JP3379419B2 - Composite reactor, manufacturing method thereof and power supply device - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a reactor for an electric / electronic device employing an inverter circuit and a DC power supply device using the reactor.

[0002]

2. Description of the Related Art Conventionally, an inverter control system, which takes advantage of its fine output control, has been widely introduced in home electric appliances and the like, and the input current waveform is improved to suppress the current peak value and improve the power factor. A reactor was being used to do this.

In recent years, due to the circumstances of electric and electronic equipment both in Japan and overseas, there has been an increasing tendency to further improve the current waveform to achieve so-called harmonic suppression, such as the introduction of a chopper circuit. The active filter method mainly taking measures on the electronic circuit, and mainly FIG.
A passive filter system in which two individual reactors shown in 9 are connected between a rectifying diode bridge and a smoothing capacitor has been adopted.

That is, as shown in FIG. 29, a conventional individual reactor has an E-shaped iron core 102 having a core gap formed in a central magnetic leg portion, an I-shaped iron core 101 facing the E-shaped iron core 102, a coil 103, and a core 103. Has an insulating paper 104 for insulating the
It is configured to be attached to an electric device via the attachment plate 105.

[0005]

In the case of the conventional active filter method, almost complete effect can be expected as a harmonic current suppressing measure, but the cost becomes high, and a practically lower cost measure is desired. . Therefore, even with the passive filter method, which is more cost effective than the active filter method, it is possible to configure the required two inductances with two independent reactors, but it has the drawback of making the equipment heavy and increasing the volume. Was there. Even if an attempt was made to realize a reactor in which the two required inductances were simply integrated as they were, the mutual inductance had a large effect and the harmonic current suppressing effect was poor.

The present invention has been made to solve the above problems, and an object of the present invention is to provide a composite reactor suitable for a passive filter for suppressing harmonic current, which is cheaper, smaller and lighter than conventional ones, a manufacturing method thereof, and a power supply device. .

[0007]

A first means of the present invention for achieving this object is to laminate a first iron core portion on which electromagnetic steel sheets are laminated and a first coil is attached, and to laminate electromagnetic steel sheets. A bridging iron core portion for forming an unsaturated closed magnetic circuit in the first and second iron core portions through a predetermined core gap by laminating a second iron core portion having the second coil inserted therein and an electromagnetic steel plate. Have
There is provided a third iron core portion in which the magnetic fluxes of the first coil and the second coil flow in mutually offset directions during at least a part of each cycle of the commercial power source. The third iron core part is arranged between the bridging core parts via a small core gap smaller than the core gap, and the first, second and third iron core parts and the bridging core part are fixed. It is fixed integrally by means.

The third means of the present invention is, in the first means, an iron core portion dimension such that at least the end surfaces of the first, second and third iron core portions are respectively housed in both end surfaces of the bridging iron core portion, It is a butt position.

According to a fourth means of the present invention, in the first means, the cross-sectional area of the third iron core portion is 5% or more of the sum of the cross-sectional areas of the first iron core portion and the second iron core portion. It is a thing.

The fifth means of the present invention is the first means, wherein in the first means, the size of the small core gap between the third iron core portion and the bridging iron core portion is set between the first iron core portion and the bridging iron core portion. Of 40% or less of the predetermined core gap dimension and 40% or less of the predetermined core gap dimension between the second iron core portion and the bridging iron core portion.

The sixth means of the present invention is the same as the first means, wherein the unsaturated magnetic circuit formed by the iron core portions is
The two coils are integrally fixed so as to have any one of the shape of a substantially day shape, the shape of a substantially square shape, and the shape of a substantially square shape when viewed from above and below.

Further, according to the manufacturing method of the present invention, the first iron core portion formed by laminating the electromagnetic steel plates having the first coil inserted therein and the electromagnetic steel sheets having the second coil inserted therein are laminated. A second iron core portion and a bridging iron core portion formed by laminating electromagnetic steel sheets for forming an unsaturated magnetic path on the first and second iron core portions via predetermined core gaps, respectively. A third core portion in which magnetic fluxes of the first coil and the second coil flow in mutually offset directions during at least a part of each cycle of the commercial power supply; By disposing the third core portion between the bridging core portions via a magnetic flux path, a magnetic path having an approximately day shape, an eye shape, or a square shape is formed, and reactor characteristics such as an inductance value are formed. The core gap size is determined by pressing the bridge core while measuring Adjusting the thickness of the gap spacer,
The bridging core portion is fixed by the fixing means while maintaining the pressing force when the required characteristics are obtained to manufacture the composite reactor.

The power supply device of the present invention is a power supply device for rectifying a single-phase alternating current by using the composite reactor of the first means to form a direct-current power supply, which is a full-wave rectifying diode bridge and a smoothing capacitor. A series circuit of a first coil of a reactor and a diode and a series circuit of a second coil of a reactor and a capacitor are connected in parallel between the two and are used.

Further, another power supply device of the present invention is a power supply device which rectifies a single-phase alternating current by using the composite reactor of the first means to form a direct current power supply, and is a latter stage of a full-wave rectification diode bridge. And a series circuit including the first coil of the reactor and the smoothing capacitor of the diode, and the second circuit of the reactor.
The coil and the series circuit of the capacitor are connected in parallel and used.

[0015]

BEST MODE FOR CARRYING OUT THE INVENTION The first means of the present invention is to form two square V-shaped unsaturated magnetic paths sharing a third iron core portion and obtain two integrated inductances. As a result, the number of man-hours required to assemble the reactor can be greatly reduced compared to the conventional case where two independent reactors are used for passive filters, and the man-hours required to mount the reactor on equipment are reduced by about half. It has the effect of being able to.

According to the second means of the present invention, the smaller of the width and depth of the magnetic path cross-section of each of the first, second and third iron cores is taken as the lamination thickness, whereby the number of laminated iron cores is set. Is reduced, which has the effect of reducing the number of manufacturing steps for each core.

According to the third means of the present invention, the end faces of the first, second, and third iron core parts are prevented from being assembled outside the end faces of the bridging iron core parts. The leakage fluxes from the second and third iron core portions are minimized and kept constant, which has the effect of suppressing variations in reactor characteristics due to iron core deviation during assembly.

According to a fourth aspect of the present invention, in the first means, the magnetic path cross-sectional area of the third core portion, which is the common magnetic path of the two magnetic circuits forming the two inductances, is usually the first.
100% of the sum of the cross-sectional areas of the iron core part and the second iron core part, where required 5% or more, the specified reactor characteristics can be obtained, and the core usage can be greatly reduced, downsized and lightened. It has the ability to

In the fifth means of the present invention, the size of the minute core gap between the third iron core portion and the bridging iron core portion is smaller than the core gap between the other iron core portions and the bridging iron core portion. By setting it, there is an effect that the mutual influence between the two inductances can be suppressed to a level that does not pose a problem in practical use.

The sixth means of the present invention actually embodies the magnetic path configuration of the first means, and has an effect of improving the assembling method, workability, occupied area, etc. according to the magnetic path configuration. Have.

The manufacturing method of the present invention has the function of easily adjusting the core gap size which gives the predetermined reactor characteristics, by using the core gap spacer made of an inexpensive material having elasticity in the thickness direction.

In the power supply device of the present invention, the Lc resonance current flows through each of the two coils forming the harmonic suppression circuit,
The currents of opposite phases flow in every constant conduction period of one cycle of the power supply. As a result, the magnetic fluxes in the offset directions merge with each other in the third iron core portion for at least a part of each cycle of the commercial power supply, and in actuality, only a small amount of the combined magnetic flux offset each other flows. .
Therefore, the third iron core only needs to form as many magnetic paths as are required to flow the combined magnetic flux, and originally, the magnetic flux flowing in the first iron core portion and the magnetic flux flowing in the second iron core portion join together. Therefore, where the total cross-sectional area of the first iron core portion and the second iron core portion is required, the cross-sectional area of 1/2 or less of that is required.

An embodiment of the present invention will be described below with reference to FIGS. 1 to 28. (First Embodiment) The first embodiment will be described with reference to FIGS. 1 to 4.

In FIG. 1, a first iron core portion 1 formed by laminating short-fence type electromagnetic steel sheets and forming a block by means such as welding, extrusion pressure welding, and adhesion is inserted in a coil 2. Similarly, the second iron core portion 3 and the coil 4 are also combined. Third
The iron core part 5 is formed by stacking short fence type electromagnetic steel plates to form a block. The first core portion 1, the third core portion 5, and the second core portion 3 thus arranged are arranged in this order, and the gap spacer 6 made of an insulating sheet having elasticity in the thickness direction is formed. Two bridge iron core parts 8 formed by stacking trapezoidal electromagnetic steel plates are abutted to each other via 7 to form a magnetic path having a shape in which the letter "L" is laid sideways. First coil 2,
The second coil 4 is used as an independent inductance, and the magnetic flux generated by each coil 2 and 4 passes through the core gap secured by the thickness of the gap spacers 6 and 7 at the butt portion of each iron core. It flows through the magnetic path in the shape of
It functions as two reactors. The core gap between the third core portion 5 and the bridging core portion 8 may be eliminated depending on required reactor characteristics.

Out of the five iron core portions 1, 3, 5, 8 forming the day-shaped magnetic path, the two outer iron core portions are welded and fixed to each other by the fixing metal fittings 10, and then the others. An attachment plate 9 for attaching to the equipment is welded and fixed to the bridging core portion 8. After that, the reactor as a whole is subjected to varnish impregnation treatment.

Also, the first coil 2 and the second coil 4 are respectively the inductances Lc, AC for the DC power supply device (for inverter air conditioner, for example) having the harmonic current suppressing circuit as shown in FIGS. Each of them is connected as a DC inductance Ld and made to function. 2 and 3 are generally well known as a power supply circuit provided with a harmonic current suppressing circuit, and the operation of suppressing the harmonic current will be schematically described by taking the circuit of FIG. 2 as an example. That is, Lc,
The series resonance circuit of C ₁ causes a resonance current having a frequency about twice that of the power supply to flow from the rise time of the power supply voltage to expand the current conduction angle in the first half, while the series circuit of Ld and D causes By causing a delayed current to flow, it contributes to the expansion of the conduction angle in the latter half. As a result, the input current I of the power supply device that combines these two currents ic and id can be combined into a smooth current waveform with a wide current conduction angle, that is, a current waveform that contains only a few harmonic currents. For reference, an example of the current waveform is shown in FIG.

There is no problem in the case where the two inductances Lc and Ld are composed of two independent reactors as in the conventional case. However, as in the present invention, the two inductances are integrated into one reactor. If you want to configure
It is important how to reduce the coupling between the two inductances.

FIG. 5 shows the flow of magnetic fluxes φA and φB generated by the current ic flowing through the first coil 2. That is, φA represents the magnetic flux flowing in the closed circuit of the first iron core portion 1, the bridging iron core portion 8, the third iron core portion 5, and the bridging iron core portion 8, and φB
Indicates a magnetic flux flowing through a closed circuit of the iron core portion 1, the iron core portion 8, the iron core portion 3, and the iron core portion 8. In order to reduce the mutual coupling between the two inductances, this φB must be eliminated or minimized. In the present invention, in order to realize this, the first iron core portion 1, the second iron core portion 3, the third iron core portion 3,
The core gap size of the iron core part 5 is set as follows. That is, most of the core gap dimension required to obtain the inductance characteristic of the inductance Lc is formed between the first iron core portion 1 and the two bridging iron core portions 8 (1.5 mm in this embodiment), The core gap between the third iron core portion 5 which is the common magnetic leg and the bridging iron core 8 is almost eliminated (0 to 0.35 mm). Further, most of the core gap size required to obtain the inductance characteristic of the inductance Ld is formed between the second iron core portion 3 and the two bridging iron core portions 8 (1.5 mm in this embodiment). .

As a result, the magnetic resistance of the magnetic path including the second iron core portion 3 through which the magnetic flux φB flows is orders of magnitude larger than the magnetic resistance of the magnetic path including the third iron core portion 5 that is the common magnetic leg. Therefore, φB hardly actually flows. That is, the magnetic flux generated in the first coil 2 is the third magnetic flux which is the common magnetic leg.
Most of the current flows in the closed circuit passing through the iron core part 5 as φA, and the magnetic flux interlinking with the second coil 4 forming the other inductance Ld flows only to a practically negligible amount.

On the contrary, regarding the flow of the magnetic flux generated by the current of the second coil 4, as in the above description, most of the magnetic flux generated by the second coil 4 is the third magnetic core 5 which is the common magnetic leg.
The magnetic flux flowing through the first coil 2 and flowing over the third core portion 5 is almost eliminated.

In this way, it was possible to realize an integrated reactor which has almost no magnetic mutual influence even if the two inductances function at the same time, or which can be practically ignored. For reference, in FIG. 6, what is the relative value of the core gap of the third iron core portion 5 compared with the case of the other first iron core portion 1 and the second iron core portion 3 and what is the harmonic current? The tendency of the suppression effect is shown by taking the third harmonic of the harmonic current suppression value as an example. The waveform of the current flowing through each coil of the composite reactor of the present invention is almost the same as that when two independent reactors are used (FIG. 4).

When the conventional independent two reactors are used, the electromagnetic design of the reactor is such that a magnetic flux proportional to the sum S ₁ + S ₂ of the integrated values of the current Ic flows in the AC reactor. A magnetic path cross section is required, and on the other hand, in the DC reactor, a magnetic flux proportional to the integral value S ₃ of the current Id flows, so a magnetic path cross section corresponding to this is required.

On the other hand, as in the embodiment of the present invention, when two magnetic circuits that are magnetically almost independent are provided side by side through the third iron core portion 5 which is the common magnetic leg, it is shown in FIG. When the currents Ic and Id flow through the first coil 2 and the second coil 4, respectively, ic and i are applied to the third iron core portion 5, respectively.
The magnetic flux corresponding to d merges. That is, i
A combined magnetic flux corresponding to the combined current I of c and id flows through the third iron core part 5. As is apparent from FIG. 4, as a result of canceling out the S ₂ portion and the S ₃ portion of Ic and Id, which are in opposite phases to each other, the integrated value S ₄ of the combined current I uses two conventional independent reactors. The current is greatly reduced compared to the sum S ₁ + S ₂ + S ₃ of the currents.

As can be seen from the above, when the conventional two independent reactors are integrated as in the present invention, the magnetic path disconnection of the third iron core portion 5 is originally made. Where the area should have a value corresponding to each integrated value S ₁ + S ₂ + S ₃ , a magnetic path cross-sectional area corresponding to the integrated value S ₄ will suffice. This S ₄ is S ₁ + S ₂
The ratio with respect to + S ₃ changes depending on the circuit constant / reactor characteristics adjusted in accordance with the target set value for harmonic current suppression, but is about one half in this embodiment. Therefore, the cross section of the magnetic path of the third iron core portion 5 is about half that of the conventional example.
Since the amount of iron core can be greatly reduced, the reactor can be made compact, lightweight and low cost. For reference, in FIG. 7, what is the relative value of the cross-sectional area of the third iron core portion 5 to the total value of the cross-sectional areas of the first iron core portion 1 and the second iron core portion 2 and how much? The tendency of the harmonic current suppression effect to become the harmonic current suppression value
Harmonics are shown as an example.

It is to be noted that, as the iron core material of the third iron core portion 5, a magnetically more permeable magnetic steel sheet such as a grain-oriented silicon steel sheet is used, or the thickness thereof is thinned, so that the harmonic current is also prevented. By maintaining the required magnetic permeability, the third core portion 5
It is possible to further reduce the cross section of the magnetic path.

Further, since the electromagnetic steel plates used for the iron core parts 1, 3, 5 and the bridging iron core part 8 can be made into a simple short fence type or a trapezoidal type, an expensive punching die is not necessary and can be easily manufactured by shearing or the like. The size of the electromagnetic steel sheet can be freely set as compared with the conventional iron core shape such as the EI type. As a result, the size of the iron cores 1, 3, 5, 8 for housing the coils can be designed to be the minimum required size for each model, so that the amount of material used for the iron cores 1, 3, 5, 8 can be reduced. it can.

Further, as shown in FIG. 1, regarding the two bridging core portions 8, the material of the electromagnetic steel plate 11 used for the bridging core portion 8 is formed by cutting the ineffective corner portions in view of the flow of magnetic flux. The amount is reduced and the weight of the reactor is reduced. Further, the angle of the trapezoidal electromagnetic steel sheet 11 is, as shown in FIG.
The following shows an example of the case where the electromagnetic steel plate 11 is selected within the above range and is manufactured without material loss.

Further, as shown in FIG. 9, when the width dimension A of the magnetic path cross section of the iron cores 1, 3, 5 is larger than the depth dimension B (laminated thickness), the depth dimension B is set to the iron core portions 1, 3 respectively. , 5
It is advantageous to reduce the punching cost of the electromagnetic steel plates used for the iron cores 1, 3, and 5 because the number of laminated sheets can be reduced by making the laminated thickness. Note that FIG. 10 shows a case where the dimensions A and B are the dimension A (laminated thickness) <dimension B, which is the opposite of that in FIG.

Further, by adopting an insulating sheet as the core gap spacers 6 and 7 necessary to secure the core gap and having the functions of securing the core gap dimension and insulating, it is possible to save the members.

Further, the first iron core portion 1 and the second iron core portion 3
Are completely separated and insulated from the two bridging core portions 8, that is, the ground by the core gap spacers 6 and 7 which also serve as insulating sheets. Therefore, it is possible to realize a configuration in which the coils 2 and 4 are not required to be insulated from the iron core portions 1 and 3. As a result, the number of insulating materials can be reduced, and the number of assembling steps can be reduced by simplifying the insulating structure. Furthermore, as described above, since the insulation between the coils 2 and 4 and the iron cores 1 and 3 is not required, it is not necessary to provide the insulation distance between the coils 2 and 4 and the iron cores 1 and 3, respectively, and the winding is performed. Since the inner diameter of the wire can be minimized, the amount of electric wire used can be greatly reduced. It is also possible to wind the coil directly around the iron core,
It is also possible to reduce the number of manufacturing steps by eliminating the need for a core jig and eliminating the work of separating the coil after winding from the core jig.

Further, as shown in FIG. 11, a U-shaped coil protection member 12 is attached to the outer periphery of the first iron core portion 1 or the second iron core portion 3 having a rectangular cross section, and the coil 2 or the coil is attached from above. If 4 is wound directly, it is useful as a structure for preventing coil scratches in the iron core corner portion 13 during winding.

Further, as shown in FIG. 12, the iron core parts 1, 3
It is also useful as a structure in which the coil protection member is not used at all, by subjecting the iron core corner portion 13 to rounding and winding the coil 2 or the coil 4 directly from above.

Further, FIGS. 13 (A), (B) and 14 (A)
As shown in (B), at the side end of the iron core 1 or 3, the coil protection member 14 having R on the end face is installed,
A structure in which the coil 2 or 4 is directly wound from above is also useful for preventing the coil damage due to the winding in the iron core corner portion 13.

Further, due to the limitation of the characteristics of the reactor, the thickness of the gap spacers 6 and 7 for ensuring the core gap requires a considerable accuracy. Attempting to achieve this dimensional accuracy with a material that is not elastic in the thickness direction is very expensive. On the other hand, in the present embodiment, an inexpensive material having elasticity in the thickness direction, such as glass nonwoven fabric, polyester nonwoven fabric, or uncalendered aramid paper, is used as the gap spacers 6 and 7, and the two bridging core portions are used. When the core gap portion is pressed by pressing from above and below 8, the thickness of the elastic core gap spacers 6 and 7, that is, the core gap size changes according to the pressing force. At this time, it is easy to connect the measuring devices to the coils 2 and 4 at the same time, press the coil while measuring the inductance value, and fix the fixing metal fitting 10 while maintaining the pressing force when the required inductance value is reached. It is possible to create a reactor with the required inductance value. By using an inexpensive material having elasticity as the gap spacer in this way, the material cost can be reduced.

Further, as shown in FIG. 15, the iron core parts 1, 3,
The leakage magnetic flux can be absorbed by the bridging core portion 8 by setting the respective iron core dimensions and the abutting positions so that the end surfaces of 5 are always accommodated within the end surface of the bridging core portion 8. It is possible to suppress variations in reactor characteristics due to misalignment of the cores with each other.

16 to 23 show examples of combinations of iron core shapes useful for forming a V-shaped magnetic path. These are also useful as a reactor structure having the same effect as this embodiment.

(Embodiment 2) Furthermore, an example in which a part or the whole of the composite reactor of the present invention is molded with resin will be described as Embodiment 2 (not shown). That is, by molding, the iron core parts 1, 3, 5, 8 and the coils 2, 4 are securely fixed, and the molding part is easily provided with a terminal fixing part, a mounting part for other equipment, etc. It is possible to obtain a structure having a small number of man-hours and being rich in mass productivity. In particular, by molding the entire composite reactor, the entire composite reactor is more completely fixed and is isolated and protected from the outside, so it is extremely waterproof and suppresses noise and vibration generated from the composite reactor. It is possible to obtain an optimized reactor structure.

(Third Embodiment) Furthermore, FIG. 24 shows a third embodiment in which the composite reactor of the present invention is fixed by projection welding of an iron core.

At least one portion of each of the two trapezoidal bridging core portions 8 abutted on the third iron core portion 5 is subjected to projection welding so that the two bridging core portions 8 and the third And the iron core part 5 of. At this time, the iron core parts 1 and 3 and the coils 2 and 4 are separated by the gap spacers 6 and 6, respectively.
The two bridging core portions 8 are fixed by being pressed from above and below while being installed at a predetermined position together with 7. A projection 15 for projection welding is provided on the bridging core portion 8 or the third core portion 5 for projection welding. With this configuration, the reactor can be fixed without using the fixing metal fitting 10 of FIG. 1, so that the material cost can be reduced, and the external dimensions of the reactor can be reduced by the amount of the fixing metal fitting 10 being removed, and the reactor can be installed in the equipment. It is effective in terms of storability.

By impregnating this with varnish, the abutting portions of the iron core portions and the coils 2, 4 and the like are adhered and fixed to each other, so that the entire reactor is completely fixed.

(Fourth Embodiment) Further, a fourth embodiment relating to the fixing of the reactor is shown in FIGS. In FIGS. 25 (A) and 25 (B), the vicinity of the third core portion 5 at the substantially center of the reactor is clamped by the substantially U-shaped fixing metal fitting 16 and protruded from two through holes 9A provided in the mounting plate 9. The fixing metal fitting 16 has the tip thereof welded and fixed around the through hole 9A of the mounting plate.

With this structure, the iron core parts 1, 3, 5,
Not only the coil 8 and the coils 2 and 4 are fixed, but also the reactor and the mounting plate 9 are fixed at the same time.

Therefore, it is possible to obtain a reactor structure which has a small number of assembling steps and is rich in mass productivity. Further, since the fixing metal fitting 10 of FIG. 1 is not necessary, the outer dimension is reduced by that much, which contributes to downsizing.

The fixing member 16 can be made of a non-magnetic material such as stainless steel if necessary.

(Fifth Embodiment) FIG. 26 shows a fifth embodiment of the magnetic path shape of the iron core. It should be noted that parts common to those in the first embodiment will be described by unifying them with the same reference numerals as those in FIG.

FIG. 26 shows a combination of the cores 1 and 3 with the coils 2 and 4 and the gap spacers 6 and 7, respectively.
One set is housed in each of the windows of the day-shaped magnetic path to form a magnetic path having a substantially U-shape. Here, the day-shaped magnetic path has two C-shaped iron cores 17 and 18 and one I-shaped iron core 19. Then, as in the case of the first embodiment, the I-shaped iron core 19 corresponds to the iron core portion 5 of the first embodiment by operating as two reactors in the DC power supply device shown in FIGS. 2 and 3. The core cross-sectional area is about half that of the original one.

In this case, since the core gap size at all butting points of the iron core is a fixed size, it is possible to obtain a reactor structure having stable reactor characteristics without variations in core gap size. This structure is suitable for being fixed by welding at the ends of the core butts, but other fixing means may be used. Although the size in the height direction increases, it is suitable for reducing the occupied area.

(Sixth Embodiment) FIG. 27 shows a sixth embodiment of the magnetic path shape of the iron core. FIG. 27 shows iron cores 1 and 3, coils 2 and 4, and core gap spacers 6 and 7.
In Fig. 2, the two sets respectively combined are arranged side by side in a square-shaped magnetic path made of at least one iron core to form a substantially V-shaped magnetic path. Here, an example in which the V-shaped magnetic path is composed of the L-shaped iron cores 20 and 21 is shown.

Also in the case of this sixth embodiment, the first embodiment
In the same manner as in the above case, by operating as two reactors in the DC power supply device shown in FIGS. 2 and 3, the magnetic leg portions and partial bridging portions of the L-shaped iron cores 20 and 21 are the iron cores of the first embodiment. 5, which similarly requires a narrow magnetic path cross section.

Also in this case, as in the fifth embodiment, the core gap size at all butting points of the iron core portion is a fixed size, so that a reactor structure having stable reactor characteristics without variations in core gap size can be obtained. . Also in this case, the abutting portions of the L-shaped iron core 20 and the L-shaped iron core 21 are suitable to be fixed by welding, but other fixing means may be used.

(Embodiment 7) FIG. 28 shows Embodiment 7 relating to the magnetic path shape of the iron core.

From the L-shaped core portions 22 and 23, two sets each of which is composed of the core portions 1 and 3 and the coils 2 and 4 and the gap spacers 6 and 7 and the core portion 5 which is interposed between the two sets are provided. It is arranged in the V-shaped magnetic path. In this way, the magnetic path configuration is such that three magnetic legs are arranged in parallel in the V-shaped magnetic path. This is useful as a reactor configuration in which the mutual influence of the two inductances is further reduced.

[0063]

As is apparent from the above description, the composite reactor of the present invention comprises the first iron core portion having the first coil inserted therein and the second iron core portion having the second coil inserted therein. , By adjusting the distribution of the core gap size of the abutting part of the third iron core part and the bridging iron core part in which the magnetic fluxes of the respective coils cancel each other, the coupling of the two magnetic circuits is minimized and It is possible to realize an integrated hybrid reactor that can obtain almost independent interaction.
It has an excellent effect of being lightweight and low cost.

Further, since the number of laminated layers can be reduced by selecting the core size for the laminated thickness of the laminated iron core, the punching cost of the electromagnetic steel sheets can be reduced.

Further, by setting the abutting position and the iron core size so that the end faces of the three magnetic legs do not protrude from the bridging iron core portion, the leakage magnetic flux generated by the abutting displacement of the iron core is absorbed and stabilized. The reactor characteristics can be obtained.

LC flowing through two inductances
Due to the action of the resonance current, the magnetic fluxes merging with the third iron core portion, which is the common magnetic leg of the two magnetic circuits, have opposite phases to each other and cancel each other, so that the magnetic path of the third iron core portion is made to reciprocate. It is possible to minimize the required magnetic path cross section to 5%, and it is also possible to realize a compact, lightweight and low cost composite reactor.

In addition, the first coil and the second coil are inserted so that the small core gap size between the third core portion and the bridging core portion, which is the common magnetic leg of the two magnetic circuits, is provided. By setting the core gap size of the first or second iron core portion to 40% or less, the mutual influence of the two magnetic circuits can be suppressed to a level at which there is no practical problem.

Also, by selecting the magnetic path shape formed by each iron core portion into a letter shape, a letter shape, a square shape, etc., a useful structure in terms of assembling and occupying space can be obtained as necessary. You can also choose.

Further, in the method for manufacturing the composite reactor of the present invention, the thickness of the gap spacer, which is the core gap size, is adjusted while measuring the characteristics such as the inductance value, and the pressing force when the required characteristics are obtained. Since the iron cores are fixed with fixing means while maintaining the above, it is necessary to improve the thickness dimensional accuracy when extremely expensive materials are required because the gap spacers require extremely high-precision thickness dimensions. An inexpensive material that does not need to be used can be used as the gap spacer, the cost of the material can be reduced, and the inductance value can be freely set by adjusting the pressing force.

Further, the power supply device of the present invention uses the composite reactor of the present invention in the harmonic suppression circuit, and the harmonic regulation value (I
It has an excellent effect that the EC equivalent level) can be completely cleared over all orders.

[Brief description of drawings]

FIG. 1 is a schematic front view of a composite reactor according to a first embodiment of the present invention.

FIG. 2 is a first power supply device in which the same composite reactor is used.
circuit diagram

FIG. 3 is a second circuit diagram of the power supply device.

FIG. 4 is a waveform diagram of a current flowing through the composite reactor.

FIG. 5 is an unsaturated closed magnetic circuit diagram showing the flow of magnetic flux generated in the first coil of the same composite reactor.

FIG. 6 is a characteristic diagram showing the relationship between each core gap and the third harmonic current in the same composite reactor.

FIG. 7 is a characteristic diagram showing the relationship between the cross-sectional area of each core and the third harmonic current of the same composite reactor.

FIG. 8 is a cutaway view of a pressing process of an electromagnetic steel sheet used for an iron core of the composite reactor.

FIG. 9 is a perspective view showing an example of the stacking direction of each core of the composite reactor.

FIG. 10 is a perspective view showing another example of the stacking direction of each core of the composite reactor.

FIG. 11 is a perspective view showing a state in which a coil protection member is arranged on an iron core portion of the composite reactor.

FIG. 12 is a perspective view showing an iron core portion of the composite reactor.

FIG. 13 (A) is a perspective view showing a coil insertion state of an iron core portion of the same composite reactor. FIG. 13 (B) is an enlarged perspective view of the coil protection member of FIG. 13 (A).

FIG. 14A is a perspective view showing another coil insertion state of the iron core portion of the same composite reactor, and FIG. 14B is an enlarged perspective view of the coil protection member of FIG. 14A.

FIG. 15 is a conceptual diagram showing an assembled arrangement state of an iron core portion of the same composite reactor.

FIG. 16 is a conceptual diagram showing a second example of an iron core portion of the same composite reactor.

FIG. 17 is a conceptual diagram showing a third example of an iron core portion of the same composite reactor.

FIG. 18 is a conceptual diagram showing a fourth example of an iron core portion of the same composite reactor.

FIG. 19 is a conceptual diagram showing a fifth example of an iron core portion of the same composite reactor.

FIG. 20 is a conceptual diagram showing a sixth example of an iron core portion of the same composite reactor.

FIG. 21 is a conceptual diagram showing a seventh example of an iron core portion of the same composite reactor.

FIG. 22 is a conceptual diagram showing an eighth example of an iron core portion of the same composite reactor.

FIG. 23 is a conceptual diagram showing a ninth example of an iron core portion of the same composite reactor.

FIG. 24 is a conceptual diagram of assembly of a composite reactor according to the third embodiment.

FIG. 25 (A) is a front view of the composite reactor of the fourth embodiment, and FIG. 25 (B) is a perspective view of essential parts showing the mounting state of the fixing metal fitting of FIG.

FIG. 26 is a front view showing a tenth example of the core of the composite reactor according to the fifth embodiment.

FIG. 27 is a front view showing an eleventh example of the iron core portion of the composite reactor of the sixth embodiment.

FIG. 28 is a front view showing a twelfth example of the iron core portion of the composite reactor according to the seventh embodiment.

FIG. 29 is a front view of a conventional individual reactor.

[Explanation of symbols]

1, 3, 5, 8 Iron core 2,4 coils 6,7 Gap spacer 9 Mounting plate 9A Mounting plate through hole 10 Fixing bracket 11 Electrical steel sheet 12 Coil protection member 13 Iron core corner 14 Coil protection member having R at the corner 15 Projection welding projections 16 U-shaped fixing bracket 17,18 C-shaped iron core 19 I-shaped iron core 20, 21, 22, 23 L-shaped iron core

Continuation of front page (51) Int.Cl. ⁷ identification code FI H02M 7/06 H01F 27/24 H (56) Reference JP-A 61-259514 (JP, A) JP-A 7-22258 (JP, A) ) JP-A-8-339924 (JP, A) JP-A-9-134825 (JP, A) JP-A-8-149812 (JP, A) JP-A-9-163744 (JP, A) JP-A-9- 237722 (JP, A) JP 7-263262 (JP, A) JP 55-22837 (JP, A) JP 56-15017 (JP, A) JP 10-163046 (JP, A) Unexamined Japanese Patent Publication No. 9-148185 (JP, A) Actual development 5-36821 (JP, U) Actual development 3-92016 (JP, U) Actual development 4-133415 (JP, U) (58) Fields investigated (Int.Cl. ⁷ , DB name) H01F 37 H01F 27 H01F 38 H02M 7

Claims (19)

(57) [Claims] 1. A first iron core portion having electromagnetic steel sheets laminated and a first coil inserted therein, a second iron core portion having electromagnetic steel sheets laminated and a second coil inserted therein, and an electromagnetic steel sheet laminated together. The first and second iron core portions each have a bridging iron core portion for forming an unsaturated closed magnetic circuit via a predetermined core gap,
A third core portion in which the magnetic fluxes of the coil and the second coil flow in mutually offset directions during at least a part of each cycle of the commercial power source, and the third core portion is separated from the predetermined core gap. The third core and the bridge are arranged between the bridging cores via a small core gap having a small gap.
The size of the minute core gap between the magnetic core and the
Of the specified core gap size between the core and the bridge core
40% or less, and the cross-sectional area of the third iron core is the first iron
5% or more of the sum of the cross-sectional areas of the core and the second iron core,
A composite reactor in which the first, second, and third iron core parts and the bridging iron core parts are integrally fixed by a fixing means. 2. A core gap and a gap spacer are interposed.
The composite reactor according to claim 1, which is secured by the above method. 3. The gap spacer is provided at least in the thickness direction.
The composite type according to claim 2, wherein a member having elasticity is used for
Reactor. 4. An insulating sheet is used as the gap spacer.
The composite reactor according to claim 2, which is used. 5. If the gap spacer is a porous material
The composite type rear rivet according to claim 2, wherein the fiber material is used.
Ta. 6. A protrusion of at least each iron core portion as a fixing means.
The composite according to claim 1, wherein the bonded portion is fixed by varnish impregnation.
Shaped reactor. 7. A part or the whole of the resin is used as the fixing means.
The composite rear according to claim 1, which is cast or resin-molded.
Kuta. 8. The bridge core according to claim 1, wherein the bridge core has a trapezoidal shape.
Composite reactor. 9. The magnetic path cross section of the first, second and third cores
The smaller of the width and depth dimensions is the laminate thickness
The composite reactor according to claim 1, wherein the composite reactors are stacked in the same direction. 10. At least first, second, and third iron core portions
Such as the end face of the falls within both end faces of the respective bridging core portion
The composite type according to claim 1, wherein the dimensions of the core and the abutting position are set.
Reactor. 11. Iron core corner portions of the first and second iron core portions
A contract in which a coil is wound through a U-shaped coil protection member.
The composite reactor according to claim 1. 12. The core corners of the first and second cores
The R process is applied, and the coil is wound around the R process.
Complex reactor. 13. A less number of first and second iron core portions, respectively.
Both have R at the corners of the iron core at both ends of the pair of opposite sides.
A coil protective member is attached to wind the coil.
Mounted combined reactor. 14. A protrusion between a third core portion and two bridging core portions.
Claim that fixed the welded part by projection welding
Item 2. The composite reactor according to item 1. 15. A reactor is provided with a substantially U-shaped metal fitting.
Hold the central part and attach it to the outer end face of one bridging core
From the through hole of the metal mounting plate,
Protruding two points on the tip and using this as a mounting plate around the through hole
The composite reactor according to claim 1, which is fixed by welding. 16. Unsaturated magnetism formed by each core
The circuit looks like the two coils are positioned one above the other
It can be in the shape of a square, a square, or a square.
2. The composite type rear aku according to claim 1, wherein
Ta. 17. A magnetic steel sheet on which a first coil is attached is laminated.
A layered first core and a second coil are attached to the electric core.
A second iron core portion formed by laminating magnetic steel sheets, and the first and second
Unsaturated through the specified core gap in the iron core
Bridging iron core formed by laminating electromagnetic steel sheets for forming a magnetic path
Each of the magnets by the first coil and the second coil.
The bundles will remain at each other for at least some period of each cycle of utility power.
A third iron core portion that flows in an offset direction,
Through a small core gap that is smaller than the core gap of
Arranging the third core portion between the bridging core portions
Therefore, form a magnetic path in the shape of a day, the shape of an eye, or the shape of a square.
And do not measure the reactor characteristics such as inductance value.
And the minute gap between the third core and the bridging core.
The core gap size is set to the first core portion and the bridging core portion.
Bridge within 40% of the specified core gap size between
The core gap size is pressed by pressing the magnetic core .
Adjust the thickness of the pacer and press when the desired characteristics are obtained
While maintaining the force, the bridge core is fixed by the fixing means.
Manufacturing method of combined reactor. 18. A composite reactor according to claim 1 is used.
A power supply unit that rectifies single-phase AC to form a DC power supply
There is a diode bridge for full-wave rectification and a capacitor for smoothing.
First coil and diode of combined reactor between sensors
Of the series circuit and the second coil and the coil of the composite reactor.
A power supply unit that is connected in parallel with a capacitor series circuit. 19. A composite reactor according to claim 1 is used.
A power supply unit that rectifies single-phase AC to form a DC power supply
There is a composite in the latter stage of the diode bridge for full wave rectification.
-Type reactor first coil and diode smoothing capacitor
And a second circuit of the composite reactor.
Power supply device in which a capacitor and a series circuit of capacitors are connected in parallel.
Place