A new approach to the working out of a reactor for power line filters

Abstract

In the paper, it is analyzed features of production of reactor’s windings for heavy duty power line filters (designed for currents of hundreds and thousands amperes), for example, of several U-shaped segments of every turn which are cut out of a flat metal sheet with thickness of 2…5 mm; these segments are being appropriately bended, placed on the core and every two adjacent segments connected to create a continuous sequence of turns that cover the core. Also it is analyzed technical solutions, in which it is suggested to carry out the reactor winding in the form of insulated wires harness, with the aim of winding flexibility increase and simplification of winding technology on the toroidal core. It is showed the complexity and high price of windings manufacture by known methods. It is proposed a new technology of winding creation with using of bare multicore flexible wire, the diameter of every wire in the wire harness not exceeding 0.5 mm. In other specific form of execution the wire harness is being formed of one or several wire harnesses of smaller diameter, every wire harness of smaller diameter consisting of non-insulated wires and having the diameter of 1 to 5 mm, the ratio between the diameter of wire harness of smaller diameter and the diameter of non-insulated wires which consist the wires harness of smaller diameter being within 20 to 40 units. This technology allows greatly simplify the process of winding’s winding itself and connection of every winding’s end with the tip, and simultaneously to get the reliable connection of every winding’s end with the tip, providing the minimal transient resistance between the winding and the tip, and to speed up the process of manufacturing the reactor as a whole.