JP2009032995A - Reactor device - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a reactor device suppressing the propagation of vibration from a core to a case, and to provide a designing method of the reactor device. <P>SOLUTION: In the core 1 in a track shape having a pair of support sections Ra supported by the case, the shape of the gapless core 1 is designed. The interval (length in the X direction of a magnetic path long line l) between the magnetic path long lines l in each support section Ra, length in the direction of the magnetic path long line l, the width of the support section Ra in the core 1, the interval of the core 1, and the interval between the magnetic path long line l and a side Ra1 in the support section Ra of the core 1 are set to A, B, C, d (d, interval between respective support sections Ra), and w, respectively. In this case, for reducing vibration propagated to the case, components in the X direction of vibration generated in the core 1 because of magnetostriction should be minimized. In this case, since a relationship of 2C+d=A+2w has been established, a formula of d=A-2C+2w is formed. When the sectional shape of the core 1 is determined, magnetic simulation is performed to obtain displacement ΔX in the direction of X per unit length of the support section Ra because of magnetostriction is obtained by a formula of ΔX = A×λ<SB>L</SB>-2C×λ<SB>W</SB>, where λ<SB>L</SB>and λ<SB>W</SB>indicate a peculiar elongation percentage to a magnetic field and a shrinkage factor to a magnetic field, respectively. However, for securing a space for winding a coil, a restriction condition of d≥2k should be met with k as the lamination thickness of the coil. Thus a core shape for bringing ΔX closer to zero may be determined under the restriction condition while performing a magnetic simulation. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention mainly relates to a reactor device mounted on a fuel cell vehicle, a hybrid vehicle, or the like, and particularly relates to a vibration reduction measure.

  In recent years, automobiles that drive a motor with a battery have been developed, such as hybrid vehicles and fuel cell vehicles, due to environmental problems. A boost converter disposed in a fuel cell vehicle, a hybrid vehicle, or the like includes a reactor that stores and releases energy. The reactor has a core formed by stacking a plurality of partial cores with a gap spacer interposed therebetween, and a coil wound around the core. When a current flows through the coil, a magnetic field is generated inside the core, a magnetic attractive force is generated between the partial cores sandwiching the gap spacer, and the reactor vibrates. The reactor device is configured by housing a reactor in a case, but when reactor vibration propagates to the case, noise is emitted to the outside of the reactor device. In addition, the amount of heat generated inside the reactor device may increase due to the vibration of the reactor.

  One problem is how to reduce the vibration of the reactor device. In particular, it is required to reduce high-frequency noise in the vicinity of 10 kHz (5 to 20 kHz). Therefore, conventionally, many proposals have been made to reduce the vibration of the reactor that leads to the noise of the reactor device.

For example, Patent Document 1 discloses that a low magnetostrictive dust core is provided by adding an organic compound having an action of changing the amount of magnetostriction to a powder made of a soft magnetic material.
JP 2006-332328 A

  With the technique of the above-mentioned patent document 1, it is possible to suppress vibration generated in the reactor to some extent by reducing the magnetostriction amount of the core. However, there is a certain limit in reducing the amount of magnetostriction by adding an organic compound.

  The objective of this invention is providing the reactor apparatus which has a structure which can reduce a vibration by setting it as the shape which makes magnetostriction amount as small as possible.

  The reactor apparatus design method of the present invention is based on a track-shaped core having a pair of opposed support portions, and performs a magnetic simulation while under the limiting conditions in a direction orthogonal to the pair of support portions. This is a method for determining a core shape for suppressing vibration due to magnetostriction.

  By this method, a reactor device is designed by suppressing a component in a direction in which the core is supported by the case among vibrations generated by the magnetostriction of the core. Therefore, a reactor device is designed that has little propagation of vibration from the core to the case, that is, little vibration of the case.

  In the above design, the distance between the magnetic path length lines of each support part and the distance between the support parts can be obtained so that the displacement due to magnetostriction in the direction orthogonal to the support part approaches zero.

  The reactor device of the present invention includes a track-shaped core having a pair of opposing support portions, and a case that accommodates the core while supporting the core with the support portion, and the interval between the pair of support portions of the core is It is set so as to suppress vibration due to magnetostriction in the direction orthogonal to the support portion.

  Thereby, among the vibrations generated by the magnetostriction of the core, the component in the direction in which the core is supported by the case is suppressed, so that the propagation of vibration to the case is suppressed, and the vibration in the case can be suppressed.

  When the case has a pair of sides parallel to the support portion of the core, the pair of sides protrudes outward at a portion located on the side of the coil, thereby manufacturing the case. Cost and space can be reduced.

  Since the support portion of the core has a portion protruding outward, the amount of magnetic flux of the core can be increased by effectively using the space of the case.

  Since the core is mainly composed of a sintered soft magnetic material, the manufacturing cost can be reduced.

  According to the reactor device and the design method of the present invention, it is possible to suppress the propagation of vibration from the core to the case, and thus it is possible to reduce the vibration of the case.

-Design assumptions-
FIG. 1 is a diagram for explaining parameters as a premise for designing a reactor apparatus according to the present invention. In the present invention, it is assumed that there is no gap spacer, that is, a single core that is not divided into partial cores. When a magnetic material having a low magnetic permeability is used, a reactor having desired reactor characteristics can be obtained without a gap spacer. In that case, the vibration due to magnetostriction becomes a problem, not the vibration caused by the magnetic attractive force between the partial cores sandwiching the gap spacer, which has been a problem in the past. Therefore, in the present invention, a design for suppressing propagation of vibrations due to magnetostriction to the case is performed.

  In FIG. 1, a magnetic path length line l that draws a closed loop defines the magnetic path length of the core 1. Here, in the present specification, a line continuously connecting the centers of the magnetic flux amounts obtained by integrating the magnetic flux density in each cross section is referred to as a “magnetic path long line”. In each cross section of the core 1, the magnetic flux density is higher in the central portion than in the peripheral portion, so that the magnetic path length line 1 is shifted from the central point with respect to the central point of the width of the core 1.

  And in the core whose planar shape is a rectangular shape, as shown in FIG. 1, the magnetic path length line 1 is also a rectangular shape. Here, in the present embodiment, as shown in FIG. 4, a portion supported by the case 3 is a support portion Ra, and a portion other than the support portion Ra is an open portion. A direction orthogonal to the support portion Ra is defined as an X direction, and a direction parallel to the support portion Ra is defined as a Y direction. The length of the magnetic path long line l in the X direction is A, the length in the Y direction is B, the width of the support portion Ra of the core 1 is C, the interval between the cores 1 is d, and the magnetic path long line l The distance between the support portion Ra of the core 1 and the side surface Ra1 is w. At this time, in order to reduce the vibration propagated to the case, the X-direction component of the vibration generated in the core 1 by magnetostriction should be made as small as possible.

At this time, as shown in FIG.
2C + d = A + 2w
The following formula (1)
d = A-2C + 2w (1)
Is established.

On the other hand, when the cross-sectional shape of the core is determined, the displacement ΔX per unit length of the support portion Ra due to magnetostriction in the X direction is calculated by the following equation (2) from the magnetic simulation.
ΔX = A · λ _L -2C · λ _W (2)
Is required. However, (lambda) _L shows the intrinsic elongation rate with respect to the magnetic field of a magnetic material, and (lambda) _W shows the intrinsic shrinkage rate with respect to the magnetic field of a magnetic material. For example, in the case of a dust core made by Sumitomo Electric Industries, when a magnetic field having a magnetic flux density of 0.7 T (Tesla) is applied, the elongation λ _L is 1.53 ppm and the shrinkage λ _W is 0.84 ppm. is there.

However, in order to ensure a space for winding the coil, k is the thickness of the coil stack, and the following formula (3)
d ≧ 2k (3)
Restrictions are imposed.
Therefore, it is only necessary to determine a core shape for making ΔX close to zero under a limiting condition while performing a magnetic simulation.

-Design Procedure FIG. 2 is a block diagram showing a configuration of a design device used for designing the reactor device. FIG. 3 is a flowchart showing the design procedure of the reactor device.
The design device 50 includes a CPU 51 as a central processing unit, a display device 52 connected to the CPU 51, a memory 53 for storing calculation results and various data of the CPU 51, and a program input device 54 for inputting magnetic simulation software and the like. And. The design is performed by the CPU 51 using the design device 50 according to the procedure shown in FIG.

  First, when the cross-sectional shape of the core is determined in step ST1, magnetic simulation software is input from the program input device 54 to perform a magnetic simulation, and the result is stored in the memory 53 in step ST2.

At this time, the cross-sectional shape such as the width C of the core is determined in advance from the reactor value necessary for the reactor device, and the distance w between the magnetic path length line 1 and the side surface Ra1 of the support portion Ra is obtained from the magnetic simulation. Also, the length of the magnetic path length can be obtained from the magnetic simulation.
Further, in order to suppress the propagation of vibration to the case, the displacement ΔX of the support portion Ra (support portion) due to magnetostriction is desired to be as close to zero as possible. Therefore, when a condition for ΔX = 0 is obtained in equation (2), the following equation (4) is obtained.
A / 2C = λ _W / λ _L (4)
It becomes.
When A is obtained from equation (4), d is obtained from equation (1).

However, since it is necessary to satisfy the limit condition of Expression (3), it is determined in step ST3 whether the calculated A and d satisfy the limit value. If the determination result is YES, the process proceeds to step ST4 to store the calculated value in the memory.
In step ST6, another dimension B is determined based on A and d. If the magnetic path length and w are determined, when A is determined, B is also determined.

  On the other hand, if the determination result in step ST4 is NO, the process proceeds to step ST5. Then, the lower limit value shown in Expression (3) is set to d, and further, A is calculated by substituting d into Expression (1), and the corrected A and d are stored in the memory 53. In step ST6, dimensions such as B are determined based on the corrected A and d.

  According to the design method of the reactor device of the present invention, the dimensions A, d, and B for making the displacement Δx caused by the magnetostriction in the direction orthogonal to the support portion Ra (x direction) as close to zero as possible can be obtained. That is, the shape for suppressing the vibration propagated to the case from the reactor device having the single core without the gap spacer can be determined.

(Embodiment 1 regarding the structure of a reactor device)
Next, an embodiment of a reactor device designed by the above design method will be described.
FIG. 4 is a perspective view showing a schematic configuration of reactor apparatus A1 in the first embodiment. FIG. 5 is a perspective view showing only the core in the embodiment. FIG. 6 is a top view of reactor device A1 according to the first embodiment, with the case and the middle case broken away.

As shown in FIGS. 4 to 6, the reactor device A <b> 1 of the present embodiment includes a core 1, a coil 2 that surrounds the periphery of the core 1 in an annular shape, a middle case 4 that houses the core 1, the coil 2, and the like, And a case 3 for storing the entirety.
The core 1 has a track shape in a planar shape, and has a pair of support portions Ra extending in the X direction and a pair of open portions Rb. In the present embodiment, the core 1 is not divided into partial cores, and no gap spacer is provided.

  The case 3 includes a pair of short side portions 3a extending in the X direction orthogonal to the support portion Ra of the core 1 (that is, parallel to the open portion Rb), and 1 extending in the Y direction parallel to each support portion Ra of the core 1. A pair of supporting portions 3b is provided, and a portion near the center of each supporting portion 3b is a protruding portion 3c protruding outward. The coil 2 and the middle case 3 that covers the coil 2 are housed inside the protruding portion 3c.

Here, in the present embodiment, a gap Sp exists between the front end surface Rb1 of the open portion Rb of the core 1 and the short side portion 3a of the case 3. On the other hand, the long side part 3b of the case 3 and the side surface Ra1 of the support part Ra of the core 1 are in contact. That is, the core 1 is supported by the case 3 on the side surface Ra1 of the support portion Ra extending in the direction intersecting the surface of the gap spacer 11. However, the term “support” as used herein refers to support for limiting the degree of freedom in plan, and in terms of weight, the core 1 is supported by the lower surface of the core 1 contacting the bottom surface of the case 3. .
The dimensions A, B, d, etc., shown in FIG. 1 of the core 1 are designed so that vibration caused by magnetostriction in the X direction approaches zero by the above-described design.

  The coil 2 is almost entirely covered with an insulating film, and only a pair of terminals 23 are exposed from the insulating film. As described above, the coil 2 is configured by connecting the two annular portions 21 covering the respective support portions Ra of the core 1 by the connecting portions 22, and when energized, the two annular portions 21 are sequentially connected from one terminal 23. Then, an alternating current flows through the other terminal 23.

-Material of each part of reactor device-
The core 1 is made of a soft magnetic material also called a high magnetic permeability material. Examples of soft magnetic materials include pure iron, soft iron, magnetic steel, silicon steel, permalloy, sendust, ferrite, and amorphous materials of magnetic alloys. A reactor that requires high frequency and high power, such as for driving an engine of a hybrid vehicle, is required to have a small iron loss in a frequency region of 1 kHz or higher. Moreover, in order to suppress vibration, it is preferable that the magnetostriction of the core 1 is small.

  In the present embodiment, each of the cores 1 is made of a sintered soft magnetic material. In this embodiment, as a sintered soft magnetic material, iron-based soft magnetic powder produced by an atomization method is surface-coated with a phosphate insulating coating and a resin binder, and the surface-coated powder is press-molded and then sintered at a high temperature. The result is used.

  As the soft magnetic material, there is a non-oriented silicon steel plate in addition to the sintered soft magnetic material, and in particular, an unstrained silicon steel plate having about 6% silicon is frequently used because the magnetostriction is close to zero. This unstrained silicon steel plate is expensive because it is expensive to manufacture. On the other hand, the sintered soft magnetic material has low coercive force characteristics and is cheaper than the unstrained silicon steel sheet, but has a disadvantage that the magnetostriction is larger than that of the unstrained silicon steel sheet.

  The case 3 is made of a material having good thermal conductivity and workability, such as Mg or Mg alloy, aluminum or aluminum alloy, and the heat generated in the reactor is released from the case 3 to the outside. Has been.

  According to the reactor device of the present embodiment, the side surface Ra1 of the support portion Ra of the core 1 is in contact with the long side portion 3b of the case 3, and the core 1 is supported by the case 3 on the side surface Ra1. That is, the core 1 is supported in the X direction. A gap Sp is interposed between the short side 3a of the case 3 and the tip end surface Rb1 of the open portion Rb of the core 1. The dimensions A, B, d, etc., shown in FIG. 1 of the core 1 are designed so that the vibration caused by the magnetostriction in the X direction approaches zero by the above-described design. It is suppressed and the vibration of the case 3 is reduced.

  In the present embodiment, the long side portion 3b parallel to the support portion Ra of the case 3 is provided with the protruding portion 3c protruding outward. However, the flat long side portion 3b may be used. However, in that case, it is necessary to increase the thickness of the long side portion 3b by the thickness of the coil 2 in the region where the coil 2 is not wound, which increases the cost of the material constituting the case and is useless. Will create space. On the other hand, the manufacturing cost and the space occupied by the reactor device can be reduced by providing the protruding portion 3c as in the present embodiment.

(Embodiment 2)
FIG. 7 is a top view of reactor device A2 according to the second embodiment, with the case and the middle case broken away. As shown in the figure, in the present embodiment, the planar shape of the case 3 is a rectangular shape, and no protruding portion as in the first embodiment is provided. That is, in the present embodiment, the long side portion 3b has a flat plate shape. On the other hand, the support portion Ra of the core 1 is provided with a protruding portion Rc protruding outward. The side surface Ra1 of the support portion Ra in the protruding portion Rc and the long side portion 3b of the case 3 are in contact with each other, and between the tip end surface Rb1 of the connection Rb of the core 1 and the short side portion 3a of the case 3 A gap Sp is interposed. Since other structures are the same as those described in the first embodiment, the same reference numerals as those in the first embodiment are given and description thereof is omitted.

  Also in the present embodiment, the core 1 and the case 3 are not in contact with each other in the Y direction, and the core 1 and the case 3 are in contact with each other through the side surface Ra1 in the X direction. The degree of freedom of 1 is limited. Therefore, the same effect as Embodiment 1 can be exhibited.

  In particular, in the present embodiment, the projecting portion Rc is provided on the support portion Ra of the core 1 so that the planar shape of the case 3 is rectangular, thereby simplifying the shape and increasing the magnetic flux generated by the projecting portion Rc. The amount can be increased.

(Other embodiments)
In each of the above embodiments, the gap spacer is not provided, but the support portion may be provided with a gap spacer. In that case, since the main component of the vibration caused by the magnetic attractive force is generated in the Y direction, the vibration propagating to the case 3 is reduced in the X direction. Therefore, a remarkable vibration reduction effect is exhibited together with the effect of the present invention.

In each of the above embodiments, the middle case 4 that covers the coil 2 is provided, but the middle case 4 is not necessarily required. This is because even if the middle case 4 is not provided, the surface of the coil 2 is protected by an insulator, so that it is possible to ensure insulation performance by increasing the thickness of the insulator. However, the intermediate case 4 is useful in order to ensure the insulation and the relative positioning of the core 1 with respect to the case 3 to ensure the use state of the reactor device and the reliability at the time of assembly. is there. When the middle case 4 is provided, the heat generated in the coil 2 is transferred to the case 3 because the middle case 4 and the protruding portion 3c of the case 3 are in contact with each other as in the present embodiment. This will improve the heat dissipation.
When the middle case 4 is provided, the heat radiation performance can be further improved by reducing the resin thickness, making it as close as possible to the heat radiating case 4 or using a material having high thermal conductivity. .

  A spring member may be interposed between the support portion Ra of the core 1 and the long side portion 3b of the case 3. In that case, components other than the main component of vibration generated in the core can be prevented from propagating to the case 3.

  Further, when a sintered soft magnetic material is used as the material of the core 1, although the manufacturing cost is reduced, the vibration due to magnetostriction is larger than that of the unstrained silicon steel sheet. Propagation to case 3 can be suppressed.

  The structure of the embodiment of the present invention disclosed above is merely an example, and the scope of the present invention is not limited to the scope of these descriptions. The scope of the present invention is indicated by the description of the scope of claims, and further includes meanings equivalent to the description of the scope of claims and all modifications within the scope.

  The reactor device of the present invention can be used as a component such as a boost converter in a hybrid vehicle, a fuel cell vehicle, and a factory / household power supply system.

It is a figure for demonstrating the parameter used as the premise which designs the reactor apparatus by this invention. It is a block diagram which shows the structure of the design apparatus used for design of a reactor apparatus. It is a flowchart which shows the design procedure of a reactor apparatus. It is a perspective view which shows schematic structure of the reactor apparatus in Embodiment 1. FIG. FIG. 3 is a perspective view showing a structure of a core in the first embodiment. It is a top view of the reactor apparatus which concerns on Embodiment 1 which shows a case and a middle case by fracture. It is a top view of the reactor apparatus which concerns on Embodiment 2 which shows a case and a middle case by fracture | rupture.

Explanation of symbols

A Reactor device Ra Support portion Ra1 Side surface Rb Open portion Rb1 Tip surface Rc Protrusion portion 1 Core 2 Coil 3 Case 3a Short side portion 3b Long side portion 3c Protrusion portion 4 Middle case 21 Annular portion 22 Connection portion 23 Terminal

Claims (7)

A method for designing a reactor device including a track-shaped core having a pair of opposing support portions,
(A) calculating a core shape for suppressing vibration due to magnetostriction in a direction orthogonal to the pair of support portions by magnetic simulation, and storing the calculation result in a memory;
(B) extracting a calculation result of the magnetic simulation from a memory and determining a core shape under a limiting condition;
A method for designing a reactor device, including: In the design method of the reactor apparatus of Claim 1,
In the step (a), the distance between the magnetic path length lines of the support parts and the distance between the support parts are set so that the displacement due to magnetostriction in the direction orthogonal to the pair of support parts approaches zero. What is the desired reactor device design method? A track-shaped core having a pair of opposed support portions opposed to each other;
A coil provided around the core;
A case for storing the core and the coil while supporting the core in the support portion;
The reactor device is configured such that an interval between the pair of support portions of the core is set so as to suppress vibration due to magnetostriction in a direction orthogonal to the support portions. The reactor device according to claim 3,
The reactor is a reactor device that is a single core without a gap spacer. The reactor device according to claim 3 or 4,
The case has a pair of sides parallel to the support portion of the core,
The pair of side portions is a reactor device that protrudes outward at a portion located on a side of the coil. The reactor device according to claim 3 or 4,
The reactor is a reactor device in which the support portion of the core has a portion protruding outward in a portion not covered with the coil. In the reactor apparatus as described in any one of Claims 3-6,
Each of the partial cores of the core is a reactor device configured with a sintered soft magnetic material as a main component.

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