Vacuum induction heating power supply high-efficiency multi-lamination core intermediate frequency transformer

Abstract

The present application relates to the technical field of transformer, in particular to a high-efficiency multi-lamination core medium-frequency transformer of vacuum induction heating power supply, the full-pitch iron sheet adopts 45° chamfer form, the full-pitch iron sheet is mutually superposed to form an iron core, the water cooling group penetrates the iron core, when cooling water flows in from one end of the water cooling group and flows out from the other end, heat exchange occurs with the iron core, the conductor transposition group includes a first conductor and a second conductor, the first conductor and the second conductor are transposed in the middle part; the 45° full-pitch iron core reduces the local loss of the transition of the iron core, reduces the overall loss of the iron core by about 50%, the iron core reduces the magnetic density in the transition area, reduces the local temperature rise of the iron core, improves the safety and stability of the equipment operation, through the multi-stage lamination structure design, the effective iron core cross-sectional area is increased by more than 35%, and then the no-load loss is reduced by about 25%, the water cooling group is separated from the water and electricity, and the safety hidden danger caused by the contact between the cooling water and the live conductor is avoided.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of transformers, and particularly to a high-efficiency multi-lamination core medium-frequency transformer for a vacuum induction heating power supply. BACKGROUND

[0002] A medium-frequency transformer is a key component in a vacuum medium-frequency induction heating power supply, and is widely used in the departments of metallurgy, national defense, and mechanical processing, and in the fields of casting, forging, and the manufacturing of ships, aircraft, and automobiles. However, with the increasing requirements for energy efficiency and device stability in the industrial field, the traditional wound core transformer gradually exposes many technical bottlenecks, such as limited wire cross-sectional area, large eddy current loss, poor cooling effect, and the like, and is difficult to meet the requirements for high efficiency and low loss energy transmission. In addition, the heat dissipation structure of the traditional transformer is complex, which increases the volume and manufacturing cost of the system, and limits its applicability in some application scenarios. At present, technologies such as water-cooled coils and lamination core are developed to improve the performance of the medium-frequency transformer. The water-cooled structure can effectively solve the heat dissipation problem of the coil and the core, and prolong the service life of the device.

[0003] However, the existing technologies still have some limitations, such as low integration of the water-cooled coil and the core cooling structure, low mechanical manufacturing efficiency, and inability to sufficiently reduce the core loss. On the other hand, due to the limitation of the wire winding space of the traditional wound core transformer, the cross-sectional area of the wire cannot be increased, the wire loss is large, and the core filling factor is low, resulting in poor overall efficiency. SUMMARY

[0004] The main purpose of the present application is to provide a high-efficiency multi-lamination core medium-frequency transformer for a vacuum induction heating power supply to solve the problems of insufficient reduction of core loss, large wire loss, and low core filling factor in the related art.

[0005] In order to achieve the above-mentioned purpose, according to one aspect of the present application, a high-efficiency multi-lamination core medium-frequency transformer for a vacuum induction heating power supply is provided, comprising a transformer, wherein a primary winding and a secondary winding are fixedly arranged on the transformer, and further comprising: full-pitch laminated sheets, which are in the form of 45° chamfer and are stacked to form a core;

[0006] a water-cooled group, which penetrates the core and exchanges heat with the core when cooling water flows in from one end of the water-cooled group and flows out from the other end;

[0007] a conductor transposition group, which comprises a first conductor and a second conductor, and the first conductor and the second conductor are transposed in the middle part.

[0008] Further, the primary winding is fixedly provided with a plurality of outgoing terminals, and the outgoing terminals are connected with an external power supply to transmit the electric energy of the external power supply to the primary winding.

[0009] Furthermore, the secondary winding receives energy from the primary winding through the transformer's magnetic field.

[0010] Furthermore, multiple layers of coils are wound around the outside of the iron core to form a transformer.

[0011] Furthermore, the transformer employs a resin casting process to integrally cast the coil and the iron core.

[0012] Furthermore, the cross-sectional area of ​​the transition region of the iron core increases from 1 times that of the right angle to 1.414 times, according to the magnetic density calculation formula.

[0013] ;

[0014] Where B is the magnetic flux density, Φ is the magnetic flux, and A is the cross-sectional area. Due to the increase in the cross-sectional area of ​​the transition region, the magnetic flux density decreases to 0.707 of its original value, that is, the magnetic flux density decreases from... Reduced to 0.707 Since the loss is proportional to the square of the magnetic flux density, the core loss is reduced to:

[0015] ;

[0016] Losses were reduced by 50%.

[0017] Furthermore, the water-cooling assembly includes a water-cooling pipe and an insulating pipe, the insulating pipe passing through the iron core and the coil.

[0018] Furthermore, the water-cooling pipe is radially disposed inside the insulating pipe, and the insulating pipe isolates the water-cooling pipe from the iron core and the coil.

[0019] Furthermore, the water-cooling pipe has an inlet at one end and an outlet at the other end. Cooling water flows out of the water-cooling pipe from the inlet and then out through the outlet. The water-cooling pipe is located inside the insulating pipe and passes through the iron core and coil radially.

[0020] Furthermore, the conductor transposition group adopts a design of transposing the first and second conductors, with the cross-sectional area of ​​the two conductors being half of the original. This causes the potentials of the first and second conductors to cancel each other out. The circulating current loss and eddy current loss are proportional to the cross-sectional area of ​​the conductors, and the potential difference leads to a current concentration effect inside the conductors. In a traditional single copper tube conductor, eddy current loss... It is proportional to the conductor thickness d, that is:

[0021] ;

[0022] The cross-sectional area of ​​the two conductors is 50% of the original, meaning the conductor thickness is reduced from d to... The eddy current loss of each conductor becomes:

[0023] ;

[0024] Therefore, after splitting into two conductors, the eddy current loss of each conductor is only 1 / 4 of the original. In the two-conductor structure, although the eddy current loss of each conductor is reduced by 75% (i.e., only 1 / 4 of the original), since there are two conductors, the total eddy current loss is the sum of the losses of the two conductors:

[0025] ;

[0026] In the dual-conductor structure, the eddy current loss is half that of the single-conductor structure, which means the eddy current loss is reduced by 50%.

[0027] Compared with the prior art, the present invention has the following beneficial effects:

[0028] I. The high-efficiency multi-layer iron core intermediate frequency transformer of the vacuum induction heating power supply of the present invention optimizes the magnetic flux density and reduces the loss. The 45° full-core iron core increases the cross-sectional area of ​​the transition region, which reduces the magnetic flux density by 30%, reduces the local loss at the iron core transition, and reduces the overall loss of the iron core by about 50%.

[0029] II. The local temperature rise of the high-efficiency multi-layer iron core intermediate frequency transformer of the vacuum induction heating power supply of the present invention is reduced: the magnetic flux density of the iron core is reduced in the transition region, and the local magnetic loss is reduced, thus effectively reducing the local temperature rise of the iron core. Compared with the traditional design, the local temperature rise is reduced by about 5°C, thereby improving the safety and stability of equipment operation.

[0030] III. Improved space utilization of the high-efficiency multi-layer iron core intermediate frequency transformer of the vacuum induction heating power supply of the present invention: Through the multi-stage lamination structure design, the present invention achieves a space utilization rate of more than 95% in the same volume, increases the effective iron core cross-sectional area by more than 35%, and reduces no-load loss by about 25%;

[0031] IV. Optimization of the heat dissipation system of the high-efficiency multi-layer iron core intermediate frequency transformer of the vacuum induction heating power supply of the present invention: the water-cooling group with water and electricity separation avoids the safety hazards caused by the contact between cooling water and live conductors in traditional transformers, and the cooling effect is more efficient, which can dissipate heat for both coils and iron core at the same time, further optimizing the thermal management of the equipment.

[0032] V. The high-efficiency multi-layer iron core intermediate frequency transformer of the vacuum induction heating power supply of the present invention reduces eddy current losses: by transposing the two conductors, the induced electromotive force in the conductor is effectively offset, reducing circulating current and eddy current losses. Compared with the traditional single copper tube conductor, the double conductor structure reduces eddy current losses by 50%.

[0033] VI. Mechanical strength and simplification of the high-efficiency multi-layer iron core intermediate frequency transformer of the vacuum induction heating power supply of the present invention: The coil and iron core are fixed in one piece by resin casting process, which greatly improves the mechanical strength of the equipment, ensures that the equipment remains stable when working under high load, shortens the production cycle, and improves the durability of the equipment. Attached Figure Description

[0034] Figure 1 This is a schematic diagram of the overall high-efficiency multi-layer iron core intermediate frequency transformer of the vacuum induction heating power supply of the present invention.

[0035] Figure 2 This is a top view of the full-size iron sheet of the high-efficiency multi-layer iron core intermediate frequency transformer of the vacuum induction heating power supply of the present invention.

[0036] Figure 3 This is a top view of the fully stacked iron core of the high-efficiency multi-layered iron core intermediate frequency transformer of the vacuum induction heating power supply of the present invention.

[0037] Figure 4 This is a schematic diagram of the water-cooling section of the high-efficiency multi-layer iron core intermediate frequency transformer of the vacuum induction heating power supply of the present invention.

[0038] Figure 5 This is a schematic diagram of the double conductor structure of the high-efficiency multi-layer iron core intermediate frequency transformer of the vacuum induction heating power supply of the present invention.

[0039] Illustration:

[0040] 1. Primary winding; 2. Secondary winding; 3. Transformer; 4. All-copper sheet; 5. Water-cooled pipe; 6. First conductor; 7. Second conductor; 8. Insulating pipe. Detailed Implementation

[0041] To further illustrate the technical means and effects of the present invention in achieving its intended purpose, the following detailed description of the specific implementation methods, structures, features, and effects of the present invention, in conjunction with the accompanying drawings and preferred embodiments, is provided below.

[0042] Please see Figures 1 to 5 This embodiment provides a high-efficiency multi-layer iron core intermediate frequency transformer for vacuum induction heating power supply, including a transformer 3. A primary winding 1 and a secondary winding 2 are fixedly mounted on the transformer 3. It also includes: all-copper iron sheets 4, which are chamfered at 45°. The all-copper iron sheets 4 are stacked to form the iron core. This design reduces the magnetic flux density of the iron core in the transition region by 30% compared to the magnetic flux density of the iron core column, resulting in a 5°C reduction in the local temperature rise of the iron core, thereby reducing local heat accumulation. Through heat conduction theory, reducing losses directly lowers the local temperature rise. This improvement effectively avoids equipment performance degradation due to local overheating, improving equipment reliability and service life.

[0043] The water cooling unit runs through the iron core. When cooling water flows in from one end of the water cooling unit and flows out from the other end, it exchanges heat with the iron core.

[0044] The conductor transposition group includes a first conductor 6 and a second conductor 7, which are transposed in the middle.

[0045] The primary winding 1 is fixedly provided with multiple lead-out terminals, which are connected to an external power source to transfer electrical energy from the external power source to the primary winding 1.

[0046] Secondary winding 2 receives energy from primary winding 1 through the magnetic field of transformer 3.

[0047] The iron core is wound with multiple layers of coils to form transformer 3.

[0048] Transformer 3 adopts a resin casting process to integrally cast the coil and the iron core, which simplifies the assembly process of the coil and the iron core. After the coil and the iron core are assembled, they are arranged according to the position of the outgoing line. The iron core and the coil are integrally cast with resin, and the terminal block and water nozzle extend out of the casting body. This process not only improves the cooling efficiency, but also enhances the mechanical strength and structural compactness.

[0049] The iron core, made of a full-diameter iron sheet with a 45° chamfer, has a transition region cross-sectional area that increases from 1 times that of the right-angled version to 1.414 times. According to the magnetic density calculation formula:

[0050] ;

[0051] B is the magnetic flux density, Φ is the magnetic flux, and A is the cross-sectional area. Due to the increase in the cross-sectional area of ​​the transition region, the magnetic flux density decreases to 0.707 of its original value, that is, the magnetic flux density decreases from... Reduced to 0.707 Since the loss is proportional to the square of the magnetic flux density, the core loss is reduced to:

[0052] ;

[0053] Losses are reduced by 50%. Traditional wound core structures have a 25% space waste due to the different winding lengths of the inner and outer coils, resulting in low utilization of the outer coil. This invention, through a multi-stage laminated structure, ensures consistent inner and outer lengths, increasing space utilization to 95% and thus increasing the effective core cross-section by over 35%. This directly impacts the reduction of no-load losses. Compared to traditional no-load losses, the increase in effective area can reduce no-load losses by approximately 25%. Furthermore, the reduced magnetic flux density in the transition region directly reduces local magnetic losses.

[0054] The water-cooling assembly includes a water-cooling tube 5 and an insulating tube 8, with the insulating tube 8 passing through the iron core and the coil.

[0055] The water-cooling pipe 5 is arranged radially inside the insulating pipe 8, and the insulating pipe 8 isolates the water-cooling pipe 5 from the iron core and the coil.

[0056] The water-cooled pipe 5 has an inlet at one end and an outlet at the other. Cooling water flows out of the inlet and then out of the outlet. The water-cooled pipe 5 is located inside the insulating pipe 8 and radially penetrates the iron core and coil. The insulating pipe 8 isolates the water-cooled pipe 5 from the iron core and coil, thus achieving a water-electricity separation design and ensuring that no electrical safety hazards are generated when the cooling water comes into contact with the iron core and coil. The water-cooled pipe 5 is radially positioned between the iron core and coil through the insulating pipe 8, ensuring that the cooling water can effectively exchange heat with the iron core while preventing direct contact between the cooling water and live parts, thereby improving the safety and heat dissipation performance of the equipment.

[0057] The water-cooled pipe 5 is housed within the insulating pipe 8 and positioned inside the iron core and coil. The insulating pipe 8 isolates the water-cooled pipe 5 from the coil, ensuring the cooling water is not energized. This achieves complete separation of the cooling water from the electrical components of the coil. The cooling water carries away the heat generated by the coil's operation through the water-cooled pipe 5. Due to the water-electricity separation design, the cooling water is not energized, ensuring the system's safety and reliability while improving heat dissipation efficiency. The cooling water system can effectively dissipate heat from both the coil and the iron core simultaneously, avoiding localized overheating caused by concentrated heat. Because the heat dissipation structure of the coil and iron core is integrated, the system does not require a separate cooling device, simplifying the structural design. This water-cooling structure not only improves the equipment's cooling performance but also reduces the overall temperature rise, with localized temperature rise reduced by approximately 5°C.

[0058] The conductor transposition group employs a design that transposes the first conductor 6 and the second conductor 7, with the cross-sectional area of ​​the two conductors being half of the original. This allows the potentials of the first conductor 6 and the second conductor 7 to cancel each other out, reducing circulating current and thus lowering eddy current losses. Circulating current losses and eddy current losses are directly proportional to the cross-sectional area of ​​the conductors, and the potential difference leads to a current concentration effect inside the conductor. In traditional single-tube copper conductors, eddy current losses... It is proportional to the conductor thickness d, that is:

[0059] ;

[0060] Because this invention uses two conductors with a cross-sectional area of ​​50% of the original, the conductor thickness is reduced from d to... The eddy current loss of each conductor becomes:

[0061] ;

[0062] Therefore, after splitting into two conductors, the eddy current loss of each conductor is only 1 / 4 of the original. In the two-conductor structure, although the eddy current loss of each conductor is reduced by 75%, that is, only 1 / 4 of the original, since there are two conductors, the total eddy current loss is the sum of the losses of the two conductors:

[0063] ;

[0064] In the double conductor structure, the eddy current loss is half that of the single conductor, that is, the eddy current loss is reduced by 50%. Through the transposition structure, the potential in the conductor is canceled out, and the circulating current is almost zero, which further reduces the circulating current loss from 35%.

[0065] The two conductors are connected in parallel and transposed in the middle. The cross-sectional area of ​​each conductor is half that of the original single conductor, which means that the thickness of each conductor is reduced from d to d / 2. Through this arrangement, the induced electromotive forces between the conductors can cancel each other out, thereby reducing the circulating current and eddy current losses within the conductors;

[0066] The two conductors are arranged along the iron core and are associated with the magnetic field of the iron core. Since the magnetic flux distribution of the iron core is optimized in the transition region of the iron core (the magnetic flux density is reduced by the 45° sag connection design), the potential difference between the two conductors is further reduced, forming a more stable current conduction path. Eddy current loss is proportional to the conductor thickness. This arrangement reduces the current concentration effect.

[0067] Multiple 45° angled full-diameter iron sheets are stacked in four layers to form an iron core. The cross-sectional area of ​​the transition region of this iron core increases from 1 times that of the original right-angle iron core to 1.414 times, reducing iron core losses. At the same time, the inner and outer lengths of this iron core are consistent, increasing the space utilization rate to 95%, thereby increasing the effective iron core cross-section by more than 35% and reducing no-load losses. The primary winding 1 is connected to an external power source through multiple leads to receive externally supplied electrical energy. Through the magnetic field of transformer 3, the energy is transferred to the secondary winding 2, which then absorbs the energy transferred from the primary winding 1. The power is output to the external load in the form of appropriate voltage or current. Cooling water is added to the inlet of the water-cooling pipe 5. The cooling water flows forward along the water-cooling pipe 5 and comes into contact with the iron core and the coil respectively. It exchanges heat with the iron core and the coil, taking away the heat from the contact surface. After the heat exchange, the temperature of the cooling water increases and then flows out from the outlet of the water-cooling pipe 5. The cooling water continuously enters from the inlet of the water-cooling pipe 5 and flows out from the outlet, continuously dissipating heat for the iron core and the coil. During the power transmission process, the iron core and the coil are always kept at a low temperature, which extends the service life of the iron core and the coil.

[0068] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Although the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art can make some modifications or alterations to the above-disclosed technical content to create equivalent embodiments without departing from the scope of the present invention. Any simple modifications, equivalent changes and alterations made to the above embodiments based on the technical essence of the present invention without departing from the scope of the present invention shall still fall within the scope of the present invention.

Claims

1. A high-efficiency multi-layer iron core intermediate frequency transformer for vacuum induction heating power supply, comprising a transformer (3), characterized in that, The transformer (3) is fixedly provided with a primary winding (1) and a secondary winding (2), and also includes: All-copper iron sheet (4), wherein the all-copper iron sheet (4) adopts a 45° chamfered form, and the all-copper iron sheets (4) are stacked on each other to form an iron core; The water cooling unit penetrates the iron core. When cooling water flows in from one end of the water cooling unit and flows out from the other end, it exchanges heat with the iron core. A conductor transposition group, comprising a first conductor (6) and a second conductor (7), wherein the first conductor (6) and the second conductor (7) are transposed at the middle. The water-cooling assembly includes a water-cooling pipe (5) and an insulating pipe (8), wherein the insulating pipe (8) passes through the iron core and the coil; The water-cooling pipe (5) is radially disposed inside the insulating pipe (8), and the insulating pipe (8) isolates the water-cooling pipe (5) from the iron core and the coil; The conductor transposition group adopts a design of transposing the first conductor (6) and the second conductor (7), and the cross-sectional area of ​​the two conductors is half of the original, so that the potentials of the first conductor (6) and the second conductor (7) cancel each other out. The circulating current loss and eddy current loss are proportional to the cross-sectional area of ​​the conductor, and the potential difference will lead to the current concentration effect inside the conductor. In the traditional single copper tube conductor, the eddy current loss is... It is proportional to the conductor thickness d, that is: ； The cross-sectional area of ​​the two conductors is 50% of the original, meaning the conductor thickness is reduced from d to... The eddy current loss of each conductor becomes: ； Therefore, after splitting into two conductors, the eddy current loss of each conductor is only 1 / 4 of the original. In the two-conductor structure, the eddy current loss of each conductor is reduced by 75%, reaching 1 / 4 of the original. The total eddy current loss of the two conductors is the sum of the losses of the two conductors: ； In the dual-conductor structure, the eddy current loss is half that of the single-conductor structure, which means the eddy current loss is reduced by 50%.

2. The high-efficiency multi-layer iron core intermediate frequency transformer for vacuum induction heating power supply according to claim 1, characterized in that, The primary winding (1) is fixedly provided with multiple lead-out terminals, which are connected to an external power source to transfer electrical energy from the external power source to the primary winding (1).

3. The high-efficiency multi-layer iron core intermediate frequency transformer for vacuum induction heating power supply according to claim 2, characterized in that, The secondary winding (2) receives energy from the primary winding (1) through the magnetic field of the transformer (3).

4. The high-efficiency multi-layer iron core intermediate frequency transformer for vacuum induction heating power supply according to claim 1, characterized in that, The iron core is wound with multiple layers of coils to form a transformer (3).

5. The high-efficiency multi-layer iron core intermediate frequency transformer for vacuum induction heating power supply according to claim 4, characterized in that, The transformer (3) is formed by resin casting process, in which the coil and the iron core are cast as a whole.

6. The high-efficiency multi-layer iron core intermediate frequency transformer for vacuum induction heating power supply according to claim 1, characterized in that, The cross-sectional area of ​​the transition region of the iron core increases from 1 times that of the right angle to 1.414 times, according to the magnetic density calculation formula: ； Where B is the magnetic flux density, Φ is the magnetic flux, and A is the cross-sectional area. Due to the increase in the cross-sectional area of ​​the transition region, the magnetic flux density decreases to 0.707 of its original value. Reduced to 0.707 Since the loss is proportional to the square of the magnetic flux density, the core loss is reduced to: ； That is, the loss was reduced by 50%.

7. The high-efficiency multi-layer iron core intermediate frequency transformer for vacuum induction heating power supply according to claim 1, characterized in that, The water-cooled pipe (5) has an inlet at one end and an outlet at the other end. Cooling water flows out of the water-cooled pipe (5) from the inlet and then out through the outlet. The water-cooled pipe (5) is located inside the insulating pipe (8) and passes through the iron core and coil radially.

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