Preparation method of magnetic integrated matrix transformer

Abstract

The invention discloses a preparation method of a magnetic integrated matrix transformer. The preparation method comprises the following steps: calculating a turns ratio of an input power supply and an output power supply of the magnetic integrated matrix transformer to be prepared; determining the number of turns of the secondary winding according to the output power supply; calculating the number of turns of a primary winding according to the turns ratio of the transformer and the number of turns of a secondary winding; calculating an available setting space of a magnetic core in the magnetic integrated matrix transformer according to the power supply framework and the output power supply; calculating the number of settable layers according to the available setting space and the thickness of the printed circuit board with the winding layer; the winding structure of the sub-transformer is designed according to the settable layer number, each printed circuit board with the winding layer is provided with one of a primary winding and a secondary winding, the width of the primary winding and the width of the secondary winding are the same, and the primary winding and the secondary winding of each sub-transformer are of a sandwich structure; through the preparation method, the design process is flexible and simplified, so that the purposes of minimizing the winding loss and improving the preparation efficiency are achieved.

Description

Technical Field

[0001] The present application relates to the technical field of electric power, and in particular to a method for preparing a magnetic integrated matrix transformer. Background Art

[0002] As the amount of computing in data centers increases, the demand for switching power supplies used in data centers also increases. Improving the power density of switching power supplies will become the only way to meet the power consumption of data centers.

[0003] Among the core components of the switching power supply, the transformer occupies the absolute volume of the entire switching power supply. Therefore, effectively reducing the size of the transformer in the power converter can maximize the power density of the switching power supply, and increasing the switching frequency is one of the effective means to reduce the volume and weight of the transformer and increase its power density. However, increasing the frequency will increase additional losses on the one hand, and reduce the utilization rate of the magnetic core on the other hand. If the converter works in a wider frequency range, it will also bring about the problem of larger transformer size. Therefore, the current transformer design often cannot take into account the converter's high frequency, small size and high efficiency requirements.

[0004] Magnetic integrated matrix transformer technology, such as: Pranav Raj Prakash, Ahmed Nabih and Qiang Li, "Design Optimization of PCB Winding Matrix Transformer for 400V / 12V Unregulated LLC Converter" 2021IEEE Energy Conversion Congress and Exposition (ECCE) integrates multiple separate magnetic cores into a single integrated magnetic core, fully utilizes the core structure and winding structure of the transformer, reconstructs and optimizes the core structure based on customized magnetic cores, and integrates the transformer in one magnetic core. Most of the current magnetic integrated matrix transformers use compact copper foil in printed circuit boards to replace the round copper wire of traditional power transformers. This can reduce the size of the power transformer and reduce the AC loss of the winding at high frequencies, effectively reduce the loss of magnetic components, and reduce the size and weight of the converter, especially for low-voltage and high-current applications such as server power supplies. For example, in a 3kW server power supply with 400V input and 12V output, the primary-to-secondary turns ratio N of the LLC resonant circuit transformer is P :N s1 :N s2 It is 16:1:1. The magnetic integrated matrix transformer design with input windings in series and output windings in parallel can be used to divide the original single transformer into several sub-transformers to bear the large current on the secondary side respectively, which can effectively reduce the loss of the secondary winding and the connection impedance between the secondary winding and the rectifier circuit, and reduce the loss of contact impedance.

[0005] However, the existing magnetic integrated matrix transformer designs are mostly customized products. After the design is completed according to certain gain and frequency range indicators, it cannot be changed. It is not flexible enough and has low versatility. When the transformer is used in different working occasions, the transformer design indicators such as the transformer turns ratio or the number of secondary side paths change, and new magnetic parts need to be redesigned and customized. At the same time, when the transformer secondary winding has multiple outputs, whether it is asymmetric magnetic circuits, inconsistent winding parameters or multiple secondary sides in parallel, it will cause current sharing problems for the transformer. In this way, not only is the design process complicated, but it is also time-consuming.

[0006] Therefore, the prior art is indeed in need of further providing more improved solutions. Summary of the invention

[0007] In view of the above-mentioned deficiencies in the prior art, the main purpose of this application is to provide a method for preparing a magnetically integrated matrix transformer, simplify the process of designing a magnetically integrated matrix transformer according to customized parameters, achieve minimum winding loss of the matrix transformer and achieve the purpose of improving preparation efficiency.

[0008] To achieve the above purpose, the main technical means adopted in this application is to make a method for preparing a magnetic integrated matrix transformer, comprising the following steps: Obtaining an input power supply and an output power supply of a magnetic integrated matrix transformer to be prepared, and calculating a transformer turns ratio of the magnetic integrated matrix transformer; Determining the number of turns of the secondary winding according to the output power supply; Calculating the number of turns of the primary winding according to the transformer turns ratio and the number of turns of the secondary winding; Determine the available setting space of the magnetic core in the magnetic integrated matrix transformer according to the power supply architecture and the output power supply; Calculating the number of layers that can be arranged on the printed circuit board with the winding layer according to the available arrangement space and the thickness of the printed circuit board with the winding layer; The winding structure of the sub-transformer is designed according to the number of layers that can be set on the printed circuit board with winding layers; wherein each printed circuit board with winding layers is provided with one of the primary winding or the secondary winding, and the width of the primary winding or the secondary winding is the same, and the primary winding and the secondary winding of each sub-transformer are formed in a sandwich structure; According to the winding structure of the sub-transformer, the number of turns of the primary winding of the sub-transformer is obtained; and The number of the sub-transformers is determined according to the number of turns of the primary winding of the sub-transformer and the number of turns of the total primary winding.

[0009] Preferably, the method further includes the following sub-steps when executing the step of "obtaining the input power supply and the output power supply of the magnetic integrated matrix transformer to be prepared, and calculating the transformer turns ratio of the magnetic integrated matrix transformer": The transformer turns ratio is calculated according to the input voltage of the input power supply and the output voltage of the output power supply.

[0010] Preferably, the method further comprises the following sub-steps when executing the step of “determining the number of turns of the secondary winding according to the output power”: Calculating an output current according to the output power of the output power supply and the output voltage; The number of turns of the secondary winding is determined according to the output current.

[0011] Through the above-mentioned preparation method, according to the input power supply and the output power supply of the magnetic integrated matrix transformer to be prepared, the number of turns of the primary winding and the number of turns of the secondary winding are obtained, and according to the circuit architecture and the output power supply, the available setting space of the magnetic core in the magnetic integrated matrix transformer is obtained, and according to the available setting space and the thickness of the printed circuit board with the winding layer, the number of layers that can be set on the printed circuit board with the winding layer is calculated, so as to design the winding structure of the sub-transformer according to the number of layers that can be set, wherein the setting of each printed circuit board with a winding layer is One of the primary winding or the secondary winding and the width of the primary winding or the secondary winding are the same, and the primary winding and the secondary winding of each sub-transformer are composed of a sandwich structure. In this way, the magnetic integrated matrix transformer can be prepared according to the circuit architecture of the magnetic integrated matrix transformer to be prepared, the input parameters to be prepared, the output parameters to be prepared, the available setting space of the magnetic core and the number of configurable layers of the printed circuit board, and the process of designing the magnetic integrated matrix transformer is flexible and simplified, so as to minimize the loss of the matrix transformer winding and achieve the purpose of improving the preparation efficiency.

[0012] To achieve the above purpose, another main technical means adopted by the present application is a method for preparing a magnetic integrated matrix transformer, comprising the following steps: Obtaining an input power supply and an output power supply of a magnetic integrated matrix transformer to be prepared, and calculating a transformer turns ratio of the magnetic integrated matrix transformer; Determining the number of turns of the secondary winding according to the output power supply; The number of turns of the primary winding is calculated according to the transformer turns ratio and the number of turns of the secondary winding; wherein the primary winding and the secondary winding are arranged on a printed circuit board to form a printed circuit board having a winding layer; Determining the number of the printed circuit boards according to the output power supply, the number of turns of the primary winding, and the number of turns of the secondary winding; Determining the number of sub-transformers according to the output power of the output power supply; and The stacking of the primary winding and the secondary winding of each sub-transformer is a sandwich structure in which the primary winding is outside and the secondary winding is inside, or the secondary winding is outside and the primary winding is inside.

[0013] Through the above-mentioned preparation method, according to the input power supply and the output power supply of the magnetic integrated matrix transformer to be prepared, the number of turns of the primary winding and the number of turns of the secondary winding are obtained, and according to the circuit architecture and the output power supply, the available setting space of the magnetic core in the magnetic integrated matrix transformer is obtained, and according to the available setting space and the thickness of the printed circuit board with the winding layer, the number of layers that can be set on the printed circuit board with the winding layer is calculated, so as to design the winding structure of the sub-transformer according to the number of layers that can be set, wherein the setting of each printed circuit board with a winding layer is One of the primary winding or the secondary winding and the width of the primary winding or the secondary winding are the same, and the primary winding and the secondary winding of each sub-transformer are composed of a sandwich structure. In this way, the magnetic integrated matrix transformer can be prepared according to the circuit architecture of the magnetic integrated matrix transformer to be prepared, the input parameters to be prepared, the output parameters to be prepared, the available setting space of the magnetic core and the number of configurable layers of the printed circuit board, and the process of designing the magnetic integrated matrix transformer is flexible and simplified, so as to minimize the loss of the matrix transformer winding and achieve the purpose of improving the preparation efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] The drawings described herein are used to provide a further understanding of the present application and constitute a part of the present application. The illustrative embodiments of the present application and their descriptions are used to explain the present application and do not constitute an improper limitation on the present application. In the drawings:

[0015] Figure 1 It is a flow chart of the preparation method of the magnetic integrated matrix transformer of the present application.

[0016] Figure 2 It is another method flow chart of the magnetic integrated matrix transformer of the present application.

[0017] Figure 3 This is another method flow chart of the magnetic integrated matrix transformer of the present application.

[0018] Figure 4 It is a method flow chart of another embodiment of the magnetic integrated matrix transformer of the present application. DETAILED DESCRIPTION

[0019] The following will be combined with the drawings in the embodiments of the present application to clearly and completely describe the technical solutions in the embodiments of the present application. Obviously, the described embodiments are part of the embodiments of the present application, not all of the embodiments. Based on the embodiments in the present application, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of this application.

[0020] Regarding the preparation method of the magnetic integrated matrix transformer of the present application, Figure 1 As shown, the method comprises the following steps: Obtaining an input power supply and an output power supply of a magnetic integrated matrix transformer to be prepared, and calculating a transformer turns ratio of the magnetic integrated matrix transformer (S10); Determining the number of turns of the secondary winding according to the output power supply (S20); Calculating the number of turns of the primary winding according to the transformer turns ratio and the number of turns of the secondary winding (S30); Determining the available arrangement space of the magnetic core in the magnetic integrated matrix transformer according to the power supply architecture and the output power supply (S40); Calculating the number of layers that can be arranged on the printed circuit board with the winding layer according to the available arrangement space and the thickness of the printed circuit board with the winding layer (S50); The winding structure of the sub-transformer is designed according to the number of layers that can be set on the printed circuit board with the winding layer; wherein each printed circuit board with the winding layer is provided with one of the primary winding or the secondary winding, and the width of the primary winding or the secondary winding is the same, and the primary winding and the secondary winding of each sub-transformer are formed in a sandwich structure (S60); According to the winding structure of the sub-transformer, the number of turns of the primary winding of the sub-transformer is obtained (S70); and The number of the sub-transformers is determined according to the number of turns of the primary winding of the sub-transformer and the number of turns of the total primary winding (S80).

[0021] Therefore, through the above-mentioned preparation method, each turn of the primary winding or each turn of the secondary winding of each sub-transformer only occupies one layer of the printed circuit board having a winding layer and the width of each turn of the primary winding or each turn of the secondary winding is the same, so as to achieve the lowest loss of the primary winding and the secondary winding, and the magnetic integrated matrix transformer can be prepared according to the circuit architecture of the magnetic integrated matrix transformer to be prepared, the input parameters to be prepared, the output parameters to be prepared, the available setting space of the magnetic core, and the number of configurable layers of the printed circuit board.

[0022] Another specific embodiment, such as Figure 2As shown, the aforementioned method is executed to the step of "obtaining the input power supply and the output power supply of the magnetic integrated matrix transformer to be prepared, and calculating the transformer turns ratio of the magnetic integrated matrix transformer (S10)", and further includes the following sub-steps: The transformer turns ratio is calculated according to the input voltage of the input power supply and the output voltage of the output power supply (S11).

[0023] Another specific embodiment, as Figure 3 As shown, the method is executed to the step of "determining the number of turns of the secondary winding according to the output power (S20)", and further includes the following sub-steps: Calculating an output current according to the output power of the output power supply and the output voltage (S21); The number of turns of the secondary winding is determined according to the output current (S22).

[0024] In the above embodiment, the transformer turns ratio is calculated according to the following equation (1):

[0025]

[0026] n is the transformer turns ratio; M g is the DC gain of the LLC resonant circuit; V in is the input voltage; V out is the output voltage.

[0027] Further, the number of turns of the primary winding is calculated according to the following equation (2):

[0028]

[0029] n is the transformer turns ratio; N P is the number of turns of the primary winding; N S is the number of turns of the secondary winding.

[0030] For example, the preparation method of the magnetic integrated matrix transformer of the present application is used in the LLC resonant circuit, and the preparation specifications are as follows: the input voltage is 400V, the output voltage is 12V, and the output power is 3.2kW. According to the input voltage of 400V and the output voltage of 12V, the transformer turns ratio is calculated by equation (1) to be 16.66 (the DC gain M of the LLC resonant circuit). g =1, the efficiency is optimal, so set M g=1). In general, the number of transformer turns is an integer number of turns, and for a matrix transformer that outputs low voltage and high current, the transformer needs to be split into multiple sub-transformers. Therefore, the transformer turns ratio is set to 16 to facilitate the subsequent smooth splitting into the sub-transformers. Next, according to the output power of 3.2kW and the output voltage of 12V, the output power is divided by the output voltage to calculate the output current I=266.66A. For the secondary winding with high current, in order to reduce the loss of the secondary winding, the number of turns of the secondary winding is set to 1 as the lowest impedance to minimize the loss of the secondary winding. In the magnetic integrated matrix transformer, a printed circuit board architecture is adopted. Through a multi-layer printed circuit board, the transformer of the primary winding and the secondary winding can be satisfied. The turns ratio can also realize a parallel structure of multi-layer secondary windings with relatively low height to reduce the impedance of the large current of the secondary winding and significantly reduce the loss of the secondary winding. The full-wave rectification circuit of the rear end can further reduce the overall output impedance. In the LLC resonant circuit, the turns ratio of the secondary winding is the same. Therefore, the turns ratio of the transformer and the turns ratio of the secondary winding are 16:1:1. The turns ratio of the transformer calculated by equation (1) is n=16. The turns of the primary winding are further calculated according to equation (2), N S is 1, so the number of turns of the primary winding is N P It is 16. Then, according to the server (Common Redundant Power Supplies, CRPS) power supply architecture and the output power of 3.2kW, the available setting space of the magnetic core in the magnetic integrated matrix transformer is determined. That is to say, before determining the available design space of the magnetic core in the magnetic integrated matrix transformer, the design of other components in the server power supply architecture is first carried out. After the design of other components, the available setting space required by other components can be confirmed. The remaining space is the available setting space of the magnetic core. Subsequently, according to the available setting space and the thickness of the printed circuit board with the winding layer, the number of layers that can be set of the printed circuit board with the winding layer is calculated. Specifically, when the voltage of the input power and the output power meets the safety distance requirements, the copper foil thickness of the winding required by the current of the magnetic integrated matrix transformer, and the thickness of the printed circuit board with the winding layer, the number of layers that can be set of the printed circuit board with the winding layer is calculated.

[0031] According to the number of turns of the primary winding and the number of turns of the secondary winding, the printed circuit board with the winding layer is sandwiched to form the sub-transformer. In detail, in order to minimize the loss of the magnetic integrated matrix transformer, the magnetic integrated matrix transformer must be designed in a relatively symmetrical manner. In the available printed circuit board, the primary winding and the secondary winding of each sub-transformer each only occupy one layer of the printed circuit board and the winding width of each layer is the same, and the primary winding and the secondary winding of each sub-transformer must meet the sandwich structure stacking. Subsequently, the number of sub-transformers is determined according to the number of turns of the primary winding and the total number of turns of the primary winding. According to the number of sub-transformers and the number of turns of the primary winding, the number of turns of the primary winding of each sub-transformer is calculated, so that the width of the primary winding and the secondary winding of each sub-transformer are the same, so that the current density is the same, and the magnetic integrated matrix transformer is more symmetrical, so as to achieve the minimum total loss of the magnetic integrated matrix transformer.

[0032] In addition, regarding another embodiment of the method for preparing the magnetic integrated matrix transformer of the present application, as shown in FIG. Figure 4 As shown, another main technical means adopted by the present application is a method for preparing a magnetic integrated matrix transformer, comprising the following steps: Obtaining the input power supply and the output power supply of the magnetic integrated matrix transformer to be prepared, and calculating the transformer turns ratio of the magnetic integrated matrix transformer (S10'); Determining the number of turns of the secondary winding according to the output power supply (S20'); Calculating the number of turns of the primary winding according to the transformer turns ratio and the number of turns of the secondary winding; wherein the primary winding and the secondary winding are arranged on a printed circuit board to form a printed circuit board having a winding layer (S30'); Determining the number of printed circuit boards having winding layers according to the output power supply, the number of turns of the primary winding, and the number of turns of the secondary winding (S40'); The number of sub-transformers is determined according to the output power of the output power supply (S50'); and wherein the stacking of the primary winding and the secondary winding of each sub-transformer is a sandwich structure formed by the primary winding being outside and the secondary winding being inside, or the secondary winding being outside and the primary winding being inside (S60').

[0033] The above method is executed to the step of "obtaining the input power supply and the output power supply of the magnetic integrated matrix transformer to be prepared, and calculating the transformer turns ratio of the magnetic integrated matrix transformer (S10')", and further includes the above-mentioned sub-step "calculating the transformer turns ratio (S11) based on the input voltage of the input power supply and the output voltage of the output power supply".

[0034] In addition, the aforementioned method executes the step of "determining the number of turns of the secondary winding according to the output power supply (S20')", and also includes the above-mentioned sub-step of "calculating the output current (S21) according to the output power of the output power supply and the output voltage; determining the number of turns of the secondary winding (S22) according to the output current".

[0035] In summary, through the above preparation method, according to the input power supply and the output power supply of the magnetic integrated matrix transformer to be prepared, the number of turns of the primary winding and the number of turns of the secondary winding are obtained, and according to the circuit architecture and the output power supply, the available setting space of the magnetic core in the magnetic integrated matrix transformer is obtained, and according to the available setting space and the thickness of the printed circuit board with the winding layer, the number of layers that can be set on the printed circuit board with the winding layer is calculated, so as to design the winding structure of the sub-transformer according to the number of layers that can be set, wherein each printed circuit board with a winding layer The primary winding or the secondary winding is set to one of them and the width of the primary winding or the secondary winding is the same, and the primary winding and the secondary winding of each sub-transformer are composed of a sandwich structure. In this way, the magnetic integrated matrix transformer can be prepared according to the circuit architecture of the magnetic integrated matrix transformer to be prepared, the input parameters to be prepared, the output parameters to be prepared, the available setting space of the magnetic core and the number of configurable layers of the printed circuit board, and the process of designing the magnetic integrated matrix transformer is flexible and simplified, so as to minimize the loss of the matrix transformer winding and achieve the purpose of improving the preparation efficiency.

[0036] It should be noted that, in this article, the terms "include", "comprises" or any other variations thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or device. In the absence of further restrictions, an element defined by the sentence "comprises a ..." does not exclude the existence of other identical elements in the process, method, article or device including the element.

[0037] The embodiments of the present application are described above in conjunction with the accompanying drawings, but the present application is not limited to the above-mentioned specific implementation methods. The above-mentioned specific implementation methods are merely illustrative and not restrictive. Under the guidance of the present application, ordinary technicians in this field can also make many forms without departing from the scope of protection of the purpose of the present application and the claims, all of which belong to the scope of protection of the present application.

Claims

1. A method for preparing a magnetic integrated matrix transformer, characterized in that: The method comprises the following steps: Obtaining an input power supply and an output power supply of a magnetic integrated matrix transformer to be prepared, and calculating a transformer turns ratio of the magnetic integrated matrix transformer; Determining the number of turns of the secondary winding according to the output power supply; Calculating the number of turns of the primary winding according to the transformer turns ratio and the number of turns of the secondary winding; Determine the available setting space of the magnetic core in the magnetic integrated matrix transformer according to the power supply architecture and the output power supply; Calculating the number of layers that can be arranged on the printed circuit board with the winding layer according to the available arrangement space and the thickness of the printed circuit board with the winding layer; The winding structure of the sub-transformer is designed according to the number of layers that can be set on the printed circuit board with winding layers; wherein each printed circuit board with winding layers is provided with one of the primary winding or the secondary winding, and the width of the primary winding or the secondary winding is the same, and the primary winding and the secondary winding of each sub-transformer are formed in a sandwich structure; According to the winding structure of the sub-transformer, the number of turns of the primary winding of the sub-transformer is obtained; and The number of the sub-transformers is determined according to the number of turns of the primary winding of the sub-transformer and the number of turns of the total primary winding.

2. The method for preparing a magnetic integrated matrix transformer according to claim 1, characterized in that: The aforementioned method is executed to the step of "obtaining the input power supply and the output power supply of the magnetic integrated matrix transformer to be prepared, and calculating the transformer turns ratio of the magnetic integrated matrix transformer", and further includes the following sub-steps: The transformer turns ratio is calculated according to the input voltage of the input power supply and the output voltage of the output power supply.

3. The method for preparing a magnetic integrated matrix transformer according to claim 2, characterized in that: The aforementioned method is executed to the step of "determining the number of turns of the secondary winding according to the output power supply", and further includes the following sub-steps: Calculating an output current according to the output power of the output power supply and the output voltage; The number of turns of the secondary winding is determined according to the output current.

4. A method for preparing a magnetic integrated matrix transformer, characterized in that: The method comprises the following steps: Obtaining an input power supply and an output power supply of a magnetic integrated matrix transformer to be prepared, and calculating a transformer turns ratio of the magnetic integrated matrix transformer; Determining the number of turns of the secondary winding according to the output power supply; The number of turns of the primary winding is calculated according to the transformer turns ratio and the number of turns of the secondary winding; wherein the primary winding and the secondary winding are arranged on a printed circuit board to form a printed circuit board having a winding layer; Determining the number of the printed circuit boards having the winding layers according to the output power supply, the number of turns of the primary winding, and the number of turns of the secondary winding; Determining the number of sub-transformers according to the output power of the output power supply; and The stacking of the primary winding and the secondary winding of each sub-transformer is a sandwich structure in which the primary winding is outside and the secondary winding is inside, or the secondary winding is outside and the primary winding is inside.

5. The method for preparing a magnetic integrated matrix transformer according to claim 4, characterized in that: The aforementioned method is executed to the step of "obtaining the input power supply and the output power supply of the magnetic integrated matrix transformer to be prepared, and calculating the transformer turns ratio of the magnetic integrated matrix transformer", and further includes the following sub-steps: The transformer turns ratio is calculated according to the input voltage of the input power supply and the output voltage of the output power supply.

6. The method for preparing a magnetic integrated matrix transformer according to claim 5, characterized in that: The aforementioned method is executed to the step of "determining the number of turns of the secondary winding according to the output power supply", and further includes the following sub-steps: Calculating an output current according to the output power of the output power supply and the output voltage; The number of turns of the secondary winding is determined according to the output current.

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