1. Overview

        Magnetic composite reactor research goal is to realize the photovoltaic and wind power inverter, inverter, UPS, smart grid, such as high frequency and small production, promote the transformation of technology industry and energy saving.Project mainly studies the application of different magnetic materials in different occasions and choice, the technological requirements of reactor in different environment, different equipment application and the design of the reactor under different environmental parameters, the design of reactor structure, etc.

        Magnetic composite reactor core design with low loss and core loss than conventional reactor core loss was reduced by 30%, set around the process at the same time, improve the heat dissipation area and heat capacity.Traditional reactor overall efficiency generally about 97%, and the magnetic composite reactor can make the efficiency of 98.5% or more, greatly enhance the market competitiveness of products.At the same time, the use of composite magnetic material to make the reactance phase noise is reduced greatly, tradition reactor control within 75dB noise, and the magnetic composite reactor noise can be controlled within 50dB; Using only the standing around technology make the product around a layer, at the same time omit the use of insulating paper, reduces the noise of winding turns long on average, lower the temperature rise of the product, has excellent EMI, EMC effect, the stand around the technology cost 5~10% lower than the traditional process:Product structure design is mainly to keep the circulation of the air duct, choose not permeability structure, improve product performance and reliability.

2. The project involves technology, technology category

Magnetic composite reactor widely use of light volt power generation, wind power, power harmonic governance, inverter, smart grid, electronic information, UPS, and other fields, research related to electromagnetics, electrical machinery, electronic circuits, mechanical structure, and many other technical disciplines.
        Magnetic composite reactor is a kind of reactor, involving raw materials processing and manufacturing process.The making craft of magnetic composite reactor key for winding lines, core assembly, assembly line package, bracket, etc.
        The winding line bag need to focus on the size of the control lines and the safe distance, Angle of wire rod and wire insulation protection.Composite reactor using the core number of many, so that when the core assembly must use reliable tools, use of superior cure adhesive to ensure that the size of the core after assembling, the reliability and the electrical properties of the products. In the assembly lines and bracket must ensure that the product is flat and level, lines, and core fixed tightly, shockproof and good installation and reliable.
        Magnetic composite reactor belongs to new component technology, is a kind of high frequency components.Belongs to one of the important supporting industry "twelfth five-year" national policy, is one of the key support strategic areas in shenzhen.

3.To solve the key technical problems

Magnetic composite reactor design and research mainly to solve the key technical problems are:

(1) Efficiency Improvement

Efficiency is one of the important indicators of power electronic products must appraisal, also is the main basis of energy conservation and environmental protection.Affect the efficiency of the reactor basically has two, one is the reactor core loss, 2 it is reactor conductor loss.

a)Decrease of core loss

 Traditional reactor using silicon steel sheet design, product work in the 5 KHZ, 0.1 T, currently on the market the best core loss of 8 w/kg.Magnetic composite reactor after precise design, electromagnetic simulation and process design can use the ferrite magnetic material such as iron, silicon aluminum, iron, silicon, under the same condition, the wastage of the ferrite, iron, silicon aluminum, iron, silicon, respectively is 0.4 W/kg, 4.03 W/kg, 6.4 W/kg, so to a great extent, reduce the loss of the entire product, improve the efficiency of the product.

b)Conductor loss reduction

Main factors influencing reactor conductor loss have winding circle number, the area of the conductor, high and low temperature.Winding circle number affected by core, in the condition of high frequency, magnetic combination design with lower loss, so can choose the number of turns of a slightly less, so even in the use of the same area of the conductor will have a lower loss.At the same time, because the magnetic composite reactor has a smaller iron losses, so the rise of temperature of the product will be lower, at lower temperature, according to the physical properties of a conductor, a conductor with lower losses.

 (2) Noise issue:

Product application frequency, fever, distribution parameters, the reliability of the fixed size is the main factor affecting the noise.

a)The effect of application of frequency

Product application frequency under 20 KHZ, people easily, especially in 3 ~ 10 KHZ is one of the most sensitive frequency range.When using magnetic reactance combination design period, can increase the product application frequency to more than 20 KHZ or avoid the voice of the most sensitive frequency range, so that it can greatly reduce noise.

b) Thermal

Equipment for large product loss fever is big, high quantity of heat can make the air convection acceleration vibration, at the same time because of the influence of loss increase product temperature increase leads to product structure intensity is abate, causing more noise.Magnetic composite reactor has better loss and more excellent cooling effect, can effectively reduce noise.

（3）Temperature rise

The rise of temperature of the product depends on its efficiency (loss), product of heat dissipation area and heat dissipation ability, the condition of reactor of air gap.

a) Efficiency improvement can improve noise

As above mentioned in point 1, the use of magnetic composite design can have higher efficiency, so products will be more low temperature.

b) Increase the cooling area and heat capacity can improve the noise

Magnetic composite reactor in terms of process adopt the way of standing around, cancel the use of insulating paper, make the insulated conductors and direct contact with air, increase the heat dissipation ability;Using multiple duct design at the same time, increase the cooling area, have the effect of reducing noise.

c) The status of the air gap impact noise

Traditional reactor generally adopts the air gap, gap generally reach more than 2 mm, the size of the air gap directly affects the wastage of the products, edge magnetic flux, divergence increases at the same time, cause noise increases.Magnetic composite reactor can be used in a metal alloy magnetic powder core, the air-gap uniform distribution, basic no edge magnetic flux and magnetic, thus improving the noise.

（4）EMI&EMC

Traditional reactor with foil, layer number is more, the cooling effect is poor, a big distributed capacitance, proximity effect is serious.And magnetic composite reactor using flat wire winding around the way, there is only one layer winding, greatly reduce the distributed capacitance of the product, decrease the proximity effect, make the product has excellent EMI, EMC performance.

4.The main point of technological innovation project

This project mainly technology innovation are:

（1）The application of composite magnets

Consider the product efficiency and cost, the application of "magnets can reduce the wastage of the products, improve product application frequency, diversification and combination way, on the basis of the theory of electromagnetic and magnetic simulation can be safe and reliable products with excellent performance.

Magnetic composite reactor core design with low loss and core loss than conventional reactor core loss was reduced by 30%, set around the process at the same time, improve the heat dissipation area and heat capacity.

Traditional reactor overall efficiency generally about 97%, and the magnetic composite reactor can make the efficiency of 98.5% or more, greatly enhance the market competitiveness of products.At the same time, the use of composite magnetic material to make the reactance phase noise is reduced greatly, tradition reactor control within 75 db noise, and the magnetic composite reactor noise can be controlled within 50 db

（2）Coil winding technology application

Traditional foil around the product cooling effect is not good, layer number, distribution parameters, the average winding turns to grow up, which would influence the efficiency of the products, quality and cost.Stand around the process of the products around only one layer, at the same time omit the use of insulating paper, reduces the noise of winding turns long on average, lower the temperature rise of the product, has excellent EMI, EMC performance.The stand around the technology cost 5 ~ 10% lower than the traditional process

（3）Choose not permeability structure for structural design

In order to improve the performance and reliability of the product, product structure design is mainly to keep the circulation of the air duct, choose not permeability structure.When designing structure to reduce the use of other materials.Traditional reactor especially small power devices many patterns by shell plus potting, poor heat dissipation, high cost.

5. The main products show