Main transformer and inductor integrated configuration device, method, equipment and medium

Abstract

The invention provides a main transformer and inductor integrated configuration device, method and equipment and a medium. The device comprises a first magnetic core, a second magnetic core, a main transformer coil, an inductor coil and a base. According to the main transformer and inductor integrated configuration device provided by the invention, the main transformer coil and the inductor coil are integrated together through the double magnetic cores, and then the double magnetic cores, the main transformer coil, the inductor coil and the base which are integrated together are configured to form a magnetic loop to output resonant inductance, so that the sharing efficiency of a magnetic circuit is improved; the compact structure of the product and the efficient utilization of space are realized, the space occupied by the volume is effectively reduced, so that low manufacturing cost, high production efficiency, easy operation and the like are ensured, the problem of heat dissipation is avoided as much as possible, the stability and the service life of components in the circuit are ensured, and the production cost is reduced. Therefore, the electrical performance requirement of the power electronic system is met, and remarkable technical advantages are provided for performance optimization of the power electronic system.

Description

Technical Field

[0001] The present invention relates to the field of power electronics technology, and in particular to a device, method, equipment and medium for integrating a main transformer and an inductor. Background Art

[0002] At present, power electronic equipment has increasingly stringent requirements on the performance of components. With the development of society, there is a demand for more advanced and high-end products for power electronic equipment, and at the same time, it is becoming more and more integrated and miniaturized. This has strongly promoted the development of components along with the power electronics industry. At the same time, it has brought development opportunities to the component-high-frequency transformer / inductor manufacturing industry, which has broad prospects.

[0003] The power supply used in the on-board charger or charging pile equipment often uses the LLC circuit topology, which is composed of transformer and inductor components. Due to the high power, high voltage and high current, thicker wires and large magnetic cores are required during production. For discrete components, that is, transformers and inductors, due to the high power and correspondingly high product current, the thicker wire diameters used take up space, causing the finished product size to exceed the limit, thus affecting the layout and structure of the whole machine. A larger volume will not only take up more space, resulting in higher production costs, but may also cause heat dissipation problems, resulting in increased temperature rise, affecting the stability and service life of components.

[0004] Therefore, the conventional structures used in the existing industry cannot meet the electrical performance requirements of the power electronics industry. Such production processes and product structures will waste resources and may eventually be eliminated by the market. Summary of the invention

[0005] The present invention provides a main transformer and an inductor integrated configuration device, method, equipment and medium, which are used to solve the problem of the discrete winding of the transformer and the inductor in the prior art causing the finished product size to exceed the limit.

[0006] In a first aspect, the present invention provides a main transformer and inductor integrated configuration device, comprising a first magnetic core, a second magnetic core, a main transformer coil, an inductor coil and a base; The first magnetic core is assembled with two ends of the main transformer coil; The second magnetic core is assembled with one end of the inductor coil; The other end of the inductor coil is assembled with one end of the main transformer coil through the first magnetic core; The first magnetic core, the main transformer coil, the second magnetic core, the inductor coil and the base are assembled.

[0007] In one embodiment, the main transformer and inductor integrated configuration device further comprises a ceramic sheet and a QU magnetic sheet; The first magnetic core is assembled with two ends of the main transformer coil through the ceramic sheet and the QU magnetic sheet; The second magnetic core is assembled with one end of the inductor coil through the ceramic sheet and the QU magnetic sheet; The ceramic sheet is used to isolate components, and the QU magnetic sheet is used to guide magnetic flux.

[0008] In one embodiment, the first magnetic core comprises a first magnetic core subcomponent and a second magnetic core subcomponent; The first magnetic core subcomponent is assembled with one end of the main transformer coil through the ceramic sheet and the QU magnetic sheet; The second magnetic core subcomponent is assembled with the other end of the main transformer winding package through the ceramic sheet and the QU magnetic sheet.

[0009] In one embodiment, the first magnetic core and the second magnetic core adopt a PQU type structure; The first magnetic core subcomponent includes two central columns with a double encapsulation structure, the second magnetic core subcomponent includes two central columns with the double encapsulation structure, and the second magnetic core includes two central columns with the double encapsulation structure.

[0010] In one embodiment, any one of the central columns includes two side columns, a middle column and a bottom edge.

[0011] In one embodiment, any of the center columns is provided with an elliptical ventilation slot; and the coil structure of the main transformer coil and the inductor coil adopts an elliptical structure.

[0012] In one embodiment, the base includes an entry and exit line enclosure, a friction strip opening, and an isolation strip; The inlet and outlet wire enclosure is used to fix the pins of the main transformer coil and the inductor coil; The friction strip opening is used to configure the first magnetic core, the second magnetic core and the base together; The isolation strip is used to separate two central columns having the double-encapsulated structure.

[0013] In a second aspect, the present invention further provides a method for integrating a main transformer and an inductor, comprising: Assembling the first magnetic core with two ends of the main transformer coil; Assembling the second magnetic core with one end of the inductor coil; Assembling the other end of the inductor coil with one end of the main transformer coil through the first magnetic core; The first magnetic core, the main transformer coil, the second magnetic core, the inductor coil and the base are assembled.

[0014] In a third aspect, the present invention provides a device, comprising an electronic device, wherein the electronic device comprises a memory, a processor, and a computer program stored in the memory and executable on the processor, wherein when the processor executes the program, the steps of the method for integrated configuration of the main transformer and the inductor as described above are implemented.

[0015] In a fourth aspect, the present invention further provides a medium, comprising a non-transitory computer-readable storage medium on which a computer program is stored, and when the computer program is executed by a processor, the steps of the method for integrating the main transformer and the inductor are implemented as described above.

[0016] The main transformer and inductor integrated configuration device, method, equipment and medium provided by the present invention integrate the main transformer coil and the inductor coil through a double magnetic core, and then complete the configuration of the assembled double magnetic core, the main transformer coil, the inductor coil and the base to form a magnetic circuit output resonant inductance, thereby improving the sharing efficiency of the magnetic circuit and achieving a compact product structure and efficient use of space. This layout not only effectively reduces the space occupied by the volume, thereby ensuring low manufacturing cost, high production efficiency, easy operation, etc., but also avoids causing heat dissipation problems as much as possible, thereby ensuring the stability and service life of components in the circuit, thereby meeting the electrical performance requirements of the power electronic system and providing significant technical advantages for performance optimization of the power electronic system. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] In order to more clearly illustrate the technical solutions in the present invention or the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0018] Figure 1 It is a structural schematic diagram of the main transformer and inductor integrated configuration device provided by the present invention.

[0019] Figure 2 It is a schematic diagram of the double-clad magnetic core provided by the present invention.

[0020] Figure 3 It is a structural schematic diagram of the central column provided by the present invention.

[0021] Figure 4 It is a schematic diagram of the magnetic circuit direction provided by the present invention.

[0022] Figure 5 It is a schematic diagram of the coil structure provided by the present invention.

[0023] Figure 6It is a schematic diagram of the structure of heat dissipation between the magnetic core and the coil provided by the present invention.

[0024] Figure 7 It is a structural schematic diagram of the base provided by the present invention.

[0025] Figure 8 It is a flow chart of the main transformer and inductor integrated configuration method provided by the present invention.

[0026] Fig. 9 It is a structural schematic diagram of the electronic device provided by the present invention.

[0027] Wherein, the accompanying drawings are marked as follows: 1: first magnetic core; 2: second magnetic core; 3: main transformer winding; 4: inductor winding; 5: base; 6: ceramic sheet; 7: QU magnetic sheet; 11: first magnetic core sub-component; 12: second magnetic core sub-component; 51: inlet and outlet wire enclosure; 52: friction strip opening; 53: isolation strip; 54: clamping edge; 111: side column; 112: middle column; 113: bottom edge; 1121: elliptical ventilation slot. DETAILED DESCRIPTION

[0028] In order to make the purpose, technical solution and advantages of the present invention clearer, the technical solution of the present invention will be clearly and completely described below in conjunction with the drawings of the present invention. Obviously, the described embodiments are part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0029] The terms "first", "second", etc. in the present invention are used to distinguish similar objects, rather than to describe a specific order or sequence. It should be understood that the numbers used in this way can be interchanged where appropriate, so that the embodiments of the present invention can be implemented in an order other than those illustrated or described herein.

[0030] Combination Figure 1 , Figure 1 It is a structural schematic diagram of the main transformer and inductor integrated configuration device provided by the present invention; Figure 2 Schematic diagram of a double-clad magnetic core provided by the present invention; Figure 3 It is a structural schematic diagram of the central column provided by the present invention; Figure 4 It is a schematic diagram of the magnetic circuit direction provided by the present invention; Figure 5 is a schematic diagram of a coil structure provided by the present invention; Figure 6 It is a schematic diagram of the structure of heat dissipation between the magnetic core and the coil provided by the present invention; Figure 7 It is a structural schematic diagram of the base provided by the present invention; Figure 8It is a flow chart of the method for integrating the main transformer and the inductor provided by the present invention; Fig. 9 It is a structural schematic diagram of the electronic device provided by the present invention.

[0031] Combine the following Figure 1-Figure 9 The main transformer and inductor integrated configuration device, method, equipment and medium provided by the present invention are described.

[0032] like Figure 1 As shown, the main transformer and inductor integrated configuration device provided by the present invention comprises a first magnetic core (1), a second magnetic core (2), a main transformer coil (3), an inductor coil (4) and a base (5); The first magnetic core (1) is assembled with two ends of the main transformer winding package (3); The second magnetic core (2) is assembled with one end of the inductor coil (4); The other end of the inductor coil (4) is assembled with one end of the main transformer coil (3) through the first magnetic core (1); The first magnetic core (1), the main transformer coil (3), the second magnetic core (2), the inductor coil (4) and the base (5) are assembled.

[0033] Specifically, when making the LLC circuit topology, the resonant inductor Lr and the main transformer T1 must be assembled. Due to the space limitation of the entire machine, in order to save the space occupied by the resonant inductor Lr and the main transformer T1 when assembling them, a double magnetic core is used to integrate the resonant inductor Lr and the main transformer T1, which were originally independent components in the LLC circuit topology structure, to achieve a main-resonant integrated configuration, and use the principle of conjugate magnetic circuit cutting to reduce the volume of the magnetic core.

[0034] The dual core is a design structure used in electrical engineering to improve the performance of inductors and transformers. Its basic principle is to use two cores to cooperate with each other to enhance the function of electromagnetic equipment.

[0035] For the purpose of clear description, the two magnetic cores of the dual magnetic core are described as a first magnetic core (1) and a second magnetic core (2). The first magnetic core (1) and the second magnetic core (2) can be designed to be of the same size or of different sizes, depending on actual needs. The present invention uses different sizes for design in real-time examples.

[0036] In the LLC circuit topology, the main transformer T1 is a key device for realizing voltage conversion in the power system. During the equipment manufacturing process, the main transformer coil (3) will be used for equipment. The main transformer coil (3) is the core part of the main transformer T1 to realize voltage conversion and is responsible for transferring energy through electromagnetic induction. In the LLC circuit topology, the resonant inductor Lr is a key device for limiting current changes, filtering, energy storage, etc. in the power system. During the equipment manufacturing process, the inductor coil (4) will be used for assembly. The inductor coil (4) is the core part of the resonant inductor Lr to realize current changes, filtering, energy storage, etc. and is responsible for generating a magnetic field through current induction and generating an electromotive force according to the current change.

[0037] The use of double magnetic cores to integrate the resonant inductor Lr and the main transformer T1 can be understood as assembling the first magnetic core (1) with both ends of the main transformer coil (3), assembling the second magnetic core (2) with one end of the inductor coil (4), assembling the other end of the inductor coil (4) with one end of the main transformer coil (3) through the first magnetic core (1), and assembling the main transformer coil (3) and the inductor coil (4) together through the first magnetic core (1) and the second magnetic core (2), and then assembling the first magnetic core (1), the main transformer coil (3), the second magnetic core (2), the inductor coil (4) and the base (5) to complete the final main transformer and inductor integrated configuration to form a magnetic circuit output resonant inductor. The assembly method can be a method of bonding with epoxy glue and curing and fixing after baking.

[0038] Depend on Figure 1 From the visual diagram, the first magnetic core (1) is assembled with the left and right ends of the main transformer coil (3), the second magnetic core (2) is assembled with the left end of the inductor coil (4), the right end of the inductor coil (4) is assembled with the left end of the main transformer coil (3) through the first magnetic core (1), and the contact surface between the bottom end of the structure of the first magnetic core (1), the main transformer coil (3), the second magnetic core (2), and the inductor coil (4) assembled as one and the base (5) is further assembled to complete the final integrated configuration of the main transformer and the inductor, forming a magnetic circuit output resonant inductor.

[0039] like Figure 1 As shown, the main transformer and inductor integrated configuration device provided by the present invention also includes a ceramic sheet (6) and a QU magnetic sheet (7); The first magnetic core (1) is assembled with two ends of the main transformer winding package (3) through the ceramic sheet (6) and the QU magnetic sheet (7); The second magnetic core (2) is assembled with one end of the inductor coil (4) through the ceramic sheet (6) and the QU magnetic sheet (7); The ceramic sheet (6) is used for isolating components, and the QU magnetic sheet (7) is used for guiding magnetic flux.

[0040] Specifically, an air gap is provided between the first magnetic core (1) and the second magnetic core (2) to help the magnetic flux to be more evenly distributed in the magnetic circuit, thereby reducing the problems of local concentration of magnetic flux and magnetic saturation, improving the magnetic flux distribution, and improving the efficiency and stability of the device. The air gap between the first magnetic core (1) and the second magnetic core (2) is isolated by a ceramic sheet (6), and the magnetic flux is guided by a QU magnetic sheet (7). The ceramic sheet (6) has the function of conducting heat dissipation, and the QU magnetic sheet (7) has the function of optimizing the distribution and transmission of the magnetic flux. The overall design helps to improve the efficiency, stability and performance of the device.

[0041] Since the ceramic sheet (6) is used to isolate components and the QU magnetic sheet (7) is used to guide magnetic flux, the first magnetic core (1) is assembled with both ends of the main transformer winding (3) through the ceramic sheet (6) and the QU magnetic sheet (7), and the second magnetic core (2) is assembled with one end of the inductor winding (4) through the ceramic sheet (6) and the QU magnetic sheet (7).

[0042] It can be understood that the first magnetic core (1) is assembled with the two ends of the main transformer winding (3), specifically, the first magnetic core (1) is first bonded to the ceramic sheet (6) and the QU magnetic sheet (7) in sequence using epoxy glue, and then cured and fixed after baking. Further, the assembled first magnetic core (1), ceramic sheet (6), QU magnetic sheet (7) are bonded to the main transformer winding (3) using epoxy glue, and then cured and fixed after baking, so that the first magnetic core (1) is assembled with the two ends of the main transformer winding (3) through the ceramic sheet (6) and the QU magnetic sheet (7).

[0043] Similarly, the second magnetic core (2) is assembled with one end of the inductor winding (4). Specifically, the second magnetic core (2) is first bonded to the ceramic sheet (6) and the QU magnetic sheet (7) in sequence using epoxy glue, and then cured and fixed after baking. Further, the assembled second magnetic core (2), the ceramic sheet (6), the QU magnetic sheet (7) and the inductor winding (4) are bonded with epoxy glue, and then cured and fixed after baking, so that the second magnetic core (2) is assembled with one end of the inductor winding (4) through the ceramic sheet (6) and the QU magnetic sheet (7).

[0044] Optionally, the first magnetic core (1) comprises a first magnetic core subcomponent (11) and a second magnetic core subcomponent (12); The first magnetic core subcomponent (11) is assembled with one end of the main transformer winding package (3) through the ceramic sheet (6) and the QU magnetic sheet (7); The second magnetic core subcomponent (12) is assembled with the other end of the main transformer winding (3) via the ceramic sheet (6) and the QU magnetic sheet (7).

[0045] Specifically, the first magnetic core (1) is designed with an air gap, which is divided into a first magnetic core sub-component (11) and a second magnetic core sub-component (12). This design method can also help the magnetic flux to be more evenly distributed in the magnetic circuit, thereby reducing the problems of local concentration of magnetic flux and magnetic saturation, and improving the efficiency and stability of the equipment. The air gap between the first magnetic core sub-component (11) and the second magnetic core sub-component (12) is isolated by a ceramic sheet (6), and a QU magnetic sheet (7) is used to guide the magnetic flux.

[0046] Since the ceramic sheet (6) is used as an isolation component and the QU magnetic sheet (7) is used to guide the magnetic flux, the first magnetic core subcomponent (11) is assembled with one end of the main transformer winding (3) through the ceramic sheet (6) and the QU magnetic sheet (7), and the second magnetic core subcomponent (12) is assembled with the other end of the main transformer winding (3) through the ceramic sheet (6) and the QU magnetic sheet (7).

[0047] It can be understood that the first magnetic core sub-component (11) is assembled with one end of the main transformer winding (3), specifically, the first magnetic core sub-component (11) is first bonded to the ceramic sheet (6) and the QU magnetic sheet (7) in sequence using epoxy glue, and then cured and fixed after baking. Further, the assembled first magnetic core sub-component (11), the ceramic sheet (6), the QU magnetic sheet (7) and one end of the main transformer winding (3) are bonded with epoxy glue, and then cured and fixed after baking, so that the first magnetic core sub-component (11) is assembled with one end of the main transformer winding (3) through the ceramic sheet (6) and the QU magnetic sheet (7).

[0048] Similarly, the second magnetic core subcomponent (12) is assembled with the other end of the main transformer winding (3). Specifically, the second magnetic core subcomponent (12) is first bonded to the ceramic sheet (6) and the QU magnetic sheet (7) in sequence using epoxy glue, and then cured and fixed after baking. Further, the assembled second magnetic core subcomponent (12), the ceramic sheet (6), the QU magnetic sheet (7) and the other end of the main transformer winding (3) are bonded using epoxy glue, and then cured and fixed after baking, so that the second magnetic core subcomponent (12) is assembled with the other end of the inductor winding (4) through the ceramic sheet (6) and the QU magnetic sheet (7).

[0049] Optionally, the first magnetic core (1) and the second magnetic core (2) adopt a PQU type structure; The first magnetic core subcomponent (11) comprises two central columns having a double encapsulation structure, the second magnetic core subcomponent (12) comprises two central columns having the double encapsulation structure, and the second magnetic core (2) comprises two central columns having the double encapsulation structure.

[0050] Specifically, the first magnetic core (1) and the second magnetic core (2) both adopt a PQU type structure and can be referred to as a first PQU magnetic core and a second PQU magnetic core. The main transformer winding package (3) and the inductor winding package (4) are integrated by means of a PQU type dual magnetic core, a magnetic circuit is formed by using the bottom edge (113) of the magnetic core of the main transformer, and an air gap is formed in the middle of the magnetic core to control the inductance.

[0051] The PQU double magnetic core adopts a double-encapsulated design with ventilation holes, that is, the first magnetic core subcomponent (11) includes two central columns with a double-encapsulated structure, the second magnetic core subcomponent (12) includes two central columns with a double-encapsulated structure, and the second magnetic core (2) includes two central columns with a double-encapsulated structure. Figure 2 The back view of the two center columns with a double-wrapped tire structure is shown. The two center columns have the same structural size design, and a vent is left between the two center columns to facilitate the heat generated by the product to be taken away.

[0052] Optionally, any of the central columns comprises two side columns (111), a middle column (112) and a bottom edge (113).

[0053] Specifically, if Figure 3 As shown, any center column includes two side columns (111), a middle column (112) and a bottom edge (113).

[0054] In this structure, the main transformer T1 and the resonant inductor Lr form a magnetic circuit of bottom side (113)-center column-side column (111), and the shared bottom side (113) cuts the magnetic circuit. Figure 4 shown.

[0055] Optionally, any of the center columns (112) is provided with an elliptical ventilation slot (1121); and the coil structures of the main transformer coil (3) and the inductor coil (4) are elliptical structures.

[0056] Specifically, if Figure 5 As shown, in order to save space and cost, the coils of the main transformer coil (3) and the inductor coil (4) are wound by skeleton-free winding. Skeleton-free winding means that no traditional physical skeleton is used when winding the coils, which means that the wound coils have no central supporting skeleton, and the shape of the coils is usually maintained by their own coil structure and material properties. In addition, the coil structure of the main transformer coil (3) and the inductor coil (4) adopts an elliptical structure. Under the design of skeleton-free winding and elliptical coil structure, a sandwich structure winding method is adopted, specifically, a primary winding is first wound in one layer, and then a secondary winding is wound, and then a primary winding is wound in one layer. This design method is to reduce the influence of leakage inductance on electromagnetic interference.

[0057] Any center column (112) is provided with an elliptical ventilation slot (1121), and the main transformer coil (3) and the inductor coil (4) are both designed to be elliptical, such as Figure 6 As shown, there is enough space between the inner side of the coil and the core center column (112) to form a heat conduction vent, which is convenient for the whole device to be air-cooled and for the heat generated by the core and coil to be quickly dissipated by the airflow through the heat conduction vent when the product is working.

[0058] Optionally, the base (5) comprises an entry and exit line opening (51), a friction strip opening (52) and an isolation strip (53); The wire entry and exit opening (51) is used to fix the pins of the main transformer coil (3) and the inductor coil (4); The friction strip opening (52) is used to arrange the first magnetic core (1), the second magnetic core (2) and the base (5) together; The isolation strip (53) is used to separate the two central columns having the double-encapsulated structure.

[0059] Specifically, the main transformer and the inductor are integrated together and assembled on a predetermined base plate, which adopts a card slot design.

[0060] like Figure 7 As shown, the base (5) is provided with a clamping edge (54), and the clamping edge (54) is provided with a wire entry and exit opening (51), which is convenient for glue dispensing and fixing the pins of the main transformer wire package (3) and the inductor wire package (4), and is conducive to automatic glue dispensing by glue dispensing equipment.

[0061] like Figure 7 As shown, the contact surface between the base (5) and the magnetic core is also provided with a friction strip opening (52), so that after applying glue, the magnetic core and the base (5) can be more easily adhered together.

[0062] like Figure 7 As shown, an isolation strip (53) is also provided in the middle of the base (5) to separate the double-clad magnetic cores so as to leave a vent in the middle to facilitate the heat generated by the product to be taken away.

[0063] Due to the large size of the product, the bottom plate is provided with structures such as friction strip openings (52), isolation strips (53) and inlet and outlet wire enclosures (51), which facilitate the installation of the product when the magnetic core is fixed with glue, prevent the product from loosening, and facilitate ventilation and heat dissipation.

[0064] From all the above embodiments, it can be seen that the integrated product has a simple structure, low cost, simple operation, and is easy to install quickly, thereby reducing the cumbersome processes in the entire process flow. It has strong operability and can realize automatic mass production, improve production efficiency, reduce costs, save energy, and achieve sustainable development.

[0065] The main transformer and inductor integrated configuration device provided by the present invention integrates the main transformer coil and the inductor coil together through a double magnetic core, and then completes the configuration of the assembled double magnetic core, the main transformer coil, the inductor coil and the base to form a magnetic circuit output resonant inductance, thereby improving the sharing efficiency of the magnetic circuit and achieving a compact product structure and efficient use of space. This layout not only effectively reduces the space occupied by the volume, thereby ensuring low manufacturing cost, high production efficiency, easy operation, etc., but also avoids causing heat dissipation problems as much as possible, thereby ensuring the stability and service life of components in the circuit, thereby meeting the electrical performance requirements of the power electronic system and providing significant technical advantages for performance optimization of the power electronic system.

[0066] Further, Figure 8 Schematic diagram of the process of the main transformer and inductor integrated configuration method provided by the present invention. Figure 8 The main transformer and inductor integrated configuration method provided by the present invention may include: Step 801, assembling the first magnetic core and two ends of the main transformer coil; Step 802, assembling the second magnetic core and one end of the inductor coil; Step 803, assembling the other end of the inductor coil with one end of the main transformer coil through the first magnetic core; Step 804: Assemble the first magnetic core, the main transformer coil, the second magnetic core, the inductor coil and the base.

[0067] Specifically, when making the LLC circuit topology, the resonant inductor Lr and the main transformer T1 must be assembled. Due to the space limitation of the entire machine, in order to save the space occupied by the resonant inductor Lr and the main transformer T1 when assembling them, a double magnetic core is used to integrate the resonant inductor Lr and the main transformer T1, which were originally independent components in the LLC circuit topology structure, to achieve a main-resonant integrated configuration, and use the principle of conjugate magnetic circuit cutting to reduce the volume of the magnetic core.

[0068] The dual core is a design structure used in electrical engineering to improve the performance of inductors and transformers. Its basic principle is to use two cores to cooperate with each other to enhance the function of electromagnetic equipment.

[0069] For the purpose of clear description, the two magnetic cores of the dual magnetic core are described as a first magnetic core (1) and a second magnetic core (2). The first magnetic core (1) and the second magnetic core (2) can be designed to be of the same size or of different sizes, depending on actual needs. The present invention uses different sizes for design in real-time examples.

[0070] In the LLC circuit topology, the main transformer T1 is a key device for realizing voltage conversion in the power system. During the equipment manufacturing process, the main transformer coil (3) will be used for equipment. The main transformer coil (3) is the core part of the main transformer T1 to realize voltage conversion and is responsible for transferring energy through electromagnetic induction. In the LLC circuit topology, the resonant inductor Lr is a key device for limiting current changes, filtering, energy storage, etc. in the power system. During the equipment manufacturing process, the inductor coil (4) will be used for assembly. The inductor coil (4) is the core part of the resonant inductor Lr to realize current changes, filtering, energy storage, etc. and is responsible for generating a magnetic field through current induction and generating an electromotive force according to the current change.

[0071] The use of double magnetic cores to integrate the resonant inductor Lr and the main transformer T1 can be understood as assembling the first magnetic core (1) with both ends of the main transformer coil (3), assembling the second magnetic core (2) with one end of the inductor coil (4), assembling the other end of the inductor coil (4) with one end of the main transformer coil (3) through the first magnetic core (1), and assembling the main transformer coil (3) and the inductor coil (4) together through the first magnetic core (1) and the second magnetic core (2), and then assembling the first magnetic core (1), the main transformer coil (3), the second magnetic core (2), the inductor coil (4) and the base (5) to complete the final main transformer and inductor integrated configuration to form a magnetic circuit output resonant inductor. The assembly method can be a method of bonding with epoxy glue and curing and fixing after baking.

[0072] Depend on Figure 1 From the visual diagram, the first magnetic core (1) is assembled with the left and right ends of the main transformer coil (3), the second magnetic core (2) is assembled with the left end of the inductor coil (4), the right end of the inductor coil (4) is assembled with the left end of the main transformer coil (3) through the first magnetic core (1), and the contact surface between the bottom end of the structure of the first magnetic core (1), the main transformer coil (3), the second magnetic core (2), and the inductor coil (4) assembled as one and the base (5) is further assembled to complete the final integrated configuration of the main transformer and the inductor, forming a magnetic circuit output resonant inductor.

[0073] like Figure 1 As shown, the main transformer and inductor integrated configuration device provided by the present invention also includes a ceramic sheet (6) and a QU magnetic sheet (7); The first magnetic core (1) is assembled with two ends of the main transformer winding package (3) through the ceramic sheet (6) and the QU magnetic sheet (7); The second magnetic core (2) is assembled with one end of the inductor coil (4) through the ceramic sheet (6) and the QU magnetic sheet (7); The ceramic sheet (6) is used for isolating components, and the QU magnetic sheet (7) is used for guiding magnetic flux.

[0074] Specifically, an air gap is provided between the first magnetic core (1) and the second magnetic core (2) to help the magnetic flux to be more evenly distributed in the magnetic circuit, thereby reducing the problems of local concentration of magnetic flux and magnetic saturation, improving the magnetic flux distribution, and improving the efficiency and stability of the device. The air gap between the first magnetic core (1) and the second magnetic core (2) is isolated by a ceramic sheet (6), and the magnetic flux is guided by a QU magnetic sheet (7). The ceramic sheet (6) has the function of conducting heat dissipation, and the QU magnetic sheet (7) has the function of optimizing the distribution and transmission of the magnetic flux. The overall design helps to improve the efficiency, stability and performance of the device.

[0075] Since the ceramic sheet (6) is used for isolating components and the QU magnetic sheet (7) is used for guiding magnetic flux, the first magnetic core (1) is assembled with both ends of the main transformer winding (3) through the ceramic sheet (6) and the QU magnetic sheet (7), and the second magnetic core (2) is assembled with one end of the inductor winding (4) through the ceramic sheet (6) and the QU magnetic sheet (7).

[0076] It can be understood that the first magnetic core (1) is assembled with the two ends of the main transformer winding (3), specifically, the first magnetic core (1) is first bonded to the ceramic sheet (6) and the QU magnetic sheet (7) in sequence using epoxy glue, and then cured and fixed after baking. Further, the assembled first magnetic core (1), ceramic sheet (6), QU magnetic sheet (7) are bonded to the main transformer winding (3) using epoxy glue, and then cured and fixed after baking, so that the first magnetic core (1) is assembled with the two ends of the main transformer winding (3) through the ceramic sheet (6) and the QU magnetic sheet (7).

[0077] Similarly, the second magnetic core (2) is assembled with one end of the inductor winding (4). Specifically, the second magnetic core (2) is first bonded to the ceramic sheet (6) and the QU magnetic sheet (7) in sequence using epoxy glue, and then cured and fixed after baking. Further, the assembled second magnetic core (2), the ceramic sheet (6), the QU magnetic sheet (7) and the inductor winding (4) are bonded with epoxy glue, and then cured and fixed after baking, so that the second magnetic core (2) is assembled with one end of the inductor winding (4) through the ceramic sheet (6) and the QU magnetic sheet (7).

[0078] Optionally, the first magnetic core (1) comprises a first magnetic core subcomponent (11) and a second magnetic core subcomponent (12); The first magnetic core subcomponent (11) is assembled with one end of the main transformer winding package (3) through the ceramic sheet (6) and the QU magnetic sheet (7); The second magnetic core subcomponent (12) is assembled with the other end of the main transformer winding (3) via the ceramic sheet (6) and the QU magnetic sheet (7).

[0079] Specifically, the first magnetic core (1) is designed with an air gap, which is divided into a first magnetic core sub-component (11) and a second magnetic core sub-component (12). This design method can also help the magnetic flux to be more evenly distributed in the magnetic circuit, thereby reducing the problems of local concentration of magnetic flux and magnetic saturation, and improving the efficiency and stability of the equipment. The air gap between the first magnetic core sub-component (11) and the second magnetic core sub-component (12) is isolated by a ceramic sheet (6), and a QU magnetic sheet (7) is used to guide the magnetic flux.

[0080] Since the ceramic sheet (6) is used as an isolation component and the QU magnetic sheet (7) is used to guide the magnetic flux, the first magnetic core subcomponent (11) is assembled with one end of the main transformer winding (3) through the ceramic sheet (6) and the QU magnetic sheet (7), and the second magnetic core subcomponent (12) is assembled with the other end of the main transformer winding (3) through the ceramic sheet (6) and the QU magnetic sheet (7).

[0081] It can be understood that the first magnetic core sub-component (11) is assembled with one end of the main transformer winding (3), specifically, the first magnetic core sub-component (11) is first bonded to the ceramic sheet (6) and the QU magnetic sheet (7) in sequence using epoxy glue, and then cured and fixed after baking. Further, the assembled first magnetic core sub-component (11), the ceramic sheet (6), the QU magnetic sheet (7) and one end of the main transformer winding (3) are bonded with epoxy glue, and then cured and fixed after baking, so that the first magnetic core sub-component (11) is assembled with one end of the main transformer winding (3) through the ceramic sheet (6) and the QU magnetic sheet (7).

[0082] Similarly, the second magnetic core subcomponent (12) is assembled with the other end of the main transformer winding (3). Specifically, the second magnetic core subcomponent (12) is first bonded to the ceramic sheet (6) and the QU magnetic sheet (7) in sequence using epoxy glue, and then cured and fixed after baking. Further, the assembled second magnetic core subcomponent (12), the ceramic sheet (6), the QU magnetic sheet (7) and the other end of the main transformer winding (3) are bonded using epoxy glue, and then cured and fixed after baking, so that the second magnetic core subcomponent (12) is assembled with the other end of the inductor winding (4) through the ceramic sheet (6) and the QU magnetic sheet (7).

[0083] Optionally, the first magnetic core (1) and the second magnetic core (2) adopt a PQU type structure; The first magnetic core subcomponent (11) comprises two central columns having a double encapsulation structure, the second magnetic core subcomponent (12) comprises two central columns having the double encapsulation structure, and the second magnetic core (2) comprises two central columns having the double encapsulation structure.

[0084] Specifically, the first magnetic core (1) and the second magnetic core (2) both adopt a PQU type structure and can be referred to as a first PQU magnetic core and a second PQU magnetic core. The main transformer winding package (3) and the inductor winding package (4) are integrated by means of a PQU type dual magnetic core, a magnetic circuit is formed by using the bottom edge (113) of the magnetic core of the main transformer, and an air gap is formed in the middle of the magnetic core to control the inductance.

[0085] The PQU double magnetic core adopts a double-encapsulated design with ventilation holes, that is, the first magnetic core subcomponent (11) includes two central columns with a double-encapsulated structure, the second magnetic core subcomponent (12) includes two central columns with a double-encapsulated structure, and the second magnetic core (2) includes two central columns with a double-encapsulated structure. Figure 2 The back view of the two center columns with a double-wrapped tire structure is shown. The two center columns have the same structural size design, and a vent is left between the two center columns to facilitate the heat generated by the product to be taken away.

[0086] Optionally, any of the central columns comprises two side columns (111), a middle column (112) and a bottom edge (113).

[0087] Specifically, if Figure 3 As shown, any center column includes two side columns (111), a middle column (112) and a bottom edge (113).

[0088] In this structure, the main transformer T1 and the resonant inductor Lr form a magnetic circuit of bottom side (113)-center column-side column (111), and the shared bottom side (113) cuts the magnetic circuit. Figure 4 shown.

[0089] Optionally, any of the center columns (112) is provided with an elliptical ventilation slot (1121); and the coil structures of the main transformer coil (3) and the inductor coil (4) are elliptical structures.

[0090] Specifically, if Figure 5 As shown, in order to save space and cost, the coils of the main transformer coil (3) and the inductor coil (4) are wound by skeleton-free winding. Skeleton-free winding means that no traditional physical skeleton is used when winding the coils, which means that the wound coils have no central supporting skeleton, and the shape of the coils is usually maintained by their own coil structure and material properties. In addition, the coil structure of the main transformer coil (3) and the inductor coil (4) adopts an elliptical structure. Under the design of skeleton-free winding and elliptical coil structure, a sandwich structure winding method is adopted, specifically, a primary winding is first wound in one layer, and then a secondary winding is wound, and then a primary winding is wound in one layer. This design method is to reduce the influence of leakage inductance on electromagnetic interference.

[0091] Any center column (112) is provided with an elliptical ventilation slot (1121), and the main transformer coil (3) and the inductor coil (4) are both designed to be elliptical, such as Figure 6 As shown, there is enough space between the inner side of the coil and the core center column (112) to form a heat conduction vent, which is convenient for the whole device to be air-cooled and for the heat generated by the core and coil to be quickly dissipated by the airflow through the heat conduction vent when the product is working.

[0092] Optionally, the base (5) comprises an entry and exit line opening (51), a friction strip opening (52) and an isolation strip (53); The wire entry and exit opening (51) is used to fix the pins of the main transformer coil (3) and the inductor coil (4); The friction strip opening (52) is used to arrange the first magnetic core (1), the second magnetic core (2) and the base (5) together; The isolation strip (53) is used to separate the two central columns having the double-encapsulated structure.

[0093] Specifically, the main transformer and the inductor are integrated together and assembled on a predetermined base plate, which adopts a card slot design.

[0094] like Figure 7 As shown, the base (5) is provided with a clamping edge (54), and the clamping edge (54) is provided with a wire entry and exit opening (51), which is convenient for glue dispensing and fixing the pins of the main transformer wire package (3) and the inductor wire package (4), and is conducive to automatic glue dispensing by glue dispensing equipment.

[0095] like Figure 7 As shown, the contact surface between the base (5) and the magnetic core is also provided with a friction strip opening (52), so that after applying glue, the magnetic core and the base (5) can be more easily adhered together.

[0096] like Figure 7 As shown, an isolation strip (53) is also provided in the middle of the base (5) to separate the double-clad magnetic cores so as to leave a vent in the middle to facilitate the heat generated by the product to be taken away.

[0097] Due to the large size of the product, the bottom plate is provided with structures such as friction strip openings (52), isolation strips (53) and inlet and outlet wire enclosures (51), which facilitate the installation of the product when the magnetic core is fixed with glue, prevent the product from loosening, and facilitate ventilation and heat dissipation.

[0098] In summary of all the above embodiments, the installation sequence of the integrated product can be as follows: 1. The main transformer coil and inductor coil are now wound on the automated equipment; 2. Apply epoxy glue to the PQU double-core center column through the automated glue dispensing equipment. The robot will place the ceramic sheets and magnetic sheets in order while dispensing the glue. After placing them, they will be transported to the oven for baking through the conveyor belt. After the epoxy glue is cured, it will go to the next step. 3. Place the pre-wound main transformer coil and inductor coil on the pre-assembled ceramic sheet and magnetic sheet respectively. The PQU magnetic core is fixed by epoxy glue and cured after baking. 4. After the assembled PQU core and wire package become one, the whole is assembled to the designed base. The product pin position is based on the hole position set in the base. The base has an isolation groove to separate the double-wrapped tires. After the glue is dispensed again using the glue dispensing equipment, it is transported to the oven for baking and curing to complete the integrated product.

[0099] The above installation sequence does not describe the detailed process of each step in detail, but the detailed operation can be known based on the above embodiment content, which will not be repeated here.

[0100] The integrated product has a simple structure, low cost, simple operation and is easy to install quickly, thus reducing the cumbersome processes in the entire process. It has strong operability and can realize automatic mass production, improve production efficiency, reduce costs, save energy and achieve sustainable development.

[0101] The main transformer and inductor integrated configuration method provided by the present invention integrates the main transformer coil and the inductor coil through a double magnetic core, and then completes the configuration of the assembled double magnetic core, the main transformer coil, the inductor coil and the base to form a magnetic circuit output resonant inductance, thereby improving the sharing efficiency of the magnetic circuit and achieving a compact product structure and efficient use of space. This layout not only effectively reduces the space occupied by the volume, thereby ensuring low manufacturing cost, high production efficiency, easy operation, etc., but also avoids causing heat dissipation problems as much as possible, thereby ensuring the stability and service life of components in the circuit, thereby meeting the electrical performance requirements of the power electronic system and providing significant technical advantages for performance optimization of the power electronic system.

[0102] Fig. 9 is a schematic diagram of the structure of the electronic device provided by the present invention, such as Fig. 9As shown, the electronic device may include: a processor 910, a communication interface 920, a memory 930 and a communication bus 940, wherein the processor 910, the communication interface 920 and the memory 930 communicate with each other through the communication bus 940. The processor 910 may call the logic instructions in the memory 930 to execute the main transformer and inductor integrated configuration method, the method comprising: assembling the first magnetic core with both ends of the main transformer coil; assembling the second magnetic core with one end of the inductor coil; assembling the other end of the inductor coil with one end of the main transformer coil through the first magnetic core; assembling the first magnetic core, the main transformer coil, the second magnetic core, the inductor coil and the base.

[0103] In addition, the logic instructions in the above-mentioned memory 930 can be implemented in the form of a software functional unit and can be stored in a computer-readable storage medium when it is sold or used as an independent product. Based on this understanding, the technical solution of the present invention, in essence, or the part that contributes to the prior art or the part of the technical solution, can be embodied in the form of a software product, and the computer software product is stored in a storage medium, including a number of instructions for a computer device (which can be a personal computer, a server, or a network device, etc.) to perform all or part of the steps of the method described in each embodiment of the present invention. The aforementioned storage medium includes: U disk, mobile hard disk, read-only memory (ROM, Read-Only Memory), random access memory (RAM, Random Access Memory), disk or optical disk and other media that can store program codes.

[0104] On the other hand, the present invention also provides a computer program product, which includes a computer program stored on a non-transitory computer-readable storage medium, and the computer program includes program instructions. When the program instructions are executed by a computer, the computer can execute the main transformer and inductor integrated configuration method provided in the above embodiments, and the method includes: assembling a first magnetic core with both ends of the main transformer winding; assembling a second magnetic core with one end of the inductor winding; assembling the other end of the inductor winding with one end of the main transformer winding through the first magnetic core; assembling the first magnetic core, the main transformer winding, the second magnetic core, the inductor winding and a base.

[0105] On the other hand, the present invention also provides a non-transitory computer-readable storage medium having a computer program stored thereon. When the computer program is executed by a processor, it is implemented to execute the main transformer and inductor integrated configuration method provided in the above embodiments, the method comprising: assembling the first magnetic core with both ends of the main transformer winding; assembling the second magnetic core with one end of the inductor winding; assembling the other end of the inductor winding with one end of the main transformer winding through the first magnetic core; assembling the first magnetic core, the main transformer winding, the second magnetic core, the inductor winding and the base.

[0106] The device embodiments described above are merely illustrative, wherein the units described as separate components may or may not be physically separated, and the components displayed as units may or may not be physical units. Some or all of the modules may be selected according to actual needs to achieve the purpose of the present embodiment. Those of ordinary skill in the art may understand and implement the present invention without creative effort.

[0107] Through the description of the above implementation methods, those skilled in the art can clearly understand that each implementation method can be implemented by means of software plus a necessary general hardware platform, and of course, can also be implemented by hardware. Based on this understanding, the above technical solution is essentially or the part that contributes to the prior art can be embodied in the form of a software product, and the computer software product can be stored in a computer-readable storage medium, such as ROM / RAM, a disk, an optical disk, etc., including a number of instructions for a computer device (which can be a personal computer, a server, or a network device, etc.) to execute the methods described in each embodiment or some parts of the embodiments.

[0108] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or make equivalent replacements for some of the technical features therein. However, these modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A main transformer and inductor integrated configuration device, characterized in that: It includes a first magnetic core, a second magnetic core, a main transformer winding package, an inductor winding package and a base; The first magnetic core is assembled with two ends of the main transformer coil; The second magnetic core is assembled with one end of the inductor coil; The other end of the inductor coil is assembled with one end of the main transformer coil through the first magnetic core; The first magnetic core, the main transformer coil, the second magnetic core, the inductor coil and the base are assembled.

2. The main transformer and inductor integrated configuration device according to claim 1, characterized in that: Also includes ceramic sheets and QU magnetic sheets; The first magnetic core is assembled with two ends of the main transformer coil through the ceramic sheet and the QU magnetic sheet; The second magnetic core is assembled with one end of the inductor coil through the ceramic sheet and the QU magnetic sheet; The ceramic sheet is used to isolate components, and the QU magnetic sheet is used to guide magnetic flux.

3. The main transformer and inductor integrated configuration device according to claim 2, characterized in that: The first magnetic core comprises a first magnetic core subcomponent and a second magnetic core subcomponent; The first magnetic core subcomponent is assembled with one end of the main transformer coil through the ceramic sheet and the QU magnetic sheet; The second magnetic core subcomponent is assembled with the other end of the main transformer winding package through the ceramic sheet and the QU magnetic sheet.

4. The main transformer and inductor integrated configuration device according to claim 3, characterized in that: The first magnetic core and the second magnetic core adopt a PQU type structure; The first magnetic core subcomponent includes two central columns with a double encapsulation structure, the second magnetic core subcomponent includes two central columns with the double encapsulation structure, and the second magnetic core includes two central columns with the double encapsulation structure.

5. The main transformer and inductor integrated configuration device according to claim 4, characterized in that: Any of the central columns includes two side columns, a middle column and a bottom edge.

6. The main transformer and inductor integrated configuration device according to claim 5, characterized in that: Any of the center columns is provided with an elliptical ventilation slot; the coil structure of the main transformer coil and the inductor coil adopts an elliptical structure.

7. The main transformer and inductor integrated configuration device according to claim 4, characterized in that: The base includes an entry and exit line enclosure, a friction strip opening and an isolation strip; The inlet and outlet wire enclosure is used to fix the pins of the main transformer coil and the inductor coil; The friction strip opening is used to configure the first magnetic core, the second magnetic core and the base together; The isolation strip is used to separate two central columns having the double-encapsulated structure.

8. A method for integrating a main transformer and an inductor, characterized in that: include: Assembling the first magnetic core with two ends of the main transformer coil; Assembling the second magnetic core with one end of the inductor coil; Assembling the other end of the inductor coil with one end of the main transformer coil through the first magnetic core; The first magnetic core, the main transformer coil, the second magnetic core, the inductor coil and the base are assembled.

9. A device, comprising an electronic device, the electronic device comprising a memory, a processor, and a computer program stored in the memory and executable on the processor, characterized in that: When the processor executes the computer program, the steps of the method for integrating the main transformer and the inductor as claimed in claim 8 are implemented.

10. A medium, comprising a non-transitory computer-readable storage medium having a computer program stored thereon, characterized in that: When the computer program is executed by a processor, the steps of the method for integrating the main transformer and the inductor as claimed in claim 8 are implemented.

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