A highly efficient new energy transformer and power control system

Abstract

The present invention discloses a highly efficient new energy transformer and power control system, relating to the field of transformer technology. The input power conversion module is used to convert a DC or AC variable voltage source into a high-frequency AC output. The high-frequency isolation transformer module adopts a nanocrystalline-amorphous alloy hybrid magnetic core, the winding adopts a three-layer staggered arrangement, and is provided with an oil-liquid dual cooling system. The output rectifier inverter module is used to convert the high-frequency AC into the required DC or AC output, and integrates multi-phase synchronous rectification and active filtering functions. By designing a nanocrystalline-amorphous alloy hybrid magnetic core and a three-layer staggered winding, the present invention reduces leakage inductance and improves the coupling coefficient. This solves the problems of traditional single-material low-frequency iron cores with severe iron loss and large leakage inductance at medium and high frequencies, as well as the leakage inductance and magnetic flux unevenness caused by unreasonable coil arrangement. It effectively suppresses hysteresis and eddy current losses, minimizes leakage inductance, improves high-frequency transformer efficiency, and reduces volume and weight.

Description

Technical Field

[0001] The present invention relates to the technical field of transformers, and in particular to a high-efficiency new energy transformer and an electric energy control system. Background Art

[0002] With the increasing global adoption of renewable energy, the demand for grid-connected renewable energy sources such as wind and photovoltaic power is growing. However, existing transformers are inefficient, bulky, and experience high losses when handling variable voltage and variable frequency inputs. They also lack intelligent power quality management capabilities. Traditional power control systems typically consist of independent rectifier / inverter modules, transformers, and controllers, making it difficult to maintain optimal operating conditions under various operating conditions, resulting in reduced overall system efficiency.

[0003] For example, the current mainstream photovoltaic inverter + low-frequency transformer solution still maintains significant excitation losses under low light or partial load conditions. In wind power generation scenarios, when the output voltage and frequency of the variable-speed generator are unstable, directly converting it through a conventional oil-immersed transformer cannot achieve targeted load adaptive regulation and efficient power transfer. Furthermore, existing transformer cooling methods, which mostly use oil-immersed natural cooling or forced air cooling, cannot simultaneously achieve a compact structure and heat dissipation efficiency. They are prone to overheating when the ambient temperature rises suddenly or when operating at full load, reducing lifespan and reliability.

[0004] Patent CN110021470B discloses a transformer safety control system and a control method thereof. The above patent realizes that a temperature calculation module calculates the suitable temperature range of the transformer equipment according to the working value of the transformer equipment. The processing module compares the current temperature value of the transformer equipment with the suitable temperature range and sends an instruction signal to the control module to enable the control module to adjust the power of the cooler equipment, thereby making the current temperature value of the transformer equipment fall into the suitable temperature range, thereby saving the electric energy used by the cooler equipment and enabling the transformer equipment to reach the expected service time.

[0005] The above patent can calculate the appropriate temperature of the transformer equipment and accurately control the operation of the cooler equipment to save electricity and ensure that the transformer equipment reaches the expected service life, but it has low efficiency, bulky size and high loss when processing variable voltage / variable frequency input.

[0006] To this end, the present application proposes a high-efficiency new energy transformer and power control system that reduces leakage inductance and improves coupling coefficient. Summary of the Invention

[0007] The purpose of the present invention is to provide an efficient new energy transformer and power control system to solve the technical problems of low efficiency, bulky size and high loss when processing variable voltage / variable frequency input proposed in the above background technology.

[0008] To achieve the above objectives, the present invention provides the following technical solutions: an efficient new energy transformer power control system, comprising an input power conversion module, a high-frequency isolation transformer module, an output rectifier inverter module, and an intelligent monitoring and control unit, wherein the input power conversion module is used to convert a DC or AC variable voltage source into a high-frequency AC output, the high-frequency isolation transformer module adopts a nanocrystalline-amorphous alloy hybrid magnetic core, the winding adopts a three-layer staggered arrangement, and is provided with an oil dual cooling system, the output rectifier inverter module is used to convert the high-frequency AC into the required DC or AC output, and integrates multi-phase synchronous rectification and active filtering functions, and the intelligent monitoring and control unit is based on a DSP+FPGA hybrid architecture, and achieves full-time domain dynamic optimization and protection through the AOMC adaptive excitation control algorithm and soft-switching PWM modulation;

[0009] The nanocrystalline and amorphous alloy mixed magnetic core of the high-frequency isolation transformer module is bonded by an interlayer high thermal conductivity insulation film, and a microchannel oil cooling pipe is arranged on the outer layer of the transformer winding, and an embedded liquid cooling plate is set on the outer side of the core.

[0010] Preferably, the input power conversion module includes:

[0011] Full-bridge soft-switching inverter unit uses SiC MOSFET or GaN HEMT as the main switching device and achieves high-frequency sinusoidal wave output through PWM modulation;

[0012] A soft-switching resonant network, including a buffer resonant inductor and a resonant capacitor, enables zero voltage switching or zero current switching during the switching process of the switching device to reduce switching losses;

[0013] DC bus connection interface, used to receive DC voltage provided by photovoltaic panels or energy storage battery packs;

[0014] The full-bridge soft-switching inverter unit automatically adjusts the duty cycle according to the system load and input voltage to ensure the lowest switching loss under light load, no load and full load conditions.

[0015] Preferably, the hybrid magnetic core of the high-frequency isolation transformer module is formed by alternating stacking of nanocrystalline alloy and amorphous alloy, the interlayer bonding is made of high thermal conductivity insulating film, and the magnetic core shape is a centroid structure, and the saturation magnetic flux density is ≥1.3T to meet the low loss requirements under high-frequency working conditions of 20kHz-100kHz.

[0016] Preferably, the three-layer interleaved winding comprises:

[0017] The primary winding P is a multi-turn broadband flat copper foil winding with the width and number of turns optimized according to the designed output power and turns ratio.

[0018] The secondary winding S is wound in staggered layers with the primary winding P, and polyimide film is used as the insulation medium between the windings;

[0019] Auxiliary winding AUX, used to sample the excitation current and power the intelligent monitoring and control unit;

[0020] The primary winding P, secondary winding S and auxiliary winding AUX are arranged in an interlaced manner to minimize leakage inductance and maximize coupling. Heat dissipation gaps are left between each layer of windings to facilitate direct contact of the oil cooling pipe with the outer winding for efficient heat dissipation.

[0021] Preferably, the oil dual cooling system includes:

[0022] The micro-channel oil cooling pipeline is arranged in a ring along the outer ring of the winding, and the cooling oil is a biodegradable high thermal conductivity cooling medium;

[0023] The embedded liquid cooling plate is close to the outside of the magnetic core and removes the heat of the magnetic core through circulating coolant;

[0024] The microchannel oil cooling pipeline and embedded liquid cold plate are connected to the oil pump and liquid pump respectively through independent circulation loops. The intelligent monitoring and control unit automatically switches the oil pump and liquid pump speeds according to the temperature sensor signal to maintain optimal heat dissipation efficiency under different load conditions.

[0025] Preferably, the output rectifier inverter module specifically includes:

[0026] The secondary-side soft-switching multi-phase synchronous rectification circuit uses SiC MOSFET devices to synchronously rectify the high-frequency AC output in six or eight phases in parallel.

[0027] The middle DC-Link bus is equipped with a high-frequency film capacitor array in parallel with a low-ESR aluminum electrolytic capacitor to smooth the DC output and provide instantaneous high current.

[0028] Three-phase voltage-source inverter, using IGBT or SiC MOSFET half-bridge modules, outputs 380VAC three-phase sine wave, directly connected to the grid or supplies power to downstream loads;

[0029] Active filters, including LCL filters and voltage-type active filter modules, dynamically compensate for reactive power and suppress harmonics, making the total harmonic content on the output side ≤3%.

[0030] Preferably, the intelligent monitoring and control unit includes:

[0031] DSP chip, used to run the AOMC algorithm, maximum power point tracking algorithm and load prediction algorithm in real time;

[0032] FPGA chip, used for fast sampling, fault detection and protection logic, to achieve rapid isolation of overcurrent, overvoltage, overtemperature, short circuit and ground faults;

[0033] Temperature sensors, current transformers, voltage sampling resistors, and harmonic detection devices are used to collect transformer winding temperature, voltage, current, and harmonic content in real time;

[0034] Control strategy: When the load changes or the input source fluctuates, the DSP uses the AOMC algorithm to perform multi-level prediction and rapid adjustment of the excitation current based on the collected load current and voltage information, minimizing the transformer's excitation loss and no-load loss. When the ambient temperature rises or the winding temperature exceeds 80°C, the FPGA drives the oil and liquid pump speeds to enhance heat dissipation. When the grid experiences a short-term voltage drop or frequency deviation, the DSP controls the output inverter to activate the fault ride-through function to maintain output stability.

[0035] Preferably, the control system also includes an auxiliary supporting module, which includes a DC bus filter and lightning protection unit, a battery management and grid switching unit, and is used to automatically switch to off-grid power supply when the grid fails or the grid fails.

[0036] Preferably, the new energy transformer includes:

[0037] The hybrid core is made of alternating nanocrystalline alloy layers and amorphous alloy layers, with high thermal conductivity insulating films bonded between the layers, and the core shape is a centroid structure;

[0038] Three-layer staggered winding, including primary winding, secondary winding and auxiliary winding, which are arranged in staggered layers to minimize leakage inductance between the primary winding and the secondary winding. The auxiliary winding is used for excitation sampling and provides auxiliary power to the control board;

[0039] The microchannel oil cooling pipe is arranged around the outer ring of the winding, and the embedded liquid cooling plate is close to the outside of the magnetic core to remove the heat of the core through the circulating coolant.

[0040] Preferably, the thickness of the nanocrystalline layer of the hybrid magnetic core is 0.1-0.2 mm, the thickness of the amorphous alloy layer is 0.02-0.05 mm, the thermal conductivity of the interlayer thermal bonding film is ≥1.0 W / (m·K), the internal flow channel width of the microchannel oil cooling tube is 1-2 mm, the flow channel height is 0.5-1 mm, and the thickness of the embedded liquid cooling plate is 5-10 mm.

[0041] Compared with the prior art, the present invention has the following beneficial effects:

[0042] 1. The present invention utilizes a nanocrystalline-amorphous alloy hybrid core and three-layer interleaved windings to reduce leakage inductance and improve coupling coefficient. This solves the problems of severe iron loss and large leakage inductance in traditional single-material low-frequency cores at medium and high frequencies, as well as uneven leakage inductance and magnetic flux caused by improper coil arrangement. It effectively suppresses hysteresis and eddy current losses, minimizes leakage inductance, improves high-frequency transformer efficiency, and reduces volume and weight.

[0043] 2. This invention achieves efficient heat dissipation through the design of an oil-liquid dual cooling system. This solves the problem that traditional oil immersion or air cooling cannot achieve efficient heat dissipation in a compact size, and is prone to overheating and life degradation under high ambient temperature or full load conditions. It improves heat dissipation efficiency and enhances system reliability and lifespan.

[0044] 3. This invention utilizes adaptive optimal magnetizing current control and soft-switching PWM modulation to achieve optimal core magnetization under varying load conditions. This solves the problem of traditional transformers often operating at a fixed excitation current and experiencing excessive excitation losses at no load or light load. It also reduces core and switching losses, improving overall peak and full-load efficiency.

[0045] 4. The present invention achieves deep coupling between high-frequency transformers and power electronic modules through modular design and intelligent monitoring. It can not only be used for inverter grid connection, but can also be switched to bidirectional current conversion control in off-grid energy storage scenarios. It supports coupling with energy storage battery packs or fuel cell systems, solving the problems of traditional devices such as difficulty in capacity expansion, complex maintenance, lack of online diagnosis and remote maintenance methods, poor grid connection performance, and inability to meet fault ride-through and dynamic power factor adjustment requirements, thereby improving the system grid connection rate and reducing power quality issues. BRIEF DESCRIPTION OF THE DRAWINGS

[0046] Figure 1 Schematic diagram of electric energy control of the present invention. DETAILED DESCRIPTION

[0047] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0048] Example 1: Please refer to Figure 1, an efficient new energy transformer power control system, that is, a universal high-efficiency new energy transformer and power control system: the input power conversion module converts the 400VDC-800VDC DC power supply provided by wind power, photovoltaic or energy storage battery pack, or the 200VAC-800VAC variable frequency AC power supply, into 20kHz-100kHz high-frequency AC through a full-bridge soft-switching inverter circuit. The high-frequency isolation transformer module adopts a nanocrystalline-amorphous alloy hybrid magnetic core, a three-layer staggered winding structure, and a dual oil cooling channel to achieve high-frequency isolation and buck-boost conversion. The output rectifier inverter module rectifies the high-frequency AC into DC on the secondary side through a soft-switching multi-phase synchronous rectification circuit to generate an intermediate DC link, and then uses a three-phase voltage inverter to output 380VAC three-phase or output 400VDC to the energy storage battery pack. The output end also integrates an active filter to achieve harmonic suppression and reactive power compensation. The intelligent monitoring and control unit is based on the DSP+FPGA architecture and runs the adaptive optimal magnetizing current control AOMC algorithm. The system uses the MPPT algorithm and grid-connected control algorithm to perform excitation regulation, switch parasitic parameter compensation, overvoltage and overcurrent protection, and fault diagnosis and processing. Real-time operating data (voltage, current, power, efficiency, temperature, and harmonics, etc.) is uploaded to a cloud monitoring platform via a 4G / 5G communication module or industrial Ethernet interface, or interacts with the local EMS via the CAN bus. Real-time status, reports, and fault information are displayed on a 7-inch touchscreen HMI, supporting OTA upgrades and on-site parameter debugging. This embodiment minimizes iron loss and leakage inductance at high frequencies through a nanocrystalline-amorphous alloy hybrid core and three-layer interleaved windings. Dual oil cooling ensures a winding temperature of ≤80°C under full load. Full-bridge soft-switching inverter and soft-switching synchronous rectification technology enable a peak efficiency of 98.5% and a full-load efficiency of ≥97.5%. Compared with traditional 50Hz transformers, the system volume is reduced by ≥60% and the weight is reduced by ≥40%. The intelligent monitoring and control unit can dynamically optimize excitation and switching strategies and provide remote monitoring and fault warnings.

[0049] Example 2: Please refer to Figure 1 An efficient power control system for a new energy transformer, specifically optimized for wind power generation scenarios: In wind power generation scenarios, the generator output is three-phase variable-frequency AC, and the frequency fluctuates widely with wind speed. Based on Example 1, this embodiment introduces a two-stage rectification + multi-level inverter topology and adds dedicated wind turbine MPPT and LVRT functions to adapt to the characteristics of wind power generation:

[0050] Input-side rectification and multi-level inversion: Wind turbine-side rectification: The wind turbine output three-phase variable-frequency AC is first rectified by a three-phase diode bridge to obtain an 800VDC-1000VDC DC bus voltage; the seven-level NPC inverter: With an 800VDC-1000VDC bus as input, it outputs 25kHz high-frequency sinusoidal AC to the primary side of the high-frequency transformer through a seven-level neutral-point clamped inverter topology, which can reduce power switch stress and optimize filter design;

[0051] Wind turbine MPPT and wind speed monitoring: MPPT algorithm: The DSP collects signals from wind speed sensors, such as ultrasonic or Pitot tube anemometers, and generator output power. Based on the turbine's pump resistance characteristic curve (PU), it calculates the optimal speed or output power point in real time. It then drives excitation control and inverter duty cycle to maintain the generator operating at its maximum output power point. Overspeed and overload protection: When wind speed exceeds the storm threshold of 25 m / s, the DSP issues a shutdown command and isolates the wind turbine from the grid via an NPC inverter short-circuit command or bypass contactor, ensuring the safety of the wind turbine and the entire unit. Grid-connected LVRT function: Grid fault detection: By sampling grid-side voltage and current, if a grid voltage drop (<80% rated) or frequency deviation (±0.5 Hz) is detected, the DSP controls the seven-level NPC inverter to initiate LVRT mode. This utilizes DC-Link energy storage capacitors for short-term output compensation to maintain output voltage and frequency stability, meeting grid-connected fault ride-through requirements. Once the fault is cleared, grid connection is restored smoothly.

[0052] In this embodiment, a 400VDC-800VDC energy storage battery pack is optional. When the wind speed is too low or the grid is abnormal, the system automatically switches to energy storage power supply mode to provide temporary emergency power for downstream loads. The battery management module (BMS) monitors the SOC level in real time and initiates charging or discharging strategies to ensure the health of the energy storage system.

[0053] The two-stage rectification + multi-level inversion solution reduces the harmonics of the wind turbine-side inverter, reduces the filter size, and uses a dedicated MPPT algorithm to track the maximum power point at different wind speeds, improving power generation efficiency by approximately 5%. The LVRT function meets grid code requirements, improving the grid-connected reliability of the wind farm, and energy storage synergy and off-grid emergency functions enhance the overall flexibility of the system.

[0054] Example 3: Please refer to Figure 1 A highly efficient power control system for a new energy transformer, specifically optimized for photovoltaic power generation scenarios: In photovoltaic power generation scenarios, the output of photovoltaic modules is DC, and the voltage range is typically 200VDC-1000VDC. Based on the characteristics of photovoltaics, this embodiment, based on Example 1, optimizes the input-side MPPT algorithm and voltage range, and simplifies the rectification process.

[0055] Input-side DC-high-frequency inverter: PV module DC input: The system is directly connected to the 200VDC-800VDC PV array output without additional rectification. The DSP runs a PV-MPPT algorithm such as the incremental admittance method or the perturbation observation method to track the maximum power point of the module in real time and adjust the full-bridge inverter duty cycle to achieve optimal output. Input high-frequency AC: The full-bridge soft-switching inverter converts DC to 25kHz high-frequency AC, which is fed into the primary side of the high-frequency transformer.

[0056] High-frequency transformer, output rectification, and grid connection: The high-frequency transformer primary side is the same as in Example 1, with a nanocrystalline-amorphous hybrid core, three-layer interleaved windings, and dual oil cooling. The secondary side uses soft-switching synchronous rectification: six-phase parallel SiC MOSFET components are used to rectify the high-frequency AC to 400VDC. After intermediate DC-Link filtering, the three-phase inverter outputs 380VAC and is connected to the grid.

[0057] PV-prioritized grid connection and power smoothing: Power control: When there is sufficient sunlight and grid demand, the DSP outputs maximum power according to MPPT guidance. When grid or load demand is low, the DSP adjusts output based on grid frequency and voltage signals to match power with grid demand, preventing backfeed or voltage spikes. Anti-grid fluctuation: Since PV output is easily affected by shadows, the DSP smoothes and filters the output power to prevent sudden PWM modulation fluctuations from negatively impacting grid connection quality.

[0058] System grid-connected parameters and protection: Grid-connected detection: The grid-connected side voltage and current sampling devices monitor the grid status. When it detects grid voltage loss or frequency deviation exceeding the limit, the DSP immediately stops and short-circuits the secondary side of the transformer to prevent the PV modules from back-feeding into the grid. Cooling management: The output is relatively stable, which is better than that of PV. The temperature mainly comes from the heat generated by the transformer and power devices themselves. When the temperature rises above 75°C, the DSP automatically increases the speed of the oil and liquid pumps. When it exceeds 90°C, the output power is reduced or the system is shut down for protection.

[0059] This embodiment is designed specifically for photovoltaic scenarios. The MPPT efficiency can reach over 98%. The DC input simplifies the soft-switching inverter and rectifier topology, reducing device costs. The output grid-connected performance is excellent, with a harmonic content THD ≤ 3%, meeting low-voltage grid-connected standards. The cooling system ensures operation at an ambient temperature of 50°C and a winding temperature ≤ 80°C.

[0060] Example 4: Please refer to Figure 1A highly efficient power control system for a new energy transformer, and a bidirectional conversion solution for microgrid and energy storage system scenarios: In microgrid or energy storage system scenarios, the system can both receive input from new energy sources and charge energy storage batteries, and can also discharge energy storage to supply loads when off-grid. Therefore, based on Example 1, this embodiment adopts a bidirectional power topology to achieve DC-AC bidirectional flow capability and enhance BMS collaborative management:

[0061] Bidirectional power topology design: Bidirectional soft-switching inverter and rectifier unit: The inverter bridge arm uses SiC MOSFETs and can switch in forward and reverse modes. In charging mode, it converts 380VAC three-phase or 400VDC DC input into 20kHz high-frequency AC, feeds the primary side of the transformer, achieves voltage reduction, and then outputs the DC underlying battery pack through synchronous rectification. In discharge mode, the DC link battery voltage is converted to high-frequency AC through a full-bridge inverter, and then stepped down by the transformer and then connected to the grid or supplied to the load through a three-phase inverter.

[0062] Energy Storage Battery Management System (BMS): Real-time SOC monitoring: The BMS samples the voltage, current, and temperature of the 400-800VDC battery pack and calculates the SOC and SOH status in real time. Charge and discharge strategy: When the output power of renewable energy exceeds the load or grid connection requirements, the system automatically switches to charging mode, storing excess power in the battery. When the solar / wind output is insufficient or the grid is abnormal, it automatically switches to discharging mode, using the battery as the energy source to ensure stable load operation.

[0063] Intelligent switching and grid-connection rules: Grid connection priority: When the grid is normal and load demand is insufficient, grid connection is prioritized. When the grid fails or grid-connection conditions are not met, the DSP switches to off-grid mode based on the BMS SOC and load priority. Fault ride-through and black start: During the grid-connected fault ride-through LVRT period, the battery pack can participate in compensation output. When the grid fails completely, the system can cooperate with the BMS and DSP to perform a black start to drive the local microgrid or temporary emergency load.

[0064] The bidirectional topology meets the demand for flexible charging and discharging control in microgrid and energy storage scenarios. The DSP and BMS are highly coordinated and can seamlessly switch between grid-connected, off-grid and black start states. Since the inverter and rectifier units share the same power bridge, redundant devices are reduced, and efficiency and reliability are improved. In off-grid peak-valley scheduling scenarios, charging and discharging can be flexibly switched according to fluctuations in electricity prices to achieve economic operation.

[0065] Example 5: Please refer to Figure 1An efficient power control system for new energy transformers, with applications in modular parallel expansion and multi-system integration scenarios: To meet the expansion needs of large-scale new energy bases or multi-point distributed energy systems, this embodiment proposes a modular parallel solution: multiple "high-frequency conversion + control" modules with the same capacity can operate in parallel to achieve high power output and redundant design.

[0066] Unit module design: Each module includes: input full-bridge soft-switching inverter, single-pole high-frequency isolation transformer, secondary synchronous rectification + output inverter, DSP + FPGA control unit, HMI and communication unit, and oil dual cooling subsystem. Each module has a rated power of 100kW-500kW. Parallel system interface: The DC bus or AC output sides of N modules are connected in parallel, and current distribution is coordinated through a dedicated parallel control board. The parallel board has built-in current sharing detection and active compensation logic to ensure balanced load for each module.

[0067] Parallel control strategy: Current sharing control: The DSP samples the input and output currents of each module at high speed and aggregates the information to the parallel control board. This can be implemented based on an FPGA and adjusts the inverter and rectifier duty cycles of each module in real time to ensure that the overall output power and current distribution of the parallel system are uniform with a deviation of ≤5%. Thermal balance and cooling management: Each module in the parallel system has an independent cooling channel, and the oil pump and liquid pump are synchronously controlled by the DSP. When the total system load changes, the parallel control board instructs each module to dynamically adjust the cooling rate according to its own temperature status to achieve thermal balance. Fault redundancy and hot swapping: When a module fails or requires maintenance, the parallel control board automatically resets the module current to zero and issues an alarm. The remaining modules automatically compensate for the output current to ensure continuous power supply to the system. The back-end can also replace or maintain the faulty module online.

[0068] Multi-system integration and microgrid collaboration: Integration with SCADA / EMS: The parallel system communicates with the upper-level SCADA / EMS system in real time via CAN bus, supporting overall power scheduling, power factor optimization, reactive power compensation, and microgrid voltage / frequency control. Multi-point distributed access: In large-scale wind power or photovoltaic bases, multiple parallel clusters can be deployed in a distributed manner. Each cluster is interconnected through a local microgrid, and distributed DSP collaboration is used to achieve grid frequency and voltage stability.

[0069] Modular parallel expansion can flexibly match the power requirements of different scenarios and can be expanded to the MW level. The current sharing and thermal balancing strategies ensure the long-term stable operation of each module. The fault redundancy and hot-swappable design improve the system reliability and maintainability. It is deeply integrated with the upper-level SCADA / EMS to achieve intelligent network-side coordinated scheduling and microgrid autonomy.

[0070] Working Principle: Variable power sources such as wind power, photovoltaics, or energy storage batteries are first converted into high-frequency AC power through a full-bridge soft-switching inverter. This high-frequency AC power then passes through a high-frequency isolation transformer consisting of a pre-designed nanocrystalline-amorphous hybrid magnetic core and three-layer interleaved windings to achieve voltage rise and fall and electrical isolation. Because the magnetic core is made of multiple layers of nanocrystalline and amorphous alloys and the windings are staggered, iron loss and leakage inductance are minimized, significantly improving transformer efficiency under high-frequency operation.

[0071] Multiple temperature, excitation current, voltage, and harmonic detection sensors are embedded in the primary and auxiliary windings of the transformer. These sensors feed real-time operating parameters back to the DSP+FPGA hybrid control unit. The control unit then runs an adaptive optimal magnetizing current control algorithm, dynamically adjusting the excitation current and PWM duty cycle based on load changes and ambient temperature. This ensures that the transformer core always operates in a near-optimal magnetization state, preventing core saturation and minimizing no-load excitation losses and full-load losses.

[0072] The high-frequency isolation transformer's secondary side outputs high-frequency AC, which is converted to stable DC via a soft-switching, multi-phase synchronous rectifier circuit. This DC is then fed through a three-phase voltage-source inverter to a 380VAC grid or a 400VDC busbar for integration into the energy storage system. Both the rectification and inversion stages utilize soft-switching technology and active filtering, significantly reducing switching losses and harmonic content. Real-time monitoring of output power, power factor, and harmonic levels is also fed back to the control unit for closed-loop optimization and meeting power quality requirements in various operating modes, including grid-connected, energy storage, and off-grid.

[0073] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above and that the invention can be embodied in other specific forms without departing from the spirit or essential characteristics of the invention. Therefore, the embodiments should be considered in all respects as illustrative and non-restrictive, and the scope of the invention is defined by the appended claims, not the foregoing description, and all variations within the meaning and range of equivalents of the claims are intended to be included therein. Any reference sign in a claim should not be construed as limiting the claim to which it relates.

Claims

1. An efficient new energy transformer power control system, comprising an input power conversion module, a high-frequency isolation transformer module, an output rectifier inverter module, and an intelligent monitoring and control unit, characterized in that: The input power conversion module is used to convert a DC or AC variable voltage source into a high-frequency AC output. The high-frequency isolation transformer module uses a nanocrystalline-amorphous alloy hybrid core, the winding adopts a three-layer staggered arrangement, and is equipped with an oil dual cooling system. The output rectifier inverter module is used to convert high-frequency AC into the required DC or AC output and integrates multi-phase synchronous rectification and active filtering functions. The intelligent monitoring and control unit is based on a DSP+FPGA hybrid architecture and achieves full-time domain dynamic optimization and protection through an adaptive optimal magnetizing current control algorithm and soft-switching PWM modulation. The nanocrystalline and amorphous alloy hybrid magnetic core of the high-frequency isolation transformer module is bonded by interlayer high thermal conductivity insulation film, and microchannel oil cooling pipes are arranged on the outer layer of the transformer winding, and an embedded liquid cooling plate is set on the outer side of the core; The input power conversion module includes: Full-bridge soft-switching inverter unit uses SiC MOSFET or GaN HEMT as the main switching device and achieves high-frequency sinusoidal wave output through PWM modulation; A soft-switching resonant network, including a buffer resonant inductor and a resonant capacitor, enables zero voltage switching or zero current switching during the switching process of the switching device to reduce switching losses; DC bus connection interface, used to receive DC voltage provided by photovoltaic panels or energy storage battery packs; The full-bridge soft-switching inverter unit automatically adjusts the duty cycle according to the system load and input voltage to ensure the lowest switching loss under light load, no load and full load conditions; The three-layer interleaved winding includes: The primary winding P is a multi-turn broadband flat copper foil winding with the width and number of turns optimized according to the designed output power and turns ratio. The secondary winding S is wound in staggered layers with the primary winding P, and polyimide film is used as the insulation medium between the windings; Auxiliary winding AUX, used to sample the excitation current and power the intelligent monitoring and control unit; The primary winding P, secondary winding S, and auxiliary winding AUX are arranged in a staggered manner to minimize leakage inductance and maximize coupling. Heat dissipation gaps are left between each layer of windings to allow the oil cooling pipe to directly contact the outer winding for efficient heat dissipation. The oil dual cooling system includes: The micro-channel oil cooling pipeline is arranged in a ring along the outer ring of the winding, and the cooling oil is a biodegradable high thermal conductivity cooling medium; The embedded liquid cooling plate is close to the outside of the magnetic core and removes the heat of the magnetic core through circulating coolant; The microchannel oil cooling pipeline and embedded liquid cold plate are connected to the oil pump and liquid pump respectively through independent circulation loops. The intelligent monitoring and control unit automatically switches the oil pump and liquid pump speeds according to the temperature sensor signal to maintain optimal heat dissipation efficiency under different load conditions. The output rectifier inverter module specifically includes: The secondary-side soft-switching multi-phase synchronous rectification circuit uses SiC MOSFET devices to synchronously rectify the high-frequency AC output in six or eight phases in parallel. The middle DC-Link bus is equipped with a high-frequency film capacitor array in parallel with low-ESR aluminum electrolytic capacitors to smooth the DC output and provide instantaneous high current. Three-phase voltage-source inverter, using IGBT or SiC MOSFET half-bridge modules, outputs 380VAC three-phase sine wave, directly connected to the grid or supplies power to downstream loads; Active filter, including LCL filter and voltage-type active filter module, dynamically compensates for reactive power and suppresses harmonics, making the total harmonic content on the output side ≤3%; The intelligent monitoring and control unit includes: DSP chip, used to run the adaptive optimal magnetizing current control algorithm, maximum power point tracking algorithm and load prediction algorithm in real time; FPGA chip, used for fast sampling, fault detection and protection logic, to achieve rapid isolation of overcurrent, overvoltage, overtemperature, short circuit and ground faults; Temperature sensors, current transformers, voltage sampling resistors, and harmonic detection devices are used to collect transformer winding temperature, voltage, current, and harmonic content in real time; Control strategy: When the load changes or the input source fluctuates, the DSP uses the collected load current and voltage information to perform multi-level prediction and rapid adjustment of the excitation current through an adaptive optimal magnetizing current control algorithm to minimize the transformer's excitation loss and no-load loss. When the ambient temperature rises or the winding temperature exceeds 80°C, the FPGA drives the oil and liquid pump speeds to enhance heat dissipation. When a short-term grid voltage drop or frequency deviation occurs, the DSP controls the output inverter to activate the fault ride-through function to maintain output stability.

2. The power control system of a high-efficiency new energy transformer according to claim 1 is characterized in that: The hybrid magnetic core of the high-frequency isolation transformer module is made of alternating nanocrystalline alloys and amorphous alloys, and the interlayer bonding is made of high thermal conductivity insulating film. The saturation magnetic flux density is ≥1.3T to meet the low loss requirements under high-frequency working conditions of 20kHz-100kHz.

3. The power control system of a high-efficiency new energy transformer according to claim 1 is characterized in that: The control system also includes an auxiliary supporting module, which includes a DC bus filter and lightning protection unit, a battery management and grid switching unit, and is used to automatically switch to off-grid power supply when grid connection fails or the grid fails.

4. A high-efficiency new energy transformer, suitable for the power control system of a high-efficiency new energy transformer according to any one of claims 1 to 3, characterized in that: The new energy transformer includes: The hybrid core is made of alternating nanocrystalline alloy layers and amorphous alloy layers, with high thermal conductivity insulating films bonded between the layers; Three-layer staggered winding, including primary winding, secondary winding and auxiliary winding, which are arranged in staggered layers to minimize leakage inductance between the primary winding and the secondary winding. The auxiliary winding is used for excitation sampling and provides auxiliary power to the control board; The microchannel oil cooling pipe is arranged around the outer ring of the winding, and the embedded liquid cooling plate is close to the outside of the magnetic core to remove the heat of the core through the circulating coolant.

5. The high-efficiency new energy transformer according to claim 4, characterized in that: The thickness of the nanocrystalline layer of the hybrid magnetic core is 0.1-0.2 mm, the thickness of the amorphous alloy layer is 0.02-0.05 mm, the thermal conductivity of the interlayer thermal bonding film is ≥1.0 W / (m·K), the internal flow channel width of the microchannel oil cooling tube is 1-2 mm, the flow channel height is 0.5-1 mm, and the thickness of the embedded liquid cooling plate is 5-10 mm.

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