Reactor and transformer magnetic integrated transformer

Abstract

The invention discloses a reactor and transformer magnetic integrated transformer, which relates to the technical field of transformers and comprises a frame body, a magnetic core and a winding cluster. The magnetic core is spliced into a square shape by iron-silicon blocks pressed by iron-silicon powder, a first rib frame is arranged on one side of the magnetic core, and a second rib frame is arranged on the other side of the magnetic core. The reactor winding is wound outside the first rib frame, the transformer winding is wound outside the second rib frame, and gaps are reserved between adjacent end faces. The frame body comprises a base, an upper cover plate, a lower retainer and an upper retainer which are connected and fixed through split bolts, so that the structural stability is enhanced; the transformer is made of an iron-silicon material, can work in a frequency range of 50-10KHZ, and realizes low loss and high efficiency. The transformer and the reactor are integrated, and the transformer has multiple functions of voltage transformation, filtering, energy storage, current limiting and the like. The input pins are respectively connected with different power supply systems, stable current can be provided for the load, various load requirements are met, and the circuit has a wide application prospect in the field of power electronics.

Description

Technical Field

[0001] The present invention relates to the technical field of transformers, and specifically to an integrated transformer of a reactor and a transformer magnetically. Background Art

[0002] Transformers and reactors, as key electrical equipment, play a crucial role in power transmission, transformation, filtering and other links. However, existing transformer and reactor products have many limitations in design and application, and it is difficult to meet the growing power demand and the development trend of high frequency, high efficiency and miniaturization.

[0003] At present, common transformer products on the market are mostly made of silicon steel sheets, and transformers and reactors are usually of a split structure. Although this split-structure design can meet the basic electrical function requirements to a certain extent, it brings many drawbacks, such as: 1. Transformers and reactors with a split structure need to be installed and arranged separately, resulting in a large floor area for the entire electrical system. In some application scenarios with high space requirements, such as aerospace and electric vehicle fields, the excessive floor area will seriously limit the integration and compactness of the equipment, increase the volume and weight of the system, and is not conducive to the miniaturization and lightweight development of the equipment; 2. Due to the electrical connection and energy transmission between the transformer and the reactor in the split structure, additional line losses and electromagnetic interference will be generated. At the same time, the hysteresis loss and eddy current loss of the silicon steel sheet material itself are relatively high, resulting in a reduction in the energy conversion efficiency of the entire system. In high-frequency application scenarios, this loss problem will be more prominent, causing serious heating of the equipment and affecting the reliability and service life of the equipment; 3. The operating frequency range of traditional silicon steel sheet transformers and reactors is relatively narrow, and they can generally only operate in working scenarios of 50 - 400HZ. With the continuous development of power electronics technology, high frequency has become an important development trend of electrical equipment. In high-frequency application scenarios, the magnetic properties of silicon steel sheet materials will decrease significantly, resulting in unstable inductance and increased losses of the equipment, and unable to meet the requirements of high-frequency and high-efficiency power conversion; 4. Existing transformers are mostly made of silicon steel sheet materials. Although silicon steel sheet materials have certain magnetic properties, they have obvious deficiencies in high-frequency applications. The magnetic permeability of silicon steel sheets will decrease at high frequencies, resulting in an increase in the losses of the magnetic core. At the same time, the eddy current loss of silicon steel sheets will increase sharply with the increase of frequency. In addition, the processing technology of silicon steel sheets is complex and the cost is high, which limits its application in high-frequency and high-power electrical equipment; 5. Traditional transformers and reactors are independent devices with relatively single functions. In practical applications, it is often necessary to design and install transformers and reactors separately to achieve various functions such as voltage transformation, filtering, and energy storage. This decentralized design and installation method not only increases the complexity and cost of the system, but also reduces the reliability and stability of the system. For example, in applications where voltage transformation and filtering are required simultaneously, complex electrical connections and coordinated control are needed between the split-structured transformers and reactors, which are prone to failures and interferences, affecting the overall performance of the system; 6. In some application scenarios with high requirements for energy stability and current limiting, such as power electronic converters, uninterruptible power supplies, etc., existing transformer and reactor products often fail to meet the requirements. Since the current of the inductor cannot change suddenly, when the large current is turned on and off on the primary side, there is a lack of effective current limiting measures, which is likely to cause the current to suddenly increase and damage the switching tube. At the same time, when the primary energy turn-off current suddenly decreases, it is easy to cause system instability and affect the normal operation of the load.

[0004] In summary, existing transformer and reactor products have many deficiencies in terms of structure, materials, functional integration, and performance, and are difficult to meet the requirements of modern power electronic systems for high frequency, high efficiency, miniaturization, multi-function, and stability. Therefore, it is of great practical significance and market demand to develop a new type of magnetically integrated transformer of reactor and transformer. By integrating the transformer and the reactor into one product and adopting new materials and structural designs, the problems existing in existing products can be effectively solved, the performance and reliability of the electrical system can be improved, and the further development of power electronic technology can be promoted. Summary of the Invention

[0005] Aiming at the deficiencies of the prior art, the present invention provides a magnetically integrated transformer of reactor and transformer, which solves the problems of large floor area, high loss, and inapplicability to high-frequency applications of the split structure of existing transformers and reactors.

[0006] To achieve the above objectives, the present invention is realized through the following technical solutions: A magnetically integrated transformer of reactor and transformer includes a frame body, a magnetic core, and a winding cluster. The magnetic core is fixed inside the frame body. The winding cluster includes a reactor winding and a transformer winding. The reactor winding and the transformer winding are respectively wound on both sides of the magnetic core. The magnetic core is a structure formed by splicing several iron-silicon blocks pressed from iron-silicon powder.

[0007] Further, the frame body includes a base and an upper cover plate. The base and the upper cover plate are respectively located below and above the magnetic core, and the base and the upper cover plate are connected by a plurality of tie bolts. By tightening the plurality of tie bolts, the base and the upper cover plate form a clamping binding force on the magnetic core to achieve assembly and fixation.

[0008] Furthermore, the frame body further includes a lower cage located above the base and an upper cage located below the upper cover plate. The lower cage and the upper cage are inserted into the interior of the magnetic core in an opposing manner. As the tension bolts are tightened, the lower cage and the upper cage are respectively squeezed by the base and the upper cover plate for constrained fixation.

[0009] Furthermore, after the magnetic core is spliced, it forms a "mouth" - shaped structure. One side is provided with a first rib frame, and the other side is provided with a second rib frame. The reactor winding is wound around the outside of the first rib frame, and the transformer winding is wound around the outside of the second rib frame.

[0010] Furthermore, after the reactor winding and the transformer winding are wound, a gap is reserved between adjacent end faces.

[0011] Furthermore, a first input pin and a fourth input pin are respectively provided on the upper part of the reactor winding, and a second input pin and a third input pin are respectively provided on the upper part of the transformer winding.

[0012] Furthermore, when accessing the circuit, the first input pin is connected to the high - voltage live wire of the 320V power supply system, and the second input pin is connected to the high - voltage neutral wire of the 320V power supply system.

[0013] Furthermore, when accessing the circuit, the third input pin is connected to the DC power supply system.

[0014] Furthermore, when accessing the circuit, the fourth input pin is connected to the load system through a switch module.

[0015] The present invention provides a reactor and transformer magnetically integrated transformer. Compared with the prior art, it has the following beneficial effects: 1. This reactor and transformer magnetically integrated transformer integrates the transformer and the reactor into one product, changing the traditional way of separate installation and arrangement of the split structure. This integrated design greatly reduces the occupied space of the equipment in the electrical system, especially suitable for application scenarios with strict space requirements, such as aerospace equipment, electric vehicles, etc. In a limited space, more functions can be integrated, improving the integration and compactness of the equipment, and providing strong support for the miniaturization and lightweight design of the system; 2. Replacing traditional silicon steel sheets with iron-silicon blocks pressed from iron-silicon powder is a major innovation of this product. The iron-silicon material enables the product to operate in the frequency range of 50 - 10KHZ, which is significantly broader than the 50 - 400HZ range that traditional silicon steel sheet transformers can only operate in. This characteristic allows the transformer to meet the requirements of both power frequency high-current applications and high-frequency high-current applications, providing strong support for the development of high-frequency power electronics technology. The iron-silicon material has the characteristic of low loss. In a high-frequency working environment, its hysteresis loss and eddy current loss are significantly lower than those of silicon steel sheet materials. This makes the energy conversion efficiency of this transformer higher during operation, with less heat generation, not only reducing energy consumption but also improving the reliability and service life of the equipment. At the same time, the low-loss characteristic also helps to reduce the volume and weight of the equipment, further realizing the miniaturization and light-weight of the equipment; 3. Integrating the transformer and the reactor into one product realizes the integration of multiple functions such as voltage transformation, filtering, current enhancement, and current limitation. In the power system, this design of multi-functional integration reduces the number of devices and connection lines, simplifies the system structure and control logic. For example, in application scenarios where voltage transformation and filtering are required simultaneously, there is no need to install a transformer and a reactor separately, reducing the complexity and cost of the system, while improving the reliability and stability of the system. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 is a schematic diagram of the split structure of the present invention; Figure 2 is a schematic diagram of the split structure of the frame body in the present invention; Figure 3 is a schematic diagram of the structure of the magnetic core in the present invention; Figure 4 is a schematic diagram of the structure of the winding cluster in the present invention; Figure 5 is a schematic diagram of the assembled structure of the present invention; Figure 6 is a half-sectional view after the present invention is assembled; Figure 7 is a schematic diagram of the structure of the circuit where the integrated transformer of the present invention is located during use.

[0017] In the figure: 1. Frame body; 11. Base; 12. Upper cover plate; 13. Tie bolts; 14. Lower cage; 15. Upper cage; 2. Magnetic core; 21. Iron-silicon block; 22. First rib; 23. Second rib; 3. Winding cluster; 31. Reactor winding; 32. Transformer winding; 33. First input pin; 34. Second input pin; 35. Third input pin; 36. Fourth input pin. DETAILED DESCRIPTION OF THE INVENTION

[0018] The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts shall fall within the protection scope of the present invention.

[0019] Please refer to Figures 1-6 , the present invention provides a technical solution: a reactor and transformer magnetically integrated transformer, mainly composed of a frame body 1, a magnetic core 2, and a winding cluster 3. The magnetic core 2 is formed by splicing a number of iron-silicon blocks 21 pressed from iron-silicon powder into a "mouth" shape structure. This structure enables the magnetic core 2 to have good magnetic properties and can meet the requirements of medium and high-frequency applications. On one side of the "mouth" shape structure, a first rib frame 22 is provided, and on the other side, a second rib frame 23 is provided. The winding cluster 3 includes a reactor winding 31 and a transformer winding 32. The reactor winding 31 is wound around the outside of the first rib frame 22, and the transformer winding 32 is wound around the outside of the second rib frame 23. After the reactor winding 31 and the transformer winding 32 are wound, a gap is reserved between adjacent end faces to reduce interference between each other and improve electrical performance; Existing transformer products mostly use silicon steel sheets, and the transformer and the reactor are in a split structure. This split structure has problems such as large floor area and large losses, and is particularly unsuitable for high-frequency application scenarios. This reactor and transformer magnetically integrated transformer has been improved for these problems. The iron-silicon blocks pressed from iron-silicon powder are used to replace the original silicon steel sheets, enabling the product to work in a working scenario of 50 - 10KHZ, meeting both the power frequency large current scenario and the high-frequency large current scenario. At the same time, the transformer and the reactor are integrated into one product, realizing multiple functions such as voltage transformation, filtering, current enhancement, and current limitation; The frame body 1 includes a base 11, an upper cover plate 12, a lower holder 14, and an upper holder 15. The base 11 and the upper cover plate 12 are respectively located at the lower and upper parts of the magnetic core 2, and the base 11 and the upper cover plate 12 are connected by a number of tie bolts 13. The lower holder 14 is located above the base 11, and the upper holder 15 is located below the upper cover plate 12. The lower holder 14 and the upper holder 15 are inserted into the inside of the magnetic core 2 in opposite directions; During the assembly process, first, wind the reactor winding 31 around the outside of the first rib frame 22, and wind the transformer winding 32 around the outside of the second rib frame 23. During the winding process, it is necessary to ensure that the windings are wound tightly and evenly to ensure the stability of electrical performance; insert the lower cage 14 and the upper cage 15 into the inside of the wound magnetic core 2 and the winding cluster 3 as a whole respectively. The installation of the lower cage 14 and the upper cage 15 can strengthen the stability of the structure after assembly and improve the assembly strength; place the base 11 at the lower part of the lower cage 14, and put the upper cover plate 12 into the upper part of the upper cage 15. Then connect several tension bolts 13 between the base 11 and the upper cover plate 12; tighten several tension bolts 13. As the tension bolts 13 are continuously tightened, the upper cover plate 12, the upper cage 15, the base 11, and the lower cage 14 generate opposite binding forces on the magnetic core 2, so that the magnetic core 2 is firmly fixed inside the frame body 1, and at this time the assembly of the integrated transformer is completed. In this process, the lower cage 14 and the upper cage 15 will be respectively squeezed by the base 11 and the upper cover plate 12, so as to be constrained and fixed; Electrical connection: Please refer to the attachment Figures 6-7 On the upper part of the reactor winding 31, a first input pin 33 and a fourth input pin 36 are respectively provided, and on the upper part of the transformer winding 32, a second input pin 34 and a third input pin 35 are respectively provided. When accessing the circuit, the first input pin 33 is connected to the high-voltage live wire of the 320V power supply system, the second input pin 34 is connected to the high-voltage neutral wire of the 320V power supply system, the third input pin 35 is connected to the DC power supply system, and the fourth input pin 36 is connected to the load system through the switch module; Working principle: 1. Voltage transformation and filtering function: The input pin 1 (the first input pin 33) of the wire coil is connected to the high-voltage live wire, and the output pin 2 (the second input pin 34) is connected to the high-voltage neutral wire. An equal intermediate-high frequency sine or trapezoidal wave current will be induced between the wire coils (the relevant part of the transformer winding 32) on the secondary side. Through the control of the rectifier bridge stack, the required current is obtained for the load, realizing the application of the transformer and the filter inductor.

[0020] 2. Energy storage and energy replenishment function: A 1000A DC current source needs to be connected to the secondary side. When the primary side is not working, or when the energy supplied by the primary side is insufficient, the secondary energy can replenish the output through the charging and discharging of the inductor. Then the battery replenishes the energy of the inductor through switch control. This inductor can be an energy storage inductor (BOOST inductor), and the working frequency is 5KHZ.

[0021] 3. Energy stability and current limiting function: Since the switching frequency of the bridge rectifier and the on / off of the primary side are controlled by the control module, the stability of the output energy is affected by the power supply on both sides. The inductor acts as a large energy source, and the bridge rectifier acts as a chopper and a DC converter. When the energy of the DC source is insufficient, the system can also charge the DC battery. At the same time, due to the fact that the current of the inductor cannot change suddenly, this inductor can also play a role in current limiting when the primary side is turned on and off with large current, preventing the product current from suddenly increasing and damaging the switching tube, and preventing the system from becoming unstable due to the sudden decrease of the primary energy turn-off current.

Claims

1. A reactor and transformer magnetically integrated transformer, comprising a frame body (1), a magnetic core (2), and a winding cluster (3), wherein the magnetic core (2) is fixed inside the frame body (1), the winding cluster (3) comprises a reactor winding (31) and a transformer winding (32), the reactor winding (31) and the transformer winding (32) are respectively wound on two sides of the magnetic core (2), and the magnetic core (2) is a structure formed by splicing a plurality of iron silicon blocks (21) pressed from iron silicon powder.

2. The reactor and transformer magnetic integrated transformer according to claim 1, characterized in that: The frame body (1) comprises a base (11) and an upper cover plate (12), wherein the base (11) and the upper cover plate (12) are respectively located at the lower part and the upper part of the magnetic core (2), and the base (11) and the upper cover plate (12) are connected via a plurality of tension bolts (13), and by tightening the plurality of tension bolts (13), the base (11) and the upper cover plate (12) form a clamping constraint force on the magnetic core (2), thereby achieving assembly fixation.

3. The reactor and transformer magnetic integrated transformer according to claim 2, characterized in that: The frame body (1) further comprises a lower retaining frame (14) located on the upper part of the base (11) and an upper retaining frame (15) located on the lower part of the upper cover plate (12). The lower retaining frame (14) and the upper retaining frame (15) are inserted into the interior of the magnetic core (2) in opposite directions. As the tension bolts (13) are tightened, the lower retaining frame (14) and the upper retaining frame (15) are respectively squeezed by the base (11) and the upper cover plate (12) to be constrained and fixed.

4. The reactor and transformer magnetic integrated transformer according to claim 1, characterized in that: After being spliced ​​together, the magnetic core (2) forms a "mouth"-shaped structure, with one side being provided as a No. 1 rib frame (22) and the other side being provided as a No. 2 rib frame (23), the reactor winding (31) being wound around the outside of the No. 1 rib frame (22), and the transformer winding (32) being wound around the outside of the No. 2 rib frame (23).

5. The reactor and transformer magnetic integrated transformer according to claim 4, characterized in that: After the reactor winding (31) and the transformer winding (32) are wound, gaps are reserved between adjacent end surfaces.

6. The reactor and transformer magnetic integrated transformer according to claim 1, characterized in that: The upper portion of the reactor winding (31) is provided with a first input pin (33) and a fourth input pin (36), and the upper portion of the transformer winding (32) is provided with a second input pin (34) and a third input pin (35).

7. The reactor and transformer magnetic integrated transformer according to claim 6, characterized in that: When connected to the circuit, the first input pin (33) is connected to the high-voltage live wire of the 320V power supply system, and the second input pin (34) is connected to the high-voltage neutral wire of the 320V power supply system.

8. The reactor and transformer magnetic integrated transformer according to claim 6, characterized in that: When connected to the circuit, the third input pin (35) is connected to the DC power supply system.

9. The reactor and transformer magnetic integrated transformer according to claim 6, characterized in that: When connected to the circuit, the fourth input pin (36) is connected to the load system through the switch module.

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