A high-power integrated structure automatic transformer

Abstract

The invention belongs to the technical field of transformers, and specifically discloses a high-power integrated structure automation transformer, comprising: a secondary output end, which is used to generate current through an alternating magnetic field; the secondary output end includes a rigid power transmission structure; all the rigid power transmission structures are connected in sequence along the extension direction of the axis; a primary input end; the primary input end is used to generate an alternating magnetic field through input current; an assembly cavity is formed between adjacent rigid power transmission structures, and the primary input end is surrounded in the assembly cavity; a magnetic core, on which an annular assembly groove is formed, and the annular assembly groove is plugged with the end of the secondary output end; it has the following advantages: through the integrated rigid power transmission structure, the assembly process is simplified, the production efficiency and consistency are improved, the assembly error is reduced, the primary input end is ensured to effectively generate an alternating magnetic field, the thermal management is optimized, the stable connection between the magnetic core and the secondary output end is improved, and the work efficiency and stability are improved.

Description

Technical Field

[0001] The present invention relates to the technical field of transformers, and in particular to a high-power integrated structure automation transformer. Background Art

[0002] In the prior art, high-power flat-plate transformers usually adopt a frameless design, and their structure consists of a magnetic core, a primary coil, a secondary coil and a base. As independent components, the primary coil and the secondary coil need to be assembled by manual or semi-automatic assembly processes. This assembly process not only complicates the production process, but also seriously affects the production efficiency, product consistency and stability. Especially in the production of high-power flat-plate transformers, this traditional assembly process leads to a slow production rhythm, making it difficult to achieve automated assembly line operations, resulting in low production efficiency.

[0003] In addition, since the primary coil and the secondary coil are separate entities during the assembly process, it is difficult to ensure complete accuracy in their docking and installation, resulting in poor product consistency and difficulty in ensuring performance stability. In this case, the quality of the transformer fluctuates greatly, which brings additional challenges to production and increases manufacturing costs. Traditional processes not only require a lot of manual intervention, but also require more parts processing, further increasing production costs.

[0004] Therefore, a high-power integrated structure automation transformer is proposed to solve the above-mentioned problems. Summary of the invention

[0005] The present invention aims to provide a high-power integrated structure automation transformer to solve or improve the above-mentioned technical problem that the flat-plate transformer adopts a frameless design and an assembly process, resulting in low production efficiency, poor product consistency and high cost.

[0006] In view of this, a first aspect of the present invention is to provide a high-power integrated structure automation transformer.

[0007] The first aspect of the present invention provides a high-power integrated structure automation transformer, comprising: a secondary output end; the secondary output end comprises a plurality of rigid power transmission structures, each of the rigid power transmission structures extends circumferentially around an axis, and all the rigid power transmission structures are connected in sequence along the extension direction of the axis; each of the rigid power transmission structures is a rigid circumferential arc structure, used to generate current in an alternating magnetic field and output it to the outside, and the inner surface of the rigid power transmission structure is connected and fixed by injection molding along the extension direction of the axis; a primary input end, at least one of which is provided; the primary input end is used to generate the alternating magnetic field by input current; an assembly cavity is formed between adjacent rigid power transmission structures, and the primary input end is surrounded in the assembly cavity; a magnetic core is used to couple the alternating magnetic field to the secondary output end; an annular assembly groove is formed on the magnetic core, and the annular assembly groove is plugged into the end of the secondary output end to fix the magnetic core on the secondary output end.

[0008] In any of the above technical solutions, the inner surface of the rigid power transmission structure is connected and fixed by injection molding along the extension direction of the axis, and the secondary output end is a tubular structure; the arc inner end of the secondary output end is integrally formed by injection molding material; the arc outer end of the secondary output end is formed by assembling the outer end side walls of all the rigid power transmission structures.

[0009] In any of the above technical solutions, a positioning hole is formed at the inner end of the arc of the secondary output end, and a positioning column is formed on the inner end side wall of the annular assembly groove, and the positioning column is matched with the positioning hole.

[0010] In any of the above technical solutions, at least two through openings are opened on the magnetic core along the circumference of the secondary output end, and each of the through openings is connected to the annular assembly groove in a direction perpendicular to the axis to form a heat dissipation channel passing through the rigid power transmission structure and the primary input end.

[0011] In any of the above technical solutions, the inner side wall of the rigid power transmission structure is provided with a positioning groove, and the injection molding material fills the positioning groove during injection molding; all the positioning grooves are correspondingly arranged along the extension direction of the axis.

[0012] In any of the above technical solutions, the outer end side wall of the rigid power transmission structure is formed with a heat dissipation fin, and the heat dissipation fin is located inside the through-hole; along the direction perpendicular to the axis, the heat dissipation fin corresponds to the positioning groove.

[0013] In any of the above technical solutions, the outer end side wall of the annular assembly groove is matched with the arc outer end of the secondary output end.

[0014] In any of the above technical solutions, two magnetic cores are provided, and after the two magnetic cores are butted together, they form an annular cavity for accommodating the secondary output end through the annular assembly groove.

[0015] In any of the above technical solutions, the injection molding material covers a portion of the circumferential surface of the rigid power transmission structure during injection molding.

[0016] In any of the above technical solutions, the primary input end is wrapped with an insulating layer to isolate the adjacent rigid power transmission structure.

[0017] Compared with the prior art, the present invention has the following beneficial effects:

[0018] By connecting multiple rigid transmission structures in sequence along the axis and forming them into an integrated form, the traditional assembly process is effectively simplified, multiple assembly steps are eliminated, and assembly errors caused by manual assembly or semi-automatic assembly processes are avoided. The transformer production process can be automated and assembled, which greatly improves production efficiency, reduces manual intervention in the production process, and further improves production stability and consistency.

[0019] The inconsistency problem caused by the tolerance and error accumulation between components in the traditional assembly process is avoided, ensuring the high consistency of the size and position of each component, thereby significantly improving the product consistency and long-term stability of the transformer.

[0020] This ensures that the primary input end can effectively generate an alternating magnetic field through current, while reducing the heat accumulation problem that may be caused by uneven current density. In addition, the magnetic core is plugged into the end of the secondary output end through the annular assembly groove, ensuring a stable connection between the magnetic core and the secondary output end, which helps to more effectively couple the alternating magnetic field to the secondary output end and improve the working efficiency of the transformer.

[0021] Additional aspects and advantages of embodiments according to the present invention will become apparent in the following description or may be learned through practice of embodiments according to the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] The above and / or additional aspects and advantages of the present invention will become apparent and easily understood from the description of the embodiments in conjunction with the following drawings, in which:

[0023] Figure 1 It is a schematic diagram of the assembled structure of the present invention;

[0024] Figure 2 It is a schematic diagram of the structure explosion of the present invention;

[0025] Figure 3 is a structural schematic diagram of a secondary output terminal of the present invention;

[0026] Figure 4 It is a schematic diagram of the rigid power transmission structure of the present invention.

[0027] in, Figure 1-Figure 4 The corresponding relationship between the reference numerals and the component names is as follows:

[0028] 1 secondary output end, 101 rigid power transmission structure, 1011 positioning groove, 1012 heat dissipation fin, 102 assembly cavity, 103 arc inner end, 104 arc outer end, 105 positioning hole, 2 primary input end, 3 magnetic core, 301 annular assembly groove, 302 positioning column, 303 through-opening. DETAILED DESCRIPTION

[0029] In order to more clearly understand the above-mentioned purpose, features and advantages of the present invention, the present invention is further described in detail below in conjunction with the accompanying drawings and specific embodiments. It should be noted that the embodiments of the present application and the features in the embodiments can be combined with each other without conflict.

[0030] In the following description, many specific details are set forth to facilitate a full understanding of the present invention. However, the present invention may also be implemented in other ways different from those described herein. Therefore, the protection scope of the present invention is not limited to the specific embodiments disclosed below.

[0031] See also Figure 1-Figure 4 , a high-power integrated structure automation transformer according to some embodiments of the present invention is described below.

[0032] The embodiment of the first aspect of the present invention provides a high-power integrated structure automation transformer. In some embodiments of the present invention, such as Figure 1-Figure 4 As shown, the transformer includes:

[0033] Secondary output terminal 1; the secondary output terminal 1 includes a plurality of rigid power transmission structures 101, each of which extends circumferentially around an axis, and all of which are connected in sequence along the extension direction of the axis; each of which is a rigid circumferential arc structure, used to generate current in an alternating magnetic field and output it to the outside, and the inner surface of the rigid power transmission structure 101 is connected and fixed along the extension direction of the axis by injection molding; the assembly tolerance caused by assembly is eliminated, the operation steps of the assembly end are reduced, and the final product use accuracy is improved. The rigid power transmission structure 101 is specifically a copper sheet, and power transmission is carried out by connecting a conductive wire to the copper sheet.

[0034] At least one primary input terminal 2 is provided; the primary input terminal 2 is used to generate an alternating magnetic field through input current; an assembly cavity 102 is formed between adjacent rigid power transmission structures 101, and the primary input terminal 2 is surrounded in the assembly cavity 102. The primary input terminal 2 is specifically a pancake structure of a multi-layer coil.

[0035] The magnetic core 3 is used to couple the alternating magnetic field to the secondary output terminal 1 ; an annular assembly groove 301 is formed on the magnetic core 3 , and the annular assembly groove 301 is plugged into the end of the secondary output terminal 1 to fix the magnetic core 3 on the secondary output terminal 1 .

[0036] The present invention provides a high-power integrated structure automation transformer, in which the secondary output terminal 1 is responsible for transmitting the current generated by the transformer through electromagnetic induction to an external circuit. In an embodiment of the present invention, the secondary output terminal 1 includes a plurality of rigid transmission structures 101, and each rigid transmission structure 101 extends circumferentially around an axis. These rigid transmission structures 101 are made of highly conductive copper sheets, and power is transmitted by connecting conductive wires on the copper sheets; the secondary output terminal 1 can efficiently transmit the current generated by magnetic field induction through a plurality of rigid transmission structures 101. The high conductivity of the copper sheet ensures that the energy loss of the current during transmission is minimized, thereby improving the overall efficiency of the transformer; the rigid transmission structure 101 enables the entire secondary output terminal 1 to have high mechanical strength and stability, and can effectively withstand the thermal stress and mechanical stress generated during the current transmission process, thereby ensuring the reliability of the transformer under high load operation.

[0037] Multiple rigid power transmission structures 101 are the core components of the secondary output terminal 1. Each structure extends circumferentially around an axis and is connected in sequence along the extension direction of the axis to form an overall skeleton structure. By connecting multiple rigid power transmission structures 101 in sequence along the axis direction, an overall skeleton structure is formed, which not only supports the secondary coil, but also plays a role in fixing and positioning. The integrated skeleton avoids the structural instability problem caused by assembly tolerance in the traditional assembly process, and ensures the consistency of the geometric shape and electrical performance of the transformer; because the rigid power transmission structure 101 is pre-integrated and connected, the assembly tolerance that may be generated in the traditional assembly process is eliminated. The overall skeleton structure simplifies the assembly process of the transformer, reduces assembly steps and manual intervention. Through the automated assembly line production method, efficient and large-scale production can be achieved, which improves production efficiency and reduces production costs.

[0038] In the embodiment of the present invention, the rigid power transmission structure 101 is specifically copper sheets, which transmit electricity by connecting conductive wires thereon; as the main material of the rigid power transmission structure 101, the copper sheets have excellent electrical conductivity, can efficiently transmit current, and reduce power loss. Through the connection of the conductive wires, a stable current transmission path is formed between the copper sheets, ensuring the efficient flow of electric energy inside and outside the transformer; the copper sheets will generate heat during the transmission of current, and good electrical conductivity not only improves the current transmission efficiency, but also helps to evenly distribute and dissipate heat, prevent local overheating, and improve the thermal stability and service life of the transformer; the connection of the conductive wires not only realizes power transmission, but also enhances the mechanical connection strength between the copper sheets, improving the stability of the overall structure.

[0039] By connecting multiple rigid power transmission structures 101 in sequence along the axial direction, the overall skeleton structure formed has significant technical advantages: the traditional transformer adopts an assembly process, and the primary coil and the secondary coil are independent components, which need to be assembled manually or semi-automatically, which is easy to produce assembly tolerances, affecting the consistency and performance of the product. The present invention eliminates the tolerance problem in the assembly process through an integrated overall skeleton structure, ensuring the high consistency of the structure and electrical performance of each component. The integrated overall skeleton structure simplifies the assembly process of the transformer, reduces the assembly steps and manual intervention, and can better adapt to automated assembly line production. This not only significantly improves production efficiency, but also reduces production costs, allowing products to enter the market at a more competitive price. Since the overall skeleton structure avoids the errors and unstable factors that may occur in the traditional assembly process, the transformer product can maintain highly consistent structure and electrical performance during the manufacturing process. This consistency not only improves the quality and reliability of the product, but also enhances the competitiveness of the product in the market, and meets the user's demand for high-performance and high-power transformers. By simplifying the production process and improving production efficiency, the overall skeleton structure of the present invention effectively reduces the manufacturing cost. It reduces the need for manual intervention and parts processing, and reduces the complexity of the production line, thereby achieving a significant overall reduction in costs, bringing higher profit margins and market competitiveness to the company.

[0040] By using multiple copper sheets as the rigid power transmission structure 101 and connecting them in sequence along the axial direction to form an overall skeleton structure, the mechanical strength and electrical performance consistency of the transformer are ensured; the copper sheets have high electrical conductivity and good thermal conductivity.

[0041] The primary input terminal 2 is the power input part of the transformer, and at least one is provided for receiving an alternating current from an external power source, and generating an alternating magnetic field through the current, thereby realizing the conversion and transmission of electric energy; the primary input terminal 2 receives the external alternating current through the pancake structure of the multi-layer coil. When the current passes through these coils, a strong alternating magnetic field is generated. The multi-layer coil can effectively increase the number of turns of the coil, improve the efficiency of magnetic field generation, and ensure that the transformer can still maintain a stable magnetic field strength under high-power operation; the pancake structure of the multi-layer coil not only optimizes the space utilization rate and makes the transformer more compact, but also enhances the electromagnetic induction effect by multi-layer superposition, thereby improving the energy conversion efficiency of the transformer. In addition, the multi-layer coil structure helps to evenly distribute the current, reduce local overheating, and extend the service life of the transformer.

[0042] The assembly cavity 102 formed between adjacent rigid power transmission structures 101 is a spatial structure surrounded by the primary input terminal 2, which plays a key role in magnetic field coupling and structural support; the assembly cavity 102 allows the multi-layer coil pancake structure of the primary input terminal 2 to be surrounded therein, ensuring the concentration and efficient conduction of the alternating magnetic field. The assembly cavity 102 minimizes magnetic field leakage through optimized geometry and material selection, ensuring that the magnetic field can be evenly and efficiently transmitted to the rigid power transmission structure 101 of the secondary output terminal 1; the assembly cavity 102 is not only a channel for magnetic field conduction, but also plays a role in supporting the primary input terminal 2 and the rigid power transmission structure 101. The multi-layer coil will generate a certain amount of heat during operation. The assembly cavity 102 helps the heat to be quickly conducted to the outside of the transformer through optimized ventilation or integrated heat sinks, preventing overheating and ensuring the long-term stable operation of the transformer under high load.

[0043] The primary input terminal 2 and the secondary output terminal 1 achieve efficient electromagnetic coupling through the assembly cavity 102 and the magnetic core 3, jointly ensuring the efficient energy conversion and stable current output of the transformer; the alternating magnetic field generated by the multi-layer coil of the primary input terminal 2 is transmitted to the magnetic core 3 through the assembly cavity 102, and the magnetic core 3 efficiently couples the magnetic field to the rigid power transmission structure 101 of the secondary output terminal 1; the primary input terminal 2 and the secondary output terminal 1 are tightly connected through the overall skeleton structure, avoiding the structural inconsistency problem caused by assembly tolerance in the traditional assembly process. The multi-layer coil pancake structure of the primary input terminal 2 and the rigid power transmission structure 101 of the secondary output terminal 1 are integrated through the assembly cavity 102, which simplifies the production process and reduces assembly steps and manual intervention.

[0044] The magnetic core 3 is the core component of the transformer, which is mainly responsible for guiding and enhancing the alternating magnetic field generated by the primary input terminal 2, thereby achieving efficient electromagnetic coupling and energy transmission. The magnetic core 3 is usually made of a highly permeable material (such as silicon steel sheet) to ensure the concentration and efficient transmission of the magnetic flux, reduce the leakage of the magnetic field and energy loss; the alternating magnetic field generated by the primary input terminal 2 is effectively guided to the secondary output terminal 1 through the magnetic core 3. The high permeability material of the magnetic core 3 can significantly enhance the strength and uniformity of the magnetic field, ensuring that the magnetic flux can be efficiently transmitted to the rigid transmission structure 101 of the secondary output terminal 1. High-quality magnetic core 3 materials can reduce hysteresis loss and eddy current loss, and improve the overall efficiency of the transformer. In addition to the electromagnetic function, the magnetic core 3 also provides mechanical support for other components of the transformer, ensuring that each component maintains a stable position and shape during operation, and preventing structural deformation or damage caused by vibration or external impact.

[0045] The annular assembly groove 301 formed on the magnetic core 3 is intended to achieve a firm fixation and efficient coupling between the magnetic core 3 and the secondary output terminal 1. The annular assembly groove 301 is located around the magnetic core 3 and is plugged into the end of the secondary output terminal 1 to firmly fix the magnetic core 3 on the rigid power transmission structure 101 of the secondary output terminal 1. Through the pre-designed plug-in structure, the assembly of the magnetic core 3 can be completed quickly and accurately in the automated assembly line production, reducing manual intervention and assembly steps and improving production efficiency. In the traditional assembly process, the connection between the magnetic core 3 and the secondary output terminal 1 is prone to structural instability or uneven electromagnetic coupling due to assembly tolerances.

[0046] Through the annular assembly groove 301, the magnetic core 3 and the rigid power transmission structure 101 of the secondary output terminal 1 achieve tight mechanical and electromagnetic coupling. The alternating magnetic field guided by the magnetic core 3 can act on the copper sheet in the secondary power transmission structure more efficiently, improve the electromagnetic induction efficiency, and ensure that the secondary output terminal 1 can stably and efficiently generate and transmit current. The annular assembly groove 301 not only realizes the mechanical fixation of the magnetic core 3 and the secondary output terminal 1, but also enhances the overall mechanical strength and stability of the transformer through the support of the overall skeleton structure. The high thermal conductivity of the copper sheet combined with the thermal management of the magnetic core 3 ensures that the heat generated by the transformer during operation can be quickly and evenly dissipated, preventing local overheating and improving the thermal stability and service life of the equipment.

[0047] In any of the above embodiments, the inner surface of the rigid power transmission structure 101 is connected and fixed along the extension direction of the axis by injection molding. Injection molding can, on the one hand, enable all rigid power transmission structures 101 to be assembled into a complete body in one process step, and the mold cavity can ensure more accurate overall structural accuracy, thereby reducing the cumulative error caused by multiple assemblies. On the other hand, the plastic structure formed by injection molding can form an insulator, thereby ensuring that the power generated by the rigid power transmission structure 101 will not be lost outward, and the secondary output end 1 is a tubular structure.

[0048] The arc inner end 103 of the secondary output end 1 is integrally formed by injection molding of the injection molding material.

[0049] The arc outer end 104 of the secondary output terminal 1 is formed by assembling the outer end side walls of all the rigid power transmission structures 101 .

[0050] In this embodiment, the inner surfaces of multiple rigid power transmission structures 101 (specifically copper sheets) are connected and fixed along the extension direction of the axis by injection molding technology. Through the injection molding process, all rigid power transmission structures 101 are assembled into an integral body in one process step. This method not only simplifies the assembly process, but also ensures the close connection between the various rigid power transmission structures 101 to form a unified skeleton structure. Using the mold cavity for injection molding can achieve higher overall structural accuracy during the manufacturing process. This precise molding process reduces the cumulative error caused by multiple assemblies and ensures the geometric accuracy of the overall structure of the transformer and the consistency of electrical performance. The plastic material used for injection molding forms an effective insulator between the rigid power transmission structures 101, preventing accidental leakage of electricity between the power transmission structures. Through the isolation of the plastic insulator, the efficient transmission of electricity inside the transformer is guaranteed, and energy loss and potential safety hazards caused by electrical leakage are avoided.

[0051] The secondary output terminal 1 is a tubular structure, which further optimizes the current transmission and mechanical stability. The arc inner end 103 of the secondary output terminal 1 is integrally formed with the rigid power transmission structure 101 through injection molding material. This one-piece molding method not only ensures the tight connection between the arc inner end 103 and the rigid power transmission structure 101, but also enhances the mechanical strength and electrical continuity of the overall structure. The arc outer end 104 of the secondary output terminal 1 is formed by assembling the outer end side walls of all rigid power transmission structures 101. Through the assembly of the outer end side walls, the secondary output terminal 1 of the transformer has higher vibration and impact resistance, ensuring the stability and reliability of the transformer under various operating environments.

[0052] The injection molding process allows the connection and fixation of multiple rigid transmission structures 101 to be completed in a single process step, greatly simplifying the production process. This method reduces the time and resources required for traditional multi-step assembly and significantly improves production efficiency. The injection molding process is highly adaptable to automated assembly line production, and can realize large-scale, high-precision production processes, reducing the need for manual intervention, reducing human errors, and further improving production efficiency and product consistency. Injection molding ensures the accurate positioning and connection of the rigid transmission structure 101 during the molding process through the precise design and manufacture of the mold. This precise control not only improves the structural stability of the transformer, but also ensures the consistency of electrical performance and reduces electrical performance fluctuations caused by structural errors. The plastic insulator formed during the injection molding process effectively isolates the electrical connections between the rigid transmission structures 101, prevents unexpected leakage of electricity, and improves the electrical safety and reliability of the transformer.

[0053] In any of the above embodiments, a positioning hole 105 is formed at the arc inner end 103 of the secondary output terminal 1, and a positioning column 302 is formed on the inner end side wall of the annular assembly groove 301. The positioning column 302 is adapted to the positioning hole 105 so that the secondary output terminal 1 can be seamlessly assembled with the magnetic core 3. The positioning column 302 and the positioning hole 105 avoid the problem of incomplete fixation of the assembly position between the magnetic core 3 and the secondary output terminal 1 in the prior art.

[0054] In this embodiment, the precise matching of the positioning hole 105 and the positioning post 302 can ensure that the secondary output terminal 1 and the magnetic core 3 are fixed in position during installation, avoiding the looseness or deviation problems that may occur in the traditional assembly process. The location selection of the positioning hole 105 at the inner end of the secondary output terminal 1 takes into account the specific requirements of the installation of the magnetic core 3, and can accurately connect the two to ensure that no loosening occurs during the entire operation process. The positioning post 302 is located on the inner end side wall of the annular assembly groove 301, and is specifically used to match the positioning hole 105 of the secondary output terminal 1.

[0055] In the conventional technology, the connection between the secondary output terminal 1 and the magnetic core 3 often has the risk of incomplete assembly and fixing, especially when relying on manual assembly, the magnetic core 3 may not be in complete contact with the secondary output terminal 1 due to assembly errors, affecting the electrical performance and stability of the transformer. By setting the cooperation of the positioning hole 105 and the positioning column 302, the present invention can ensure that the two can be accurately docked during the assembly process, avoiding the accumulation of errors during assembly, and greatly improving the manufacturing consistency and stability of the transformer. The cooperation of the positioning hole 105 and the positioning column 302 makes the displacement during the assembly process almost zero, ensuring that the secondary output terminal 1 and the magnetic core 3 are always in the correct position during the entire use process, and preventing any electrical performance fluctuations or structural instability caused by improper position. The cooperation structure of the positioning hole 105 and the positioning column 302 enables the automated assembly equipment to complete the assembly of the transformer in an efficient and accurate mode. Through the automated assembly equipment, the positioning column 302 and the positioning hole 105 can be efficiently docked, further reducing the time cost and human errors in the production process.

[0056] In the actual production process, it can effectively reduce the inconsistency caused by manual assembly and improve the quality consistency of products. Precise assembly enables each component of the transformer to work stably in a fixed position, avoiding relative movement between components, thereby improving the mechanical stability of the transformer and the reliability in long-term operation.

[0057] In any of the above embodiments, at least two through openings 303 are further provided on the magnetic core 3 along the circumference of the secondary output terminal 1, and each through opening 303 is connected to the annular assembly groove 301 in a direction perpendicular to the axis to form a heat dissipation channel passing through the rigid power transmission structure 101 and the primary input terminal 2, so as to continuously remove the heat generated by the rigid power transmission structure 101 and the primary input terminal 2 during operation.

[0058] In this embodiment, each through-hole 303 is connected to the annular assembly groove 301 in a direction perpendicular to the axis. The annular assembly groove 301 itself is a key structure for fixing the secondary output terminal 1. By combining the through-hole 303 with the annular assembly groove 301, a heat dissipation channel running through the magnetic core 3 is formed. This channel runs through the key components of the transformer, ensuring that heat can be quickly conducted from the rigid power transmission structure 101 and the primary input terminal 2, thereby maintaining the temperature stability of the transformer during operation. By evenly opening the through-holes 303 along the circumference, it can be ensured that heat is evenly dissipated from various components of the transformer, avoiding local overheating problems caused by excessive heat concentration. Uniform heat distribution helps to improve the overall thermal management efficiency of the transformer and extend its service life.

[0059] When the transformer is working, when the current passes through the rigid power transmission structure 101 (such as a copper sheet), a certain amount of heat will be generated due to the flow of current and the effect of resistance. Since the rigid power transmission structure 101 is closely connected to other components, the heat must be dissipated through an effective heat dissipation method to avoid damage to the structure due to excessive temperature or affect the electrical performance. The primary input terminal 2, especially its multi-layer coil structure, will also generate heat due to the passage of current during operation. This heat must be taken away in time through the heat dissipation channel to prevent the temperature of the primary input terminal 2 from being too high, thereby affecting the stability and performance of the entire transformer. Through the through-hole 303, the heat generated by the rigid power transmission structure 101 and the primary input terminal 2 can be quickly dissipated through the heat dissipation channel, thereby avoiding heat accumulation inside the transformer and ensuring that the transformer can maintain a good operating temperature during long-term use.

[0060] The through opening 303 makes the heat inside the transformer no longer concentrated in a certain position, but can quickly diffuse to the entire heat dissipation channel, reducing the local overheating caused by heat accumulation. Since the heat dissipation channel effectively takes away the heat generated by the rigid transmission structure 101 and the primary input terminal 2, the operating temperature of the transformer can be controlled within a stable range, thereby ensuring the structural stability of each component. The thermal stress on each component of the transformer during operation is effectively alleviated, avoiding the mechanical stress caused by temperature difference changes, and reducing the deformation or damage of components caused by thermal expansion. Small temperature fluctuations help to improve the overall reliability and stability of the transformer and avoid unstable performance due to excessive temperature or excessive fluctuations.

[0061] In any of the above embodiments, a positioning groove 1011 is provided on the inner side wall of the rigid power transmission structure 101, and the injection molding material fills the positioning groove 1011 during injection molding. The positioning groove 1011 can be used to pre-fix detection and calibration of all rigid power transmission structures 101, and the rigid power transmission structure 101 can be firmly fixed after injection molding.

[0062] All the positioning grooves 1011 are correspondingly arranged along the extension direction of the axis to ensure that all the rigid power transmission structures 101 can be calibrated together along the extension direction of the axis.

[0063] In this embodiment, before injection molding, all rigid power transmission structures 101 have been firmly fixed in the mold. This step ensures that the rigid power transmission structure 101 will not move or deviate from the predetermined position during the injection molding process. The pre-fixing process is completed by the mold and the auxiliary fixing device, thereby ensuring the accurate positioning of each rigid power transmission structure 101. After the rigid power transmission structure 101 is fixed in the mold, during the injection molding process, the injection material will fill the positioning groove 1011, further ensuring the precise fixation and alignment of all rigid power transmission structures 101.

[0064] The positioning groove 1011 not only ensures the stability of the position of each rigid power transmission structure 101, but also plays a key role in avoiding structural problems caused by thermal expansion, mechanical impact or displacement during long-term operation. The positioning groove 1011 allows the rigid power transmission structure 101 to be fixed in the initial position after injection molding, avoiding deviations during the assembly process. Since the rigid power transmission structure 101 has been fixed in the positioning groove 1011 by the injection molding material, they can maintain a stable position during the subsequent thermal expansion process, preventing structural displacement or deformation caused by thermal expansion, thereby improving the consistency and stability of the product.

[0065] The arrangement of the positioning grooves 1011 ensures that all rigid power transmission structures 101 can be precisely aligned along the axis direction, thereby maintaining the high consistency and stability of the entire structure during the injection molding process. All positioning grooves 1011 are evenly distributed along the axis direction, ensuring that each rigid power transmission structure 101 can be precisely calibrated along the axis direction during the injection molding process.

[0066] The traditional assembly process requires multiple steps and manual intervention, but by pre-fixing the rigid power transmission structure 101 in the mold and completing the fixation in one step through injection molding, the complicated assembly process is avoided. This not only improves the production speed, but also greatly reduces the time and cost of manual operation. In this way, the electrical and mechanical properties of the transformer can be highly consistent in mass production, avoiding the quality fluctuations that may occur in the traditional assembly process.

[0067] In any of the above embodiments, the outer side wall of the rigid power transmission structure 101 is formed with a heat dissipation fin 1012, and the heat dissipation fin 1012 is located inside the through opening 303. The heat dissipation fin 1012 helps to pre-dissipate heat in the through opening 303, and can prioritize the thermal stability of the secondary output in a high-power transformer.

[0068] In a direction perpendicular to the axis, the heat dissipation fins 1012 correspond to the positioning grooves 1011 to ensure the structural uniformity of the rigid power transmission structure 101 relative to the alternating magnetic field in the circumferential direction.

[0069] In this embodiment, the heat dissipation fins 1012 can effectively improve the heat exchange efficiency by increasing the surface area and enhancing air circulation. They are arranged on the outer side wall of the rigid power transmission structure 101 and are located inside the through-hole 303. This position can maximize the use of the space between the magnetic core 3 and other components for heat dissipation. During operation, the heat generated inside the transformer is quickly transferred to the outside air through the heat dissipation fins 1012, thereby reducing the internal temperature of the transformer and avoiding overheating. Through the heat dissipation fins 1012, the heat can be preferentially dissipated in the through-hole 303 area, thereby effectively alleviating the problem of heat accumulation under high power load. The heat dissipation fins 1012 not only help to improve the thermal stability of the transformer, but also enable the transformer to operate stably for a long time under high load conditions, and it is not easy for the overheating protection mechanism to be activated.

[0070] In a high-power transformer, as the load increases, the secondary output terminal 1 will bear higher power and current, thereby generating greater heat. The heat sink 1012 can effectively help to quickly remove this heat, preventing the secondary output terminal 1 from being overheated and affecting the overall working performance of the transformer. The heat sink 1012 not only increases the surface area of ​​heat exchange, but also promotes air convection, thereby improving the efficiency of heat dissipation. Through the heat sink 1012, the transformer can continuously remove heat, avoiding electrical failures or performance degradation caused by excessive temperature, thereby greatly improving the service life of the transformer.

[0071] The heat dissipation fins 1012 are closely matched with the through-holes 303. The through-holes 303 form a heat dissipation channel with the structure of the heat dissipation fins 1012 in a direction perpendicular to the axis. The heat dissipation fins 1012 are located inside the through-holes 303, ensuring that the heat dissipation efficiency can be maximized in the process of heat dissipation through the through-holes 303. Under high-power working conditions, the through-holes 303 not only serve as a channel for heat conduction, but also can accommodate air flow, using the effect of air flow to help quickly take away the heat from the secondary output terminal 1. In the area of ​​the secondary output terminal 1, the heat dissipation fins 1012 effectively prevent heat accumulation and avoid damage or performance degradation caused by high temperature.

[0072] The arrangement of the heat dissipation fins 1012 ensures that the heat dissipation fins 1012 can be evenly distributed on the outside of the rigid power transmission structure 101 along the circumferential direction. This structural uniformity not only improves the efficiency of heat conduction, but also ensures that the transformer can maintain good structural stability under the influence of the alternating magnetic field during operation. Due to the uniform arrangement of the heat dissipation fins 1012, it is possible to ensure that the electromagnetic performance of the rigid power transmission structure 101 under the action of the alternating magnetic field remains consistent, avoiding uneven current distribution due to structural unevenness, thereby improving the working efficiency and stability of the transformer.

[0073] In any of the above embodiments, the outer side wall of the annular assembly groove 301 is matched with the arc outer end 104 of the secondary output terminal 1 .

[0074] In this embodiment, the outer end side wall of the annular assembly groove 301 is adapted to the arc outer end 104 of the secondary output terminal 1, ensuring a tight connection between the two. This precise adaptation relationship helps to effectively fix the secondary output terminal 1 during the assembly process, avoiding the looseness or instability caused by assembly tolerances in the prior art. The precise fit between the annular assembly groove 301 and the arc outer end 104 of the secondary output terminal 1 can not only ensure the stable fixation of the component, but also effectively reduce the assembly error in production, ensuring that the working performance of the transformer can meet the design requirements. This fit avoids the problems of uneven electromagnetic field or unstable power transmission caused by assembly errors, and further improves the electromagnetic compatibility and thermal stability of the transformer.

[0075] The outer side wall of the annular assembly groove 301 is matched with the arc outer end 104 of the secondary output terminal 1, thereby ensuring the stability of the secondary output terminal 1 in the overall structure of the transformer. The adaptation structure realizes the dual functions of fixing and supporting through precise matching, so that the secondary output terminal 1 can always maintain a stable position and structure when cooperating with other components, avoiding the misalignment of components that may be caused by thermal expansion and contraction or external forces. In the prior art, due to the large number of assembly links, especially for transformers that need to be assembled multiple times, certain assembly tolerances usually occur, and these errors may cause the instability of the transformer performance. Through the precise adaptation of the annular assembly groove 301 and the arc outer end 104 of the secondary output terminal 1, the present invention significantly reduces the performance fluctuations caused by assembly errors.

[0076] In any of the above embodiments, two magnetic cores 3 are provided, and after the two magnetic cores 3 are butt-jointed, they form an annular cavity for accommodating the secondary output terminal 1 through the annular assembly groove 301 .

[0077] In this embodiment, in the high-power transformer, the main function of the magnetic core 3 is to provide a closed magnetic circuit so as to effectively couple the alternating magnetic field generated by the primary input terminal 2 to the secondary output terminal 1. This process depends on the material and structure of the magnetic core 3. The magnetic core 3 must have sufficient magnetic permeability to withstand strong electromagnetic interference and effectively guide the magnetic field during operation. The docking of the two magnetic cores 3 not only enhances the closedness of the overall magnetic circuit, but also allows the size and shape of the magnetic core 3 to be flexibly adjusted according to the power requirements of the transformer, thereby improving the transmission efficiency of the magnetic field. By precisely docking the two magnetic cores 3, the present invention ensures the stability of the structure of the magnetic core 3 while ensuring the magnetic field coupling efficiency. The annular cavity formed by the docking of the two magnetic cores 3 not only provides a storage space for the secondary output terminal 1, but also optimizes the overall load distribution of the magnetic core 3, so that the magnetic core 3 can evenly distribute the heat caused by the current, thereby avoiding the problem of local overheating. In addition, the docking of the two magnetic cores 3 also ensures the symmetry of the overall structure of the transformer, making the distribution of the magnetic field more uniform and improving the electromagnetic efficiency of the transformer. Due to the precise matching of the butt joint, the magnetic field coupling between the magnetic core 3 and the secondary output terminal 1 is tighter, thereby improving the output performance and stability of the transformer.

[0078] In any of the above embodiments, the injection molding material covers part of the circumferential surface of the rigid power transmission structure 101 during injection molding, and the thickness of the rigid power transmission structure 101 gradually increases near the axis, so that the injection molding material can embrace part of the structure of the rigid power transmission structure 101 after cooling.

[0079] In this embodiment, the injection molding material only covers a portion of the circumferential surface of the rigid power transmission structure 101, which means that only a portion of the outer area is covered, while the inner side or core portion remains exposed. The injection molding material of the covered portion not only plays the role of electrical insulation to prevent current leakage, but also improves the mechanical strength of the overall structure by strengthening the mechanical fixation of the outer surface. Especially in a high-load working environment, the injection molding material can effectively enhance the stability of the transformer and avoid structural loosening caused by external impact or vibration.

[0080] The injection molding material will shrink due to the decrease in temperature during the cooling process, thereby exerting a tight wrapping force on the rigid power transmission structure 101. Since the injection molding material only covers the outer portion of the rigid power transmission structure 101 and does not completely wrap the entire structure, the core portion of the rigid power transmission structure 101 can still remain relatively independent during the cooling process, which is conducive to the dissipation of heat and avoids local overheating that may be caused by complete wrapping. Through this cooling and shrinking effect, the injection molding material can ensure that the rigid power transmission structure 101 is firmly fixed, while avoiding multiple assembly and assembly errors in traditional assembly processes, providing higher product consistency and stability.

[0081] In any of the above embodiments, the primary input end 2 is wrapped with an insulating layer to isolate the adjacent rigid power transmission structure 101 .

[0082] In this embodiment, the primary function of the insulating layer wrapped around the primary input terminal 2 is to provide electrical isolation to ensure that there is no electrical contact between the primary input terminal 2 and surrounding components, especially the adjacent rigid transmission structure 101. This layer of insulating material effectively blocks electrical interference and faults that may be caused by current leakage or short circuit, thereby improving the safety and reliability of the transformer. Especially in high-power and high-voltage working environments, the insulating layer provides the necessary electrical protection to prevent current crossing or electrical short circuit between the high-voltage and low-voltage parts. The insulating layer can also suppress electromagnetic interference (EMI).

[0083] In the description of the present invention, it should be understood that the terms "longitudinal", "lateral", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside" and "outside" etc., indicating orientations or positional relationships, are based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention, 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 should not be understood as a limitation on the present invention.

[0084] The embodiments described above are only descriptions of the preferred modes of the present invention, and are not intended to limit the scope of the present invention. Without departing from the design spirit of the present invention, various modifications and improvements made to the technical solutions of the present invention by ordinary technicians in this field should all fall within the protection scope determined by the claims of the present invention.

Claims

1. A high-power integrated structure automation transformer, characterized in that: include: Secondary output terminal; The secondary output end includes a plurality of rigid power transmission structures, each of which extends circumferentially around an axis, and all of the rigid power transmission structures are sequentially connected along the extension direction of the axis; each of the rigid power transmission structures is a rigid circumferential arc structure, which is used to generate current in an alternating magnetic field and output it to the outside, and the inner surface of the rigid power transmission structure is connected and fixed along the extension direction of the axis by injection molding; A primary input terminal, at least one of which is provided; the primary input terminal is used to generate the alternating magnetic field through the input current; an assembly cavity is formed between adjacent rigid power transmission structures, and the primary input terminal is surrounded in the assembly cavity; A magnetic core is used to couple the alternating magnetic field to the secondary output end; an annular assembly groove is formed on the magnetic core, and the annular assembly groove is plugged into the end of the secondary output end to fix the magnetic core on the secondary output end.

2. The high-power integrated structure automation transformer according to claim 1 is characterized in that: The secondary output end is a tubular structure; The arc inner end of the secondary output end is integrally formed by injection molding of injection molding material; The arc outer end of the secondary output end is formed by assembling the outer end side walls of all the rigid power transmission structures.

3. The high-power integrated structure automation transformer according to claim 2 is characterized in that: A positioning hole is formed at the inner end of the arc of the secondary output end, and a positioning column is formed on the inner end side wall of the annular assembly groove, and the positioning column is matched with the positioning hole.

4. The high-power integrated structure automation transformer according to claim 3 is characterized in that: At least two through openings are also formed on the magnetic core along the circumference of the secondary output end, and each of the through openings is connected to the annular assembly groove in a direction perpendicular to the axis to form a heat dissipation channel passing through the rigid power transmission structure and the primary input end.

5. The high-power integrated structure automation transformer according to claim 4 is characterized in that: The inner end side wall of the rigid power transmission structure is provided with a positioning groove, and the injection molding material fills the positioning groove during injection molding; All the positioning grooves are correspondingly arranged along the extending direction of the axis.

6. The high-power integrated structure automation transformer according to claim 5, characterized in that: The outer end side wall of the rigid power transmission structure is formed with heat dissipation fins, and the heat dissipation fins are located inside the through opening; Along a direction perpendicular to the axis, the heat dissipation fins correspond to the positioning grooves.

7. The high-power integrated structure automation transformer according to claim 2 is characterized in that: The outer end side wall of the annular assembly groove is matched with the arc outer end of the secondary output end.

8. The high-power integrated structure automation transformer according to claim 7, characterized in that: Two magnetic cores are provided, and after the two magnetic cores are butted together, they form an annular cavity for accommodating the secondary output end through the annular assembly groove.

9. The high-power integrated structure automation transformer according to claim 2, characterized in that: The injection molding material covers a portion of the circumferential surface of the rigid power transmission structure during injection molding.

10. The high-power integrated structure automation transformer according to claim 1, characterized in that: The primary input end is wrapped with an insulating layer to isolate the adjacent rigid power transmission structure.

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