High-density transformer, driving circuit and motor controller

Abstract

The invention discloses a high-density transformer, a driving circuit and a motor controller. The high-density transformer comprises at least four layers of circuit boards, a primary winding, a secondary winding and a magnetic core. The at least four layers of circuit boards are arranged at intervals along a first direction; the primary winding comprises a first winding and a second winding, and the secondary winding comprises a third winding; the first winding and the second winding are integrated on two layers of circuit boards in a parallel winding mode, and the second winding is independently arranged on the other two layers of circuit boards; the magnetic core extends along a first direction and penetrates through all the windings. Through a double-wire parallel winding framework, primary side double-winding co-layer is realized, and a vertical space is remarkably compressed; therefore, on the premise of guaranteeing electrical safety, the space utilization rate is improved, and high density of the transformer is achieved.

Description

Technical Field

[0001] The present invention relates to the field of new energy vehicles, and in particular to a high-density transformer, a drive circuit, and a motor controller. Background Art

[0002] In new energy vehicle motor control systems, the isolation transformer is a core component for ensuring safe power supply to power modules. Its core functions include: providing independent power supply for the floating potential side of power modules (such as IGBTs and SiC MOSFETs), blocking the electrical connection between the high-voltage main circuit and the low-voltage control circuit, preventing the risk of common-mode noise conduction and high-voltage breakdown, and transferring primary-side energy to the secondary side through magnetic core coupling. It also provides a stable power supply for the gate drive of power switching devices, ensuring the precise triggering and shutdown of motor control signals, etc.

[0003] However, existing transformers have several drawbacks: First, due to their low winding density, existing transformers occupy a large area. Second, the unconstrained scattering of the fringing flux generated by the transformer during operation creates a high-intensity electromagnetic field around the transformer, forcing other components in the motor controller to be positioned away from the transformer. This further reduces the density of the motor controller and increases its space. These drawbacks collectively hinder the evolution of motor controllers towards compactness and high integration, making it difficult to meet the stringent requirements of new energy vehicles for optimizing powertrain space.

[0004] In summary, a solution for a high-density transformer is urgently needed. Summary of the Invention

[0005] In order to overcome the above technical defects, the object of the present invention is to provide a high-density transformer, a drive circuit and a motor controller.

[0006] A first aspect of the present invention discloses a high-density transformer comprising at least four layers of circuit boards, a primary winding, a secondary winding and a magnetic core.

[0007] At least four layers of circuit boards are arranged in a first direction, spaced apart from each other. The primary winding includes a first winding and a second winding. The secondary winding includes a third winding. The first winding and the second winding are wound in parallel on two layers of the at least four layers of the circuit board. The second winding is arranged on the other two layers of the at least four layers of the circuit board.

[0008] The magnetic core extends along a first direction. The primary winding and the secondary winding are both wound around the magnetic core.

[0009] Preferably, the first winding is on the outside and the second winding is on the inside. The first winding has one more turn than the second winding.

[0010] In one layer of the at least four layers of the circuit board, the first winding and the second winding are wound from outside to inside. In another layer, the first winding and the second winding are wound from inside to outside.

[0011] Preferably, the at least four-layer circuit board specifically includes a first layer, a second layer, a third layer, a fourth layer, a fifth layer and a sixth layer.

[0012] The primary winding occupies the second layer and the third layer, and is connected between the second layer and the third layer through the first hole.

[0013] The secondary winding occupies the fourth and fifth layers and is connected between the fourth and fifth layers via a second hole.

[0014] Preferably, at least four layers of the circuit board are insulating circuit boards, and the insulating circuit boards form electrical isolation between the magnetic core and the primary winding and the secondary winding.

[0015] Preferably, the primary winding is a low-voltage winding, and the secondary winding is a high-voltage winding.

[0016] On a plane perpendicular to the first direction, the distance between the primary winding and the magnetic core is greater than 0.4 mm, and the distance between the secondary winding and the magnetic core is greater than 0.9 mm.

[0017] Preferably, on a plane perpendicular to the first direction, a distance between the first hole and the second hole is greater than or equal to 4 mm.

[0018] Preferably, the magnetic core comprises a first magnetic column and a second magnetic column that are spaced apart from each other. The first winding and the second winding are both wound around the first magnetic column.

[0019] Preferably, the first winding is an excitation winding, the second winding is a demagnetization winding or a feedback winding, and the third winding is an output winding.

[0020] A second aspect of the present application provides a driving circuit, which includes an input circuit, an output circuit, and a high-density transformer as described above; the input circuit is electrically connected to the output circuit through the high-density transformer.

[0021] The third aspect of the present application further provides a motor controller, comprising the aforementioned driving power supply circuit.

[0022] Compared with the existing technology, the above technical solution has the following beneficial effects: 1. This application utilizes a dual-winding parallel winding architecture to integrate the first and second primary windings into a two-layer circuit board in a co-layered manner. This design transforms the winding distribution from a serial three-dimensional stacking to a planar stacking, significantly reducing the space required for the windings in the vertical direction. Furthermore, the layout of the magnetic core extending along the stacking direction of the circuit boards further enhances the compactness of the three-dimensional space. This is particularly suitable for the space requirements of highly integrated electronic devices and provides basic support for the miniaturization of transformers. 2. Furthermore, by providing a six-layer circuit board, and the outermost circuit board is not provided with a winding, and the first layer and the sixth layer are not provided with a winding, the other components of the motor controller can be tightly arranged on the first layer and the sixth layer without considering the electrical insulation between the outer layer devices, thereby further optimizing the internal space of the motor controller.

[0023] 3. Utilizing a solid insulating circuit board as the winding carrier, an insulating layer is constructed between the magnetic core and the winding. Based on this insulating layer, the distance between the first and second holes, as well as the distance between the high-voltage and low-voltage windings, is appropriately set to ensure insulation between the first and second holes, and between the high-voltage and low-voltage windings. This further miniaturizes the transformer while improving safety and stability. 4. By winding both the primary and secondary windings on the same magnetic column, the leakage inductance can be effectively reduced compared to winding the two windings on separate columns. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 A schematic diagram of the structure of the high-density transformer provided in this application; Figure 2 A schematic diagram of the projection positions of the windings of the high-density transformer provided in this application; Figure 3 A schematic diagram of the structure of the second layer circuit board of the high-density transformer provided in this application; Figure 4 A schematic structural diagram of the third-layer circuit board of the high-density transformer provided in this application; Figure 5 A schematic structural diagram of the fourth-layer circuit board of the high-density transformer provided in this application; Figure 6 A schematic structural diagram of the fifth-layer circuit board of the high-density transformer provided in this application; Figure 7 This is a schematic diagram of the driving circuit provided in this application.

[0025] Reference numerals: 100, high-density transformer; 1. Primary winding; 11. First hole; 2. The first winding; 3. Second winding; 4. Secondary winding; 41. Second hole; 5. The third winding; 6. Magnetic core; 61. First magnetic column; 62. Second magnetic column; 72, second floor; 73, third floor; 74, fourth floor; 75, fifth floor; z, first direction. DETAILED DESCRIPTION

[0026] The advantages of the present invention are further described below with reference to the accompanying drawings and specific embodiments.

[0027] Exemplary embodiments will be described in detail herein, with examples illustrated in the accompanying drawings. In the following description, when referring to the drawings, identical numerals in different figures represent identical or similar elements, unless otherwise indicated. The embodiments described in the following exemplary embodiments are not intended to represent all possible embodiments consistent with the present disclosure. Rather, they are merely examples of apparatus and methods consistent with certain aspects of the present disclosure, as detailed in the appended claims.

[0028] The terms used in this disclosure are for the purpose of describing specific embodiments only and are not intended to limit the disclosure. As used in this disclosure and the appended claims, the singular forms "a," "an," "the," and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It should also be understood that the term "and / or" as used herein refers to and encompasses any and all possible combinations of one or more of the associated listed items.

[0029] It should be understood that although the terms first, second, third, etc. may be used in the present disclosure to describe various information, such information should not be limited to these terms. These terms are only used to distinguish information of the same type from each other. For example, without departing from the scope of the present disclosure, the first information may also be referred to as the second information, and similarly, the second information may also be referred to as the first information. Depending on the context, the word "if" as used herein may be interpreted as "at the time of" or "when" or "in response to determining" In the description of the present invention, it should be understood that the terms "longitudinal", "transverse", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", etc., indicating the orientation or position relationship, are based on the orientation or position relationship shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as limiting the present invention.

[0030] In the description of the present invention, unless otherwise specified and limited, it should be noted that the terms "installed", "connected" and "connected" should be understood in a broad sense. For example, it can be a mechanical connection or an electrical connection, or it can be the internal communication between two components. It can be a direct connection or an indirect connection through an intermediate medium. For ordinary technicians in this field, the specific meanings of the above terms can be understood according to the specific circumstances.

[0031] In the following description, the suffixes such as "module", "component" or "unit" used to represent elements are only used to facilitate the description of the present invention and have no specific meaning. Therefore, "module" and "component" can be used interchangeably.

[0032] See also Figure 1-Figure 2 , Figure 1 A schematic diagram of the structure of the high-density transformer provided in this application; Figure 2 This is a schematic projection diagram of the positions of the windings of the high-density transformer provided in this application.

[0033] like Figure 1-Figure 2 As shown, the present invention discloses a high-density transformer 100, which includes at least four layers of circuit boards (not shown in the figure), a primary winding 1, a secondary winding 4 and a magnetic core 6.

[0034] At least four layers of circuit boards are arranged in a first direction z. The primary winding 1 includes a first winding 2 and a second winding 3. The secondary winding 4 includes a third winding 5. The first winding 2 and the second winding 3 are wound in parallel on two layers of the at least four layers of the circuit board. The second winding 3 is arranged on the other two layers of the at least four layers of the circuit board.

[0035] The magnetic core 6 extends along a first direction z. The primary winding 1 and the secondary winding 4 are both wound around the magnetic core 6 .

[0036] This may be understood as follows: In response to the demand for a high-density transformer 100, the high-density transformer 100 provided in this application innovatively adopts a double-wire parallel winding method to integrate the first winding 2 and the second winding 3 in the primary winding 1 into a two-layer circuit board in a co-layer manner. This design transforms the winding distribution from three-dimensional superposition to planar superposition, significantly reducing the space requirements of the winding in the vertical direction. At the same time, the layout of the magnetic core 6 extending along the stacking direction of the circuit board further enhances the compactness of the three-dimensional space. It is particularly suitable for the space requirements of highly integrated electronic devices and provides basic support for the miniaturization of transformers.

[0037] The above is an explanation of the basic concept of the present application. The specific structure of each component of the transformer will be described in detail below with reference to the accompanying drawings.

[0038] See also Figure 3-Figure 6 , Figure 3A schematic structural diagram of the second layer of the high-density transformer provided in this application; Figure 4 A schematic structural diagram of the third layer of the high-density transformer provided in this application; Figure 5 A schematic structural diagram of the fourth layer of the high-density transformer provided in this application; Figure 6 This is a schematic structural diagram of the fifth layer of the high-density transformer provided in this application.

[0039] like Figure 3-Figure 6 As shown, first, the high-density transformer 100 specifically includes no limitation on the number of layers of circuit boards.

[0040] In a possible implementation, the at least four layers of the circuit board specifically include a first layer, a second layer 72 , a third layer 73 , a fourth layer 74 , a fifth layer 75 and a sixth layer.

[0041] The primary winding 1 occupies the second layer 72 and the third layer 73 , and is connected between the second layer 72 and the third layer 73 via the first hole 11 .

[0042] The secondary winding 4 occupies the fourth layer 74 and the fifth layer 75 , and is connected between the fourth layer 74 and the fifth layer 75 via the second hole 41 .

[0043] This can be understood as follows: Based on the aforementioned bifilar winding scheme, the first winding 2 and the second winding 3 can occupy two layers of the circuit board, so at least four layers of circuit boards can be arranged in a six-layer circuit board structure arranged sequentially from the first layer to the sixth layer. Moreover, by arranging the primary winding 1 on the second layer 72 and the third layer 73, and the secondary winding 4 on the fourth layer 74 and the fifth layer 75, the first and sixth layers outside the transformer can be free of windings. This optimizes the internal space of the motor controller, allowing it to accommodate more functional components or be further miniaturized.

[0044] On the other hand, if windings are provided on the first and sixth layers, then for electrical insulation considerations, other components of the motor controller need to be arranged on the first and sixth layers away from the windings, significantly reducing space utilization. The high-density transformer 100 of the present application does not have windings on the first and sixth layers, allowing other components of the motor controller to be densely arranged on the first and sixth layers without requiring electrical insulation considerations, thereby further optimizing the internal space of the motor controller.

[0045] Those skilled in the art will appreciate that the at least four-layer circuit board may also be a four-layer circuit board, a five-layer circuit board, a seven-layer circuit board, an eight-layer circuit board, or more, and this application does not impose any limitation thereto. Similarly, the specific locations of the primary winding 1 and the secondary winding 4 are also not limited, and those skilled in the art may design them as needed.

[0046] Furthermore, the specific type of the circuit board is also not limited.

[0047] In a possible implementation, at least four layers of the circuit board are insulating circuit boards, and the insulating circuit boards form electrical isolation between the magnetic core 6 and the primary winding 1 and the secondary winding 4 .

[0048] By using solid insulation, the electrical influence between windings, between winding through-holes, and between windings and through-holes can be reduced, so that the windings and the through-holes of the windings can be arranged more closely, further improving the space utilization of the high-density transformer 100.

[0049] Therefore, it can be understood that by reasonably setting the distances between the windings and between the through holes of the windings, the space occupied by the transformer can be reasonably reduced while ensuring electrical isolation.

[0050] Furthermore, when the primary winding 1 is a low-voltage winding, on a plane perpendicular to the first direction z, the distance between the primary winding 1 and the magnetic core 6 is greater than 0.4 mm. The distance between the secondary winding 4 and the magnetic core 6 is greater than 0.9 mm. The distance between the first hole 11 and the second hole 41 is greater than or equal to 4 mm.

[0051] A solid insulating circuit board is used as a winding carrier, and an insulating layer is constructed between the magnetic core 6 and the winding. Based on the insulating layer, the distance between the first hole 11 and the second hole 41 and the distance between the primary winding 1 and the secondary winding 4 are appropriately set to ensure insulation between the first hole 11 and the second hole 41 and between the primary winding 1 and the secondary winding 4. While improving safety and stability, the transformer is further miniaturized.

[0052] Secondly, the specific designs of the primary winding 1 and the secondary winding 4 are also not limited.

[0053] like Figure 3-Figure 6 As shown, in a possible implementation, the first winding 2 is on the outside and the second winding 3 is on the inside. The first winding 2 has one more turn than the second winding 3.

[0054] Specifically, in the second layer 72, the first winding 2 and the second winding 3 are wound from outside to inside. In the third layer 73, the first winding 2 and the second winding 3 are wound from inside to outside.

[0055] Again, the specific functions of the primary winding 1 and the secondary winding 4 are also not limited.

[0056] In a possible implementation, the primary winding 1 is a low-voltage winding, and the secondary winding 4 is a high-voltage winding. In this case, the transformer is a voltage-regulating transformer.

[0057] Furthermore, the first winding 2 is an excitation winding, the second winding 3 is a demagnetization winding or a feedback winding, and the third winding 5 is an output winding, so that the transformer is used to convert a low voltage into a high voltage output.

[0058] The second winding 3 is a demagnetization winding or a feedback winding. When the second winding 3 is a demagnetization winding, the transformer's external circuit uses a forward topology, but the actual topology is not limited. When the second winding 3 is a feedback winding, it can be used to monitor the transformer's condition and provide real-time feedback to a control component (such as a motor controller). This is also not limited in this application.

[0059] Finally, those skilled in the art will appreciate that the specific structure of the magnetic core 6 is also not limited.

[0060] like Figure 1 As shown, in one possible implementation, the magnetic core 6 includes a first magnetic column 61 and a second magnetic column 62 that are spaced apart from each other. The first winding 2 and the second winding 3 are both wound around the first magnetic column 61. Compared to winding two windings on the same column, winding the two windings on the same column can effectively reduce leakage inductance.

[0061] Specifically, in a possible implementation, as Figure 1 As shown, the magnetic core 6 may include two U-shaped portions arranged opposite to each other in the first direction z, and thus may be referred to as a UU-shaped magnetic core, with one side leg of the U-shaped magnetic core serving as a first magnetic leg 61 and the other side leg serving as a second magnetic leg 62. In another possible implementation, the magnetic core 6 may also be a UI-shaped magnetic core, an EE-shaped magnetic core, an EI-shaped magnetic core, etc., which is also not limited in this application.

[0062] For example, this application also provides an embodiment: like Figure 1-Figure 7 As shown, the present application provides a high-density transformer 100, each layer of the circuit board is 16.2 mm long and 13.4 mm wide. The high-density transformer 100 is 6.4 mm high. The first magnetic column 61 and the second magnetic column 62 are 5.3 mm wide and 2.4 mm long. The excitation winding inductance is 100 uH, the demagnetization winding inductance is 64 Uh, and the output winding inductance is 256 Uh. The turns ratio excitation: demagnetization: output = 10:8:16. The primary-secondary coupling capacitor is 13 pF. The distance between the primary winding 1 and the magnetic core 6 is 0.5 mm. The distance between the secondary winding 4 and the magnetic core 6 is 1 mm. The distance between the first hole 11 and the second hole 41 is 4.5 mm.

[0063] See also Figure 7 , Figure 7 This is a schematic diagram of the driving circuit provided in this application.

[0064] like Figure 7As shown, the second aspect of the present application further provides a driving circuit, which includes an input circuit, an output circuit and the high-density transformer 100 in any of the aforementioned embodiments; the input circuit is electrically connected to the output circuit through the high-density transformer 100.

[0065] The third aspect of the present application further provides a motor controller, comprising the aforementioned drive circuit, thereby making the motor controller compact in structure.

[0066] It should be noted that the embodiments of the present invention have better practicability and do not impose any form of limitation on the present invention. Any technician familiar with the field may use the technical content disclosed above to change or modify it into an equivalent effective embodiment. However, any modification or equivalent changes and modifications made to the above embodiments based on the technical essence of the present invention without departing from the content of the technical solution of the present invention are still within the scope of the technical solution of the present invention.

Claims

1. A high-density transformer, characterized in that: include: At least four layers of circuit boards, primary windings, secondary windings, and magnetic cores; The at least four layers of circuit boards are arranged in sequence in a first direction; the primary winding includes a first winding and a second winding; the secondary winding includes a third winding; the first winding and the second winding are wound in parallel on two layers of the at least four layers of circuit boards; and the second winding is arranged on the other two layers of the at least four layers of circuit boards. The magnetic core extends along the first direction; the primary winding and the secondary winding are both wound around the magnetic core.

2. The high-density transformer according to claim 1, characterized in that The first winding is on the outside, and the second winding is on the inside; the first winding has one more turn than the second winding; On one layer of the at least four layers of the circuit board, the first winding and the second winding are wound from outside to inside; In another layer, the first winding and the second winding are wound from inside to outside.

3. The high-density transformer according to claim 1, characterized in that The at least four layers of circuit boards specifically include a first layer, a second layer, a third layer, a fourth layer, a fifth layer and a sixth layer; The primary winding occupies the second layer and the third layer, and is connected between the second layer and the third layer through a first hole; The secondary winding occupies the fourth layer and the fifth layer, and is connected between the fourth layer and the fifth layer through a second hole.

4. The high-density transformer according to claim 3, characterized in that The at least four layers of circuit boards are insulating circuit boards, and the insulating circuit boards form electrical isolation between the magnetic core and the primary winding and the secondary winding.

5. The high-density transformer according to claim 4, characterized in that: The primary winding is a low-voltage winding, and the secondary winding is a high-voltage winding; On a plane perpendicular to the first direction, the distance between the primary winding and the magnetic core is greater than 0.4 mm; the distance between the secondary winding and the magnetic core is greater than 0.9 mm.

6. The high-density transformer according to claim 5, characterized in that On a plane perpendicular to the first direction, a distance between the first hole and the second hole is greater than or equal to 4 mm.

7. The high-density transformer according to claim 1, wherein: The magnetic core includes a first magnetic column and a second magnetic column that are arranged relatively spaced apart; the first winding and the second winding are both wound around the first magnetic column.

8. The high-density transformer according to claim 1, wherein: The first winding is an excitation winding, and the second winding is a demagnetization winding or a feedback winding; The third winding is an output winding.

9. A driving circuit, characterized in that: The driving circuit includes an input circuit, an output circuit, and a high-density transformer as described in claims 1-8; the input circuit is electrically connected to the output circuit through the high-density transformer.

10. A motor controller, characterized in that: The driving power supply circuit according to claim 9 is included.

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