Lightweight magnetic integrated device for new energy automobile

Abstract

The invention discloses a light-weight magnetic integrated device for a new energy automobile, and relates to the technical field of new energy automobile accessories, the light-weight magnetic integrated device comprises an integrated main shell, a device connecting shell and an LLC transformer framework, and a main magnetic core is installed on the inner wall of the integrated main shell and the inner wall of the device connecting shell; the LLC transformer framework, the DCDC transformer primary side coil and the transformer iron core are installed on the inner side of the integrated main shell, and the resonant inductor framework and the filter inductor magnetic core are installed on the inner side of the device connecting shell. According to the invention, the magnetic integrated assembly is arranged on the inner sides of the integrated main shell and the device connecting shell, and a four-in-one magnetic piece integrated by an LLC transformer, a DCDC transformer, a resonant inductor and a filter inductor is used in a new energy electric vehicle, so that the utilization rate of a magnetic core window is optimized through cooperative work and efficient conversion among the devices, and the energy transmission efficiency is improved; the high efficiency, low loss and stability of the power supply system are realized, and the four-in-one magnetic piece can adapt to the use requirements of the new energy automobile under different voltage levels and different charging powers.

Description

Technical Field

[0001] The present invention relates to the technical field of new energy automobile accessories, in particular to a lightweight magnetic integrated device for new energy automobiles. Background Art

[0002] The "small three electrics" of new energy vehicles usually refer to the on-board charger, on-board DC / DC converter and high-voltage distribution box. It is the key equipment for connecting AC charging piles, which can convert AC power into DC power to provide charging services for new energy vehicles. The DC / DC converter is responsible for drawing power from the power battery and charging the on-board low-voltage battery. It can intelligently manage the power supply and ensure the stable operation of the vehicle's electrical appliances. OBC and DCDC play a vital role in the power system of new energy vehicles. They jointly ensure the normal operation and efficient charging of new energy vehicles.

[0003] The defects of magnetic devices in the prior art are: 1. Patent document CN112737348B discloses a magnetically integrated three-port DC-DC converter. The coordinated work and inefficient conversion between the components in the magnetically integrated converter reduce the utilization rate of the magnetic core window. The low energy transmission efficiency is not conducive to achieving high efficiency, low loss and stability of the power supply system, and cannot meet the use requirements of new energy vehicles at different voltage levels and different charging powers.

[0004] 2. Patent document CN114121451B discloses a magnetic integrated device and a magnetic integrated switching power supply. In the magnetic integrated device, when the number of turns or layers of the secondary side of the transformer is large, parasitic oscillations are prone to occur in the parasitic capacitance between layers or turns and the secondary side leakage inductance. The parasitic oscillations increase the parasitic capacitance and leakage inductance between coils, and the stability and reliability of the magnetic integrated device circuit cannot be ensured.

[0005] 3. Patent document CN218631601U discloses a magnetic integrated component and a three-phase interleaved LLC resonant converter. The converter cannot adjust the values ​​of the resonant inductor and the resonant capacitor and cannot guarantee the stability of the resonant network. Parasitic oscillations will consume part of the energy, resulting in a decrease in the overall energy conversion efficiency of the system, causing system instability and even damage to the equipment.

[0006] 4. Patent document CN113077971A discloses a magnetic component used in new energy vehicles. When in use, the magnetic component cannot dissipate the heat generated by the operation of its internal components. Excessive temperature will cause its performance to degrade or be damaged. The heat accumulation inside reduces the overall thermal management efficiency. Summary of the invention

[0007] The purpose of the present invention is to provide a lightweight magnetic integrated device for new energy vehicles to solve the problems raised in the above background technology.

[0008] To achieve the above object, the present invention provides the following technical solution: A lightweight magnetic integrated device for new energy vehicles, comprising an integrated main shell, a device connecting shell and an LLC transformer skeleton, wherein the two sets of integrated main shells are arranged opposite to each other, a device connecting shell is installed on the outer side of one set of the integrated main shells, and a magnetic integrated component is arranged on the inner sides of the integrated main shell and the device connecting shell; The magnetic integration component includes a main magnetic core, an LLC transformer skeleton, a DCDC transformer primary coil, a transformer core, a resonant inductor skeleton and a filter inductor core. The main magnetic core is respectively installed on the inner walls of the integrated main shell and the device shell, the LLC transformer skeleton, the DCDC transformer primary coil and the transformer core are installed on the inner side of the integrated main shell, and the resonant inductor skeleton and the filter inductor core are installed on the inner side of the device shell.

[0009] Preferably, the LLC transformer skeleton is installed on the outside of two groups of main magnetic cores installed oppositely in the integrated main shell, and the LLC transformer coil is installed on the outside of the LLC transformer skeleton.

[0010] Preferably, a limiting core is symmetrically installed on the inner wall of the integrated main shell, and two groups of transformer cores are respectively installed on the outside of the limiting core, the primary coil of the DCDC transformer is located between the two groups of transformer cores, and the limiting core cooperates with the primary coil of the DCDC transformer.

[0011] Preferably, an inner coil of the secondary primary winding of a DCDC transformer is installed on the outside of the transformer core, a secondary secondary winding coil of a DCDC transformer is installed on the outside of the inner coil of the secondary primary winding of the DCDC transformer, and an outer coil of the secondary primary winding of a DCDC transformer is installed on the outside of the secondary secondary winding coil of the DCDC transformer, and tape is wrapped around the connections of the inner coil of the secondary primary winding of the DCDC transformer, the secondary secondary winding coil of the DCDC transformer and the outer coil of the secondary primary winding of the DCDC transformer.

[0012] Preferably, opposite ends of the limit core are provided with split grooves, and resistance elements are installed inside the split grooves.

[0013] Preferably, the resonant inductor skeleton is installed on the outside of a group of main magnetic cores in the device shell, a resonant inductor coil is installed on the outside of the resonant inductor skeleton, a heat dissipation hole is opened through the front of the integrated main shell and the device shell, a ceramic sheet is installed on the inside of the heat dissipation hole, a frequency modulation notch is opened on the top of the integrated main shell and the device shell, and a docking notch is opened on the bottom wall of the integrated main shell and the device shell.

[0014] Preferably, the filter inductor magnetic core is mounted on the inner wall of the device shell, and a filter inductor coil is mounted on the outer side of the filter inductor magnetic core.

[0015] Preferably, a heat exhaust port is opened through the front of the device shell, a dustproof net is installed on the inner side of the heat exhaust port, a support rod is installed at the rear end center position of the dustproof net, an anti-interference cover is installed at the rear end of the support rod, an edge guide block is installed at the outer end of the anti-interference cover, and a flow hole is opened through the front of the anti-interference cover.

[0016] A method for using a lightweight magnetic integrated device for a new energy vehicle is applicable to a lightweight magnetic integrated device for a new energy vehicle. Preferably, the method for using the lightweight magnetic integrated device comprises the following steps: Step S1, the input power is efficiently converted through the LLC transformer to convert the high-voltage direct current into an intermediate voltage, and the intermediate voltage is further regulated and converted through the DCDC transformer to provide stable low-voltage direct current for low-voltage electrical appliances; Step S2, during the entire conversion process, the resonant inductor participates in the resonance process to achieve zero voltage turn-on of the switch tube and zero current turn-off of the rectifier diode, thereby reducing switching losses, and the filter inductor smoothes the output voltage, reduces voltage fluctuations and ripples, and ensures the stability and reliability of the output voltage; Step S3: When the resonant inductor generates severe heat during use, the heat generated during operation is discharged through the heat outlet, and the anti-interference cover filters out electromagnetic noise and interference signals entering through the heat outlet.

[0017] Preferably, in step S1, the following steps are also included: Step S11, the tape wound around the connection between the inner coil of the primary winding of the secondary side of the DCDC transformer, the secondary winding coil of the secondary side of the DCDC transformer and the outer coil of the primary winding of the secondary side of the DCDC transformer reduces the parasitic capacitance, and the coils in the DCDC transformer using the layered winding method further suppress parasitic oscillation; Step S12, the resistance element consumes the energy of the parasitic oscillation to reduce the amplitude of the oscillation; In step S3, the following steps are also included: Step S31: The LLC transformer and the resonant inductor dissipate the heat generated during operation through the inserted ceramic sheets.

[0018] Compared with the prior art, the present invention has the following beneficial effects: 1. The present invention provides a magnetic integrated component on the inner side of the integrated main shell and the device connection shell, and integrates the LLC transformer, DCDC transformer, resonant inductor and filter inductor used in the new energy electric vehicle. The coordinated work and efficient conversion between the components optimize the utilization rate of the magnetic core window, thereby effectively balancing the iron loss and copper loss of the transformer, improving the energy transmission efficiency, and achieving high efficiency, low loss and stability of the power supply system. The integrated design reduces the number and volume of magnetic components, thereby reducing the overall loss, significantly reducing the volume, making the space utilization inside the new energy vehicle more efficient, and meeting the lightweight design requirements of the new energy vehicle. The four-in-one magnetic component can adapt to the use requirements of the new energy vehicle at different voltage levels and different charging powers. The highly integrated design reduces the number of connectors and connecting wires, reduces the failure rate, and improves the reliability of the magnetic device when it is working.

[0019] 2. The present invention wraps tape around the connection between the inner coil of the primary winding of the secondary side of the DCDC transformer, the secondary winding coil of the secondary side of the DCDC transformer and the outer coil of the primary winding of the secondary side of the DCDC transformer. The electrical isolation between the primary and secondary windings of the transformer ensures the safety and stability of the circuit. The weight and volume of the magnetic core are reduced by using a common magnetic circuit. Higher integration can make efficient use of raw materials. The tape wrapped around the connection between the inner coil of the primary winding of the secondary side of the DCDC transformer, the secondary winding coil of the secondary side of the DCDC transformer and the outer coil of the primary winding of the secondary side of the DCDC transformer reduces parasitic capacitance. The coil using the layered winding method in the DCDC transformer further suppresses parasitic oscillation, reduces the possibility of parasitic oscillation of parasitic capacitance between layers or turns and secondary leakage inductance when the number of turns or layers of the secondary side of the LLC transformer is large, helps to reduce the interaction between parasitic capacitance and leakage inductance in the secondary winding of the LLC transformer, thereby reducing the risk of parasitic oscillation. The tape added between the coils reduces the direct coupling between the coils, helps to reduce the skin effect and the proximity effect, thereby reducing the parasitic capacitance and leakage inductance between the coils, and ensures the stability and reliability of the magnetic integrated device circuit.

[0020] 3. The present invention installs resistance elements on the inner side of the slots and adjusts the values ​​of the resonant inductor and the resonant capacitor to enhance the stability of the resonant network, thereby suppressing the occurrence of parasitic oscillations. Parasitic oscillations consume part of the energy, resulting in a decrease in the overall energy conversion efficiency of the system. The resistance elements consume the energy of the parasitic oscillations to reduce the amplitude of the oscillations, thereby preventing the parasitic oscillations from causing system instability or even damage to the equipment. Reducing the oscillation amplitude reduces the generation of harmonics in the four-in-one magnetic component, thereby reducing interference with the system, helping to reduce noise generation, and improving the quietness and reliability of the system. Reducing the oscillation amplitude enhances the anti-interference ability of the four-in-one magnetic component, making it more stable in the face of external interference. Reducing parasitic oscillations and their negative effects helps to improve the overall reliability of the system.

[0021] 4. The present invention provides a heat dissipation port through the front side of the device shell. The LLC transformer and the resonant inductor can remove the heat generated during operation through the inserted ceramic sheet. When the resonant inductor generates severe heat during use, the heat generated during operation can be discharged through the heat dissipation port. The anti-interference cover filters out electromagnetic noise and interference signals entering through the heat dissipation port, thereby improving its anti-interference performance while ensuring good heat dissipation effect, so as to reduce the impact of external electromagnetic interference on the device and reduce the crossing and interference between signal lines. The ceramic sheet prevents performance degradation or damage caused by excessive temperature. The heat dissipation port allows heat to be discharged smoothly, avoiding heat accumulation inside and improving the overall thermal management efficiency. The stable heat dissipation and electromagnetic environment help to improve the working stability of the magnetic integrated device and reduce performance fluctuations and abnormal phenomena. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 It is a schematic diagram of the three-dimensional structure of the present invention; Figure 2 It is a schematic diagram of the three-dimensional split structure of the present invention; Figure 3 It is a schematic diagram of the top view of the structure of the present invention; Figure 4 This is a schematic diagram of the internal structure of the integrated main shell of the present invention from a top view; Figure 5 It is a schematic diagram of the internal structure of the device shell viewed from above of the present invention; Figure 6 It is a schematic diagram of the enlarged structure of point A of the present invention; Figure 7 It is a schematic diagram of the internal structure of the present invention when viewed from above without any components; Figure 8 It is a schematic diagram of the winding structure of the DCDC transformer coil of the present invention; Fig. 9 It is a magnetic circuit simulation diagram of the magnetic integrated device of the present invention; Fig.10 It is the work flow chart of the present invention.

[0023] In the figure: 1. integrated main shell; 2. device shell connection; 3. main magnetic core; 4. LLC transformer skeleton; 5. LLC transformer coil; 6. DCDC transformer primary coil; 7. transformer core; 8. heat dissipation hole; 9. ceramic sheet; 10. frequency modulation gap; 11. docking gap; 12. limit core; 13. heat exhaust port; 14. split slot; 15. resistor element; 16. resonant inductor skeleton; 17. resonant inductor coil; 18. filter inductor core; 19. filter inductor coil; 20. DCDC transformer secondary primary winding inner coil; 21. DCDC transformer secondary secondary winding coil; 22. DCDC transformer secondary primary winding outer coil; 23. tape; 24. dust net; 25. support rod; 26. anti-interference cover; 27. side guide block; 28. flow hole. DETAILED DESCRIPTION

[0024] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only 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.

[0025] In the description of the present invention, it should be noted that the terms "upper", "lower", "inner", "outer", "front end", "rear end", "two ends", "one end", "the other end" and the like indicate positions or positional relationships based on the positions or positional relationships shown in the drawings, and are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply 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 present invention. In addition, the terms "first" and "second" are used for descriptive purposes only and cannot be understood as indicating or implying relative importance.

[0026] In the description of the present invention, it should be noted that, unless otherwise clearly specified and limited, the terms "installed", "provided with", "connected", etc. should be understood in a broad sense. For example, "connected" can be a fixed connection or a movable connection, or a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection, or it can be indirectly connected through an intermediate medium, or it can be the internal communication of two components. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0027] See also Figure 1 , Figure 2 , Figure 3 , Figure 4 , Figure 5 and Figure 7, an embodiment provided by the present invention: a lightweight magnetic integrated device for new energy vehicles; It comprises an integrated main shell 1, a device connection shell 2 and a magnetic integration component. Two groups of integrated main shells 1 are arranged opposite to each other. The device connection shell 2 is installed on the outer side of one group of integrated main shells 1. The inner sides of the integrated main shell 1 and the device connection shell 2 are provided with a magnetic integration component. The magnetic integration component comprises a main magnetic core 3, an LLC transformer skeleton 4, a DCDC transformer primary coil 6, a transformer core 7, a resonant inductor skeleton 16 and a filter inductor magnetic core 18. The main magnetic core 3 is respectively installed on the inner walls of the integrated main shell 1 and the device connection shell 2, the LLC transformer skeleton 4, the DCDC transformer primary coil 6 and the transformer core 7 are installed on the inner side of the integrated main shell 1, and the resonant inductor skeleton 16 and the filter inductor magnetic core 18 are installed on the inner side of the device connection shell 2. The integrated main shell 1 provides installation space for the LLC transformer skeleton 4 and the DCDC transformer primary coil 6, and the device connection shell 2 provides installation space for the resonant inductor skeleton 16 and the filter inductor core 18. The input power is efficiently converted by the LLC transformer to convert the high-voltage direct current into an intermediate voltage, and the intermediate voltage is further regulated and converted by the DCDC transformer to provide stable low-voltage direct current for low-voltage electrical appliances. During the entire conversion process, the resonant inductor participates in the resonance process to realize the zero-voltage turn-on of the switch tube and the zero-current turn-off of the rectifier diode, thereby reducing the switching loss. The filter inductor smoothes the output voltage, reduces voltage fluctuations and ripples, and ensures the stability and reliability of the output voltage. The LLC transformer, DCDC transformer, resonant inductor and filter inductor used in new energy electric vehicles are integrated into a four-in-one magnetic component. The coordinated work and efficient conversion between the components optimize the utilization rate of the core window, thereby effectively balancing the iron loss and copper loss of the transformer. The integrated design reduces the number and volume of magnetic components, thereby reducing the overall loss, and significantly reduces the volume, making the space utilization inside the new energy vehicle more efficient, meeting the lightweight design requirements of new energy vehicles; The filter inductor and the resonant inductor share a magnetic arm, the LLC transformer and the DCDC transformer share a magnetic arm, the resonant inductor and the LLC transformer share a magnetic arm, and the filter inductor and the DCDC transformer share a magnetic arm.

[0028] See also Figure 1 , Figure 2 and Figure 4 , a lightweight magnetic integrated device for new energy vehicles; It comprises an LLC transformer skeleton 4, a resonant inductor skeleton 16 and a ceramic sheet 9, wherein the LLC transformer skeleton 4 is installed on the outside of two groups of main magnetic cores 3 installed oppositely in the integrated main shell 1, and an LLC transformer coil 5 is installed on the outside of the LLC transformer skeleton 4, and a resonant inductor skeleton 16 is installed on the outside of a group of main magnetic cores 3 in the device shell 2, and a resonant inductor coil 17 is installed on the outside of the resonant inductor skeleton 16, and a heat dissipation hole 8 is opened through the front of the integrated main shell 1 and the device shell 2, and a ceramic sheet 9 is installed on the inside of the heat dissipation hole 8, and a frequency modulation notch 10 is opened on the top of the integrated main shell 1 and the device shell 2, and a docking notch 11 is opened on the bottom wall of the integrated main shell 1 and the device shell 2; The LLC transformer skeleton 4 and the LLC transformer coil 5 utilize resonant capacitors, resonant inductors and resonant networks to control the switching time and frequency of the switch tube, so that resonant oscillation is generated between the main coil and the secondary coil, thereby realizing efficient energy conversion. The LLC transformer has the characteristics of high efficiency, low electromagnetic interference and wide input and output range. The resonant inductor plays an important role in both the LLC transformer and the DCDC transformer. The working principle of the resonant inductor is based on the energy storage characteristics of the inductor. When current passes through the inductor, it will generate a magnetic field in the inductor and store energy. When the current direction changes, the magnetic field will also change direction and release energy, thereby realizing the conversion and transmission of electric energy. In the resonant state, the inductor and the capacitor will alternately store and release energy to form an oscillation process. The heat dissipation hole 8 limits the ceramic sheet 9. The ceramic sheet 9 has a high thermal conductivity and can quickly export the heat generated inside the LLC transformer and the resonant inductor. The frequency modulation notch 10 helps to increase the surface area of ​​the magnetic part, thereby improving the heat dissipation efficiency. Eddy current loss is the energy loss caused by the induced current generated by the magnetic field inside the conductor. Opening a notch in the magnetic part can destroy the continuity of the magnetic field inside the conductor, thereby reducing eddy current loss, which helps to improve the efficiency of the power electronic system in new energy vehicles and extend battery life. The frequency modulation notch 10 can also optimize the electromagnetic performance of the magnetic part. By adjusting the shape, size and position of the notch, precise control of the magnetic field distribution and inductance can be achieved, which helps to ensure the stability and reliability of the power electronic system in new energy vehicles and improve the overall performance. The four-in-one magnetic part integrates multiple functions into one component, which not only reduces weight but also reduces manufacturing costs. The notch design can further simplify the structure and reduce costs without sacrificing performance. The docking notch 11 can make the installation and maintenance of the magnetic part more convenient. In the compact space of new energy vehicles, the docking notch 11 can provide more installation space and flexibility, and also help to more easily approach and check the status of the magnetic part.

[0029] See also Figure 1 , Figure 2 and Figure 4 , a lightweight magnetic integrated device for new energy vehicles; It includes a limit core 12, a DCDC transformer primary coil 6 and a transformer core 7. The limit core 12 is symmetrically installed on the inner wall of the integrated main shell 1, and two groups of transformer cores 7 are respectively installed on the outside of the limit core 12. The DCDC transformer primary coil 6 is located between the two groups of transformer cores 7. The limit core 12 cooperates with the DCDC transformer primary coil 6. The opposite ends of the limit core 12 are provided with split grooves 14, and the inner side of the split grooves 14 is provided with a resistor element 15. The primary coil 6 of the DCDC transformer is installed at the relative center position of the two groups of limit cores 12. The primary and secondary sides of the DCDC transformer primary coil 6 and the outer coil of the transformer core 7 are separately wound to help improve the control of leakage inductance. The secondary winding receives the electric energy from the primary side and converts it into a voltage and current suitable for the load. This is because the LLC transformer works in a high-frequency mode. When the number of turns or layers of the secondary winding increases, the interaction between the parasitic capacitance between layers or turns and the leakage inductance of the secondary side may intensify, thereby causing parasitic oscillation under light load conditions. This oscillation will cause the output voltage to increase, and may even exceed the design value, posing a threat to the stability and reliability of the circuit; The slot 14 provides an installation position for the resistor element 15. The resistor element 15 consumes the energy of the parasitic oscillation and reduces the amplitude of the oscillation, preventing the parasitic oscillation from causing system instability or even damaging the equipment. Reducing the oscillation amplitude reduces the generation of harmonics by the four-in-one magnetic component, thereby reducing interference with the system. The values ​​of the resonant inductor and the resonant capacitor are adjusted to enhance the stability of the resonant network, thereby suppressing the occurrence of parasitic oscillations. Reducing the oscillation amplitude enhances the anti-interference ability of the four-in-one magnetic component, making it more stable in the face of external interference. Parasitic oscillations are often accompanied by the generation of harmonics, which will interfere with other parts of the system. Parasitic oscillations will consume part of the energy, resulting in a decrease in the overall energy conversion efficiency of the system. The energy of the parasitic oscillation is consumed by the resistor element 15, and the four-in-one magnetic component reduces this part of the energy loss and improves the energy conversion efficiency. Parasitic oscillations may make the system more sensitive to external interference. The heat generated by the parasitic oscillation will increase the heat dissipation burden of the system. By reducing the oscillation amplitude, the four-in-one magnetic component reduces the generation of heat, thereby simplifying the heat dissipation design and helping to achieve miniaturization of the system.

[0030] See also Figure 2 , Figure 4 and Figure 8 , a lightweight magnetic integrated device for new energy vehicles; It includes a DCDC transformer primary coil 6, a transformer core 7 and a DCDC transformer secondary primary winding inner coil 20. A limit core 12 is symmetrically installed on the inner wall of the integrated main shell 1, and two groups of transformer cores 7 are respectively installed on the outer sides of the limit core 12. The DCDC transformer primary coil 6 is located between the two groups of transformer cores 7. The DCDC transformer secondary primary winding inner coil 20 is installed on the outer side of the transformer core 7. The DCDC transformer secondary secondary winding coil 21 is installed on the outer side of the DCDC transformer secondary primary winding inner coil 20. The DCDC transformer secondary secondary winding coil 21 is installed on the outer side of the DCDC transformer secondary primary winding outer coil 22. The DCDC transformer secondary primary winding inner coil 20, the DCDC transformer secondary secondary winding coil 21 and the DCDC transformer secondary primary winding outer coil 22 are all wrapped with adhesive tape 23 at the connection points; The electrical isolation between the primary and secondary windings of the transformer ensures the safety and stability of the circuit. The weight and volume of the magnetic core are reduced by using a common magnetic circuit. The inner coil 20 of the secondary primary winding of the DCDC transformer, the secondary secondary winding coil 21 of the DCDC transformer and the outer coil 22 of the secondary primary winding of the DCDC transformer are wound on the outer side of the transformer core 7 by a layered winding method to further suppress parasitic oscillation. The tape 23 is wound around the connection between the inner coil 20 of the secondary primary winding of the DCDC transformer, the secondary secondary winding coil 21 of the DCDC transformer and the outer coil 22 of the secondary primary winding of the DCDC transformer. Reduce parasitic capacitance. The tape 23 has an insulating effect and will not have an adverse effect on the use status of the coil. It reduces the possibility of parasitic oscillation between the inter-layer or inter-turn parasitic capacitance and the secondary leakage inductance when the number of turns or layers of the secondary side of the LLC transformer is large. It helps to reduce the interaction between the parasitic capacitance and leakage inductance in the secondary winding of the LLC transformer, thereby reducing the risk of parasitic oscillation. The tape 23 added between the coils reduces the direct coupling between the coils, helps to reduce the skin effect and the proximity effect, thereby reducing the parasitic capacitance and leakage inductance between the coils, and ensures the stability and reliability of the magnetic integrated device circuit.

[0031] See also Figure 1 , Figure 2 , Figure 3 , Figure 5 and Figure 6 , a lightweight magnetic integrated device for new energy vehicles; It includes a resonant inductor skeleton 16, a filter inductor core 18 and a heat outlet 13. The resonant inductor skeleton 16 is installed on the outside of a group of main magnetic cores 3 in the device shell 2. A resonant inductor coil 17 is installed on the outside of the resonant inductor skeleton 16. The filter inductor core 18 is installed on the inner wall of the device shell 2. A filter inductor coil 19 is installed on the outside of the filter inductor core 18. The front of the device shell 2 is penetrated by a heat outlet 13. A dustproof net 24 is installed on the inside of the heat outlet 13. A support rod 25 is installed at the rear end center of the dustproof net 24. An anti-interference cover 26 is installed at the rear end of the support rod 25. A side guide block 27 is installed on the outer end of the anti-interference cover 26. A flow hole 28 is penetrated on the front of the anti-interference cover 26. The filter inductor is mainly used to smooth the pulsating components in the DC power supply and ensure the stability of the output voltage. It forms a low-pass filter together with the capacitor to prevent high-frequency pulsating components from passing through and only allow DC components to pass through. The working principle of the filter inductor is based on the inductor's ability to hinder current changes. When current passes through the filter inductor, it will generate a voltage opposite to the current change, thereby slowing down the current change rate and achieving a filtering effect. The heat generated when the chip device is powered on is discharged through the heat outlet 13. The dustproof net 24 prevents impurities in the external gas from entering the device shell 2. The support rod 25 ensures the stability of the anti-interference cover 26 when it is used. The anti-interference cover 26 filters out electromagnetic noise and interference signals entering through the heat outlet 13, improves the electromagnetic compatibility of the equipment, protects the LLC transformer and the internal circuit of the resonant inductor from the influence of external electromagnetic interference, ensures its normal operation, and the design of efficient heat dissipation and electromagnetic compatibility extends the service life of the LLC transformer and the resonant inductor, and reduces failures caused by overheating or electromagnetic interference.

[0032] The method for using the lightweight magnetic integrated device comprises the following steps: Step S1, the input power is efficiently converted through the LLC transformer to convert the high-voltage direct current into an intermediate voltage, and the intermediate voltage is further regulated and converted through the DCDC transformer to provide stable low-voltage direct current for low-voltage electrical appliances; Step S2, during the entire conversion process, the resonant inductor participates in the resonance process to achieve zero voltage turn-on of the switch tube and zero current turn-off of the rectifier diode, thereby reducing switching losses, and the filter inductor smoothes the output voltage, reduces voltage fluctuations and ripples, and ensures the stability and reliability of the output voltage; Step S3 : When the resonant inductor generates serious heat during use, the heat generated during operation is discharged through the heat outlet 13 , and the anti-interference cover 26 filters out electromagnetic noise and interference signals entering through the heat outlet 13 .

[0033] In step S1, the following steps are also included: Step S11, the tape 23 wound at the connection between the inner coil 20 of the secondary primary winding of the DCDC transformer, the secondary secondary winding coil 21 of the DCDC transformer and the outer coil 22 of the secondary primary winding of the DCDC transformer reduces the parasitic capacitance, and the coils in the DCDC transformer using the layered winding method further suppress parasitic oscillation; Step S12, the resistor element 15 consumes the energy of the parasitic oscillation to reduce the amplitude of the oscillation; In step S3, the following steps are also included: Step S31: The LLC transformer and the resonant inductor dissipate the heat generated during operation through the inserted ceramic sheet 9.

[0034] Working principle: When using the device, the input power is first efficiently converted through the LLC transformer to convert the high-voltage direct current into an intermediate voltage, and the intermediate voltage is further regulated and converted through the DCDC transformer to provide stable low-voltage direct current for low-voltage electrical appliances. The tape 23 wound at the connection between the inner coil 20 of the primary winding of the secondary side of the DCDC transformer, the secondary winding coil 21 of the secondary side of the DCDC transformer and the outer coil 22 of the primary winding of the secondary side of the DCDC transformer reduces the parasitic capacitance. The coil of the DCDC transformer using the layered winding method further suppresses the parasitic oscillation, and the resistance element 15 consumes the energy of the parasitic oscillation to reduce the amplitude of the oscillation. During the entire conversion process, the resonant inductor participates in the resonance process to achieve zero voltage turn-on of the switch tube and zero current turn-off of the rectifier diode, thereby reducing switching losses. The filter inductor smoothes the output voltage, reduces voltage fluctuations and ripples, and ensures the stability and reliability of the output voltage. When the resonant inductor generates severe heat during use, the heat generated during its operation is discharged through the heat outlet 13, and the anti-interference cover 26 filters out the electromagnetic noise and interference signals entering through the heat outlet 13. The LLC transformer and the resonant inductor remove the heat generated during operation through the inserted ceramic sheet 9.

[0035] It will be apparent to those skilled in the art that the invention is not limited to the details of the exemplary embodiments described above and that the invention can be implemented in other specific forms without departing from the spirit or essential features of the invention. Therefore, the embodiments should be considered exemplary and non-limiting in all respects, and the scope of the invention is defined by the appended claims rather than the foregoing description, and it is intended that all variations falling within the meaning and scope of the equivalent elements of the claims be included in the invention. Any reference numeral in a claim should not be considered as limiting the claim to which it relates.

Claims

1. A lightweight magnetic integrated device for new energy vehicles, comprising an integrated main shell (1), a device connection shell (2) and an LLC transformer skeleton (4), characterized in that: The two groups of integrated main shells (1) are arranged opposite to each other, a device connection shell (2) is installed on the outer side of one group of integrated main shells (1), and magnetic integration components are arranged on the inner sides of the integrated main shells (1) and the device connection shell (2); The magnetic integration component comprises a main magnetic core (3), an LLC transformer skeleton (4), a DCDC transformer primary coil (6), a transformer iron core (7), a resonant inductor skeleton (16) and a filter inductor magnetic core (18); the main magnetic core (3) is mounted on the inner walls of an integrated main shell (1) and a device connection shell (2), respectively; the LLC transformer skeleton (4), the DCDC transformer primary coil (6) and the transformer iron core (7) are mounted on the inner side of the integrated main shell (1); and the resonant inductor skeleton (16) and the filter inductor magnetic core (18) are mounted on the inner side of the device connection shell (2).

2. A lightweight magnetic integrated device for new energy vehicles according to claim 1, characterized in that: The LLC transformer skeleton (4) is installed on the outside of two groups of main magnetic cores (3) installed opposite to each other in the integrated main shell (1), and an LLC transformer coil (5) is installed on the outside of the LLC transformer skeleton (4).

3. The lightweight magnetic integrated device for new energy vehicles according to claim 1, characterized in that: A limiting core (12) is symmetrically mounted on the inner wall of the integrated main shell (1), and two groups of transformer iron cores (7) are respectively mounted on the outside of the limiting core (12); the DCDC transformer primary coil (6) is located between the two groups of transformer iron cores (7), and the limiting core (12) cooperates with the DCDC transformer primary coil (6).

4. The lightweight magnetic integrated device for new energy vehicles according to claim 1, characterized in that: The outer side of the transformer core (7) is provided with a DCDC transformer secondary primary winding inner coil (20), the outer side of the DCDC transformer secondary primary winding inner coil (20) is provided with a DCDC transformer secondary secondary winding coil (21), the outer side of the DCDC transformer secondary secondary winding coil (21) is provided with a DCDC transformer secondary primary winding outer coil (22), and adhesive tape (23) is wrapped around the connection points of the DCDC transformer secondary primary winding inner coil (20), the DCDC transformer secondary secondary winding coil (21) and the DCDC transformer secondary primary winding outer coil (22).

5. The lightweight magnetic integrated device for new energy vehicles according to claim 3, characterized in that: Opposite ends of the limit core (12) are provided with split grooves (14), and a resistance element (15) is installed inside the split grooves (14).

6. The lightweight magnetic integrated device for new energy vehicles according to claim 1, characterized in that: The resonant inductor skeleton (16) is installed on the outside of a group of main magnetic cores (3) in the device connection shell (2), and a resonant inductor coil (17) is installed on the outside of the resonant inductor skeleton (16). A heat dissipation hole (8) is opened through the front of the integrated main shell (1) and the device connection shell (2), and a ceramic sheet (9) is installed on the inside of the heat dissipation hole (8). A frequency modulation notch (10) is opened on the top of the integrated main shell (1) and the device connection shell (2), and a docking notch (11) is opened on the bottom wall of the integrated main shell (1) and the device connection shell (2).

7. The lightweight magnetic integrated device for new energy vehicles according to claim 1, characterized in that: The filter inductor magnetic core (18) is mounted on the inner wall of the device housing (2), and a filter inductor coil (19) is mounted on the outer side of the filter inductor magnetic core (18).

8. The lightweight magnetic integrated device for new energy vehicles according to claim 1, characterized in that: The front side of the device housing (2) is provided with a heat outlet (13), the inner side of the heat outlet (13) is provided with a dust screen (24), a support rod (25) is provided at the rear end center position of the dust screen (24), an anti-interference cover (26) is provided at the rear end of the support rod (25), an edge guide block (27) is provided at the outer end of the anti-interference cover (26), and a flow hole (28) is provided at the front side of the anti-interference cover (26).

9. A method for using a lightweight magnetic integrated device for a new energy vehicle, applicable to a lightweight magnetic integrated device for a new energy vehicle according to any one of claims 1 to 8, characterized in that: The method for using the lightweight magnetic integrated device comprises the following steps: Step S1, the input power is efficiently converted through the LLC transformer to convert the high-voltage direct current into an intermediate voltage, and the intermediate voltage is further regulated and converted through the DCDC transformer to provide stable low-voltage direct current for low-voltage electrical appliances; Step S2, during the entire conversion process, the resonant inductor participates in the resonance process to achieve zero voltage turn-on of the switch tube and zero current turn-off of the rectifier diode, thereby reducing switching losses, and the filter inductor smoothes the output voltage, reduces voltage fluctuations and ripples, and ensures the stability and reliability of the output voltage; Step S3: When the resonant inductor generates severe heat during use, the heat generated during operation is discharged through the heat outlet (13), and the anti-interference cover (26) filters out electromagnetic noise and interference signals entering through the heat outlet (13).

10. The method for using a lightweight magnetic integrated device for a new energy vehicle according to claim 9, characterized in that: In the step S1, the following steps are also included: Step S11, the tape (23) wound at the connection between the inner coil (20) of the secondary primary winding of the DCDC transformer, the coil (21) of the secondary secondary winding of the DCDC transformer and the outer coil (22) of the secondary primary winding of the DCDC transformer reduces the parasitic capacitance, and the coils in the DCDC transformer using the layered winding method further suppress parasitic oscillation; Step S12, the resistor element (15) consumes the energy of the parasitic oscillation to reduce the amplitude of the oscillation; In step S3, the following steps are also included: Step S31: The LLC transformer and the resonant inductor dissipate the heat generated during operation through the ceramic sheet (9) inserted inside.

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