JP2004039770A - Reactor equipment - Google Patents

Reactor equipment Download PDF

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Publication number
JP2004039770A
JP2004039770A JP2002192962A JP2002192962A JP2004039770A JP 2004039770 A JP2004039770 A JP 2004039770A JP 2002192962 A JP2002192962 A JP 2002192962A JP 2002192962 A JP2002192962 A JP 2002192962A JP 2004039770 A JP2004039770 A JP 2004039770A
Authority
JP
Japan
Prior art keywords
reactor
iron core
core
plurality
side surface
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
JP2002192962A
Other languages
Japanese (ja)
Inventor
Masanori Kawai
Takahiko Nakamura
Michio Tatsuno
Shoji Tatsuno
中村 隆彦
河合 正則
竜野 三千生
辰野 昭司
Original Assignee
Tokyo Seiden Kk
東京精電株式会社
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Tokyo Seiden Kk, 東京精電株式会社 filed Critical Tokyo Seiden Kk
Priority to JP2002192962A priority Critical patent/JP2004039770A/en
Publication of JP2004039770A publication Critical patent/JP2004039770A/en
Application status is Pending legal-status Critical

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Abstract

An object of the present invention is to further improve the effects of saving energy, reducing loss, reducing noise, and reducing the size and weight, and at the same time, improve productivity and reduce manufacturing costs, and eliminate waste of strips.
A reactor (4) having a core (2) formed in a non-polygonal ring shape having no bent portion, and a coil (3) in which a vertical rectangular conductor (W) is wound in the circumferential direction along the cross-sectional shape of the core (2). , Formed by the plate-shaped member T, and integrally provided with a plurality of side surface holding portions 5a... Supporting a plurality of positions on the side surface 2s of the iron core 2 and a plurality of bottom surface supporting portions 7a. And a fixing member 9 for fixing the chassis 8 and the reactor 4.
[Selection diagram]
FIG.

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a reactor device suitable for use in an inverter circuit, a converter circuit, and the like.
[0002]
[Prior art and problems]
Conventionally, a reactor having a laminated core and a coil wound on the laminated core is known, and the applicant of the present application has already realized a diagram that can realize energy saving, low loss, low noise, and small size and light weight. The reactor 50 shown in FIGS. 9 and 10 was proposed.
[0003]
As shown in FIG. 9, the reactor 50 is formed by winding the band material 51p into a circular ring shape and laminating the band material 51p, and the lamination section S has a circular shape (or an approximate shape thereof) as shown in FIG. An iron core 51 and a coil 52 around which a vertical rectangular conducting wire 52w is wound over substantially the entire circumference of the wound iron core 51 are provided.
[0004]
By the way, since the coil 52 used for the reactor 50 is manufactured by winding a flat rectangular wire 52w while bending it with a rolling roll or the like, the curvature of the coil 52 cannot be reduced so much. It becomes a circle as shown by a virtual line. Further, when a wound iron core having a square cross section is used for such a circular coil 52, a considerable gap is generated between the coil 52 and the wound iron core. The shape of the lamination section S of the iron core 51 is also formed to be a circle similar to the end face shape of the coil 52.
[0005]
However, in such a reactor 50, since the shape of the lamination cross section S in the wound iron core 51 is circular, it is not easy to manufacture the wound iron core 51, and a reduction in productivity and an increase in manufacturing cost due to an increase in the number of manufacturing steps. At the same time, there is a problem that about 1/4 of waste is generated in the band material 51p in manufacturing the wound iron core 51.
[0006]
According to the present invention, with respect to such a reactor 50, the effects of improving energy saving, low loss, low noise, and reduction in size and weight can be further improved, and in addition, productivity can be improved and manufacturing cost can be reduced. Moreover, it is an object of the present invention to provide a reactor device capable of eliminating waste of a band material.
[0007]
Means and Embodiments for Solving the Problems
According to the present invention, when configuring a reactor device 1 including an iron core 2 and a reactor 4 having a coil 3 wound on the iron core 2, the iron core 2 formed in a non-polygonal ring shape having no bent portion and the reactor 2. A reactor 4 having a coil 3 in which a vertical rectangular wire W is wound in the circumferential direction along the cross-sectional shape of the iron core 2 and a plurality of side surfaces formed by a plate-shaped member T and holding a plurality of positions on the side surface 2s of the iron core 2 It is characterized by comprising a chassis 8 integrally provided with a plurality of bottom support portions 7a... That support a plurality of positions on the bottom surface 2t of the iron core 2 and a fixing member 9 for fixing the chassis 8 and the reactor 4. I do.
[0008]
In this case, according to a preferred embodiment, the iron core 2 uses a laminated core manufactured by winding a magnetic strip P having the same or a plurality of widths, and also divides the core into two or more divided cores 2a, 2b,. . The coil 3 can be manufactured by winding it around a core metal 31 having a cross-sectional shape similar to the cross-section of the iron core 2. On the other hand, the chassis 8 forms the bottom plate portion 11 and a pair of left and right side plate portions 12p and 12q by bending the plate-shaped member T into a U-shape, and also bends a part of the side plate portions 12p and 12q. The side surface holding portions 5a can be formed, and a part of the bottom plate portion 11 can be bent to form the bottom support portions 7a. Note that a part of the bottom plate portion 11 can be bent to form the side surface regulating portions 6a..., And a bottom support portion 7a. You can also. On the other hand, the side plates 12p and 12q arranged on the left and right can be connected to each other by the fixing member 9.
[0009]
【Example】
Next, a reactor device 1 according to a preferred embodiment of the present invention will be described in detail with reference to FIGS.
[0010]
First, a method for manufacturing the reactor device 1 will be specifically described with reference to FIGS.
[0011]
4 and 5 show the main part of the coil winding machine 30. The coil 3 used in the reactor device 1 according to the present embodiment can be manufactured by the coil winding machine 30. In the coil winding machine 30, reference numeral 34 denotes a rotation shaft, which is rotated at a low speed by a rotation drive mechanism 35. A support plate 36 is integrally provided at the end of the rotating shaft 34, and the fixed plate 32 is fixed to the end surface of the support plate 36, and the bar-shaped cored bar 31 projects at a right angle from the center of the fixed plate 32. The cross-sectional shape of the cored bar 31 is similar to the cross-sectional shape of a laminated core (iron core) 2 described later, and has a cross-sectional shape slightly larger than the cross-sectional shape. The core metal 31 is exchangeable according to the type of the coil 3 to be manufactured. Further, a pressure plate 33 that can be displaced along the metal core 31 is mounted on the metal core 31. Therefore, the core metal 31 passes through the center of the pressure plate 33. The pressure plate 33 is pressed by a pressure mechanism 37 in the direction of arrow Fh, that is, in the direction of the fixed plate 32.
[0012]
Next, a manufacturing process of the coil 3 using the coil winding machine 30 will be described. FIG. 3 is a flowchart of the manufacturing process. C1 to C5 indicate a winding process, Y1 to Y3 indicate an iron core manufacturing process, and A1 to A4 indicate a reactor device assembling process. When manufacturing the coil 3, a rectangular wire W is prepared. As the rectangular conductor W, a copper wire having a thickness and width ratio of about 1: 5 is used. Note that the vertical rectangular conductor W refers to a case where the thickness direction of the rectangular conductor W is parallel to the axial direction of the coil 3.
[0013]
First, as shown in FIG. 4, the distal end Wf of the rectangular conductor W is fixed to the support board 36 side (step C1). Then, the pressurizing plate 33 is moved in the direction of the arrow Fh by the pressurizing mechanism 37 to press the rectangular conducting wire W between the fixed platen 32 and the pressurizing plate 33 as shown in FIG. 4 (step C2). At the same time, the flat wire W is pulled in the direction of the arrow Fb by the pulling mechanism 38 (step C3), and in this state, the core metal 31 is rotated at a low speed in the direction of the arrow Fr by the rotation drive mechanism 35 (step C4). Thereby, the rectangular conductor W is wound around the cored bar 31 and the coil 3 can be manufactured (step C5). Further, the obtained coil 3 is subjected to necessary finishing treatment such as applying an insulating film.
[0014]
On the other hand, the split core portions 2a, 2b... 2d are manufactured. First, a magnetic strip P using a silicon steel sheet is prepared. In this case, the magnetic strips P have the same width in the longitudinal direction. If necessary, a magnetic strip having a plurality of widths may be used, so that the sectional shape of the divided core portions 2a can be, for example, a combination of a plurality of squares. The magnetic strip P is layered and wound around the peripheral surface of a forming jig whose cross section is formed into an oval with no corners (shape indicated by e in FIG. 1) (step Y1). As a result, an oval ring-shaped laminated base material having no bent portion is obtained, and the laminated wound base material is cut and divided into four blocks (step Y2). 2a, 2b, 2c, and 2d appearing in FIG. 1 are four divided core portions (step Y3). In the embodiment, the shape of the laminated core 2 is exemplified by an ellipse. However, the laminated core 2 may be formed into a non-polygonal ring having no bent portion, such as a circle or an ellipse. Further, the number of divisions for the laminated winding base material is arbitrary.
[0015]
When the coil 3 and the four divided core portions 2a, 2b,... 2d are obtained, the reactor device 1 is assembled. First, a reactor 4 is manufactured by combining the coil 3 and the four divided core portions 2a, 2b... 2d (step A1). In this case, a separator sheet 21 made of glass epoxy resin having a thickness of about 0.5 [mm] shown in FIG. 1 is interposed between the divided core portions 2a, 2b. The divided core portions 2a, 2b... 2d are connected to each other. At this time, the split core portions 2a, 2b... 2d are accommodated in the internal space of the coil 3 simultaneously with the connection, and insulating paper or the like is interposed between the split core portions 2a, 2b. Thereby, reactor 4 is obtained.
[0016]
As shown in FIG. 1, the reactor 4 includes an oval ring-shaped laminated core 2 having no bent portion (corner), and a mutual interval of one turn of the coil 3 is equal to each other. , The inside narrows and the outside widens. Since this aspect is the same for the linear portion of the laminated core 2, a predetermined interval is generated between each of the turns constituting the coil 3 along the entire circumference of the laminated core 2.
[0017]
On the other hand, a chassis 8 shown in FIGS. 6 and 7 is prepared. The chassis 8 includes a plurality of side surface holding portions 5a, 5b, 5c, and 5d that hold a plurality of positions on the side surface 2s of the laminated core 2 on a plate member T made of steel (stainless steel), and a plurality of side surface regulating portions 6a, 6b, 6c, 6d, and a plurality of bottom support portions 7a, 7b, 7c, 7d that support a plurality of positions on the bottom surface 2t of the laminated core 2 are provided. Specifically, as shown in FIG. 8, the plate-shaped member T is bent into a U-shape in a side view to form a rectangular bottom plate portion 11 and a pair of left and right side plate portions 12p and 12q. In this case, the widths of the side plate portions 12p and 12q are set to be about 1/3 of the width of the bottom plate portion 11, and are each formed in a vertically long rectangular shape.
[0018]
A notch is provided near both sides of one side plate portion 12p, and a pair of side holding portions 5a and 5b are integrally formed by bending both sides at right angles, and a notch is provided near both sides of the other side plate portion 12q. By bending both sides at right angles, a pair of side holding parts 5c and 5d are integrally formed. As shown in FIG. 1, the side holding parts 5 a, 5 b, 5 c, 5 d abut (press) both sides of the side surface 2 s of the laminated core 2 forming an oval shape to press the laminated core 2 horizontally. Has the function of holding from the direction. Therefore, the tip of each side surface holding portion 5a is in surface contact with the side surface 2s of the laminated core 2 and forms a slope so as not to damage the side surface 2s. In addition, insertion holes 21p and 21q through which fixing screws 23 described later are inserted are formed near the upper ends of the side plate portions 12p and 12q, respectively.
[0019]
Further, the bottom plate portion 11 is formed by punching out four points on a line extending from the center position to four corners and bending the same at a right angle, so that the four side surface regulation portions 6a, 6b, 6c, 6d and the four bottom surface support portions 7a are formed. , 7b, 7c, 7d. At this time, the radiating holes 13a, 13b, 13c, and 13d having the required sizes are formed together by selecting a larger punching area. In this case, the side surface regulating portions 6a, 6b, 6c, 6d are located near the side surface holding portions 5a, 5b, 5c, 5d, respectively, and face the curved portion on the side surface 2s of the laminated core 2 in the horizontal direction. It has the function of regulating the position. The upper ends of the bottom support portions 7a, 7b, 7c, 7d abut on four symmetrical positions on the bottom surface 2t of the laminated core 2 to support the laminated core 2 from below. In the vicinity of the four corners of the bottom plate 11, insertion holes 22a, 22b, 22c, and 22d through which mounting screws are inserted are respectively formed.
[0020]
Then, the reactor 4 obtained in step A1 is assembled to the chassis 8 (step A2). In this case, as shown by an arrow Fu in FIG. 8, the reactor 4 is housed in the chassis 8 from above. As a result, the side holding portions 5a and 5b face one curved portion of the side surface 2s of the laminated core 2 and the side holding portions 5c and 5d face the other curved portion of the side surface 2s. Further, the side surface regulating portions 6a and 6b face one curved portion of the side surface 2s of the laminated core 2 and the side surface regulating portions 6c and 6d face the other curved portion of the side surface 2s. As a result, double position regulation for the laminated core 2 is performed. Further, the upper ends of the bottom support portions 7a, 7b, 7c, 7d abut on four symmetrical positions on the bottom surface 2t of the laminated core 2 to support the laminated core 2 from below. In order to make this positional relationship clear, the laminated core 2 is shown by a virtual line with respect to the chassis 8 shown in FIG. The side holding portions 5a, the side regulating portions 6a, and the bottom support portions 7a are inserted between the rectangular conductors W of the coil 3, as shown in FIG.
[0021]
Next, the fixing screw 23 is passed through the insertion holes 21p, 21q of the side plate portions 12p, 12q arranged on the left and right from one side, and the fastening nut 24 is screwed to the fixing screw 23 protruding to the other side. As a result, the side plate portions 12p and 12q are connected, and when the tightening nut 24 is tightened, each of the side surface holding portions 5a, 5b, 5c, and 5d abuts on the curved portion of the side surface 2s of the laminated core 2 (pressure contact). Then, the chassis 8 and the reactor 4 are fixed (Step A3). The fixing screw 23 and the tightening nut 24 constitute the fixing member 9. Through the above manufacturing process, the reactor device 1 shown in FIGS. 1 and 2 is obtained (Step A4). In FIG. 2, reference numerals 3a and 3b denote lead portions derived from both ends of the coil 3.
[0022]
According to such a reactor device 1, the size and weight of the reactor 50 before the improvement can be further reduced. In particular, in the reactor 50 before the improvement, since the shape of the lamination cross section S in the core 51 is circular, it is not easy to manufacture the core 51, and a decrease in productivity and an increase in manufacturing cost due to an increase in the number of manufacturing steps. At the same time, there was a problem that about 1/4 of the strip 51p was wasted in the production of the wound core 51. However, in the reactor device 1 according to the present embodiment, all of these problems were solved, and the material cost was reduced. You. Further, since the chassis 8 can be basically formed by a single plate-shaped member T, the cost and the size and weight can be reduced from this side. In addition, since a sufficient gap is secured between the chassis 8 and the reactor 4, the heat dissipation is excellent.
[0023]
Although the embodiments have been described in detail above, the present invention is not limited to such embodiments, and departs from the gist of the present invention in details such as configuration, shape, material, quantity, numerical value, and method. It can be arbitrarily changed, added, or deleted as long as it is not performed. For example, in the embodiment, the laminated core 2 in which the magnetic strip P using a silicon steel plate is laminated as the core is illustrated, but the core is made of amorphous, permalloy, nanocrystalline alloy, ferrite, Fe-Al-Si alloy, pure iron. It does not preclude the use of a sintered iron core or a laminated iron core using iron or the like.
[0024]
【The invention's effect】
As described above, the reactor device according to the present invention includes a core formed in a non-polygonal ring shape having no bent portion, and a coil in which a vertical rectangular conductor is circumferentially wound along the cross-sectional shape of the core. And a chassis formed by a plate-like member, integrally provided with a plurality of side surface holding portions for holding a plurality of positions on the side surface of the iron core and a plurality of bottom surface support portions for supporting the plurality of positions on the bottom surface of the iron core, and the chassis And a fixing member for fixing the reactor, the following remarkable effects are obtained.
[0025]
(1) With respect to the reactor before the improvement (reactor 50 in FIGS. 9 and 10), the effect of improving energy saving, low loss, low noise, and reduction in size and weight can be further improved, and additionally, production is improved. It is possible to improve the performance and to reduce the production cost, and it is possible to eliminate waste of the band material.
[0026]
(2) Basically, the chassis can be formed by a single plate-shaped member, so that the cost and size and weight can be reduced from this side as well.
[0027]
(3) A sufficient gap is secured between the chassis and the reactor by the side surface holding portion and the bottom surface supporting portion, so that the heat dissipation is excellent.
[Brief description of the drawings]
FIG. 1 is a plan view in which a part of a reactor of a reactor device according to a preferred embodiment of the present invention is broken and omitted.
FIG. 2 is a sectional side view of the reactor device,
FIG. 3 is a flowchart of a manufacturing process according to a method of manufacturing the reactor device,
FIG. 4 is a partial cross-sectional side view showing a main part of a coil winding machine used in the method of manufacturing the reactor device.
FIG. 5 is a perspective view showing a main part of the coil winding machine;
FIG. 6 is a plan view of a chassis used for the reactor device,
FIG. 7 is a sectional view taken along line XX of FIG. 6 of a chassis used in the reactor device.
FIG. 8 is an explanatory view of a manufacturing process of the reactor device.
FIG. 9 is a plan view in which a part of a reactor before improvement is omitted.
FIG. 10 is a sectional side view in which a part of the reactor is omitted,
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Reactor device 2 Iron core 2a ... Split iron core part 2s Iron core side surface 2t Iron core bottom surface 3 Coil 4 Reactor 5a ... Side holding part 6a ... Side regulating part 7a ... Bottom support part 8 Chassis 9 Fixing member 11 Bottom plate part 12p Side plate part 12q Side plate Portion 13a Heat radiating hole 31 Metal core W Flat wire T Plate-shaped member P Magnetic strip

Claims (8)

  1. In a reactor device having an iron core and a reactor having a coil wound on the iron core, a non-polygonal ring-shaped iron core having no bent portion and a vertical rectangular conductor are formed along the cross-sectional shape of the iron core. A reactor having a coil wound in the direction, a plurality of side surface holding portions formed by a plate-shaped member, holding a plurality of positions on the side surface of the iron core, and a plurality of bottom surface support portions supporting a plurality of positions on the bottom surface of the iron core. A reactor device comprising: a chassis provided integrally; and a fixing member for fixing the chassis and the reactor.
  2. The reactor device according to claim 1, wherein the core is a laminated core manufactured by winding a magnetic strip having the same width or a plurality of widths.
  3. The reactor device according to claim 1, wherein the iron core is configured by combining a plurality of divided iron core portions.
  4. The reactor device according to claim 1, wherein the coil is wound around a metal core having a cross-sectional shape similar to a cross-section of the iron core.
  5. The chassis forms the bottom plate portion and a pair of left and right side plate portions by bending the plate-shaped member into a U-shape, and forms the side surface holding portion by bending a part of the side plate portion. The reactor apparatus according to claim 1, wherein the bottom plate is formed by bending a part of the bottom plate.
  6. The reactor device according to claim 5, wherein the chassis has a side surface regulating portion formed by bending a part of the bottom plate portion.
  7. The reactor device according to claim 5, wherein the chassis has the bottom support portion and the heat radiation hole formed together by punching a part of the bottom plate portion.
  8. The reactor device according to claim 5, further comprising a fixing member that connects the side plate portions arranged on the left and right sides.
JP2002192962A 2002-07-02 2002-07-02 Reactor equipment Pending JP2004039770A (en)

Priority Applications (1)

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Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1564480A2 (en) 2004-02-17 2005-08-17 Ichikoh Industries, Ltd. Projector type vehicular lamp device
JP2008042094A (en) * 2006-08-09 2008-02-21 Denso Corp Reactor
JP2009032994A (en) * 2007-07-28 2009-02-12 Sumitomo Electric Ind Ltd Reactor device
WO2011132361A1 (en) * 2010-04-23 2011-10-27 住友電装株式会社 Reactor

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1564480A2 (en) 2004-02-17 2005-08-17 Ichikoh Industries, Ltd. Projector type vehicular lamp device
JP2008042094A (en) * 2006-08-09 2008-02-21 Denso Corp Reactor
JP4635982B2 (en) * 2006-08-09 2011-02-23 株式会社デンソー reactor
JP2009032994A (en) * 2007-07-28 2009-02-12 Sumitomo Electric Ind Ltd Reactor device
WO2011132361A1 (en) * 2010-04-23 2011-10-27 住友電装株式会社 Reactor
US8717133B2 (en) 2010-04-23 2014-05-06 Sumitomo Wiring Systems, Ltd. Reactor

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