Dry-type high-frequency transformer cooling system based on heat pipe cooling

Abstract

According to the dry-type high-frequency transformer cooling system based on heat pipe cooling, in the dry-type high-frequency transformer cooling system based on heat pipe cooling, a low-voltage winding surrounds the adjacent part of a pair of iron cores; the high-voltage winding surrounds the low-voltage winding; at least one first heat pipe is distributed on two sides of the iron core and clings to the side surface of the iron core, and the upper part of the first heat pipe is bent; at least one second heat pipe is distributed between the two iron cores, and one end of the second heat pipe is bent along the curved surfaces of the iron cores; the at least one third heat pipe is distributed between the second heat pipes; the cooling fins are in heat conduction connection with the first heat pipe, the second heat pipe and the third heat pipe. And the cooling fan is connected with the cooling fins.

Description

Technical Field

[0001] The present invention relates to the technical field of power semiconductor devices, in particular to a dry-type high-frequency transformer cooling system based on heat pipe cooling. Background Art

[0002] Solid-state transformers have broad application prospects in medium-voltage scenarios such as DC distribution networks, energy storage power stations, data centers, and rail transit. High-frequency transformers are a key component of solid-state transformers. To meet insulation requirements, these transformers often use epoxy resin cast dry insulation. However, epoxy resin has low thermal conductivity, which hinders efficient heat dissipation. Furthermore, high-frequency transformers operate at high frequencies and have high loss density, generating much more heat per unit volume than traditional power-frequency transformers. When heat generated within a high-frequency transformer cannot be effectively dissipated, the internal temperature rises, affecting the reliability and lifespan of the insulation material. Therefore, efficient and reliable heat dissipation is one of the challenges in optimizing dry-type high-frequency transformers.

[0003] Air cooling is the most common heat dissipation method. Air cooling has the advantages of simple installation and low cost. However, for epoxy-cast dry-type high-frequency transformers, the epoxy-cast insulation hinders the effective dissipation of heat inside the transformer. Traditional air cooling methods cannot effectively remove the heat inside the transformer. Therefore, to avoid excessive temperature rise inside the transformer, the core magnetic flux density or winding current density is often reduced to reduce the loss density of the transformer. This restricts the improvement of the power density of dry-type high-frequency transformers.

[0004] Water cooling effectively removes heat from the transformer by placing heat-conducting aluminum plates and water-cooling channels inside the transformer. However, this approach carries drawbacks such as leakage risk, bulkiness, complex maintenance, and high costs. Furthermore, it is not suitable for applications with high insulation voltages. As the voltage level, capacity, and power density of dry-type high-frequency transformers increase, the limitations of air and water cooling become increasingly prominent, creating an urgent need for efficient and compact active cooling solutions.

[0005] Using natural convection to cool high-power dry-type high-frequency transformers is highly dependent on the heat dissipation area and air convection efficiency, resulting in low heat dissipation efficiency. Furthermore, due to the low thermal conductivity of epoxy resin, natural convection cannot effectively remove heat from the transformer. Using forced air cooling to cool high-power dry-type high-frequency transformers is difficult to effectively dissipate heat from within the transformer, and the cooling device is bulky, consumes a lot of power, and is noisy. Using water cooling to cool high-power dry-type high-frequency transformers is subject to issues such as liquid leakage, bulky size, complex maintenance, and high cost, and is not suitable for applications with high insulation voltages.

[0006] The information disclosed in this Background section is only for enhancement of understanding of the background of the invention and therefore it may contain information that does not form the prior art that is already known to a person of ordinary skill in the art. Summary of the Invention

[0007] In response to the shortcomings or defects of the above-mentioned existing technologies, a dry-type high-frequency transformer cooling system based on heat pipe cooling is provided to solve the problem that the internal heat of high-power dry-type high-frequency transformers is difficult to effectively dissipate, while achieving an increase in the power density of the high-frequency transformer and a reduction in the power consumption of the heat dissipation device.

[0008] The purpose of the present invention is achieved through the following technical solutions.

[0009] A dry-type high-frequency transformer cooling system based on heat pipe cooling includes: A pair of iron cores; a low-voltage winding, which surrounds adjacent portions of a pair of cores; a high voltage winding surrounding the low voltage winding; at least one first heat pipe, which is distributed on both sides of the iron core and arranged closely to the side surfaces of the iron core, and the upper portion of the first heat pipe is bent; At least one second heat pipe, which is distributed between the two iron cores and one end of the second heat pipe is bent along the curved surface of the iron core; at least one third heat pipe, which is distributed between the second heat pipes; a heat sink thermally connecting the first heat pipe, the second heat pipe, and the third heat pipe; A heat dissipation fan is connected to the heat dissipation fins.

[0010] The dry-type high-frequency transformer cooling system based on heat pipe cooling further includes an epoxy resin casting body surrounding the high-voltage winding.

[0011] In the dry-type high-frequency transformer cooling system based on heat pipe cooling, a gap is left between the high-voltage winding and the low-voltage winding, and a gap is left between the high-voltage winding and the iron core.

[0012] In the dry-type high-frequency transformer cooling system based on heat pipe cooling, the first heat pipe extends vertically and the upper part is bent 90 degrees to form a horizontal surface in close contact with the heat sink.

[0013] In the dry-type high-frequency transformer cooling system based on heat pipe cooling, at least one first heat pipe extends vertically close to the side of the iron core and is surrounded by the low-voltage winding.

[0014] In the dry-type high-frequency transformer cooling system based on heat pipe cooling, the other end of the second heat pipe opposite to the bent end extends horizontally on the surface of the iron core.

[0015] In the dry-type high-frequency transformer cooling system based on heat pipe cooling, the third heat pipes are arranged at equal intervals and parallel to the other end of the second heat pipe.

[0016] In the dry-type high-frequency transformer cooling system based on heat pipe cooling, the top ends of the first heat pipe, the second heat pipe and the third heat pipe are on the same horizontal plane.

[0017] In the dry-type high-frequency transformer cooling system based on heat pipe cooling, the heat sink is a fin-type heat sink.

[0018] In the dry-type high-frequency transformer cooling system based on heat pipe cooling, the cooling fan is a DC cooling fan.

[0019] Compared to the prior art, the present invention offers the following advantages: It addresses the challenges of high internal temperatures in high-power dry-type high-frequency transformers and the inability of existing cooling systems to efficiently dissipate internal heat, as well as the bulk, high cost, and high power consumption of existing high-power dry-type high-frequency transformer cooling systems. The present invention effectively conducts away internal heat, reduces internal hotspot temperatures, and ensures reliable operation of the high-power dry-type high-frequency transformer. This significantly reduces the size, cost, and power consumption of the cooling system, while simultaneously increasing the transformer's power density while ensuring heat dissipation efficiency. Compared to natural cooling systems, heat pipe cooling systems can effectively dissipate heat within high-power dry-type high-frequency transformers, reducing both the overall transformer temperature and hotspot temperatures. Compared to forced air cooling systems, heat pipe cooling systems can effectively dissipate heat within high-power dry-type high-frequency transformers, reducing hotspot temperatures, improving heat dissipation efficiency, and reducing the size, cost, and power consumption of the cooling equipment. Furthermore, because heat pipe cooling more efficiently removes heat from the transformer, the transformer can operate at higher magnetic flux densities and current densities. Therefore, heat pipe cooling systems can reduce the size of dry-type high-frequency transformers and achieve higher power density. Compared with water-cooled heat dissipation systems, cooling systems based on heat pipe cooling have simple structures, small sizes, high reliability, low maintenance costs, and can achieve higher insulation levels.

[0020] The above description is only an overview of the technical solution of the present invention. In order to make the technical means of the present invention clearer and easier to understand, so that those skilled in the art can implement it according to the contents of the description, and in order to make the above and other purposes, features and advantages of the present invention more obvious and easy to understand, the specific embodiments of the present invention are illustrated below. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Various other advantages and benefits of the present invention will become apparent to those skilled in the art upon reading the detailed description of the preferred embodiments below. The accompanying drawings are intended only to illustrate preferred embodiments and are not to be construed as limiting the present invention. It should be understood that the drawings described below are merely examples of the present invention, and that those skilled in the art will be able to derive other drawings from these drawings without inventive effort. Throughout the drawings, identical reference numerals are used to denote identical components.

[0022] In the attached figure: Figure 1 A schematic diagram showing the heat pipe positions of a dry-type high-frequency transformer cooling system based on heat pipe cooling according to the present invention; Figure 2 A schematic structural diagram of a dry-type high-frequency transformer cooling system based on heat pipe cooling according to the present invention is shown.

[0023] The present invention will be further explained below with reference to the accompanying drawings and embodiments. DETAILED DESCRIPTION

[0024] Specific embodiments of the present invention will be described in more detail below with reference to the accompanying drawings. Although specific embodiments of the present invention are shown in the accompanying drawings, it should be understood that the present invention can be implemented in various forms and should not be limited by the embodiments set forth herein. Rather, these embodiments are provided to enable a more thorough understanding of the present invention and to fully convey the scope of the present invention to those skilled in the art.

[0025] It should be noted that certain words are used in the specification and claims to refer to specific components. Those skilled in the art should understand that technicians may use different nouns to refer to the same component. This specification and claims do not use the difference in nouns as a way to distinguish components, but use the difference in the functions of the components as the criterion for distinction. As mentioned throughout the specification and claims, "including" or "comprising" is an open term, so it should be interpreted as "including but not limited to". The subsequent description of the specification is a preferred embodiment of the present invention, but the description is based on the general principles of the specification and is not intended to limit the scope of the invention. The scope of protection of the present invention shall be as defined in the attached claims.

[0026] To facilitate understanding of the embodiments of the present invention, several specific embodiments will be further explained below with reference to the accompanying drawings. However, the accompanying drawings do not limit the embodiments of the present invention.

[0027] For better understanding, Figures 1 to 2 As shown, a dry-type high-frequency transformer cooling system based on heat pipe cooling includes: a pair of iron cores 21; a low voltage winding 19 which surrounds adjacent portions of a pair of cores 21; a high voltage winding 20 , which surrounds the low voltage winding 19 ; At least one first heat pipe, which is distributed on both sides of the iron core and arranged close to the side of the iron core 21, and the upper part of the first heat pipe is bent; At least one second heat pipe, which is distributed between the two cores 21 and one end of the second heat pipe is bent along the curved surface of the core 21; at least one third heat pipe, which is distributed between the second heat pipes; a heat sink 23, which is thermally connected to the first heat pipe, the second heat pipe, and the third heat pipe; The heat dissipation fan 24 is connected to the heat dissipation fins 23 .

[0028] In a preferred embodiment of the dry-type high-frequency transformer cooling system based on heat pipe cooling, an epoxy resin casting body is further included surrounding the high-voltage winding 20 .

[0029] In a preferred embodiment of the dry-type high-frequency transformer cooling system based on heat pipe cooling, a gap is left between the high-voltage winding 20 and the low-voltage winding 19 , and a gap is left between the high-voltage winding 20 and the iron core 21 .

[0030] In a preferred embodiment of the dry-type high-frequency transformer cooling system based on heat pipe cooling, the first heat pipe extends vertically and is bent 90 degrees at the upper portion to form a horizontal surface in close contact with the heat sink 23 .

[0031] In a preferred embodiment of the dry-type high-frequency transformer cooling system based on heat pipe cooling, at least one first heat pipe extends vertically close to the side of the iron core 21 and is surrounded by the low-voltage winding 19 .

[0032] In a preferred embodiment of the dry-type high-frequency transformer cooling system based on heat pipe cooling, the other end of the second heat pipe opposite to the bent end extends horizontally on the surface of the iron core 21 .

[0033] In a preferred embodiment of the dry-type high-frequency transformer cooling system based on heat pipe cooling, the third heat pipes are arranged at equal intervals and parallel to the other end of the second heat pipe.

[0034] In a preferred embodiment of the dry-type high-frequency transformer cooling system based on heat pipe cooling, the top ends of the first heat pipe, the second heat pipe and the third heat pipe are on the same horizontal plane.

[0035] In a preferred embodiment of the dry-type high-frequency transformer cooling system based on heat pipe cooling, the heat sink 23 is a fin-type heat sink.

[0036] In a preferred embodiment of the dry-type high-frequency transformer cooling system based on heat pipe cooling, the cooling fan 24 is a DC cooling fan.

[0037] In one embodiment, the heat pipe consists of a vacuum-sealed copper tube shell, an internal capillary wick, and a phase-change working fluid (such as deionized water). Its working principle is that the working fluid is vaporized by absorbing heat from the evaporation section, and liquefied after releasing latent heat in the condensation section. The liquid then flows back to the evaporation section through capillary force and gravity to complete the cycle. This phase-change heat transfer mechanism makes the equivalent thermal conductivity of the heat pipe extremely high.

[0038] In one embodiment, Figure 1 This is a schematic diagram of the heat pipe positions of the dry-type high-frequency transformer cooling system based on heat pipe cooling of the present invention. 1-18 are all heat pipes, 19 is a low-voltage winding, 20 is a high-voltage winding, and 21 is an iron core. Heat pipes 1-10 are the first heat pipes distributed on both sides of the iron core. These 10 heat pipes are placed close to the sides of the iron core, and their upper parts are bent 90 degrees. Heat pipes 11-14 are the second heat pipes distributed between the two iron cores, wherein heat pipes 11 and 13 are bent along the curved surface of the iron core to one side, and heat pipes 12 and 14 are bent along the curved surface of the iron core to the other side. Heat pipes 15, 16, 17, and 18 are distributed between heat pipes 11, 12, 13, and 14. Figure 2 The figure is a schematic diagram of the high-frequency transformer of the present invention, wherein 22 is an epoxy resin casting, 23 is a finned heat sink, and 24 is a cooling fan. The upper portion of the heat pipe 1-10 placed on the side of the core is bent outward 90 degrees, and the horizontal plane formed by it is in close contact with the finned heat sink. Among them, the heat pipes 2-4 and 7-9 are close to the core and close to the winding, mainly used for heat dissipation of the winding and the core column. The heat pipes 1, 5, 6, and 10 are close to the cores on both sides and are mainly used for heat dissipation of the core side columns. The heat pipes 11-14 placed between the two cores are in close contact with the finned heat sink after bending along the core, mainly used for heat dissipation of the core center column. The heat pipes 15-18 are also in close contact with the finned heat sink, and their main function is to make the temperature distribution of the heat sink more uniform and improve the heat dissipation efficiency of the heat sink. The length and width of the heat sink are similar to those of the transformer, and the height of the heat sink is relatively small. Six DC cooling fans are placed on the upper part of the heat sink for heat dissipation of the heat sink, and the wind direction of the cooling fans is towards the heat sink.

[0039] In the present invention, the volume occupied by the heat sink and the cooling fan is relatively small, which has little effect on the power density of the dry-type high-frequency transformer. In addition, the dry-type high-frequency transformer based on heat pipe cooling of the present invention eliminates heat dissipation equipment such as external fans, thereby reducing the volume and power consumption of the heat dissipation equipment.

[0040] The basic principles of the present application have been described above in conjunction with specific embodiments. However, it should be noted that the advantages, strengths, and effects mentioned in this application are merely illustrative and not restrictive, and it should not be assumed that these advantages, strengths, and effects are required of each embodiment of this application. In addition, the specific details disclosed above are merely illustrative and facilitating understanding, and are not restrictive. The above details do not limit this application to necessarily being implemented using the above specific details.

[0041] The above description has been provided for the purpose of illustration and description. Furthermore, this description is not intended to limit the embodiments of the present application to the forms disclosed herein. Although a number of example aspects and embodiments have been discussed above, those skilled in the art will recognize certain variations, modifications, alterations, additions, and sub-combinations thereof.

Claims

1. A dry-type high-frequency transformer cooling system based on heat pipe cooling, characterized in that: These include, A pair of iron cores; a low-voltage winding, which surrounds adjacent portions of a pair of cores; a high voltage winding surrounding the low voltage winding; at least one first heat pipe, which is distributed on both sides of the iron core and arranged closely to the side surfaces of the iron core, and the upper portion of the first heat pipe is bent; At least one second heat pipe, which is distributed between the two iron cores and one end of the second heat pipe is bent along the curved surface of the iron core; at least one third heat pipe, which is distributed between the second heat pipes; a heat sink thermally connecting the first heat pipe, the second heat pipe, and the third heat pipe; A heat dissipation fan is connected to the heat dissipation fins.

2. The dry-type high-frequency transformer cooling system based on heat pipe cooling according to claim 1, characterized in that: Preferably, the invention further comprises an epoxy resin casting body surrounding the high voltage winding.

3. The dry-type high-frequency transformer cooling system based on heat pipe cooling according to claim 1, characterized in that: A gap is left between the high-voltage winding and the low-voltage winding, and a gap is left between the high-voltage winding and the iron core.

4. The dry-type high-frequency transformer cooling system based on heat pipe cooling according to claim 1, characterized in that: The first heat pipe extends vertically and has an upper portion bent 90 degrees to form a horizontal surface in close contact with the heat sink.

5. The dry-type high-frequency transformer cooling system based on heat pipe cooling according to claim 1, characterized in that: At least one first heat pipe extends vertically close to the side surface of the core and is surrounded by the low-voltage winding.

6. The dry-type high-frequency transformer cooling system based on heat pipe cooling according to claim 1, characterized in that: The other end of the second heat pipe opposite to the bent end extends horizontally on the surface of the core.

7. The dry-type high-frequency transformer cooling system based on heat pipe cooling according to claim 6, characterized in that: The third heat pipes are arranged at equal intervals and parallel to the other end of the second heat pipe.

8. The dry-type high-frequency transformer cooling system based on heat pipe cooling according to claim 1, characterized in that: The top ends of the first heat pipe, the second heat pipe and the third heat pipe are on the same horizontal plane.

9. The dry-type high-frequency transformer cooling system based on heat pipe cooling according to claim 1, characterized in that: The heat sink is a fin-type heat sink.

10. The dry-type high-frequency transformer cooling system based on heat pipe cooling according to claim 1, characterized in that: The cooling fan is a DC cooling fan.

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