JP2014216586A - Resistor, wind generator system, motor control system, and manufacturing method for resistor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a resistor with excellent heat dissipation, wind generator system, motor control system, and manufacturing method for resistor.SOLUTION: Each of resistors 10 includes a resistive element R which is folded back at a predetermined position in the lengthwise direction and has a plurality of overlapping sections 22 overlapped through clearances; insulation sheets ST inserted between the plurality of overlapping sections 22.

Description

  The present invention relates to a resistor, a wind power generation system, a motor control system, and a method for manufacturing a resistor.

  In Patent Document 1, the both ends of a plurality of flat resistance elements are alternately welded and connected in series in a zigzag shape, and the projections formed on the welded ends are slotted in a rectangular frame. Describes an electric vehicle resistor inserted and supported.

Japanese Utility Model Publication No. 60-25103

Here, the resistor is generally used continuously. However, in order to flow a large current in a short time (for example, a maximum current of 500 A for 7 seconds or less), it is desired to develop a resistor with excellent heat dissipation.
It is an object of the present invention to provide a resistor, a wind power generation system, a motor control system, and a method for manufacturing a resistor that are excellent in heat dissipation.

The resistor according to the first aspect of the present invention that meets the above-mentioned object is a resistor having a plurality of folded portions that are folded at predetermined positions in the longitudinal direction and stacked via a gap,
And an insulating sheet inserted between the plurality of folded portions.

In the resistor according to the first invention,
The material of the resistor is metal,
The material of the insulating sheet is preferably mica.

In the resistor according to the first invention,
It is preferable that the resistor into which the insulating sheet is inserted is covered with an insulator.

In the resistor according to the first invention,
The insulator includes a first insulating portion that covers the outside of the resistor;
And a second insulating portion that covers the outside of the first insulating portion.

In the resistor according to the first invention,
The material of the first insulating part and the second insulating part is preferably soft laminated mica.

  A wind power generation system according to a second invention that meets the above object includes the resistor according to the first invention.

  An electric motor control system according to a third invention that meets the above object includes the resistor according to the first invention.

A method of manufacturing a resistor according to a fourth invention that meets the above-described object includes a step of processing a metal body into a strip shape,
Folding the metal body at a predetermined position in the longitudinal direction, and forming a resistor having a plurality of folded portions stacked via a gap;
Inserting an insulating sheet into the gap;
Applying a force in the direction of compressing and crushing the resistor;
Attaching a terminal to each end of the resistor;
Covering the resistor in which the insulating sheet is inserted with an insulator.

  ADVANTAGE OF THE INVENTION According to this invention, the manufacturing method of the resistor excellent in heat dissipation, a wind power generator system, an electric motor control system, and a resistor can be provided.

It is a perspective view of the resistor concerning one embodiment of the present invention. It is a perspective view of the resistor of the resistor. It is explanatory drawing which shows the process in which an insulating sheet is inserted in the resistor of the same resistor. It is explanatory drawing which shows the process in which the resistor of the same resistor is covered with a 1st insulating part. It is explanatory drawing which shows the process in which the resistor of the same resistor is covered with a 2nd insulation part. It is explanatory drawing which shows the state by which the fastening body was attached to the resistor of the resistor.

  Next, embodiments of the present invention will be described with reference to the accompanying drawings for understanding of the present invention. In each drawing, portions not related to the description may be omitted.

The resistor 10 (refer FIG. 1) which concerns on one embodiment of this invention is used for a wind power generation system or an electric motor control system, for example, and can flow the electric current for a maximum of 500 A and 7 seconds or less, for example. In addition, the resistor 100 shown in FIG. 1 is configured in such a manner that the resistors 10 are arranged in a direction crossing the longitudinal direction and connected in series.
The resistor 10 has a rectangular parallelepiped shape. The resistor 10 includes a resistor R, an insulating sheet ST, an insulator 16, a terminal 18, and a fastening body 20 (see FIGS. 1 and 3).

The resistor R is made of metal, for example. As shown in FIG. 2, the resistor R has a plurality of folded portions 22 that are folded back at predetermined positions in the longitudinal direction and overlapped via gaps.
Note that the resistor R is not limited to a metal as long as it functions as a resistor.

The insulating sheet ST is, for example, soft laminated mica (an example of mica). As shown in FIG. 3, the insulating sheet ST is inserted between the plurality of folded portions 22 formed in the resistor R, respectively.
Since the insulating sheet ST is inserted between each of the plurality of folded portions 22, insulation between adjacent folded portions 22 is ensured. Further, the heat generated in the resistor R is transferred to the outside through the insulating sheet ST.

The insulator 16 (see FIG. 1) is composed of at least a first insulating portion 161 (see FIG. 4) and a second insulating portion 162 (see FIG. 5), and covers the resistor R and the insulating sheet ST.
As shown in FIG. 4, the first insulating portion 161 includes sheet-like first to sixth sheet members 161 a to 161 f. The material of each of the members 161a to 161f is, for example, soft laminated mica.
The first to sixth sheet members 161a to 161f are respectively a front side, a back side, a left side, a right side, and an upper side of the resistor R in which an insulating sheet ST (not shown in FIG. 4) is inserted. And to cover the lower surface side.

As shown in FIG. 5, the second insulating portion 162 includes channel-shaped first to fourth channel members 162 a to 162 d. The material of each member 162a-162d is a soft laminated mica, for example.
The first to fourth channel members 162a to 162d have a recess side inside, and the resistor R and the insulating sheet ST covered with the first insulating portion 161 are respectively an upper surface side, a lower surface side, a front side, and It is provided so as to cover from the back side. However, the first and second channel members 162a and 162b are disposed below the third and fourth channel members 162c and 162d (see FIG. 6).

  The terminal 18 is a plate-shaped metal, for example. The material of the terminal 18 is, for example, stainless steel (SUS304). As shown in FIG. 1, the terminal 18 is provided so as to protrude in the same direction from the end portion of the resistor 10 in the longitudinal direction. Specifically, as shown in FIG. 3, the resistor R is provided at both ends. One terminal 18 is welded to the upper surface of the end of the resistor R. The other terminal 18 is welded to the lower surface of the end of the resistor R.

  As shown in FIG. 6, the fastening body 20 (see FIG. 1) includes first to third fasteners 20 a to 20 c for fixing the second insulating portion 162 by sandwiching the second insulating portion 162 from both sides. Yes. The first to third fasteners 20 a to 20 c are arranged at intervals in the longitudinal direction of the resistor 10. Since the first to third fasteners are respectively disposed in the longitudinal direction of the resistor 10, the terminals 18 are compared with the case in which the first to third fasteners are disposed in a direction (vertical direction) orthogonal to the longitudinal direction of the resistor 10. The creepage distance from is secured.

The first fastener 20a includes at least a left metal fitting 20aL located on the left side surface and a right metal fitting 20aR located on the right side surface.
The left metal fitting 20aL has a contact portion 202 that comes into contact with the upper surface, the side surface, and the lower surface of the left side of the second insulating portion 162 when viewed from the back side. The left metal fitting 20aL includes an upper claw 204U that protrudes upward from the upper end portion of the contact portion 202 and a lower claw 204D that protrudes downward from the lower end portion of the contact portion 202.

The right metal fitting 20aR has a contact portion 202 that contacts the upper surface, the side surface, and the lower surface of the right side of the second insulating portion 162 when viewed from the back side. The right metal fitting 20aR has an upper claw 204U that protrudes upward from the upper end portion of the contact portion 202 and a lower claw 204D that protrudes downward from the lower end portion of the contact portion 202.
The first fastener 20a is connected to the ground.

  The second fastener 20b is disposed closer to the terminal 18 in the longitudinal direction of the resistor 10 than the first fastener 20a. The structure of the second fastener 20b is the same as that of the first fastener 20a, and the left metal fitting 20bL and the right metal fitting 20bR each have a contact portion, an upper claw, and a lower claw. However, the width dimension (dimension w shown in FIG. 6) of the second fastener 20b is smaller than the width dimension of the first fastener 20a.

  The 3rd fastener 20c is arrange | positioned on the opposite side to the terminal 18 side of the longitudinal direction of the resistor 10 rather than the 1st fastener 20a. The configuration of the third fastener 20c is the same as that of the first fastener 20a, and the left metal fitting 20cL and the right metal fitting 20cR each have a contact portion, an upper claw, and a lower claw. However, the width dimension of the third fastener 20c is smaller than the width dimension of the first fastener.

  Next, a method for manufacturing the resistor 10 will be described. The resistor 10 is manufactured through the steps shown below.

(Process S1)
A metal body to be the resistor R is processed into a strip shape. The material of the resistor R is, for example, a heating resistor such as HOM125.

(Process S2)
The metal bodies are folded back at predetermined positions in the longitudinal direction. As a result, a resistor R having a plurality of folded portions 22 that are overlapped via the gap is formed (see FIG. 2).

(Process S3)
The insulating sheet ST is inserted into each gap formed between the adjacent folded portions 22 (see FIG. 3). Each insulating sheet ST is in the shape of a strip, and its size is such that it protrudes from the folded portion 22 by, for example, 2 to 5 mm.

(Process S4)
In order to make the resistor R and each insulating sheet ST more closely contact each other, a force is applied in a direction in which the resistor R is compressed and crushed in a state where each resistor sheet R is inserted into the resistor R.

(Process S5)
The terminals 18 are attached to both ends of the resistor R by TIG welding.

(Step S6)
The first insulating portion 161 covers the resistor R in which the insulating sheet ST is inserted except for the portion of the terminal 18 (see FIG. 4).

(Step S7)
The resistor R is further covered with the second insulating portion 162 (see FIG. 5). Specifically, first, the resistor R and the insulating sheet ST covered with the first insulating portion 161 are covered from the upper surface side and the lower surface side using the first and second channel members 162a and 162b, respectively. The distal ends of the first and second channel members 162a and 162b are abutted with each other at the center in the vertical direction on the left and right side surfaces of the resistor R.
Next, the first and second channel members 162a and 162b are covered from the front side and the back side using the third and fourth channel members 162c and 162d, respectively. The distal ends of the third and fourth channel members 162c and 162d are abutted against each other at the longitudinal center portions (position X shown in FIG. 6) of the left and right side surfaces of the resistor R.

  Thus, since the third and fourth channel members 162c, 162d cover the first and second channel members 162a, 162b, the third and fourth channel members are covered by the first and second channel members. The form of the insulator 16 is stabilized as compared with the case of covering.

(Step S8)
The second insulating portion 162 is sandwiched by the first fastener 20a, and the upper claw 204U and the lower claw 204D of the left metal fitting 20aL and the right metal fitting 20aR are TIG welded to each other (see FIG. 6).

(Process S9)
The second insulating portion 162 is sandwiched by the second fastener 20b, and the upper and lower claws of the left metal fitting 20bL and the right metal fitting 20bR are TIG welded respectively.

(Step S10)
The second insulating portion 162 is sandwiched by the third fastener 20c, and the upper and lower claws of the left metal fitting 20cL and the right metal fitting 20cR are TIG welded together.

  The resistor 10 is manufactured by performing the above steps. In order to manufacture the resistor 100 having a desired resistance value by connecting the single resistors 10 in series, the following steps are further performed.

(Process S11)
The necessary numbers of resistors 10 are arranged with the terminals 18 aligned.

(Process S12)
Adjacent terminals 18 are welded with a copper bar 30 and the resistors 10 are connected in series. As a result, the resistor 100 shown in FIG. 1 is completed.

(Process S13)
The claws of the first fasteners 20a of the resistors 10 are TIG welded to each other by, for example, a stainless steel plate (not shown), and the resistors 10 are integrated.

(Step S14)
The integrated resistor 100 is housed in a housing. Each first fastener 20a is connected to a housing (not shown) connected to the ground. Accordingly, each first fastener 20a is connected to the ground.

The resistor 10 manufactured by the above-described process is excellent in heat dissipation because the heat generated in the resistor R is released to the outside through the insulating sheet ST.
It should be noted that the above-described steps may be replaced and executed if possible without being sequentially executed.

The present invention is not limited to the above-described embodiment, and modifications can be made without changing the gist of the present invention. For example, a case where the invention is configured by combining some or all of the above-described embodiments and modifications is also included in the technical scope of the present invention.
The above expressions such as “upper side” and “lower side” are merely used for convenience of explanation, and the installation direction of the resistor is not limited.

10: resistor, 16: insulator, 18: terminal, 20: fastener, 20a: first fastener, 20aL: left bracket, 20aR: right bracket, 20b: second fastener, 20c: third Fastener, 22: folded portion, 30: copper bar, 100: resistor, 161: first insulating portion, 161a: first sheet member, 161b: second sheet member, 161c: third sheet member , 161d: fourth sheet member, 161e: fifth sheet member, 161f: sixth sheet member, 162: second insulating portion, 162a: first channel member, 162b: second channel member, 162c : Third channel member, 162d: fourth channel member, 202: contact portion, 204D: lower nail, 204U: upper nail, R: resistor, ST: insulating sheet

Claims (8)

A resistor having a plurality of folded portions that are folded at predetermined positions in the longitudinal direction and stacked via a gap;
And an insulating sheet inserted between the plurality of folded portions. The resistor of claim 1, wherein
The material of the resistor is metal,
The insulating sheet is made of mica. The resistor according to claim 1 or 2,
A resistor in which the resistor in which the insulating sheet is inserted is covered with an insulator. The resistor of claim 3,
The insulator includes a first insulating portion that covers the outside of the resistor;
And a second insulating portion that covers the outside of the first insulating portion. The resistor of claim 4, wherein
A resistor in which the material of the first insulating part and the second insulating part is soft laminated mica.   The wind power generation system provided with the resistor of any one of Claims 1-5.   The electric motor control system provided with the resistor of any one of Claims 1-5. Processing the metal body into a strip shape;
Folding the metal body at a predetermined position in the longitudinal direction, and forming a resistor having a plurality of folded portions stacked via a gap;
Inserting an insulating sheet into the gap;
Applying a force in the direction of compressing and crushing the resistor;
Attaching a terminal to each end of the resistor;
Covering the resistor with the insulating sheet inserted therein with an insulator.

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