JP3161494U - Winding core type unsaturated reactor with air gap - Google Patents

Abstract

The present invention provides a high performance unsaturated reactor which is reduced in size and has a high inductance value and a low manufacturing cost in place of the conventional voided core type unsaturated reactor using an EI type punched electromagnetic steel sheet. SOLUTION: A wound core having a high magnetic permeability and low magnetic resistance is used for the iron core, and this is wound around and attached to a winding mold, cured with an insulating varnish, dried, and dried on a wound core with a thin-blade disk-shaped rotating grindstone. We have developed and manufactured a voided core-type unsaturated reactor that can be miniaturized by applying a new tool that cuts the gap and has little change in inductance. [Selection] Figure 2

Description

  The present invention is a technical field related to improving the performance and reducing manufacturing costs of unsaturated reactors belonging to electromagnetic devices used in DC and AC circuits.

"Electrical Engineering Handbook", 16 editions, chapter 14 reactors, pages 838-839, 1978. Yoshimoto Omoto, Shouta Miyairi, "Contemporary Electrical Engineering Course Electrical Equipment III", Chapter 4, Reactor, pages 43-58, published by Ohm Co., Ltd., February 1957. Patent publication 2003-257745, wound core type reactor, wound core type transformer, and manufacturing methods thereof.

Reactors, like transformers, have a variety of characteristics, applications and forms ranging from those for power transmission systems to those for telecommunications equipment.
A linear reactor (or called a non-saturated reactor) whose inductance is constant regardless of the magnitude of the flowing current due to its characteristics, and a nonlinear reactor (or called a saturated reactor) whose inductance changes depending on the magnitude of the flowing current. is there.
When the reactor is used as a circuit element of the device, the operating condition of the circuit changes if the magnitude of the inductance changes due to the change of the flowing current, and if this causes a hindrance to the operation of the device, the unsaturated reactor is adopted. The

  Non-saturated reactors are classified into air core reactors and iron core type reactors in terms of structure. The air-core type has almost no inductance because the magnetic path is not saturated. However, since the magnetic permeability is low, the structure is large and an extremely large installation place is required. There are two types of core type: closed core type unsaturated reactor and void core type unsaturated reactor. As shown in Non-Patent Documents 1 and 2, since the magnetic permeability is high in the iron core type, the magnetic flux interlinking with the winding coil becomes very large, and a large inductance value can be obtained even with a small size. It is not frequently used because there are defects that are likely to occur.

The closed core type has a drawback that a magnetic flux due to a magnetomotive force is generated when a current is passed through a wound winding coil, so that the magnetic saturation value inherent to the iron magnetic path is easily reached, and the inductance decreases with increasing current flow. The air core type with air gap has intermediate performance between the air core type and the closed core type, and the magnetic resistance of the magnetic path is increased due to the air gap, and the generated magnetic flux is low even if a large current is passed through the winding coil. The magnetic saturation value is not reached, and the inductance values are almost the same regardless of the magnitude of the conduction current. As a result, the core reactor with a gap is selected as the unsaturated reactor.
The present invention relates to a technique for improving the characteristics and reducing the manufacturing cost of a voided core type unsaturated reactor that is widely used in the field of electric power and electronic communication.

Up to now, the core-type unsaturated reactor with a gap has a magnetic path formed by laminating iron magnetic paths using EI-type punched magnetic steel sheets, and a certain interval of gaps are given to the cross section of the magnetic path to cause magnetic saturation. The structure is not allowed. When laminating, the magnetic steel sheets punched out one by one are butt-joined, so the magnetic resistance of the iron magnetic path becomes large and the magnetic flux cannot be made large, and as a result it is difficult to obtain a large value of inductance. Met.
Since it is necessary to increase the magnetic flux and increase the cross section of the iron magnetic path in order to produce unsaturated reactance with a large inductance value, the core-type unsaturated reactor with a gap increases the physique volume and increases the production cost. There are issues to be solved.

  At the same time, it is necessary to sandwich the EI-type punched electromagnetic steel sheets one by one in a winding coil prepared in advance, and there is a problem of raising the manufacturing cost.

  Instead of the EI punched electromagnetic steel sheet, a wound core having a structure in which a long electromagnetic steel sheet is wound in a belt shape has been used for a transformer or the like. Since the wound core has no butt joint in the magnetic path, the magnetic resistance is small and the magnetic flux can be increased. When the same inductance value is obtained, the physique capacity can be reduced compared to the EI electromagnetic steel sheet core. However, there is a problem to be overcome in terms of machining that it is difficult to cut the wound core magnetic path with a thin-blade disk-shaped rotating grindstone or a gold saw in order to create a gap in the wound core due to the hardness of the material.

  Although the patent literature shows a method for creating a gap in the cross section of the wound core magnetic path, it is necessary to cut and wrap the wound cores one by one and combine them together. There is a problem to be solved in manufacturing that raises costs and loses the features of the wound core.

The use of a wound core is more effective for reducing the size and weight and reducing the manufacturing cost than the conventional core-type unsaturated reactor with a void is made of an EI punched electromagnetic steel plate.
The present invention proposes a voided wound core type unsaturated reactor in which the core of the voided core type unsaturated reactor is constituted by a wound core, and shows the means for solving the problems to be solved in manufacturing as follows. .

First, a belt-shaped electrical steel sheet was first rewound around each side of the winding formwork according to the size of the "B" -shaped winding formwork, with a cylindrical space at the center. Alternatively, two or more wound cores are wound to complete the wound core. FIG. 1 shows a wound iron core and a winding formwork.
Next, the entire structure composed of the wound winding formwork and the wound iron core is impregnated with an electrically insulating varnish solution, and then taken out and dried. After drying, all the wound cores are cut with a thin-blade disk-shaped rotating grindstone to cut the magnetic path cross-sections to create voids, thereby completing voided core-type unsaturated reactors. FIG. 2 shows a configuration diagram thereof.

  In order to maintain the gap length in the wound iron core with high accuracy, after cutting with a thin blade-shaped rotating grindstone, a flat plate material having a thickness corresponding to the gap length is sandwiched in the electrically insulating magnetic path cross section. If necessary, they are bound with a nonmagnetic hard band to prevent the wound core from unwinding.

  When adjusting the inductance value of the iron core type unsaturated reactor with a gap, it is possible to provide a winding intermediate terminal on the winding coil of the winding mold frame and select a terminal according to the circuit constant.

  It is also possible to finely adjust the inductance value by mutually rotating the gap arrangement positions of the wound cores. This is because the way of the lines of magnetic force due to the magnetic flux fringing in the gap changes.

  An embodiment for realizing the present invention is a drawing after completion of FIG.

Effect of device

  Table 1 shows the degree of non-saturation of the voided wound core type reactor proposed in the present invention. The specifications of the prototype coreless type unsaturated reactor with a gap are two wound cores, the gap spacing is 2 mm, the winding diameter is 1.0 mm, the number of turns is 185 (solid line), and 1.2 mm is 120 (broken line). is there. It is the result of measuring the value of the inductance when the current is increased in this reactor. According to this, both show a substantially constant value with a wide variation range of the current value. It can be seen from this that the non-saturation characteristic is sufficiently obtained.

Table 2 shows the measurement results in the case where the wound core-type reactor with the gap proposed in the present invention has two wound cores, and the gap positions are adjusted by changing each other. The measurement conditions are as follows: (1) When both gaps are directed inward, (2) When placed so that their backs face each other, (3) When placed so as to be parallel to each other, (4 ) The result of measuring the inductance value for the arrangement condition when one side is rotated 90 degrees is shown. From this, the case of (1) was selected as 1 and compared with the other cases. In the case of (2), it was 1.23 times, in (3) it was 1.16 times, and in (4) it was 1.19 times. Thus, there is an effect that the inductance value of the wound core type unsaturated reactor with a gap can be finely adjusted by the difference in the relative position of the gap.

Best mode for carrying out the invention

  FIG. 2 shows the best mode for carrying out the present invention.

  As shown in Tables 1 and 2, the degree of non-saturation region and the fine adjustment function of the inductance were confirmed, and examples were shown.

  The voided wound core type unsaturated reactor according to the present invention is reduced in manufacturing cost by being smaller and lighter and easy to manufacture, and has excellent characteristics without saturation. It has the feature of being adjustable, and is expected to be used and introduced in the industrial fields for electronic communication and electric power that will require unsaturated reactors.

FIG. 1 shows components of a voided wound core type unsaturated reactor according to the present invention. Reference numeral (1) indicates a wound iron core, and (2) indicates the start and end of winding of the winding coil. (3) is a "B" -shaped winding formwork on which windings have been wound.
FIG. 2 is a completed drawing of a voided wound core type unsaturated reactor in which a void is cut in the wound core portion after being attached and dried. Reference numeral (4) represents a gap in the wound iron core.

Shows the components of a voided wound core type unsaturated reactor according to the present invention. Reference numeral (1) indicates a wound iron core, and (2) indicates the start and end of winding of the winding coil. (3) is a "B" -shaped winding formwork on which windings have been wound. FIG. 4 is a completed view of a voided wound core type unsaturated reactor in which a void is cut in the wound core portion after impregnating and drying the attached electric insulating varnish. Reference numeral (4) represents a gap in the wound core.

The present invention relates to a technical field related to performance improvement and production cost reduction of unsaturated reactors belonging to electromagnetic devices used in DC and AC circuits.

"Electrical Engineering Handbook", 16 editions, chapter 14 reactors, pages 838-839, 1978. Yoshimoto Omoto, Shouta Miyairi, "Contemporary Electrical Engineering Course Electrical Equipment III", Chapter 4, Reactor, pages 43-58, published by Ohm Co., Ltd., February 1957.

Patent publication 2003-257745, wound core type reactor, wound core type transformer, and manufacturing methods thereof.

Reactors, like transformers, have a variety of characteristics, applications and forms ranging from those for power transmission systems to those for telecommunications equipment.
A linear reactor (or called a non-saturated reactor) whose inductance is constant regardless of the magnitude of the flowing current due to its characteristics, and a nonlinear reactor (or called a saturated reactor) whose inductance changes depending on the magnitude of the flowing current. is there.
When the reactor is used as a circuit element of the device, the operating condition of the circuit changes when the magnitude of the inductance changes due to the change of the reading current, and if this causes trouble in the operation of the device, the unsaturated reactor is adopted. .

  Non-saturated reactors are classified into air core reactors and iron core type reactors in terms of structure. The air-core type has almost no inductance because the magnetic path is not saturated. However, since the magnetic permeability is low, the structure is large and an extremely large installation place is required. There are two types of core type: closed core type unsaturated reactor and void core type unsaturated reactor. As shown in Non-Patent Documents 1 and 2, since the magnetic permeability is high in the iron core type, the magnetic flux interlinking with the winding coil becomes very large, and a large inductance value can be obtained even with a small size. It is not frequently used because there are defects that are likely to occur.

The closed core type has a drawback that a magnetic flux due to a magnetomotive force is generated when a current is passed through a wound winding coil, so that the magnetic saturation value inherent to the iron magnetic path is easily reached, and the inductance decreases with increasing current flow. The air core type with air gap has intermediate performance between the air core type and the closed core type, and the magnetic resistance of the magnetic path is increased due to the air gap, and the generated magnetic flux is low even if a large current is passed through the winding coil. The magnetic saturation value is not reached, and the inductance values are almost the same regardless of the magnitude of the conduction current. As a result, the core reactor with a gap is selected as the unsaturated reactor.
The present invention relates to a technique for improving the characteristics and reducing the manufacturing cost of a voided core type unsaturated reactor that is widely used in the field of electric power and electronic communication.

Up to now, the core-type unsaturated reactor with a gap has a magnetic path formed by laminating iron magnetic paths using EI-type punched magnetic steel sheets, and a certain interval of gaps are given to the cross section of the magnetic path to cause magnetic saturation. The structure is not allowed. When laminating, the magnetic steel sheets punched out one by one are butt-joined, so the magnetic resistance of the iron magnetic path becomes large and the magnetic flux cannot be made large, and as a result it is difficult to obtain a large value of inductance. Met.
Since it is necessary to increase the magnetic flux and increase the cross section of the iron magnetic path in order to produce unsaturated reactance with a large inductance value, the core-type unsaturated reactor with a gap increases the physique volume and increases the production cost. There are issues to be solved.

  At the same time, it is essential to sandwich the EI-type punched electromagnetic steel sheets one by one in a winding coil prepared in advance, and there is a problem that the manufacturing cost is increased.

Instead of the EI punched electromagnetic steel sheet, a wound core having a structure in which a long electromagnetic steel sheet is wound in a belt shape has been used for a transformer or the like. Since the wound core has no butt joint in the magnetic path, the magnetic resistance is small and the magnetic flux can be increased. When the same inductance value is obtained, the physique capacity can be reduced compared to the EI electromagnetic steel sheet core. However, there is a problem to be overcome in terms of machining that it is difficult to cut the wound core magnetic path with a thin-blade disk-shaped rotating grindstone or a gold saw in order to create a gap in the wound core due to the hardness of the material.

  Although the patent literature shows a method for creating a gap in the cross section of the wound core magnetic path, it is necessary to cut and wrap the wound cores one by one and combine them, and it is manufactured in the same way as when using EI punched electrical steel sheets. There is a problem to be solved in manufacturing that raises costs and loses the features of the wound core.

The use of a wound core is more effective for reducing the size and weight and reducing the manufacturing cost than the conventional core-type unsaturated reactor with a void is made of an EI punched electromagnetic steel plate.
The present invention proposes a voided wound core type unsaturated reactor in which the core of the voided core type unsaturated reactor is constituted by a wound core, and shows the means for solving the problems to be solved in manufacturing as follows. .

First, a belt-shaped electrical steel sheet was first rewound around each side of the winding formwork according to the size of the "B" -shaped winding formwork, with a cylindrical space at the center. Alternatively, two or more wound cores are wound to complete the wound core. FIG. 1 shows a wound iron core and a winding formwork.
Next, the entire structure consisting of the wound wire form and the wound iron core is impregnated with an electrically insulating varnish solution, and then taken out and dried. After drying, all the wound cores are cut with a thin-blade disk-shaped rotating grindstone to cut the magnetic path cross-sections to create voids, thereby completing voided core-type unsaturated reactors. FIG. 2 shows a configuration diagram thereof.

  In order to maintain the gap length in the wound iron core with high accuracy, after cutting with a thin blade rotating grindstone, a flat plate material having a thickness corresponding to the gap length is sandwiched between electrically insulating magnetic path sections. If necessary, they are bound with a nonmagnetic hard band to prevent the wound core from unwinding.

  When adjusting the inductance value of the iron core type unsaturated reactor with a gap, it is possible to provide a winding intermediate terminal on the winding coil of the wire frame and select a terminal along the circuit constant.

It is also possible to finely adjust the inductance value by mutually rotating the gap arrangement positions of the wound cores. This is because the way of the lines of magnetic force due to the magnetic flux fringing in the gap changes.

Table 1 shows the degree of non-saturation of the voided wound core type reactor proposed in the present invention. The specifications of the prototype coreless type unsaturated reactor with a gap are two wound cores, the gap spacing is 2 mm, the winding diameter is 1.0 mm, the number of turns is 185 (solid line), and 1.2 mm is 120 (broken line). is there. It is the result of measuring the value of the inductance when the current is increased in this reactor. According to this, both show a substantially constant value with a wide variation range of the current value. It can be seen from this that the non-saturation characteristic is sufficiently obtained.

  FIG. 2 shows the best mode for carrying out the present invention.

  As shown in Tables 1 and 2, the degree of non-saturation region and the fine adjustment function of the inductance were confirmed, and examples were shown.

An embodiment for realizing the present invention is a drawing after completion of FIG.
Table 2 shows the measurement results in the case where the wound core-type reactor with the gap proposed in the present invention has two wound cores, and the gap positions are adjusted by changing each other. The measurement conditions are as follows: (1) When both gaps are directed inward, (2) When placed so that their backs face each other, (3) When placed so as to be parallel to each other, (4 ) The result of measuring the inductance value for the arrangement condition when one side is rotated 90 degrees is shown. From this, the case of (1) was selected as 1 and compared with the other cases. In the case of (2), it was 1.23 times, in (3) it was 1.16 times, and in (4) it was 1.19 times. Thus, there is an effect that the inductance value of the wound core type unsaturated reactor with a gap can be finely adjusted by the difference in the relative position of the gap.

FIG. 1 shows components of a voided wound core type unsaturated reactor according to the present invention.
FIG. 2 is a completed view of a void-wound wound core type unsaturated reactor in which a void is cut in the wound iron core after impregnating and drying the attached electrically insulating varnish.

The voided wound core type unsaturated reactor according to the present invention is reduced in manufacturing cost by being smaller and lighter and simpler to manufacture, and has excellent characteristics without saturation. It has the feature of being adjustable, and is expected to be used and introduced in the industrial fields for electronic communication and electric power that will require unsaturated reactors in the future.

Reference numeral 1 denotes a wound iron core.
Reference numeral 2 indicates the beginning and end of winding of the winding coil.
Reference numeral 3 denotes a “B” -shaped winding formwork on which windings have been wound.
Reference numeral 4 represents a gap in the wound core.

Claims (5)

  Winding of “B” shape using one or more wound cores with a space in the magnetic path cross section of a magnetic steel coil wound core wound in a belt shape with a space in the center A voided wound iron core type unsaturated reactor characterized by being wound around a winding formwork.   The voided wound core type unsaturated reactor according to claim 1, wherein after the step of incorporating the wound core into the winding formwork, the machined machining is facilitated after being impregnated with an electric insulating varnish and cured. .   The void according to claim 1, wherein only the wound iron core after hardening shown in claim 2 is provided with a void in a long cross-section of the wound core magnetic path by cutting with a thin blade disk-shaped rotary grindstone or a gold saw. Attached iron core type unsaturated reactor.   In order to maintain the specified width in the gap of the gap-wound core shown in claim 3, a non-magnetic body having electrical insulation is sandwiched, and if necessary, a non-magnetic body is used to prevent the gap-winding core from unwinding. The hollow wound core type unsaturated reactor according to claim 1, wherein a cylindrical portion of the hollow wound core is bundled.   When using two or more wound cores with gaps, it is possible to adjust the value of inductance by changing the orientation angle between the gaps of the wound cores and the gaps of other wound cores. A voided wound core type unsaturated reactor according to claim 1.

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