JP2019004126A - Iron core and reactor equipped with coil - Google Patents

Abstract

To prevent the temperature of a reactor from being easily raised.SOLUTION: A core body (5) of a reactor (6) includes: an outer peripheral part iron core (20) constituted of a plurality of outer peripheral part iron core parts (24-27); at least three iron cores (41-44) coupled to the plurality of outer peripheral part iron core parts; and coils (51-54) wound around at least three iron cores. Between one iron core of at least three iron cores and the other iron core adjacent thereto, magnetically coupleable gaps (101-104) are formed. The reactor includes covering parts (61-64) for at least partially covering the iron core to be insulated from the coil.SELECTED DRAWING: Figure 1A

Description

  The present invention relates to a reactor including an iron core and a coil.

  The reactor includes a plurality of iron core coils, and each iron core coil includes an iron core and a coil wound around the iron core. A predetermined gap is formed between the plurality of iron cores. For example, see Patent Document 1 and Patent Document 2.

  By the way, there is also a reactor in which a plurality of iron cores and a coil wound around the iron core are arranged inside the outer periphery iron core composed of a plurality of outer periphery iron core portions. In such a reactor, each iron core is formed integrally with each of the outer peripheral core portions. A predetermined gap is formed between adjacent iron cores at the center of the reactor.

JP 2000-77242 A JP 2008-210998A

  In such a reactor, the coil is mounted on the iron core while being accommodated in the casing. For this reason, the heat generated from the coil when the reactor is energized easily accumulates in the casing. As a result, there has been a problem that the temperature of the coil is rapidly increased and the temperature of the reactor is likely to rise.

  Furthermore, one casing is composed of a plurality of parts, and as the number of coils increases, the number of casing parts also increases.

  Therefore, a reactor that prevents the temperature from rising easily is desired.

  According to a first aspect of the present disclosure, a core main body is provided, and the core main body includes an outer peripheral core composed of a plurality of outer peripheral cores, and at least three coupled to the plurality of outer peripheral cores. And a coil wound around the at least three iron cores, and there is no magnetic force between one of the at least three iron cores and another iron core adjacent to the one iron core. An electrically connectable gap is formed, and a reactor is provided that further includes a covering portion that at least partially covers the iron core to insulate it from the coil.

  In the first aspect, the coil is not accommodated in the casing, and is attached to the iron core through the covering portion in an exposed state. For this reason, when the reactor is energized, heat from the coil is released to the outside, and as a result, the temperature of the reactor can be prevented from rising easily.

  These and other objects, features and advantages of the present invention will become more apparent from the detailed description of exemplary embodiments of the present invention illustrated in the accompanying drawings.

It is an end elevation of a reactor based on a first embodiment. It is a partial perspective view of the reactor shown by FIG. 1A. It is a 1st perspective view which shows the manufacturing process of the reactor shown by FIG. 1A. It is a 2nd perspective view which shows the manufacturing process of the reactor shown by FIG. 1A. It is a 3rd perspective view which shows the manufacturing process of the reactor shown by FIG. 1A. It is an end view of another reactor. It is a 1st perspective view which shows the manufacturing process of the reactor shown by FIG. 3A. It is a 2nd perspective view which shows the manufacturing process of the reactor shown by FIG. 3A. It is a 1st perspective view which shows the manufacturing process of the reactor based on 2nd embodiment. It is a 2nd perspective view which shows the manufacturing process of the reactor based on 2nd embodiment. It is an end view of the reactor based on 3rd embodiment. It is an end view of the reactor based on 4th embodiment. It is a perspective view of the coating | coated part used for the reactor shown by FIG. 6A. It is a perspective view of another coating | coated part. It is a 1st perspective view which shows the manufacturing process of the reactor based on 4th embodiment. It is a 2nd perspective view which shows the manufacturing process of the reactor based on 4th embodiment. It is a 3rd perspective view which shows the manufacturing process of the reactor based on 4th embodiment. It is a perspective view of the coating | coated part used for the reactor based on 5th embodiment. It is an end view of the reactor based on 6th embodiment.

  Embodiments of the present invention will be described below with reference to the accompanying drawings. In the following drawings, the same members are denoted by the same reference numerals. In order to facilitate understanding, the scales of these drawings are appropriately changed.

  In the following description, a three-phase reactor will be mainly described as an example, but the application of the present disclosure is not limited to a three-phase reactor, and can be widely applied to a multi-phase reactor in which a constant inductance is required in each phase. is there. In addition, the reactor according to the present disclosure is not limited to those provided on the primary side and the secondary side of the inverter in industrial robots and machine tools, and can be applied to various devices.

  FIG. 1A is an end view of a reactor according to the first embodiment, and FIG. 1B is a partial perspective view of the reactor shown in FIG. 1A. As shown in FIG. 1A and FIG. 1B, the core body 5 of the reactor 6 includes an annular outer peripheral core 20 and at least three core coils 31 to 31 arranged at equal intervals in the circumferential direction on the inner surface of the outer peripheral core 20. 33. The number of iron cores is preferably a multiple of 3, whereby the reactor 6 can be used as a three-phase reactor. The outer peripheral iron core 20 may have another shape, for example, a circular shape. Each of the iron core coils 31 to 33 includes iron cores 41 to 43 and coils 51 to 53 wound around the iron cores 41 to 43.

  The outer peripheral core 20 is composed of a plurality of, for example, three outer peripheral core portions 24 to 26 divided in the circumferential direction. The outer peripheral core portions 24 to 26 are integrally formed with the iron cores 41 to 43, respectively. The outer peripheral core portions 24 to 26 and the iron cores 41 to 43 are formed by laminating a plurality of iron plates, carbon steel plates, and electromagnetic steel plates, or formed from a dust core. Thus, when the outer peripheral core 20 is composed of a plurality of outer peripheral core portions 24 to 26, such an outer peripheral core 20 is easily manufactured even when the outer peripheral core 20 is large. it can. In addition, the number of the iron cores 41-43 and the number of the outer peripheral part iron core parts 24-26 may not necessarily correspond.

  As can be seen from FIG. 1A, the iron cores 41 to 43 have approximately the same dimensions, and are arranged at approximately equal intervals in the circumferential direction of the outer peripheral iron core 20. In FIG. 1A, the radially outer end portions of the iron cores 41 to 43 are joined to the outer peripheral iron core 20.

  Further, the inner ends in the radial direction of the iron cores 41 to 43 converge toward the center of the outer peripheral iron core 20, and the tip angle is about 120 degrees. And the radial direction inner side edge part of the iron cores 41-43 is mutually spaced apart via the gaps 101-103 which can be connected magnetically.

  In other words, in the first embodiment, the radially inner end of the iron core 41 is separated from the radially inner ends of the two adjacent iron cores 42 and 43 via the gaps 101 and 103. The same applies to the other iron cores 42 to 43. The gaps 101 to 103 are ideally equal in size, but may not be equal. As can be seen from FIG. 1A, the intersection of the gaps 101 to 103 is located at the center of the core body 5. The core body 5 is formed rotationally symmetrical around this center.

  In the first embodiment, the iron core coils 31 to 33 are arranged inside the outer peripheral iron core 20. In other words, the iron core coils 31 to 33 are surrounded by the outer peripheral iron core 20. For this reason, it is possible to reduce leakage of magnetic flux from the coils 51 to 53 to the outside of the outer peripheral core 20.

  Referring to FIG. 1A again, covering portions 61 to 63 made of an insulating material are disposed between the outer peripheral core portions 24 to 26 and the coils 51 to 53, respectively. Each of the covering portions 61 to 63 serves as an insulator that at least partially covers the iron cores 41 to 43 and insulates them from the coils 51 to 53.

  2A to 2C are perspective views showing manufacturing steps of the reactor shown in FIG. 1A. Below, attaching the coil 51 to the iron core 41 formed integrally with the outer peripheral iron core portion 24 will be described. Since the other iron cores 42 and 43 are substantially the same, the description thereof is omitted.

  The covering portion 61 is a cylindrical member having a rectangular cross section made of an insulating material such as insulating paper or a resin material. Further, additional covering portions 61 a and 61 b are attached to one edge portion of both side surfaces of the covering portion 61. The additional covering portions 61 a and 61 b serve to insulate from the coil 51 by at least partially covering the inner surface of the outer peripheral core portion 24. For this reason, the additional covering portions 61 a and 61 b have a shape corresponding to the inner surface of the outer peripheral core portion 24. For this purpose, the additional covering parts 61a, 61b are preferably formed from a flexible insulating material, for example insulating paper.

  As shown by an arrow in FIG. 2A, the cylindrical covering portion 61 is moved toward the iron core 41, thereby inserting the iron core 41 into the covering portion 61. As shown in FIG. 4B, the thickness of the covering portion 61 is relatively small. Then, as shown in FIGS. 2B and 2C, the exposed coil 51 not accommodated in the casing is moved toward the iron core 41, thereby inserting the iron core 41 and the covering portion 61 into the coil 51. The covering portions 62 and 63 are similarly attached to the other iron cores 42 and 43 formed integrally with the other outer peripheral core portions 25 and 26, and then the exposed coils 52 and 53 are similarly attached. Thereafter, the iron cores 41 to 43 are assembled as shown in FIG. 1A, thereby manufacturing the reactor 6.

  Incidentally, FIG. 3A is an end view of the core body of another reactor. A core body 5 ′ of another reactor 6 ′ shown in FIG. 3A has a configuration substantially similar to that of the core body 5 described with reference to FIG. 1A. In FIG. 3A, casings 91-93 are mounted on iron cores 41-43, respectively, and coils 51-53 are housed in casings 91-93, respectively. The casing 91 includes two half-shaped portions 91a and 91b and a lid portion 91c. The same applies to the other casings 92 and 93.

  3B and 3C are perspective views showing manufacturing steps of the reactor shown in FIG. 3A. As shown in FIG. 3B, the two half-shaped portions 91a and 91b of the casing 91 are attached to both ends of the coil 51 in the axial direction. Next, as shown in FIG. 3C, the lid portion 91 c is attached, so that the coil 51 is accommodated in the casing 91. Thereafter, the casing 91 is attached to the iron core 41 in the same manner as described above. Thereafter, the iron cores 41 to 43 are assembled as shown in FIG. 3A, whereby the reactor 6 ′ is manufactured. In the case of the reactor 6 ′ thus manufactured, there is a problem that heat of the coils 51 to 53 is easily trapped in the casings 91 to 93 during energization.

  On the other hand, in 1st embodiment, the coils 51-53 are not accommodated in the casings 91-93, and are attached to the iron cores 41-43 through the coating | coated parts 61-63 in the exposed state. For this reason, when the reactor 6 is energized, the heat from the coils 51 to 53 is released to the outside, and as a result, the temperature of the reactor 6 can be prevented from rising easily. Furthermore, since only one covering portion 61 is sufficient for one coil 51, the number of parts does not increase significantly even when the number of coils increases.

  As described above, the additional covering portions 61 a and 61 b of the covering portion 61 have a shape corresponding to the inner surface of the outer peripheral core portion 24. For this reason, when the coating | coated part 61 is attached to the iron core 41, as FIG. 2B shows, the additional coating | coated parts 61a and 61b will coat | cover the inner surface of the outer peripheral part iron core part 24 partially. The additional covering portions 61 a and 61 b can prevent the end surface of the coil 51 from contacting the inner surface of the outer peripheral core portion 24. For this reason, it is not always necessary to form a gap between the coil 51 and the additional covering portions 61a and 61b. The same applies to the additional covering portions 62a and 62b of the other covering portions 62 and the additional covering portions 63a and 63b of the other covering portions 63. Therefore, when the additional covering portions 61a to 63b are provided, the reactor 6 can be downsized.

  Furthermore, FIG. 4A and FIG. 4B are perspective views which show the manufacturing process of the reactor based on 2nd embodiment. The covering portion 61 shown in FIG. 4A includes a protruding portion 61 c that protrudes from one end surface of the iron core 41. The protruding portion 61c shown in FIG. 4A includes a portion extending from the additional covering portions 61a and 61b and a portion protruding from the covering portion 61 as a tubular member. However, the protrusion part 61c should just contain at least one of the part extended from the additional coating | coated parts 61a and 61b and the part protruded from the coating | coated part 61 as a cylindrical member. Further, the covering portion 61 may include another protruding portion 61 c that protrudes from the other end surface of the iron core 41.

  When the covering portion 61 having such a protruding portion 61c is used, the protruding portion 61c protrudes upward from the end surfaces of the iron core 41 and the outer peripheral iron core portion 24 as shown in FIG. 4B. Thereby, the insulation of the inner surface of the outer peripheral part core part 24 and the coil 51 can be improved more.

  The configuration of the core body 5 is not limited to that shown in FIG. Even the core body 5 having another configuration in which a plurality of iron core coils are surrounded by the outer peripheral iron core 20 is included in the scope of the present disclosure.

  FIG. 5 is a cross-sectional view of the reactor 6 in the third embodiment. The core body 5 of the reactor 6 shown in FIG. 5 has a substantially octagonal outer peripheral core 20 and four cores similar to those described above that are in contact with or coupled to the inner surface of the outer peripheral core 20. Coils 31 to 34 are included. These iron core coils 31 to 34 are arranged at approximately equal intervals in the circumferential direction of the reactor 6. Moreover, it is preferable that the number of iron cores is an even number of 4 or more, so that the reactor 6 can be used as a single-phase reactor.

  As can be seen from the drawings, each of the iron core coils 31 to 34 includes iron cores 41 to 44 extending in the radial direction and coils 51 to 54 wound around the iron core. The outer ends in the radial direction of the iron cores 41 to 44 are in contact with the outer peripheral core 20 or are formed integrally with the outer peripheral core 20.

  Further, the radially inner ends of the iron cores 41 to 44 are located in the vicinity of the center of the outer peripheral iron core 20. In FIG. 5, the inner ends in the radial direction of the iron cores 41 to 44 converge toward the center of the outer peripheral core 20, and the tip angle is about 90 degrees. And the radial direction inner side edge part of the iron cores 41-44 is mutually spaced apart via the gaps 101-104 which can be connected magnetically.

  Also in the third embodiment, the coils 51 to 54 are mounted on the iron cores 41 to 44 through the covering portions 61 to 64 in the same manner as described above. And each coating | coated part 61-64 contains the same additional coating | coated parts 61a-64b as having mentioned above. For this reason, it will be understood that the same effect as described above can be obtained. In addition, it is preferable that the additional coating | coated parts 61a-64b are areas sufficient to coat | cover the side surface of a corresponding coil. Further, the covering portions 61 to 64 may be provided with protruding portions 61c to 64d similar to those described above.

  FIG. 6A is an end view of the reactor according to the fourth embodiment, and FIG. 6B is a perspective view of a covering portion used in the reactor shown in FIG. 6A. As can be seen from these drawings, the covering portion 60 in the fourth embodiment is a substantially Y-shaped single member having three cylindrical portions 71 to 73 arranged at equal intervals in the circumferential direction. The covering portion 60 is made of an insulating material such as insulating paper or a resin material. When the cylindrical portions 71 to 73 of the covering portion 60 are attached to the iron cores 41 to 43, the covering portion 60 covers the iron cores 41 to 43 as a whole and insulates them from the coils 51 to 53. As can be seen from FIG. 6A, the radially inner ends of the iron cores 41 to 43 and the gaps 101 to 103 are not exposed and are covered with the covering portion 60.

  FIG. 6C is a perspective view of another covering portion. The cylinder parts 71 to 73 of the other covering part 60 shown in FIG. 6C have shapes that roughly correspond to the iron cores 41 to 43, respectively. The cylinder portions 71 to 73 are separated from each other by the partition portion 75. The partition part 75 has a substantially Y shape corresponding to the gaps 101 to 103. The partition portion 75 is preferably formed of a nonmagnetic material or an insulating material similar to that of the covering portion 60.

  When the other covering portion 60 shown in FIG. 6C is mounted, the partition portion 75 comes into contact with the gaps 101 to 103. Accordingly, the dimensions of the gaps 101 to 103 are maintained by the partition portion 75. For this reason, even when the reactor 6 is energized, the iron cores 41 to 43 do not vibrate. Therefore, the noise from the reactor 6 and the vibration of the reactor 6 can be suppressed.

  FIG. 7A to FIG. 7C are perspective views showing the manufacturing process of the reactor based on the fourth embodiment. In the following, the case where the covering portion 60 including the partition portion 75 is mounted on the iron cores 41 to 43 will be described, but the same applies to the case of the covering portion 60 not having the partition portion 75.

  First, as shown in FIG. 7A, the covering portion 60 is moved toward the coil 51, thereby inserting the cylindrical portion 71 of the covering portion 60 into the coil 51. As described above, the coil 51 (and the other coils 52 and 53) are in an exposed state not accommodated in the casing. Then, as shown in FIGS. 7B and 7C, 41 that is integral with the outer peripheral core portion 24 is moved toward the cylindrical portion 71 of the covering portion 60, whereby the iron core 41 is moved to the cylindrical portion 71 and the coil 51. insert. The other exposed cores 42 and 43 formed integrally with the other outer peripheral core portions 25 and 26 are similarly similarly mounted with the exposed coils 52 and 53 and cylindrical portions 72 and 73 at the same time.

  Thereby, the reactor 6 shown by FIG. 6A is manufactured. Also in this case, since the exposed coils 51 to 53 are insulated by the covering portion 60, the same effect as described above can be obtained. Further, when the covering portion 60 is used, the number of parts can be reduced, so that it will be understood that the covering portion 60 can be attached to the iron cores 41 to 43 more easily.

  Further, FIG. 8 is a perspective view of a covering portion used in the reactor according to the fifth embodiment. On the upper surface of the cylindrical portion 71 of the covering portion 60 shown in FIG. 8, a protruding portion 79 is provided at a position corresponding to the outer side in the radial direction than the coil 51. The height of the protrusion 79 is preferably smaller than the thickness of the coil 51. Such a protrusion 79 is preferably attached after the coil 51 is mounted on the cylindrical portion 71. Further, the protruding portion 79 may be attached to the lower surface of the cylindrical portion 71, or may be attached to both the upper and lower surfaces of the cylindrical portion 71. In addition, although not shown in drawing, the projection part 79 shall be similarly attached to the other cylinder parts 72 and 73. FIG. When such a protrusion 79 is attached, the coils 51 to 53 are fixed at the mounting position. Therefore, it is possible to avoid the coils 51 to 53 coming into contact with the outer peripheral core portions 24 to 25 after the reactor 6 is assembled.

  Furthermore, FIG. 9 is an end view of the reactor based on the sixth embodiment. FIG. 9 is a view similar to FIG. In FIG. 9, a substantially X-shaped covering portion 60 having four cylindrical portions 71 to 74 is attached to the iron cores 41 to 44. In this case as well, it is obvious that the reactor 6 can be manufactured in the same manner as described above, and therefore the same effect as described above can be obtained.

Aspects of the Present Disclosure According to a first aspect, a core body (5) is provided, and the core body includes an outer peripheral iron core (20) composed of a plurality of outer peripheral iron core portions (24 to 27), and Including at least three iron cores (41 to 44) coupled to a plurality of outer peripheral iron core portions and coils (51 to 54) wound around the at least three iron cores. A magnetically connectable gap (101 to 104) is formed between one of the iron cores and another iron core adjacent to the one iron core, and at least partly covers the iron core. A reactor (6) having a covering portion (60, 61 to 64) that is insulated from the coil is provided.
According to a second aspect, in the first aspect, an additional covering portion (61a to 64b) that further covers at least partially the inner surface of the outer peripheral core portion and insulates from the coil is provided.
According to the 3rd aspect, in the 1st or 2nd aspect, the said coating | coated part contains the protrusion part (61c-64c) which protrudes from the end surface of the said iron core.
According to a fourth aspect, the covering portion is a single member that at least partially covers the at least three iron cores and insulates the coils corresponding to the at least three iron cores.
According to the fifth aspect, the covering part includes a partition part (75) provided at a position corresponding to the gap.
According to the sixth aspect, the protrusion (79) is provided on the outer surface of the covering portion corresponding to the outer side in the radial direction than the coil.
According to a seventh aspect, in any one of the first to sixth aspects, the number of the at least three iron cores is a multiple of three.
According to the eighth aspect, in any one of the first to sixth aspects, the number of the at least three iron cores is an even number of 4 or more.

Effect of Embodiment In the first embodiment, the coil is not housed in the casing, and is attached to the iron core through the covering portion in an exposed state. For this reason, when the reactor is energized, heat from the coil is released to the outside, and as a result, the temperature of the reactor can be prevented from rising easily.
In the second aspect, there is no need to form a gap between the coil and the additional covering portion, and thus the reactor can be miniaturized.
In the 3rd aspect, the insulation of the inner surface of an outer peripheral part iron core part and a coil can be improved more.
In the fourth aspect, since the number of parts can be reduced, the covering portion can be more easily attached to the iron core.
In the fifth aspect, since the size of the gap is maintained by the partition portion, it is possible to suppress noise from the reactor and vibration of the reactor.
In the sixth aspect, the coil can be prevented from coming into contact with the outer peripheral core portion.
In the seventh aspect, the reactor can be used as a three-phase reactor.
In the eighth aspect, the reactor can be used as a single-phase reactor.

  Although the present invention has been described using exemplary embodiments, those skilled in the art can make the above-described changes and various other changes, omissions, and additions without departing from the scope of the invention. You will understand. Further, it is within the scope of the present disclosure to appropriately combine some of the embodiments described above.

5 Core body 6 Reactor 20 Outer peripheral iron core 24-27 Outer peripheral iron core part 31-34 Iron core coil 41-44 Iron core 51-54 Coil 60, 61-64 Covering part 61a-64b Additional covering part 61c-64c Protruding part 71-74 Cylindrical part 75 Partition part 79 Projection part 81-84 Outer edge corresponding position 101-104 Gap

Claims (8)

Comprising a core body,
The core body includes an outer peripheral core composed of a plurality of outer peripheral core portions, at least three iron cores coupled to the plurality of outer peripheral core portions, and a coil wound around the at least three iron cores, Contains
A magnetically connectable gap is formed between one of the at least three iron cores and another iron core adjacent to the one iron core,
further,
A reactor comprising a covering portion that at least partially covers the iron core to insulate the core from the coil.   Furthermore, the reactor of Claim 1 which comprises the additional coating | coated part which coat | covers the inner surface of the said outer peripheral part core part at least partially, and insulates from the said coil.   The reactor according to claim 1, wherein the covering portion includes a protruding portion protruding from an end surface of the iron core.   The reactor according to any one of claims 1 to 3, wherein the covering portion is a single member that at least partially covers the at least three iron cores and insulates the coils from the coils corresponding to the at least three iron cores. .   The reactor according to claim 4, wherein the covering portion includes a partition portion provided at a position corresponding to the gap.   The reactor according to any one of claims 1 to 5, wherein a projection is provided on an outer surface of the covering portion corresponding to an outer side in the radial direction than the coil.   The reactor according to claim 1, wherein the number of the at least three iron cores is a multiple of three.   The reactor according to any one of claims 1 to 6, wherein the number of the at least three iron cores is an even number of 4 or more.

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