JP2013016682A - Reactor - Google Patents

Reactor Download PDF

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Publication number
JP2013016682A
JP2013016682A JP2011149020A JP2011149020A JP2013016682A JP 2013016682 A JP2013016682 A JP 2013016682A JP 2011149020 A JP2011149020 A JP 2011149020A JP 2011149020 A JP2011149020 A JP 2011149020A JP 2013016682 A JP2013016682 A JP 2013016682A
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Japan
Prior art keywords
core body
core
gap
body
reactor
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Withdrawn
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JP2011149020A
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Japanese (ja)
Inventor
Nobuki Shinohara
伸樹 篠原
Mao Nobusaka
真央 延坂
Takashi Atsumi
貴司 渥美
Shinya Urata
信也 浦田
Hideo Nakai
英雄 中井
Original Assignee
Toyota Motor Corp
トヨタ自動車株式会社
Toyota Central R&D Labs Inc
株式会社豊田中央研究所
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Priority to JP2011149020A priority Critical patent/JP2013016682A/en
Publication of JP2013016682A publication Critical patent/JP2013016682A/en
Application status is Withdrawn legal-status Critical

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Abstract

A reactor having a structure capable of easily manufacturing a core body and preventing generation of leakage magnetic flux is provided.
A third core body 25 has one end in contact with the base body 11 and the other end side extending to the second core body 20 side, a core portion 26 around which a coil 30 is wound, On the end side, it is provided so as to project toward the pair of side walls 12 and 12, and is disposed with the second core body 20 and the first gap G1 therebetween, and the pair of side walls 12 and 12 and the second gap G2 are separated from each other. And a gap plate 27 disposed apart from each other.
[Selection] Figure 6

Description

  The present invention relates generally to a reactor, and more specifically to a reactor that is mounted on a vehicle and used for a converter that steps up and down a voltage.

Hybrid vehicles (Hybrid) against the background of energy and environmental issues
Vehicle) and electric vehicles (Electric Vehicle) are attracting much attention. For example, a hybrid vehicle is a vehicle that uses a motor powered by a DC power source as a power source in addition to a conventional engine. That is, a power source is obtained by driving the engine, a DC voltage from a DC power source is converted into an AC voltage by an inverter, and a motor is rotated by the converted AC voltage to obtain a power source.

  A hybrid vehicle having such a configuration is equipped with a converter for stepping up and down direct current between a direct current power source and an inverter. For the converter, a reactor having a core body and a coil wound around the core body is used.

  A reactor 500 disclosed in Japanese Patent Application Laid-Open No. 08-316049 (Patent Document 1) is shown in FIG. A first core body 510 having an E-shaped cross section and a second core body 520 having an I-shaped cross section are used, and a coil 530 is wound around a leg portion 510c provided in the center of the first core body 510. A gap G is provided between the leg portion 510c and the second core body 520.

  FIG. 10 shows a reactor 550 disclosed in Japanese Patent Application Laid-Open No. 2010-27946 (Patent Document 2). A first core body 560 and a second core body 570 having an E-shaped cross section are used. A first leg 560 c is provided at the center of the first core body 560, and a second leg 570 c is provided at the center of the second core body 570. The width of the second leg portion 570c is smaller than the width of the first leg portion 560c.

  A coil 580 is wound around the first leg 560c and the second leg 570c, and a gap G is provided between the tip of the first leg 560c and the tip of the second leg 570c.

Japanese Patent Laid-Open No. 08-316049 JP 2010-27946 A

  In the reactor 500 shown in FIG. 9, the magnetic flux F passes through the gap G, but the magnetic flux F tends to pass through the shortest path. Therefore, a leakage magnetic flux FL is generated in the gap G. This leakage magnetic flux FL interlinks with the coil 530 and causes coil vortex loss.

  In the reactor 550 shown in FIG. 10, the spread of the magnetic flux F is expected to be suppressed by making the width of the second leg portion 570c smaller than the width of the first leg portion 560c. However, although the width of the second leg portion 570c is smaller, it is necessary to pass all the magnetic flux F in this region, so that magnetic saturation is likely to occur. The occurrence of magnetic saturation is a factor that causes the generation of leakage flux FL.

  In order to avoid the generation of leakage magnetic flux, development of a core body having various shapes is conceivable. However, when the shape is complicated, it becomes difficult to manufacture the core body and also causes an increase in manufacturing cost.

  Accordingly, the present invention has been made in view of the above problems, and an object of the present invention is to provide a reactor having a structure that can easily manufacture a core body and prevent generation of leakage magnetic flux. There is.

  In the reactor according to the present invention, the first core body including a rectangular base body and a pair of side walls standing from both sides of the base body, and the first core body is arranged so as to span the pair of side walls, A rectangular second core body defining a housing space with the first core body, a third core body disposed in the housing space, and a winding core disposed in the housing space and wound around the third core body Coil.

  One end of the third core body is in contact with the base body, the other end side extends to the second core body side, the core portion around which the coil is wound, and the pair of the third core body on the other end side of the core portion. The gap plate is provided so as to project toward the side wall, and is disposed with the second gap between the second core body and the first gap, and is disposed with the pair of side walls and the second gap therebetween.

  In another embodiment, the width of the first gap is set smaller than the width of the second gap.

In another embodiment, the coil is all housed in the housing space.
In another embodiment, the first core body includes a powder core in which the base body and the pair of side walls are integrally molded with a powder containing magnetic powder, and the second core body includes magnetic powder. The third core body is composed of a dust core in which the core portion and the gap plate are integrally molded with a powder containing magnetic powder.

  According to the reactor based on this invention, it becomes possible to provide a reactor provided with the structure which can manufacture a core body easily and can prevent generation | occurrence | production of a leakage magnetic flux.

It is a figure which represents typically the drive unit of a hybrid vehicle. It is an electric circuit diagram which shows the structure of PCU in FIG. It is a disassembled perspective view of the reactor in embodiment which comprises the converter in FIG. It is a top view of the reactor in embodiment. It is a top view of the state which removed the 1st core body of the reactor in embodiment. It is sectional drawing of the reactor in embodiment. It is a top view of the other reactor in embodiment. It is a front view of the other reactor in embodiment. It is sectional drawing which shows the structure of the reactor in background art (patent document 1). It is sectional drawing which shows the structure of the reactor in background art (patent document 2).

  A reactor according to an embodiment of the present invention will be described below with reference to the drawings. Note that in the embodiments described below, when referring to the number, amount, and the like, the scope of the present invention is not necessarily limited to the number, amount, and the like unless otherwise specified. The same parts and corresponding parts are denoted by the same reference numerals, and redundant description may not be repeated. In addition, it is planned from the beginning to use the structures in the embodiments in appropriate combinations.

(Hybrid vehicle drive unit)
FIG. 1 schematically shows a drive unit of a hybrid vehicle. In the present embodiment, the reactor according to the present invention is applied to a converter mounted on a hybrid vehicle as a vehicle. First, an HV system for driving a hybrid vehicle will be described.

  Referring to FIG. 1, drive unit 1000 is provided in a hybrid vehicle that uses an internal combustion engine such as a gasoline engine or a diesel engine and a chargeable / dischargeable battery 800 as power sources. Drive unit 1000 includes motor generator 100, housing 200, speed reduction mechanism 300, differential mechanism 400, drive shaft receiving portion 900, and terminal block 600.

  The motor generator 100 is a rotating electrical machine having a function as an electric motor or a generator. Motor generator 100 includes a rotating shaft 110, a rotor 130, and a stator 140. The rotating shaft 110 is rotatably attached to the housing 200 via a bearing 120. The rotor 130 rotates integrally with the rotating shaft 110.

  The power output from the motor generator 100 is transmitted from the speed reduction mechanism 300 to the drive shaft receiving portion 900 via the differential mechanism 400. The driving force transmitted to the drive shaft receiving portion 900 is transmitted as a rotational force to the wheels via the drive shaft, thereby causing the vehicle to travel.

  On the other hand, during regenerative braking of the hybrid vehicle, the wheels are rotated by the inertial force of the vehicle body. Motor generator 100 is driven through drive shaft receiving portion 900, differential mechanism 400 and reduction mechanism 300 by the rotational force from the wheels. At this time, the motor generator 100 operates as a generator. The electric power generated by the motor generator 100 is supplied to the battery 800 via a PCU (Power Control Unit) 700.

(Electric circuit diagram showing the configuration of the PCU)
FIG. 2 is an electric circuit diagram showing the configuration of the PCU in FIG. Referring to FIG. 2, PCU 700 includes a converter 710, an inverter 720, a control device 730, capacitors C1 and C2, power supply lines PL1 to PL3, and output lines 740U, 740V, and 740W.

  Converter 710 is connected to battery 800 via power supply lines PL1 and PL3. Inverter 720 is connected to converter 710 through power supply lines PL2 and PL3. Inverter 720 is connected to motor generator 100 via output lines 740U, 740V, and 740W. The battery 800 is a direct current power source, and is formed of a secondary battery such as a nickel metal hydride battery or a lithium ion battery. Battery 800 is charged with the DC power supplied to converter 710 or supplied from converter 710.

Converter 710 includes an upper arm and a lower arm made of semiconductor modules, and a reactor L. The upper arm and the lower arm are connected in series between the power supply lines PL2 and PL3. The upper arm connected to the power supply line PL2 includes a power transistor (IGBT: Insulated Gate Bipolar Transistor) Q1 and a diode D1 connected in antiparallel to the power transistor Q1. The lower arm connected to the power supply line PL3 includes a power transistor Q2 and a diode D2 connected in antiparallel to the power transistor Q2. Reactor L is connected between power supply line PL1 and a connection point between the upper arm and the lower arm.

  Converter 710 boosts the DC voltage received from battery 800 using reactor L, and supplies the boosted voltage to power supply line PL2. Converter 710 steps down the DC voltage received from inverter 720 and charges battery 800.

  Inverter 720 includes a U-phase arm 750U, a V-phase arm 750V, and a W-phase arm 750W. U-phase arm 750U, V-phase arm 750V, and W-phase arm 750W are connected in parallel between power supply lines PL2 and PL3. Each of U-phase arm 750U, V-phase arm 750V, and W-phase arm 750W is composed of an upper arm and a lower arm made of semiconductor modules. The upper arm and lower arm of each phase arm are connected in series between power supply lines PL2 and PL3.

  The upper arm of U-phase arm 750U is composed of power transistor (IGBT) Q3 and diode D3 connected in antiparallel to power transistor Q3. The lower arm of U-phase arm 750U includes power transistor Q4 and diode D4 connected in antiparallel to power transistor Q4. The upper arm of V-phase arm 750V includes power transistor Q5 and diode D5 connected in antiparallel to power transistor Q5. The lower arm of V-phase arm 750V includes power transistor Q6 and diode D6 connected in antiparallel to power transistor Q6. The upper arm of W-phase arm 750W includes power transistor Q7 and diode D7 connected in antiparallel to power transistor Q7. The lower arm of W-phase arm 750W includes power transistor Q8 and diode D8 connected in antiparallel to power transistor Q8. The connection point of the power transistor of each phase arm is connected to the anti-neutral point side of the coil of the corresponding phase of motor generator 100 via corresponding output lines 740U, 740V, and 740W.

  In the figure, a case where the upper arm and the lower arm of the U-phase arm 750U to the W-phase arm 750W are each composed of one semiconductor module composed of a power transistor and a diode is shown. The semiconductor module may be configured.

  Inverter 720 converts a DC voltage received from power supply line PL <b> 2 into an AC voltage based on a control signal from control device 730, and outputs the AC voltage to motor generator 100. Inverter 720 rectifies the AC voltage generated by motor generator 100 into a DC voltage and supplies it to power supply line PL2.

  Capacitor C1 is connected between power supply lines PL1 and PL3, and smoothes the voltage level of power supply line PL1. Capacitor C2 is connected between power supply lines PL2 and PL3, and smoothes the voltage level of power supply line PL2.

  Control device 730 calculates each phase coil voltage of motor generator 100 based on the torque command value of motor generator 100, each phase current value, and the input voltage of inverter 720. Based on the calculation result, control device 730 generates a PWM (Pulse Width Modulation) signal for turning on / off power transistors Q <b> 3 to Q <b> 8 and outputs the generated signal to inverter 720. Each phase current value of motor generator 100 is detected by a current sensor incorporated in a semiconductor module constituting each arm of inverter 720. This current sensor is disposed in the semiconductor module so as to improve the S / N ratio. Control device 730 calculates the duty ratio of power transistors Q1 and Q2 for optimizing the input voltage of inverter 720 based on the torque command value and the motor speed described above. Based on the result, control device 730 generates a PWM signal for turning on / off power transistors Q1, Q2 and outputs the PWM signal to converter 710.

  Control device 730 controls the switching operation of power transistors Q <b> 1 to Q <b> 8 in converter 710 and inverter 720 to convert AC voltage generated by motor generator 100 into DC voltage and charge battery 800.

(Reactor 1)
FIG. 3 is an exploded perspective view showing reactor 1 in the present embodiment, which constitutes the converter in FIG. Referring to FIG. 3, reactor 1 in the present embodiment includes first core body 10, second core body 20, coil 30, and third core body 25 around which coil 30 is wound.

  The first core body 10 includes a rectangular base body 11 and a pair of side walls 12, 12 rising from both sides of the base body 11. The second core body 20 has a rectangular shape (plate shape) and is disposed so as to be spanned between the pair of side walls 12 and 12. In the present embodiment, the outer shape of the base body 11 and the outer shape of the second core body 20 are the same (vertical length L1, horizontal length L2, see FIG. 5).

  By arranging the second core body 20 on the pair of side walls 12, 12 of the first core body 10, a cubic accommodation space A <b> 1 is defined between the first core body 10 and the second core body 20. The

  The third core body 25 is disposed in the accommodation space A1. The third core body 25 is arranged so that one end thereof is in contact with the base body 11, and the other end side extends to the second core body 20 side, and a pair of side walls is provided on the other end side of the core part 26. 12 and 12 and a gap plate 27 provided so as to project toward the side. A coil 30 is wound around the core portion 26 so as to surround the core portion 26.

  The assembled state of reactor 1 in the embodiment will be described with reference to FIGS. 4 to 6. 4 is a plan view of the reactor 1, FIG. 5 is a plan view of the reactor 1 with the first core body removed, and FIG. 6 is a cross-sectional view of the reactor 1.

  In the present embodiment, each of the first core body 10, the second core body 20, and the third core body 25 has an easy form, and the first core body 10 has a C-shaped cross section, The two-core body 20 has an I-shaped cross section, and the third core body 25 has a T-shaped cross section. As the first core body 10, the second core body 20, and the third core body 25, dust cores (dust cores) obtained by press molding magnetic powder are used.

  The first core body 10 is composed of a powder core in which a base body 11 and a pair of side walls 12 and 12 are integrally molded with powder containing magnetic powder, and the second core body 20 is made of powder containing magnetic powder. The third core body 25 is composed of a compacted core in which the core portion 26 and the gap plate 27 are integrally molded with a powder containing magnetic powder. The dust core is suitable for a converter mounted on a hybrid vehicle because the magnetic flux density can be greatly utilized.

  For example, soft magnetic particles are used as the magnetic powder. As the soft magnetic particles, metal magnetic particles covered with an insulating coating are used. Examples of the metal magnetic particles include iron (Fe), iron (Fe) -silicon (Si) alloy, iron (Fe) -nitrogen (N) alloy, iron (Fe) -nickel (Ni) alloy, iron (Fe) -carbon (C) alloy, iron (Fe) -boron (B) alloy, iron (Fe) -cobalt (Co) alloy, iron (Fe) -phosphorus (P) alloy, iron (Fe ) -Nickel (Ni) -cobalt (Co) -based alloy and iron (Fe) -aluminum (Al) -silicon (Si) -based alloy.

  The first core body 10, the second core body 20, and the third core body 25 are not limited to using a powder core obtained by pressure molding magnetic powder, and amorphous, ferrite, or the like is used. Thus, it is possible to mold each core body.

  As shown in FIGS. 4 and 5, in a state where the third core body 25 in which the coil 30 is wound around the winding core portion 26 is disposed in the accommodation space A1, all of the coil 30 is accommodated in the accommodation space A1. The outer shape of the base body 11 and the outer shape of the second core body 20 are designed (vertical length L1, horizontal length L2). The width (W) of the gap plate 27 is designed to be smaller than the longitudinal length L1 of the base body 11.

  As shown in FIG. 6, in a state where the third core body 25 in which the coil 30 is wound around the core portion 26 is disposed in the accommodation space A <b> 1, one end of the core portion 26 is the base of the first core body 10. It arrange | positions so that the body 11 may be contacted.

  In addition, the gap plate 27 of the third core body 25 is disposed with the lower surface of the second core body 20 and the first gap G1 therebetween, and is disposed with the pair of side walls 12 and 12 and the second gap G2 therebetween. . In the present embodiment, the width (d1) of the first gap G1 is smaller than the width (d2) of the second gap G2.

  In the reactor 1 having the above configuration, as indicated by an arrow in FIG. 6, the magnetic flux F is the first core body 10 → the pair of side walls 12 and 12 → the base body 11 → the core part 26 → the gap plate 27 → The magnetic path of the first gap G1 / second gap G2 → first core body 10 is formed.

  In addition, since the length (GL) of the first gap G1 is sufficiently long, it is possible to suppress the occurrence of magnetic saturation. Moreover, since the width (d1) of the first gap G1 is provided smaller than the width (d2) of the second gap G2, the magnetic flux F passes through the first gap G1 preferentially. Thereby, generation | occurrence | production of a coil eddy loss by the magnetic flux leakage of the magnetic flux F which passes 2nd gap G2 can be prevented.

  In addition, as described above, the outer shape of the base body 11 and the outer shape of the second core body 20 are designed so that the entire coil 30 can be accommodated in the housing space A1, so that the reactor 1 as a whole is designed. The physique can be downsized.

  Furthermore, by forming the core body into a three-part structure of the first core body 10, the second core body 20, and the third core body 25, the shape of each core body becomes an easy shape and the manufacturing cost increases. Can be suppressed.

  Note that, as described above, in the present embodiment, it is possible to reduce the size of the reactor 1 as a whole by adopting a configuration in which all of the coils 30 are accommodated in the accommodation space A1, but the configuration is limited to this configuration. It is not a thing.

  It is also possible to change the form of the core body according to the installation space of the reactor. For example, as shown in FIGS. 7 and 8, the base body 11A and the pair of side walls 12A and 12A have the same length L1 and the width W of the gap plate 27, and the length of the base body 11A is L11 (L11>). L2), and a configuration in which the coil 30 protrudes from the accommodation space A1 is also possible. 7 and 8 are a plan view and a front view of the reactor 1A with the first core body 10A removed.

  In addition, this invention can also be applied to the reactor mounted in the fuel cell hybrid vehicle (FCHV: Fuel Cell Hybrid Vehicle) or electric vehicle (EV: Electric Vehicle) which uses a fuel cell and a secondary battery as a motive power source. . In the hybrid vehicle in the present embodiment, the internal combustion engine is driven at the fuel efficiency optimum operating point, whereas in the fuel cell hybrid vehicle, the fuel cell is driven at the power generation efficiency optimum operating point. The use of the secondary battery is basically the same for both hybrid vehicles.

  Although the embodiments of the present invention have been described above, the embodiments disclosed this time should be considered as illustrative in all points and not restrictive. The scope of the present invention is defined by the terms of the claims, and is intended to include any modifications within the scope and meaning equivalent to the terms of the claims.

  1, 1A reactor, 10 1st core body, 11, 11A base body, 12, 12A side wall, 20 2nd core body, 25 3rd core body, 26 winding core part, 27 gap plate, 30 coils, 100 motor generator, 110 Rotating shaft, 120 Bearing, 130 Rotor, 140 Stator, 200 Housing, 300 Reduction mechanism, 400 Differential mechanism, 600 Terminal block, 710 Converter, 720 Inverter, 730 Controller, 740U, 740V, 740W Output line, 750U U-phase arm 750V V-phase arm, 750W W-phase arm, 800 battery, 900 drive shaft receiver, 1000 drive unit, A1 accommodation space, G1 first gap, G2 second gap.

Claims (4)

  1. A first core body including a rectangular base body and a pair of side walls standing from both sides of the base body;
    A rectangular second core body that is arranged so as to be stretched over the pair of side walls, and that defines an accommodation space between the first core body;
    A third core body disposed in the accommodation space;
    A coil disposed in the housing space and wound around the third core body,
    The third core body is
    A core part around which one end contacts the base body and the other end side extends to the second core body side and the coil is wound;
    At the other end side of the winding core portion, it is provided so as to project toward the pair of side walls, and is disposed with a first gap between the second core body and the pair of side walls and the second gap. A reactor including a gap plate disposed apart from each other.
  2.   The reactor according to claim 1, wherein a width of the first gap is smaller than a width of the second gap.
  3.   The reactor according to claim 1, wherein all of the coil is housed in the housing space.
  4. The first core body is composed of a dust core in which the base body and the pair of side walls are integrally molded with a powder containing magnetic powder,
    The second core body is composed of a powder core obtained by molding a powder containing magnetic powder,
    The reactor according to any one of claims 1 to 3, wherein the third core body includes a powder core in which the core portion and the gap plate are integrally molded with a powder containing magnetic powder.
JP2011149020A 2011-07-05 2011-07-05 Reactor Withdrawn JP2013016682A (en)

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2016058690A (en) * 2014-09-12 2016-04-21 Necトーキン株式会社 Reactor

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2016058690A (en) * 2014-09-12 2016-04-21 Necトーキン株式会社 Reactor

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