A special frame EI type inverter transformer for photovoltaics and a production process optimization method

Abstract

The present invention relates to the technical field of photovoltaic inverter transformers, and in particular to a photovoltaic special skeleton EI type inverter transformer and a production process optimization method. The photovoltaic special skeleton EI type inverter transformer comprises silicon steel sheets, a plurality of silicon steel sheets are connected and combined to form a magnetic circuit conduction frame of the inverter transformer, and an EI type I-shaped skeleton is embedded in the plurality of silicon steel sheets. The EI type I-shaped skeleton is in an I-shape, and a through hole is provided in the middle part of the EI type I-shaped skeleton, and the through hole is used to install a magnetic core material. Two U-shaped epoxy board cards are clamped in the middle position of the EI type I-shaped skeleton, and the two U-shaped epoxy board cards are spliced ​​into a rectangular barrier plate as a whole. The present invention can achieve the purpose of arbitrarily adjusting the primary and secondary winding widths of the transformer according to the winding requirements of the transformer, effectively reducing the coupling between the windings, and increasing the leakage inductance of the transformer to filter out harmonics, thereby reducing the no-load current and loss of the inverter.

Description

Technical Field

[0001] The present invention relates to the technical field of photovoltaic inverter transformers, and in particular to a photovoltaic special frame EI type inverter transformer and a production process optimization method. Background Art

[0002] In the prior art, EI type inverter transformers are widely used in power electronic equipment, especially in high-power applications such as inverters and frequency converters. However, due to its special structural design, EI type transformers often have the problem of strong coupling between windings. This strong coupling phenomenon will cause the transformer to easily generate higher harmonics during operation. These harmonics not only affect the power quality and are difficult to effectively filter out, but also further increase the no-load current and total loss of the inverter, thereby affecting the overall efficiency and stability of the system.

[0003] In addition, the skeleton design of most high-power EI-type transformers on the market is still mainly I-shaped. Although the I-shaped skeleton structure can provide certain mechanical strength and dimensional stability, its uneven magnetic flux distribution may cause saturation of the core magnetic flux when dealing with high-frequency harmonics, thereby affecting the performance of the transformer. As high-power inverters have increasingly higher requirements for efficiency and electromagnetic compatibility, the traditional EI-type transformer skeleton structure faces certain technical challenges, and new designs or optimization solutions are needed to reduce losses, improve harmonic filtering effects, and enhance the overall performance of the transformer. Summary of the invention

[0004] The present invention overcomes the shortcomings of the prior art and provides a photovoltaic special frame EI type inverter transformer and a production process optimization method.

[0005] To achieve the above object, the technical solution adopted by the present invention is:

[0006] The present invention provides a special frame EI type inverter transformer for photovoltaic use:

[0007] The photovoltaic special frame EI type inverter transformer comprises silicon steel sheets, a plurality of silicon steel sheets are superimposed and connected to form a magnetic circuit conduction frame of the inverter transformer, an EI type I-shaped frame is embedded in the plurality of silicon steel sheets, the EI type I-shaped frame is in an I-shape, a through hole is provided in the middle of the EI type I-shaped frame, the through hole is used to install a magnetic core material, two U-shaped epoxy board cards are clamped in the middle of the EI type I-shaped frame, and the two U-shaped epoxy board cards are spliced ​​into a rectangular barrier plate as a whole, so that the EI type I-shaped frame is changed into a W-shaped frame;

[0008] The production process optimization method comprises the following steps:

[0009] S101: obtaining a production process sample of an inverter transformer, performing a simulation test on the production process sample to obtain a voltage stabilization phase waveform, analyzing whether the distorted voltage at a key load node is abnormal based on the voltage stabilization phase waveform, and obtaining a load voltage distortion test result of the inverter transformer;

[0010] S102: When the load voltage distortion test result shows that the inverter transformer has an abnormal voltage load node, the non-sinusoidal current spectrum when the distorted voltage is generated is obtained through the stable voltage topology, and the magnetic flux saturation bubble diagram is constructed according to the non-sinusoidal current spectrum to obtain abnormal harmonic data, and the leakage inductance required to filter the abnormal harmonic data is calculated to adjust the winding process of the primary and secondary windings on the inverter transformer to obtain the first process optimization strategy;

[0011] S103: obtaining a magnetic field distribution diagram of a coupling region in a secondary simulation test of an inverter transformer based on the first process optimization strategy, calculating the magnetic field distribution diagram by Ampere's loop law to determine a simulated coupling coefficient, analyzing whether the simulated coupling coefficient exceeds an ideal coupling coefficient range to optimize a primary winding width and a secondary winding width of the inverter transformer, and obtaining a second process optimization strategy;

[0012] S104: If the production demand of the inverter transformer has a more ideal coupling requirement, the installation control planning of the barrier performance is carried out by installing the U-shaped epoxy board card on the EI-shaped I-shaped frame of the inverter transformer, so as to optimize the installation process of the U-shaped epoxy board card under the premise of meeting the production demand;

[0013] The step S101 specifically includes the following steps:

[0014] Obtaining a production process sample of the inverter transformer, and photographing and reconstructing the production process sample by using a structured light camera on the production line to obtain a first production process sample simulation model of the inverter transformer;

[0015] Obtain the target application scenario of the inverter transformer and the distribution of key load nodes, and use the model simulation software to preset the transformer requirement parameter strategy according to the target application scenario;

[0016] The voltage transformation requirement parameter strategy is executed on the first production process sample simulation model by the model simulation software, and the voltage stabilization phase waveform when the voltage on each key load node of the inverter transformer reaches stability is recorded based on the key load node distribution during the simulation test;

[0017] The solution of the distorted voltage equation is preset, and the finite element conversion of the voltage stabilization phase waveform of each key load node is performed using the production process sample simulation model to obtain the finite element differential equation corresponding to the voltage stabilization phase waveform at each key load node in each sub-topology field;

[0018] Determine one by one whether each of the finite element differential equations can be solved to obtain a solution to the distorted voltage equation; if it cannot be solved, mark the key load node corresponding to the voltage stabilization phase waveform of the finite element differential equation as a normal voltage load node;

[0019] If it can be solved, the key load node corresponding to the voltage-stabilizing phase waveform of the finite element differential equation is marked as an abnormal voltage load node, and the load voltage distortion test result of the inverter transformer is obtained.

[0020] Furthermore, in a preferred embodiment of the present invention, the U-shaped epoxy board card is U-shaped and is made of epoxy board material.

[0021] Furthermore, in a preferred embodiment of the present invention, the EI-shaped I-shaped frame is wound with a primary coil and a secondary coil, and the primary coil and the secondary coil are located on both sides of the U-shaped epoxy board.

[0022] Furthermore, in a preferred embodiment of the present invention, both ends of the EI-shaped I-shaped frame are connected to enameled wires.

[0023] More specifically, the step S102 includes the following steps:

[0024] When the load voltage distortion test results show that the inverter transformer has one or more abnormal voltage load nodes, a stable voltage topology domain is created by fitting the production process sample simulation model of the inverter transformer according to the voltage stabilization phase waveform of each key electric field node;

[0025] The stable voltage topology domain is divided into M sub-topology domains based on the distribution of key load nodes, and the sub-topology domain where the abnormal voltage load node is located is obtained and marked as a suspicious sub-topology domain;

[0026] Obtain the finite element differential equations of each key load node in the simulation test process of each suspicious sub-topology area during the preset time period to solve the non-sinusoidal current spectrum generated when solving the distorted voltage equation, and obtain the power spectrum network and flux saturation effect mechanism based on the big data network;

[0027] Reading the non-sinusoidal current spectrum of each key load node in each suspicious sub-topology field through an electrical power spectrum network to identify a number of harmonic features contained in each non-sinusoidal current spectrum and the harmonic frequency at which each harmonic feature appears;

[0028] The simulated magnetic flux variation of each suspicious sub-topology field in the inverter transformer simulation test process is obtained, and a magnetic flux saturation bubble diagram framework is constructed for each of the simulated magnetic flux variation based on the magnetic flux saturation effect mechanism, and a plurality of harmonic features and harmonic frequencies identified in each suspicious sub-topology field are correspondingly injected into the magnetic flux saturation bubble diagram framework for fitting operation, so as to generate a simulated magnetic flux saturation bubble diagram for each suspicious sub-topology field;

[0029] By comparing and analyzing the simulated flux saturation bubble diagram and the flux saturation bubble diagram in the critical state, an abnormal harmonic data processing package is obtained, the necessary increased leakage inductance for filtering out the abnormal harmonic data processing package is calculated, and a simulated leakage inductance area distribution diagram is generated. Based on the simulated leakage inductance area distribution diagram, the winding process of the primary and secondary windings on the inverter transformer is adjusted to obtain a first process optimization strategy.

[0030] More specifically, in the step S102, by comparing and analyzing the simulated magnetic flux saturation bubble diagram and the magnetic flux saturation bubble diagram of the critical state to obtain an abnormal harmonic data processing package, the necessary leakage inductance increase for filtering the abnormal harmonic data processing package is calculated, and a simulated leakage inductance regional distribution diagram is generated. Based on the simulated leakage inductance regional distribution diagram, the winding process of the primary and secondary windings on the inverter transformer is adjusted to obtain a first process optimization strategy, which specifically includes the following steps:

[0031] Obtain the load type on each load node in the suspicious sub-topology field, preset the allowable harmonic characteristics, allowable harmonic frequency and reasonable magnetic flux change based on the load type, and construct a fitting magnetic flux saturation critical bubble diagram according to the allowable harmonic characteristics, allowable harmonic frequency and reasonable magnetic flux change;

[0032] If the simulated magnetic flux saturation bubble diagram does not completely wrap the magnetic flux saturation critical bubble diagram, then the suspicious sub-topological area where the simulated magnetic flux saturation bubble diagram is located is marked as a normal harmonic activity area;

[0033] If the simulated magnetic flux saturation bubble diagram has completely wrapped the magnetic flux saturation critical bubble diagram, then the suspicious sub-topological area where the simulated magnetic flux saturation bubble diagram is located is marked as an abnormal harmonic activity area;

[0034] Extracting a number of abnormal harmonic amplitudes generated in an abnormal harmonic activity field within a preset time period and the flashing frequency of each abnormal harmonic amplitude, and bundling a number of abnormal harmonic amplitudes and corresponding flashing frequencies in each abnormal harmonic activity field into an abnormal harmonic data processing package;

[0035] Obtain a preset leakage inductance simulator of the inverter transformer, import the abnormal harmonic data processing packages corresponding to all abnormal harmonic activity areas into the preset leakage magnetic simulator for computational simulation, and generate the additional leakage inductance required to filter out each abnormal harmonic data processing package, which is defined as the necessary additional leakage inductance;

[0036] According to the location of each abnormal harmonic activity area on the stable voltage topology area, the corresponding necessary leakage inductance is embedded, and a designated leakage inductance area distribution map of the necessary leakage inductance increase is generated, and at the same time, a simulated leakage inductance area distribution map during the inverter transformer simulation test is obtained;

[0037] Taking the specified leakage inductance area distribution map as the optimization standard, the Hamming distance between the simulated leakage inductance area distribution map and the specified leakage inductance area distribution map is calculated, and the winding process of the primary winding and the secondary winding on the inverter transformer is optimized and adjusted according to the Hamming distance until the adjustment reaches the optimization standard, thereby obtaining the first process optimization strategy.

[0038] More specifically, the step S103 includes the following steps:

[0039] Obtain a simulation model of the inverter transformer after re-production using the first process optimization strategy, which is defined as a second production process sample simulation model, and simultaneously obtain a winding spacing distance between a primary winding and a secondary winding on the second production process sample simulation model, which is defined as a first winding spacing distance;

[0040] Based on the first winding interval distance preset coupling range interval, taking the coupling range interval as a constraint reference, according to the winding process optimized and adjusted by the first process optimization strategy, constraint planning is performed in the second production process sample simulation model until the maximum boundary range of the coupling range interval is reached, and a coupling area is generated;

[0041] Performing a secondary simulation test of the voltage transformation requirement parameter strategy on the second production process sample simulation model through model simulation software to obtain multiple sets of magnetic field strengths generated by the inverter transformer in the coupling area;

[0042] Introducing Ampere's loop law, building a distribution map framework based on the second production process sample simulation model, and calculating and fitting the multiple groups of magnetic field intensities in the distribution map framework to obtain a magnetic field distribution map;

[0043] Solving the magnetic field distribution state of the magnetic field distribution diagram by Ampere's loop law, outputting the simulated mutual inductance and simulated self-inductance between the primary winding and the secondary winding of the inverter transformer during the secondary simulation test, and determining the simulated coupling coefficient generated between the primary winding and the secondary winding of the inverter transformer during the secondary simulation test according to the combination of the simulated mutual inductance and the simulated self-inductance;

[0044] Obtaining production requirements of the inverter transformer, and presetting an ideal coupling coefficient value range according to the production requirements. If the simulated coupling coefficient does not exceed the ideal coupling coefficient value range, there is no need to adjust the primary winding width and the secondary winding width of the inverter transformer;

[0045] If the simulated coupling coefficient exceeds the ideal coupling coefficient value range, the deviation between the simulated coupling coefficient and the lower limit coefficient in the ideal coupling coefficient value range is calculated to obtain the coupling coefficient deviation, and the primary winding width and the secondary winding width of the inverter transformer are optimized according to the coupling coefficient deviation to obtain the second process optimization strategy.

[0046] More specifically, the step S104 includes the following steps:

[0047] If there is a requirement in the production demand of the inverter transformer that the simulated coupling coefficient must be close to the upper limit coefficient of the ideal coupling coefficient value range, at this time, the winding interval distance between the primary winding and the secondary winding of the inverter transformer after optimization by the second process optimization strategy is obtained, and is defined as the second winding interval distance;

[0048] Obtain an area on the EI-shaped I-shaped frame of the inverter transformer where the second winding spacing distance exists and the U-shaped epoxy board card can be installed, and mark it as an installable area;

[0049] Extracting the barrier performance index and thickness parameters of the U-shaped epoxy board card through the production log of the inverter transformer, setting a number of installable locations of the installable area based on the thickness parameters, and calculating the weight of each installable location according to the barrier performance index to obtain a plurality of location weight values;

[0050] Based on the location weight value, an initial installation solution is allocated to each installable point in such a way that the simulated coupling coefficient approaches the upper limit coefficient of the ideal coupling coefficient value range, an initialization result is obtained, a genetic algorithm is introduced to perform genetic iterative optimization on the initialization result, and an installation candidate solution for each installable location is output;

[0051] Determine whether the candidate installation solution can dominate the initial installation solution. If so, it means that the candidate installation solution can make the simulation coupling coefficient closer to the upper limit coefficient of the ideal coupling coefficient range than the initial installation solution. Therefore, the corresponding initial installation solution is updated and iteratively replaced by the candidate installation solution to generate a series of optimal installation locations.

[0052] The series of optimal installation locations are uploaded to the production equipment terminal of the inverter transformer to optimize the installation location and installation quantity selection of the U-shaped epoxy board card on the EI-type I-beam frame to meet the production requirements.

[0053] The beneficial technical effects of the present invention are:

[0054] The present invention clamps two U-shaped epoxy board cards in the middle of an EI-shaped I-shaped skeleton, thereby achieving the purpose of arbitrarily adjusting the primary and secondary winding widths of the transformer according to the transformer winding requirements, meeting different application scenarios, and improving the versatility of the inverter transformer; and the addition of the U-shaped epoxy board cards can make the primary and secondary windings of the transformer separate, effectively reducing the coupling between the windings, helping to improve the heat dissipation performance of the transformer, increasing the leakage inductance of the transformer, and achieving the effect of filtering out harmonics, thereby reducing the no-load current and loss of the inverter; at the same time, it provides a more accurate and reliable optimization strategy for the production process decision of the special skeleton EI-type inverter transformer, so as to improve the production quality of the inverter transformer and reduce the phenomenon of a sharp increase in the defective rate caused by production process errors. BRIEF DESCRIPTION OF THE DRAWINGS

[0055] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, drawings of other embodiments can be obtained based on these drawings without paying creative work.

[0056] Figure 1 This is a schematic diagram of the overall installation structure of a special frame EI type inverter transformer for photovoltaic use;

[0057] Figure 2 It is a schematic diagram of the overall structure of the U-shaped epoxy board card;

[0058] Figure 3 It is a schematic diagram of the overall structure of the EI-type I-shaped frame;

[0059] Figure 4 It is a schematic diagram of the installation structure in which a U-shaped epoxy board card is clamped on an EI-shaped I-shaped frame;

[0060] Figure 5 The present invention is a flow chart of a method for optimizing the production process of a special skeleton EI type inverter transformer for photovoltaic use.

[0061] The following are the descriptions of the reference numerals:

[0062] 1101, silicon steel sheet; 1102, EI type I-shaped frame; 1103, U-shaped epoxy board card; 1104, primary coil; 1105, secondary coil; 1106, enameled wire. DETAILED DESCRIPTION

[0063] In order to more clearly understand the above-mentioned purposes, features and advantages of the present invention, the present invention is further described in detail below in conjunction with the accompanying drawings and specific implementation methods. These drawings are all simplified schematic diagrams, which only illustrate the basic structure of the present invention in a schematic manner, and therefore only show the structures related to the present invention. It should be noted that the embodiments in this application and the features in the embodiments can be combined with each other without conflict.

[0064] In the description of the present application, it should be understood that the terms "center", "longitudinal", "lateral", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", etc., indicating the orientation or positional relationship, are based on the orientation or positional relationship shown in the drawings, and are only for the convenience of describing the present application and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as limiting the scope of protection of the present application. In addition, the terms "first", "second", etc. are only used for descriptive purposes, and cannot be understood as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Therefore, features defined as "first", "second", etc. may explicitly or implicitly include one or more of the features. In the description of the invention, unless otherwise specified, "multiple" means two or more.

[0065] In the description of this application, it should be noted that, unless otherwise clearly specified and limited, the terms "installed", "connected", and "connected" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be directly connected or indirectly connected through an intermediate medium, and it can be the internal communication of two components. For ordinary technicians in this field, the specific meanings of the above terms in this application can be understood by specific circumstances.

[0066] In order to facilitate the understanding of the present invention, the present invention will be described more fully below with reference to the relevant drawings. The preferred embodiments of the present invention are given in the drawings. However, the present invention can be implemented in many different forms and is not limited to the embodiments described herein. On the contrary, the purpose of providing these embodiments is to make the disclosure of the present invention more thoroughly understood.

[0067] like Figure 1-4 As shown, the first aspect of the present invention provides a special skeleton EI type inverter transformer for photovoltaics.

[0068] The special frame EI type inverter transformer for photovoltaic use includes silicon steel sheets 1101, and multiple silicon steel sheets 1101 are stacked and connected to form a magnetic circuit conduction frame of the inverter transformer. An EI type I-shaped frame 1102 is embedded in the multiple silicon steel sheets 1101. The EI type I-shaped frame 1102 is in an I-shape, and a through hole is opened in the middle part of the EI type I-shaped frame 1102. The through hole is used to install a magnetic core material. Two U-shaped epoxy board cards 1103 are clamped in the middle position of the EI type I-shaped frame 1102, and the two U-shaped epoxy board cards 1103 are spliced ​​into a rectangular barrier plate as a whole, so that the EI type I-shaped frame 1102 is changed into a W-shaped frame.

[0069] The U-shaped epoxy board card 1103 is U-shaped and is made of epoxy board material.

[0070] The EI-shaped I-shaped frame 1102 is wound with a primary coil 1104 and a secondary coil 1105 , and the primary coil 1104 and the secondary coil 1105 are located on both sides of the U-shaped epoxy board 1103 .

[0071] Both ends of the EI-shaped I-shaped frame 1102 are connected to enameled wires 1106 .

[0072] It should be noted that, by clamping two U-shaped epoxy board cards in the middle of the EI-shaped I-shaped skeleton of the traditional photovoltaic inverter transformer, the two U-shaped epoxy board cards are spliced ​​into a barrier whole, and the existing EI-shaped I-shaped skeleton can be changed into a W-shaped skeleton to meet different actual winding requirements, optimize the mechanical strength and dimensional stability of the inverter transformer, and improve the operating performance; at the same time, the addition of the U-shaped epoxy board card can make the primary winding and the secondary winding be wound separately, reduce the strong coupling between the primary and secondary windings of the traditional EI-type inverter transformer, filter out the transformer harmonics to the maximum extent, and reduce the no-load current and loss of the inverter transformer.

[0073] The second aspect of the present invention provides a production process optimization method for a photovoltaic special frame EI type inverter transformer, which is applied to any of the photovoltaic special frame EI type inverter transformers described above, and specifically comprises the following steps:

[0074] S101: obtaining a production process sample of an inverter transformer, performing a simulation test on the production process sample to obtain a voltage stabilization phase waveform, analyzing whether the distorted voltage at a key load node is abnormal based on the voltage stabilization phase waveform, and obtaining a load voltage distortion test result of the inverter transformer;

[0075] S102: When the load voltage distortion test result shows that the inverter transformer has an abnormal voltage load node, the non-sinusoidal current spectrum when the distorted voltage is generated is obtained through the stable voltage topology, and the magnetic flux saturation bubble diagram is constructed according to the non-sinusoidal current spectrum to obtain abnormal harmonic data, and the leakage inductance required to filter the abnormal harmonic data is calculated to adjust the winding process of the primary and secondary windings on the inverter transformer to obtain the first process optimization strategy;

[0076] S103: obtaining a magnetic field distribution diagram of a coupling region in a secondary simulation test of an inverter transformer based on the first process optimization strategy, calculating the magnetic field distribution diagram by Ampere's loop law to determine a simulated coupling coefficient, analyzing whether the simulated coupling coefficient exceeds an ideal coupling coefficient range to optimize a primary winding width and a secondary winding width of the inverter transformer, and obtaining a second process optimization strategy;

[0077] S104: If the production demand of the inverter transformer has a more idealized coupling requirement, the installation arrangement planning of the barrier performance is carried out by installing the U-shaped epoxy board card in the installable area on the EI-shaped I-beam frame of the inverter transformer, so as to optimize the installation process of the U-shaped epoxy board card while meeting the production demand.

[0078] More specifically, the step S101 includes the following steps:

[0079] Obtaining a production process sample of the inverter transformer, and photographing and reconstructing the production process sample by using a structured light camera on the production line to obtain a first production process sample simulation model of the inverter transformer;

[0080] Obtain the target application scenario of the inverter transformer and the distribution of key load nodes, and use the model simulation software to preset the transformer requirement parameter strategy according to the target application scenario;

[0081] The voltage transformation requirement parameter strategy is executed on the first production process sample simulation model by the model simulation software, and the voltage stabilization phase waveform when the voltage on each key load node of the inverter transformer reaches stability is recorded based on the key load node distribution during the simulation test;

[0082] A solution of the distorted voltage equation is preset, and a finite element conversion is performed on the voltage stabilization phase waveform of each key load node using a production process sample simulation model to obtain a finite element differential equation corresponding to the voltage stabilization phase waveform at each key load node;

[0083] Determine one by one whether each of the finite element differential equations can be solved to obtain a solution to the distorted voltage equation; if it cannot be solved, mark the key load node corresponding to the voltage stabilization phase waveform of the finite element differential equation as a normal voltage load node;

[0084] If it can be solved, the key load node corresponding to the voltage-stabilizing phase waveform of the finite element differential equation is marked as an abnormal voltage load node, and the load voltage distortion test result of the inverter transformer is obtained.

[0085] It should be noted that when there are harmonics on the output side of the inverter transformer, some load devices are highly sensitive to voltage quality, which may cause the voltage waveform of these load devices connected to the output side to be distorted, which affects the performance and life of the load devices, resulting in malfunction or damage to the load devices due to harmonic voltage, and increases the operating risk factor of the inverter transformer. Therefore, it is necessary to filter the harmonics during the operation of the inverter transformer, and in order to filter the harmonics as accurately as possible, the harmonics can be located by causing the voltage distortion phenomenon generated by the inverter transformer. Therefore, this method first conducts a simulation test on the produced inverter transformer to obtain the steady-state phase waveform output when the node connected to the load end is at a stable voltage. The steady-state phase waveform contains the phase characteristics of the voltage; the steady-state phase waveform is converted into a finite element differential equation to express the continuous characteristic form of the overall voltage. The finite element differential equation can better show the smoothness and continuity of the voltage change, making the data processing and analysis of the voltage characteristics more efficient and accurate; and the solution of the equation can represent each specific voltage phase feature contained in its continuous characteristic form. When the finite element differential equation can solve the distorted voltage equation solution, it means that the steady-state phase waveform of the finite element differential equation has a distortion feature, that is, the load voltage on the key load node is distorted, and the cause of the distortion of the key load node may be the influence of harmonics, so it is marked as an abnormal voltage load node. This method can calculate and analyze the voltage distortion condition generated at the load node end of the inverter transformer, thereby providing a reliable data analysis basis for the subsequent tracing and positioning of harmonic influences and specifying appropriate leakage inductance to filter out harmonics, effectively maximizing the accuracy of filtering out harmonics in the inverter transformer.

[0086] More specifically, the step S102 includes the following steps:

[0087] When the load voltage distortion test results show that the inverter transformer has one or more abnormal voltage load nodes, a stable voltage topology domain is created by fitting the production process sample simulation model of the inverter transformer according to the voltage stabilization phase waveform of each key electric field node;

[0088] The stable voltage topology domain is divided into M sub-topology domains based on the distribution of key load nodes, and the sub-topology domain where the abnormal voltage load node is located is obtained and marked as a suspicious sub-topology domain;

[0089] Obtain the finite element differential equations of each key load node in the simulation test process of each suspicious sub-topology area during the preset time period to solve the non-sinusoidal current spectrum generated when solving the distorted voltage equation, and obtain the power spectrum network and flux saturation effect mechanism based on the big data network;

[0090] Reading the non-sinusoidal current spectrum of each key load node in each suspicious sub-topology field through an electrical power spectrum network to identify a number of harmonic features contained in each non-sinusoidal current spectrum and the harmonic frequency at which each harmonic feature appears;

[0091] The simulated magnetic flux variation of each suspicious sub-topology field in the inverter transformer simulation test process is obtained, and a magnetic flux saturation bubble diagram framework is constructed for each of the simulated magnetic flux variation based on the magnetic flux saturation effect mechanism, and a plurality of harmonic features and harmonic frequencies identified in each suspicious sub-topology field are correspondingly injected into the magnetic flux saturation bubble diagram framework for fitting operation, so as to generate a simulated magnetic flux saturation bubble diagram for each suspicious sub-topology field;

[0092] By comparing and analyzing the simulated flux saturation bubble diagram and the flux saturation bubble diagram in the critical state, an abnormal harmonic data processing package is obtained, the necessary increased leakage inductance for filtering out the abnormal harmonic data processing package is calculated, and a simulated leakage inductance area distribution diagram is generated. Based on the simulated leakage inductance area distribution diagram, the winding process of the primary and secondary windings on the inverter transformer is adjusted to obtain a first process optimization strategy.

[0093] It should be noted that when there is voltage distortion at a key load node connected between the inverter transformer and the load end, it may be caused by the harmonic influence in the non-sinusoidal current, and the harmonics in the non-sinusoidal current may cause the inverter transformer magnetic circuit to tend to saturate, thereby affecting the normal operation of the inverter transformer and increasing its operating loss and noise. Therefore, this method can determine the amount of harmonic influence in space by calculating the magnetic flux saturation effect of harmonics on the inverter transformer magnetic circuit and calculate the leakage inductance that can accurately filter out the harmonic influence. Since the winding leakage inductance is related to the winding method, wire diameter, and number of layers of the winding coil, the winding process of the primary and secondary windings can be further adjusted according to the calculated leakage inductance. Firstly, the harmonic characteristics and harmonic frequencies of the non-sinusoidal current spectrum with voltage distortion at the abnormal voltage load node are identified, so as to provide the first calculation basis for the magnetic flux saturation effect caused by harmonics on the inverter transformer during the simulation process; then the simulated magnetic flux change of the inverter transformer in the space area with abnormal voltage distortion is obtained to provide the second calculation basis, and finally a bubble chart is constructed based on the two calculation bases to further quantify the saturation trend of the magnetic flux in the inverter transformer space caused by the non-sinusoidal current harmonics when the node generates voltage distortion, that is, the simulated magnetic flux saturation bubble chart, so that the influence of harmonics on the inverter transformer is visualized, the reliability of the analysis of whether the harmonics are normal or not is improved, the error of traditional artificial leakage inductance calculation is reduced, and the accuracy of subsequent leakage inductance calculation is effectively improved. This method can further trace the harmonic quantity by calculating the magnetic circuit saturation effect of the harmonics of the non-sinusoidal current on the inverter transformer, so that the primary coil winding process can be reasonably and accurately adjusted according to the leakage inductance required by the harmonic quantity, and the quality of the leakage inductance generated by the primary and secondary coils can be improved, so as to achieve the purpose of filtering out harmonics to the maximum extent.

[0094] More specifically, in the step S102, by comparing and analyzing the simulated magnetic flux saturation bubble diagram and the magnetic flux saturation bubble diagram of the critical state to obtain an abnormal harmonic data processing package, the necessary increase in leakage inductance for filtering the abnormal harmonic data processing package is calculated, and a simulated leakage inductance regional distribution diagram is generated. Based on the simulated leakage inductance regional distribution diagram, the winding process of the primary and secondary windings on the inverter transformer is adjusted to obtain a first process optimization strategy, which specifically includes the following steps:

[0095] Obtain the load type on each load node in the suspicious sub-topology field, preset the allowable harmonic characteristics, allowable harmonic frequency and reasonable magnetic flux change based on the load type, and construct a fitting magnetic flux saturation critical bubble diagram according to the allowable harmonic characteristics, allowable harmonic frequency and reasonable magnetic flux change;

[0096] If the simulated magnetic flux saturation bubble diagram does not completely wrap the magnetic flux saturation critical bubble diagram, then the suspicious sub-topological area where the simulated magnetic flux saturation bubble diagram is located is marked as a normal harmonic activity area;

[0097] If the simulated magnetic flux saturation bubble diagram has completely wrapped the magnetic flux saturation critical bubble diagram, then the suspicious sub-topological area where the simulated magnetic flux saturation bubble diagram is located is marked as an abnormal harmonic activity area;

[0098] Extracting a number of abnormal harmonic amplitudes generated in an abnormal harmonic activity field within a preset time period and the flashing frequency of each abnormal harmonic amplitude, and bundling a number of abnormal harmonic amplitudes and corresponding flashing frequencies in each abnormal harmonic activity field into an abnormal harmonic data processing package;

[0099] Obtain a preset leakage inductance simulator of the inverter transformer, import the abnormal harmonic data processing packages corresponding to all abnormal harmonic activity areas into the preset leakage magnetic simulator for computational simulation, and generate the additional leakage inductance required to filter out each abnormal harmonic data processing package, which is defined as the necessary additional leakage inductance;

[0100] According to the location of each abnormal harmonic activity area on the stable voltage topology area, the corresponding necessary leakage inductance is embedded, and a designated leakage inductance area distribution map of the necessary leakage inductance increase is generated, and at the same time, a simulated leakage inductance area distribution map during the inverter transformer simulation test is obtained;

[0101] Taking the specified leakage inductance area distribution map as the optimization standard, the Hamming distance between the simulated leakage inductance area distribution map and the specified leakage inductance area distribution map is calculated, and the winding process of the primary winding and the secondary winding on the inverter transformer is optimized and adjusted according to the Hamming distance until the adjustment reaches the optimization standard, thereby obtaining the first process optimization strategy.

[0102] It should be noted that the leakage inductance of the transformer is an important parameter that has a significant impact on the efficiency and performance of the transformer. Leakage inductance refers to the leakage magnetic inductance generated in the transformer due to incomplete closure of the magnetic flux. In other words, the leakage inductance may be due to improper winding methods, wire diameters, number of layers, etc. of the primary and secondary coils, which leads to part of the magnetic flux being lost during the coupling process between the two, making it impossible for this part of the magnetic flux to effectively participate in the energy conversion process of the transformer and leak into the surrounding space. Therefore, for the inverter transformer, there is a leakage in a spatial area, and the winding process of the primary and secondary windings determines whether a leakage inductance in a certain spatial range can be generated to effectively filter out abnormal harmonics. Therefore, this method constructs a flux saturation critical bubble diagram in a domain space. The flux saturation critical bubble diagram is aligned with the simulated flux saturation bubble diagram, and both are constructed by harmonic characteristics, harmonic frequencies and reasonable flux changes, so as to serve as a standard to determine whether the harmonic activity that causes the simulated flux saturation is normal; among them, if the simulated flux saturation bubble diagram does not completely wrap the flux saturation critical bubble diagram, it means that the simulated harmonic causes the inverter transformer to have a low degree of flux saturation and does not exceed the allowable threshold, so the harmonic activity in this area tends to be within the normal range; if the simulated flux saturation bubble diagram has completely wrapped the flux saturation critical bubble diagram, it means that the harmonic activity causes the inverter transformer to have a high degree of flux saturation, which is no longer within a reasonable range, so the harmonic activity in this area shows an abnormal tendency; therefore, this judgment can be used as an accurate basis for extracting abnormal harmonic data that needs to be filtered out in the inverter transformer, which is more efficient and accurate than the traditional inverter transformer harmonic calculation and tracing, and reduces unnecessary detection or calculation steps in the production test process. It is then possible to further plan and generate a simulated leakage inductance area distribution map within a space based on the known abnormal harmonic data, so as to quickly formulate the leakage inductance within the space required to filter out these harmonics, thereby accurately making corresponding optimization adjustments to the winding process of the primary and secondary windings of the inverter transformer.

[0103] It should be noted that this method can quickly and accurately trace abnormal harmonic activity data based on the flux saturation bubble diagram overlay method, reduce unnecessary detection calculation steps, and the result has small error and high credibility; it can also effectively increase the leakage inductance of the inverter transformer, improve the accuracy of the winding process of the inverter transformer, reduce the winding errors of the primary and secondary coils, which makes it difficult to generate ideal leakage inductance to efficiently filter out harmonics, and reduce the defective rate of coil winding.

[0104] More specifically, the step S103 includes the following steps:

[0105] Obtain a simulation model of the inverter transformer after re-production using the first process optimization strategy, which is defined as a second production process sample simulation model, and simultaneously obtain a winding spacing distance between a primary winding and a secondary winding on the second production process sample simulation model, which is defined as a first winding spacing distance;

[0106] Based on the first winding interval distance preset coupling range interval, taking the coupling range interval as a constraint reference, according to the winding process optimized and adjusted by the first process optimization strategy, constraint planning is performed in the second production process sample simulation model until the maximum boundary range of the coupling range interval is reached, and a coupling area is generated;

[0107] Performing a secondary simulation test of the voltage transformation requirement parameter strategy on the second production process sample simulation model through model simulation software to obtain multiple sets of magnetic field strengths generated by the inverter transformer in the coupling area;

[0108] Introducing Ampere's loop law, building a distribution map framework based on the second production process sample simulation model, and calculating and fitting the multiple groups of magnetic field intensities in the distribution map framework to obtain a magnetic field distribution map;

[0109] Solving the magnetic field distribution state of the magnetic field distribution diagram by Ampere's loop law, outputting the simulated mutual inductance and simulated self-inductance between the primary winding and the secondary winding of the inverter transformer during the secondary simulation test, and determining the simulated coupling coefficient generated between the primary winding and the secondary winding of the inverter transformer during the secondary simulation test according to the combination of the simulated mutual inductance and the simulated self-inductance;

[0110] Obtaining production requirements of the inverter transformer, and presetting an ideal coupling coefficient value range according to the production requirements. If the simulated coupling coefficient does not exceed the ideal coupling coefficient value range, there is no need to adjust the primary winding width and the secondary winding width of the inverter transformer;

[0111] If the simulated coupling coefficient exceeds the ideal coupling coefficient value range, the deviation between the simulated coupling coefficient and the lower limit coefficient in the ideal coupling coefficient value range is calculated to obtain the coupling coefficient deviation, and the primary winding width and the secondary winding width of the inverter transformer are optimized according to the coupling coefficient deviation to obtain the second process optimization strategy.

[0112] It should be noted that the coupling of the inverter transformer is usually the electromagnetic coupling between the primary winding and the secondary winding of the transformer, which is one of the core principles of the transformer's operation. Through electromagnetic induction, the current change in the primary winding will induce voltage in the secondary winding, thereby realizing the transfer of electrical energy. However, when the winding width of the primary winding or the secondary winding is inappropriate, the coupling between the two may be strong, resulting in insufficient electrical isolation between the windings, causing short circuits or interference problems, and the risk of electrical breakdown between the windings or excessive parasitic capacitance problems. Therefore, it is necessary to reasonably optimize the width process of the primary and secondary windings of the inverter transformer. Since the coupling between the inverter transformer windings can be determined by theoretical calculation and experimental testing, in view of this, the method first plans the area where coupling may occur on the inverter transformer after the winding process is adjusted by the first process optimization strategy in a simulation manner, so that the distribution of the magnetic field in the simulation process can be more accurately obtained and analyzed, which helps to improve the accuracy of subsequent calculation of the coupling coefficient; and the coupling of the transformer is mainly reflected in the mutual inductance and self-inductance between the primary and secondary windings, so the Ampere loop law can be used to solve the magnetic field distribution diagram that describes the magnetic field distribution. The Ampere loop law is one of the basic laws that can describe the relationship between the current induction characteristics and the generated magnetic field, so that the mutual inductance and self-inductance can be further determined to calculate the simulation coupling coefficient. Among them, if the simulated coupling coefficient does not exceed the ideal coupling coefficient value range, it means that the coupling formed by the current width of the primary and secondary windings is within the reasonable coupling range of the inverter transformer and meets the production requirements of the inverter transformer. Therefore, there is no need to adjust the primary winding width and the secondary winding width of the inverter transformer; on the contrary, if it exceeds, it means that there is a deviation in the width of the primary winding or the secondary winding, resulting in the final coupling failing to meet the production requirements, so it is determined that the width process is wrong. Therefore, it is necessary to further optimize the width of the primary winding or the secondary winding based on the coupling coefficient deviation between the simulated coupling coefficient and the lower limit coefficient in the ideal coupling coefficient value range to improve the rationality of the winding width process.

[0113] It should be noted that this method can accurately calculate the coupling between the primary and secondary windings and analyze the rationality of their widths according to the magnetic field distribution during the inverter transformer simulation test, so as to further accurately optimize the width process of the primary and secondary windings, and achieve different application scenarios by adjusting the primary and secondary widths, thereby improving the versatility of the transformer; and effectively reducing the coupling between the windings, while helping to improve the heat dissipation performance of the transformer and the safety factor of the inverter transformer operation.

[0114] More specifically, the step S104 includes the following steps:

[0115] If there is a requirement in the production demand of the inverter transformer that the simulated coupling coefficient must be close to the upper limit coefficient of the ideal coupling coefficient value range, at this time, the winding interval distance between the primary winding and the secondary winding of the inverter transformer after optimization by the second process optimization strategy is obtained, and is defined as the second winding interval distance;

[0116] Obtain an area on the EI-shaped I-shaped frame of the inverter transformer where the second winding spacing distance exists and the U-shaped epoxy board card can be installed, and mark it as an installable area;

[0117] Extracting the barrier performance index and thickness parameters of the U-shaped epoxy board card through the production log of the inverter transformer, setting a number of installable locations of the installable area based on the thickness parameters, and calculating the weight of each installable location according to the barrier performance index to obtain a plurality of location weight values;

[0118] Based on the location weight value, an initial installation solution is allocated to each installable point in such a way that the simulated coupling coefficient approaches the upper limit coefficient of the ideal coupling coefficient value range, an initialization result is obtained, a genetic algorithm is introduced to perform genetic iterative optimization on the initialization result, and an installation candidate solution for each installable location is output;

[0119] Determine whether the candidate installation solution can dominate the initial installation solution. If so, it means that the candidate installation solution can make the simulation coupling coefficient closer to the upper limit coefficient of the ideal coupling coefficient range than the initial installation solution. Therefore, the corresponding initial installation solution is updated and iteratively replaced by the candidate installation solution to generate a series of optimal installation locations.

[0120] The series of optimal installation locations are uploaded to the production equipment terminal of the inverter transformer to optimize the installation location and installation quantity selection of the U-shaped epoxy board card on the EI-type I-beam frame to meet the production requirements.

[0121] It should be noted that when the U-shaped epoxy board card is added to the EI-type I-beam skeleton, it means that the primary winding and the secondary winding can be wound separately. At the same time, after the width adjustment of the second process optimization strategy, this may make there be a larger regional position space between the primary and secondary windings for the U-shaped epoxy board card to be embedded. The position and number of the U-shaped epoxy board cards to be embedded need to be determined according to their own barrier properties and are not subject to specific restrictions. However, the existing inverter transformer production process is not equipped with a more reasonable U-shaped epoxy board card installation location intelligent selection technology, which makes the installation of the U-shaped epoxy board card more random, which cannot make the U-shaped epoxy board card play its due barrier performance, resulting in the coupling between the primary and secondary windings. It is difficult to meet more precise and higher production requirements. In this regard, this method is based on the requirement that when the production demand of the inverter transformer has a requirement that the simulated coupling coefficient must be close to the upper limit coefficient of the ideal coupling coefficient value range, by obtaining the installable area under the premise of width process adjustment, since the installation position and quantity of the U-shaped epoxy board card depend on the barrier performance, the barrier performance can be used as a point selection basis as the location weight; since the simulated coupling coefficient must be close to the upper limit coefficient of the ideal coupling coefficient value range, it is a process of continuous improvement and adjustment, so the location selection in this process will be based on the location weight selection point to produce different answers to the initial installation solution to correspond to whether it meets the production requirements, in order to be more accurate To determine the location, this method introduces a genetic algorithm to perform genetic iterative optimization on the initialization result, and outputs the candidate installation solution of each installable location to generate an optimized version of the installation answer of the initial installation solution; when at least one of the candidate installation solutions for each installable location is better than the initial installation solution in meeting the production demand when making the simulated coupling coefficient approach the upper limit coefficient of the ideal coupling coefficient value range, the candidate installation solution is considered to dominate the initial installation solution, and this is used as the dominating criterion to further determine whether the installation location corresponding to each candidate installation solution can replace the installation location of the initial installation solution, thereby ensuring the optimization accuracy of the installation location and quantity of the U-shaped epoxy board card.

[0122] It should be noted that if it is controllable, it means that the candidate installation solution is more capable of making the simulated coupling coefficient approach the upper limit coefficient of the ideal coupling coefficient range than the initial installation solution. Therefore, the candidate installation solution is further updated to replace the corresponding initial installation solution, so as to optimize the initial installation location according to the barrier performance of the U-shaped epoxy board card, and improve the installation rationality and efficiency of the U-shaped epoxy board card on the EI-shaped I-shaped frame inverter transformer. This method can optimize the installation process of the U-shaped epoxy board card, reduce its installation error according to performance, and improve the coupling performance of the primary and secondary windings of the inverter transformer to meet better production requirements.

[0123] In addition, the production process optimization method of the photovoltaic special skeleton EI type inverter transformer also includes the following steps:

[0124] Construct a simulation test model of a special skeleton EI type inverter transformer, slowly increase the power supply voltage through no-load test software to test the simulation test model, and record multiple simulated eddy current losses on a continuous time sequence of the special skeleton EI type inverter transformer and the corresponding output AC simulation frequency during the no-load simulation test;

[0125] Constructing a Bessel proportional curve graph, fitting the multiple simulated eddy current losses and the corresponding output alternating current simulated frequencies into the Bessel curve graph, and generating a Bessel proportional curve graph of simulated eddy current losses and alternating current simulated frequency;

[0126] The simulated eddy current loss AC simulation frequency Bessel proportional curve is obtained through the simulated eddy current loss-AC simulation frequency Bessel proportional curve diagram, which is defined as the first Bessel proportional curve;

[0127] Based on production requirements, the allowable eddy current loss of the special skeleton EI type inverter transformer and the expected AC power frequency of the corresponding output are obtained, and the allowable eddy current loss-expected AC power frequency Bessel proportional curve is constructed, which is defined as the second Bessel proportional curve;

[0128] The no-load current of the inverter transformer is analyzed by combining the slopes of the first Bessel proportional curve and the second Bessel proportional curve to obtain a no-load current analysis result. Based on the no-load current analysis result, an ideal winding wire material for the inverter transformer is used to replace the winding wire material currently used in production.

[0129] It should be noted that the wire material used to make the primary and secondary coils is a crucial indicator parameter for the safe and accurate operation of the inverter transformer. It will have an important impact on the performance and design of the inverter transformer. Suitable and excellent wire material can make the inverter transformer have higher heat dissipation performance and reduce the inverter no-load current and loss; among them, the conductivity of the wire material will affect the eddy current loss inside the transformer. If the performance of the wire material is poor, its eddy current loss will increase, resulting in more no-load current and heat loss output by the inverter transformer. In view of this, this method obtains the eddy current loss of the inverter transformer and the corresponding output AC frequency by means of no-load test. Under normal circumstances, the eddy current loss is proportional to the AC frequency. Therefore, by constructing a Bessel proportional curve diagram to visualize whether the no-load loss generated by the current wire material for the inverter transformer is reasonable, it provides a reliable selection and analysis basis for the subsequent wire process, improves the selection and optimization accuracy of the wire material, and reduces the occurrence rate of no-load loss of the inverter transformer.

[0130] In addition, the no-load current of the inverter transformer is analyzed by combining the slopes of the first Bessel proportional curve and the second Bessel proportional curve to obtain a no-load current analysis result, and the ideal winding wire material of the inverter transformer is used to replace the winding wire material currently used in production based on the no-load current analysis result, specifically including the following steps:

[0131] Setting a proportional interval of the maximum peak value to the minimum peak value, obtaining a slope value of the first Bezier proportional curve that breaks through the proportional interval, defined as a first slope value, and obtaining a slope value of the second Bezier proportional curve that breaks through the proportional interval, defined as a second slope value;

[0132] If the slope deviation of the first slope value compared to the second slope value is less than the preset slope deviation, the no-load current output by the calibration no-load test is the normal no-load current;

[0133] If the slope deviation of the first slope value compared to the second slope value is greater than the preset slope deviation, the no-load current output by the calibration no-load test is determined to be an abnormal no-load current, and a no-load current analysis result is obtained;

[0134] When the no-load current analysis result shows abnormal no-load current, the no-load current suppression amount of different winding wire materials is obtained based on the big data network, and the simulated no-load current variable of the special skeleton EI type inverter transformer in a continuous time series is obtained;

[0135] The hash state function of the simulated no-load current variable and each no-load current suppression amount is calculated, and the winding wire material corresponding to the minimum hash state function is extracted and defined as the ideal winding wire material. The ideal winding wire material is used to replace the current group wire material of the inverter transformer winding currently in production.

[0136] It should be noted that if the slope deviation of the first slope value compared to the second slope value is less than the preset slope deviation, it means that the no-load current output by the inverter transformer when the no-load loss is at the maximum peak-minimum peak does not exceed the allowable range, so it is normal. Otherwise, it means that the output no-load current has exceeded the allowable range, which is an abnormal no-load current. This method can accurately and reasonably analyze and calculate the selection and replacement of the winding wire material, so that the wire material of the primary and secondary windings is more ideal, which improves the operating safety factor of the inverter transformer, and at the same time reduces the inverter no-load current and loss, with high economic benefits.

[0137] The above is based on the ideal embodiment of the present invention, and its description is relatively specific and detailed, but it cannot be understood as limiting the scope of the invention patent. It should be pointed out that for ordinary technicians in this field, several modifications and improvements can be made without departing from the concept of the present invention, which all belong to the protection scope of the present invention. Therefore, the protection scope of the patent of the present invention shall be based on the attached claims.

Claims

1. A production process optimization method for a photovoltaic special frame EI type inverter transformer, characterized in that: The photovoltaic special frame EI type inverter transformer comprises silicon steel sheets, a plurality of silicon steel sheets are superimposed and connected to form a magnetic circuit conduction frame of the inverter transformer, an EI type I-shaped frame is embedded in the plurality of silicon steel sheets, the EI type I-shaped frame is in an I-shape, a through hole is provided in the middle of the EI type I-shaped frame, the through hole is used to install a magnetic core material, two U-shaped epoxy board cards are clamped in the middle of the EI type I-shaped frame, and the two U-shaped epoxy board cards are spliced ​​into a rectangular barrier plate as a whole, so that the EI type I-shaped frame is changed into a W-shaped frame; The production process optimization method comprises the following steps: S101: obtaining a production process sample of an inverter transformer, performing a simulation test on the production process sample to obtain a voltage stabilization phase waveform, analyzing whether the distorted voltage at a key load node is abnormal based on the voltage stabilization phase waveform, and obtaining a load voltage distortion test result of the inverter transformer; S102: When the load voltage distortion test result shows that the inverter transformer has an abnormal voltage load node, the non-sinusoidal current spectrum when the distorted voltage is generated is obtained through the stable voltage topology, and the magnetic flux saturation bubble diagram is constructed according to the non-sinusoidal current spectrum to obtain abnormal harmonic data, and the leakage inductance required to filter the abnormal harmonic data is calculated to adjust the winding process of the primary and secondary windings on the inverter transformer to obtain the first process optimization strategy; S103: obtaining a magnetic field distribution diagram of a coupling region in a secondary simulation test of an inverter transformer based on the first process optimization strategy, calculating the magnetic field distribution diagram by Ampere's loop law to determine a simulated coupling coefficient, analyzing whether the simulated coupling coefficient exceeds an ideal coupling coefficient range to optimize a primary winding width and a secondary winding width of the inverter transformer, and obtaining a second process optimization strategy; S104: If the production demand of the inverter transformer has a more ideal coupling requirement, the installation control planning of the barrier performance is carried out by installing the U-shaped epoxy board card on the EI-shaped I-shaped frame of the inverter transformer, so as to optimize the installation process of the U-shaped epoxy board card under the premise of meeting the production demand; The step S101 specifically includes the following steps: Obtaining a production process sample of the inverter transformer, and photographing and reconstructing the production process sample by using a structured light camera on the production line to obtain a first production process sample simulation model of the inverter transformer; Obtain the target application scenario of the inverter transformer and the distribution of key load nodes, and use the model simulation software to preset the transformer requirement parameter strategy according to the target application scenario; The voltage transformation requirement parameter strategy is executed on the first production process sample simulation model by the model simulation software, and the voltage stabilization phase waveform when the voltage on each key load node of the inverter transformer reaches stability is recorded based on the key load node distribution during the simulation test; The solution of the distorted voltage equation is preset, and the finite element conversion of the voltage stabilization phase waveform of each key load node is performed using the production process sample simulation model to obtain the finite element differential equation corresponding to the voltage stabilization phase waveform at each key load node in each sub-topology field; Determine one by one whether each of the finite element differential equations can be solved to obtain a solution to the distorted voltage equation; if it cannot be solved, mark the key load node corresponding to the voltage stabilization phase waveform of the finite element differential equation as a normal voltage load node; If it can be solved, the key load node corresponding to the voltage-stabilizing phase waveform of the finite element differential equation is marked as an abnormal voltage load node, and the load voltage distortion test result of the inverter transformer is obtained.

2. The method for optimizing the production process of a photovoltaic special skeleton EI type inverter transformer according to claim 1, characterized in that: The U-shaped epoxy board card is in a U-shape and is made of epoxy board material.

3. The production process optimization method of a photovoltaic special skeleton EI type inverter transformer according to claim 1 is characterized in that: The EI-shaped I-shaped frame is wound with a primary coil and a secondary coil, and the primary coil and the secondary coil are located on both sides of the U-shaped epoxy board.

4. The method for optimizing the production process of a photovoltaic special skeleton EI type inverter transformer according to claim 1, characterized in that: Both ends of the EI-shaped I-shaped frame are connected with enameled wires.

5. The method for optimizing the production process of a photovoltaic special skeleton EI type inverter transformer according to claim 1, characterized in that: The step S102 specifically includes the following steps: When the load voltage distortion test results show that the inverter transformer has one or more abnormal voltage load nodes, a stable voltage topology domain is created by fitting the production process sample simulation model of the inverter transformer according to the voltage stabilization phase waveform of each key electric field node; The stable voltage topology domain is divided into M sub-topology domains based on the distribution of key load nodes, and the sub-topology domain where the abnormal voltage load node is located is obtained and marked as a suspicious sub-topology domain; Obtain the finite element differential equations of each key load node in the simulation test process of each suspicious sub-topology area during the preset time period to solve the non-sinusoidal current spectrum generated when solving the distorted voltage equation, and obtain the power spectrum network and flux saturation effect mechanism based on the big data network; Reading the non-sinusoidal current spectrum of each key load node in each suspicious sub-topology field through an electrical power spectrum network to identify a number of harmonic features contained in each non-sinusoidal current spectrum and the harmonic frequency at which each harmonic feature appears; The simulated magnetic flux variation of each suspicious sub-topology field in the inverter transformer simulation test process is obtained, and a magnetic flux saturation bubble diagram framework is constructed for each of the simulated magnetic flux variation based on the magnetic flux saturation effect mechanism, and a plurality of harmonic features and harmonic frequencies identified in each suspicious sub-topology field are correspondingly injected into the magnetic flux saturation bubble diagram framework for fitting operation, so as to generate a simulated magnetic flux saturation bubble diagram for each suspicious sub-topology field; By comparing and analyzing the simulated flux saturation bubble diagram and the flux saturation bubble diagram in the critical state, an abnormal harmonic data processing package is obtained, the necessary increased leakage inductance for filtering out the abnormal harmonic data processing package is calculated, and a simulated leakage inductance area distribution diagram is generated. Based on the simulated leakage inductance area distribution diagram, the winding process of the primary and secondary windings on the inverter transformer is adjusted to obtain a first process optimization strategy.

6. The method for optimizing the production process of a photovoltaic special skeleton EI type inverter transformer according to claim 5, characterized in that: In the step S102, by comparing and analyzing the simulated magnetic flux saturation bubble diagram and the magnetic flux saturation bubble diagram of the critical state to obtain an abnormal harmonic data processing package, the necessary leakage inductance increase for filtering the abnormal harmonic data processing package is calculated, and a simulated leakage inductance regional distribution diagram is generated. Based on the simulated leakage inductance regional distribution diagram, the winding process of the primary and secondary windings on the inverter transformer is adjusted to obtain a first process optimization strategy, which specifically includes the following steps: Obtain the load type on each load node in the suspicious sub-topology field, preset the allowable harmonic characteristics, allowable harmonic frequency and reasonable magnetic flux change based on the load type, and construct a fitting magnetic flux saturation critical bubble diagram according to the allowable harmonic characteristics, allowable harmonic frequency and reasonable magnetic flux change; If the simulated magnetic flux saturation bubble diagram does not completely wrap the magnetic flux saturation critical bubble diagram, then the suspicious sub-topological area where the simulated magnetic flux saturation bubble diagram is located is marked as a normal harmonic activity area; If the simulated magnetic flux saturation bubble diagram has completely wrapped the magnetic flux saturation critical bubble diagram, then the suspicious sub-topological area where the simulated magnetic flux saturation bubble diagram is located is marked as an abnormal harmonic activity area; Extracting a number of abnormal harmonic amplitudes generated in an abnormal harmonic activity field within a preset time period and the flashing frequency of each abnormal harmonic amplitude, and bundling a number of abnormal harmonic amplitudes and corresponding flashing frequencies in each abnormal harmonic activity field into an abnormal harmonic data processing package; Obtain a preset leakage inductance simulator of the inverter transformer, import the abnormal harmonic data processing packages corresponding to all abnormal harmonic activity areas into the preset leakage magnetic simulator for computational simulation, and generate the additional leakage inductance required to filter out each abnormal harmonic data processing package, which is defined as the necessary additional leakage inductance; According to the location of each abnormal harmonic activity area on the stable voltage topology area, the corresponding necessary leakage inductance is embedded, and a designated leakage inductance area distribution map of the necessary leakage inductance increase is generated, and at the same time, a simulated leakage inductance area distribution map during the inverter transformer simulation test is obtained; Taking the specified leakage inductance area distribution map as the optimization standard, the Hamming distance between the simulated leakage inductance area distribution map and the specified leakage inductance area distribution map is calculated, and the winding process of the primary winding and the secondary winding on the inverter transformer is optimized and adjusted according to the Hamming distance until the adjustment reaches the optimization standard, thereby obtaining the first process optimization strategy.

7. The method for optimizing the production process of a photovoltaic special skeleton EI type inverter transformer according to claim 1, characterized in that: The step S103 specifically includes the following steps: Obtain a simulation model of the inverter transformer after re-production using the first process optimization strategy, which is defined as a second production process sample simulation model, and simultaneously obtain a winding spacing distance between a primary winding and a secondary winding on the second production process sample simulation model, which is defined as a first winding spacing distance; Based on the first winding interval distance preset coupling range interval, taking the coupling range interval as a constraint reference, according to the winding process optimized and adjusted by the first process optimization strategy, constraint planning is performed in the second production process sample simulation model until the maximum boundary range of the coupling range interval is reached, and a coupling area is generated; Performing a secondary simulation test of the voltage transformation requirement parameter strategy on the second production process sample simulation model through model simulation software to obtain multiple sets of magnetic field strengths generated by the inverter transformer in the coupling area; Introducing Ampere's loop law, building a distribution map framework based on the second production process sample simulation model, and calculating and fitting the multiple groups of magnetic field intensities in the distribution map framework to obtain a magnetic field distribution map; Solving the magnetic field distribution state of the magnetic field distribution diagram by Ampere's loop law, outputting the simulated mutual inductance and simulated self-inductance between the primary winding and the secondary winding of the inverter transformer during the secondary simulation test, and determining the simulated coupling coefficient generated between the primary winding and the secondary winding of the inverter transformer during the secondary simulation test according to the combination of the simulated mutual inductance and the simulated self-inductance; Obtaining production requirements of the inverter transformer, and presetting an ideal coupling coefficient value range according to the production requirements. If the simulated coupling coefficient does not exceed the ideal coupling coefficient value range, there is no need to adjust the primary winding width and the secondary winding width of the inverter transformer; If the simulated coupling coefficient exceeds the ideal coupling coefficient value range, the deviation between the simulated coupling coefficient and the lower limit coefficient in the ideal coupling coefficient value range is calculated to obtain the coupling coefficient deviation, and the primary winding width and the secondary winding width of the inverter transformer are optimized according to the coupling coefficient deviation to obtain the second process optimization strategy.

8. The method for optimizing the production process of a photovoltaic special frame EI type inverter transformer according to claim 1, characterized in that: The step S104 specifically includes the following steps: If there is a requirement in the production demand of the inverter transformer that the simulated coupling coefficient must be close to the upper limit coefficient of the ideal coupling coefficient value range, at this time, the winding interval distance between the primary winding and the secondary winding of the inverter transformer after optimization by the second process optimization strategy is obtained, and is defined as the second winding interval distance; Obtain an area on the EI-shaped I-shaped frame of the inverter transformer where the second winding spacing distance exists and the U-shaped epoxy board card can be installed, and mark it as an installable area; Extracting the barrier performance index and thickness parameters of the U-shaped epoxy board card through the production log of the inverter transformer, setting a number of installable locations of the installable area based on the thickness parameters, and calculating the weight of each installable location according to the barrier performance index to obtain a plurality of location weight values; Based on the location weight value, an initial installation solution is allocated to each installable point in such a way that the simulated coupling coefficient approaches the upper limit coefficient of the ideal coupling coefficient value range, an initialization result is obtained, a genetic algorithm is introduced to perform genetic iterative optimization on the initialization result, and an installation candidate solution for each installable location is output; Determine whether the candidate installation solution can dominate the initial installation solution. If so, it means that the candidate installation solution can make the simulation coupling coefficient closer to the upper limit coefficient of the ideal coupling coefficient range than the initial installation solution. Therefore, the corresponding initial installation solution is updated and iteratively replaced by the candidate installation solution to generate a series of optimal installation locations. The series of optimal installation locations are uploaded to the production equipment terminal of the inverter transformer to optimize the installation location and installation quantity selection of the U-shaped epoxy board card on the EI-type I-beam frame to meet the production requirements.

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