and placed for 5 minutes, and then is tested, so that the requirements of insulation resistance and voltage resistance testing are met;

and (3) moisture and heat property test: placing the test product in a constant temperature and humidity test box with the temperature of 40 +/-2 ℃ and the relative humidity of 90-95% R H for 48 hours, taking out the test product, fully removing water drops, and testing after 1 minute to meet the requirements of insulation resistance and voltage resistance tests;

temperature cycle test: the temperature of 70 plus or minus 3 ℃ for 24 hours, the room temperature for 1 hour, the temperature of minus 20 ℃ for 5 hours, and the room temperature for 5 hours, the test accords with the requirements of the insulation resistance and the voltage resistance test.

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