AI four-in-one PV inductor

Abstract

The invention discloses an AI four-in-one PV inductor, which belongs to the technical field of electronic components and comprises a bottom plate, five isolation parts, four U-shaped magnetic cores, a magnetic core end part and four coil windings, the U-shaped magnetic cores are connected end to end and form a closed magnetic circuit through closing of the magnetic core ends, and the coil windings are wound on arms, close to the bottom plate, of the U-shaped magnetic cores. According to the invention, the magnetic leakage rate is effectively reduced and the magnetic circuit efficiency and the electromagnetic compatibility are improved by filling the soft magnetic paste into the magnetic conductive groove in the inner side of the U-shaped magnetic core, filling the magnetic core connecting end gap into the magnetic conductivity matching agent and designing the composite material isolation part and the magnetic core grounding loop. Meanwhile, the integrated AI monitoring module can realize intelligent overload protection and state early warning, is suitable for wide-power fluctuation scenes such as a 1-5kW photovoltaic inverter, and has high efficiency, high reliability and good intelligent adaptation capability.

Description

Technical Field

[0001] This invention relates to the technical field of electronic components, and in particular to a high power density inductor structure suitable for photovoltaic inverters and artificial intelligence control power supplies. Background Technology

[0002] Inductors, as key energy storage and filtering components in power electronic systems, are widely used in high-frequency, high-power scenarios such as photovoltaic inverters, AI servo power supplies, and electric vehicle drives. With the increasing power density and intelligent development of systems, higher demands are placed on inductors: high efficiency, low loss, small size, tunability, and high electromagnetic compatibility. To meet these requirements, multi-inductor integrated structures have become a research hotspot, aiming to integrate multiple inductor units within a limited space, achieving shared magnetic circuits, reduced size, and lower cost.

[0003] Currently, the main technical routes for all-in-one inductors include: Shared core structure: The core volume is reduced by sharing the magnetic circuit arm. Nested coil structure: magnetic circuit coupling and integration are achieved through nesting of main and auxiliary coils; Modular packaging structure: multiple independent inductors are packaged into one unit, improving assembly efficiency.

[0004] However, existing technologies still have significant shortcomings in terms of magnetic circuit adjustability, electromagnetic interference suppression, structural flexibility, and intelligent adaptability.

[0005] Based on this, Chinese patent document CN203444964U discloses a four-in-one inductor, which proposes a structural scheme of a four-in-one inductor arranged in a grid pattern. In this scheme, the four inductor units share a cross-shaped magnetic circuit arm. By designing the magnetic flux directions to be opposite on the shared arm of adjacent inductors, magnetic circuit cancellation is achieved, thereby reducing the cross-sectional area of ​​the shared arm and reducing volume and weight. However, this four-in-one inductor still has the following technical problems: The magnetic circuit rigidity is not adjustable: the core structure is fixed, making it impossible to adjust the inductance value according to power changes, making it difficult to adapt to photovoltaic MPPT or AI load fluctuation scenarios; there is no electromagnetic shielding design: high-frequency switching noise suppression is not considered, resulting in insufficient EMC performance; and the applicable scenarios are limited: it is only suitable for symmetrical current conditions, and magnetic circuit imbalance and efficiency reduction occur under asymmetrical or transient loads.

[0006] Furthermore, another Chinese patent document, CN118522539A, discloses a four-in-one dual-winding inductor and its manufacturing method. In the technical solution disclosed in this patent document, a base-accommodating slot structure is used to nest and assemble the main coil, secondary coil, and internal magnetic core, forming them through a hot-pressing process to achieve multi-inductor integration and insulation isolation. However, this technical solution also has the following technical problems: complex structure and high cost: the nesting of the main and secondary coils and the multi-step hot-pressing process increase the manufacturing difficulty and cost; limited magnetic circuit coupling efficiency: the magnetic circuit distribution is limited by the base slot, making it difficult to achieve efficient magnetic flux interaction; lack of intelligent adjustability: the inductance value is a fixed design, unable to respond to dynamic system requirements; no integrated EMC design: no electromagnetic shielding or absorption structure is involved, limiting its high-frequency applicability.

[0007] In general, existing all-in-one inductor technology mainly suffers from the following technical problems: 1. Fixed magnetic circuit, lack of adjustability: The existing inductor core structure is rigid and cannot dynamically adjust the inductance value according to the operating point, such as power, frequency, temperature, etc., which leads to a decrease in efficiency under a wide range of load conditions and cannot meet the real-time optimization requirements of AI control or photovoltaic MPPT.

[0008] 2. Lack of electromagnetic compatibility design: Most existing structures do not consider the shielding and absorption of high-frequency switching noise, resulting in excessive EMI in the system and affecting the certification and reliability of the whole machine.

[0009] 3. Complex structure and low reliability: Nested coil or bonded magnetic core structures have problems such as high assembly precision requirements, concentrated thermal stress, and poor reliability.

[0010] 4. Limitations in application scenarios: Existing designs are mostly designed for traditional symmetrical operating conditions, which are difficult to adapt to asymmetrical, multi-mode, and high-transient photovoltaic and AI application scenarios.

[0011] 5. Low level of intelligent integration: It lacks integration interfaces with intelligent components such as sensors and controllers, making it impossible to build a closed-loop inductive system of "perception-decision-regulation". Summary of the Invention

[0012] Therefore, it is necessary to provide an AI four-in-one PV inductor to address the technical problems existing in the current technology.

[0013] An AI quad-in-one PV inductor, comprising: Base plate: As the supporting foundation and electrical connection platform for the entire inductor, it can be made of FR-4 epoxy glass cloth substrate or aluminum alloy carrier with polytetrafluoroethylene insulation layer on the surface.

[0014] Isolation sections: There are a total of five, evenly distributed on the base plate at intervals of 15mm to 20mm, which play a key role in insulation, positioning and ensuring the accuracy of the magnetic circuit.

[0015] Magnetic circuit assembly: Consists of four U-shaped magnetic cores and one core end. The four U-shaped magnetic cores are fixed to the four isolation parts respectively by high-temperature resistant adhesive, and are connected end to end in sequence. Finally, the opening of the core end fixed to the fifth isolation part is closed, forming a complete closed magnetic circuit frame.

[0016] Coil windings: Four coil windings are respectively wound on the arms of the four U-shaped magnetic cores closest to the base plate. The ratio of their winding length to the length of the corresponding magnetic core arm is 0.8 to 1. All coil winding leads are inserted into pre-set openings in the base plate for electrical connection. The opening diameter is designed to be 0.2mm larger than the lead diameter to facilitate installation and allow for sufficient margin.

[0017] Furthermore, the isolation part is made of a magnetic insulating material composed of epoxy resin, nanocrystalline soft magnetic powder and alumina ceramic powder, which has good insulation and magnetic permeability.

[0018] Furthermore, the inner side of the U-shaped arm of the U-shaped magnetic core is provided with a magnetically conductive groove, which is filled with soft magnetic paste. The gap between the connecting ends of adjacent U-shaped magnetic cores is filled with a magnetic permeability matching agent to optimize the magnetic circuit and reduce magnetic leakage.

[0019] Furthermore, the end of the magnetic core is divided into a magnetically conductive body and an insulating outer shell, which are detachably connected to the U-shaped magnetic core through a snap-fit ​​structure.

[0020] Furthermore, the base plate integrates temperature, current, and voltage sensors, and is equipped with an AI control module interface to achieve real-time monitoring, intelligent protection, and adaptive parameter adjustment.

[0021] Furthermore, the coil winding leads are secured by both welding and elastic clips, and are covered with heat shrink tubing to improve connection reliability and insulation level.

[0022] Compared with the prior art, the present invention has the following beneficial effects: 1. High magnetic circuit efficiency and low magnetic leakage: Through the synergistic design of magnetic grooves, soft magnetic paste, and magnetic permeability matching agent, magnetic resistance and magnetic leakage are significantly reduced, and the magnetic leakage rate can be controlled below 5%. 2. Excellent EMC performance: The composite material isolation section and the magnetic core grounding circuit effectively suppress high-frequency interference, meeting the requirements of standards such as CISPR11; 3. Reliable structure and good heat dissipation: The U-shaped magnetic core is lined with fiberglass cloth and thermal grease to improve heat dissipation; the double-fixed leads and heat shrink tubing protection enhance mechanical and insulation reliability. 4. Intelligent monitoring and protection: Integrates multiple types of sensors and AI control modules to achieve overload protection, status warning and power adaptation, with a response time of less than 80ms; 5. Wide range of applications: Applicable to a wide power range of scenarios such as 1-5kW photovoltaic inverters, it can operate stably in environments from -40℃ to 120℃ with an efficiency of over 96.5%. Attached Figure Description

[0023] Figure 1 This is a schematic diagram of the structure of an AI four-in-one PV inductor according to the present invention; Figure 2 This is an exploded structural diagram of one embodiment of an AI four-in-one PV inductor according to the present invention; Figure 3 This is a cross-sectional structural schematic diagram of another embodiment of the AI ​​four-in-one PV inductor of the present invention; Figure 4 This is an exploded structural diagram of another embodiment of an AI four-in-one PV inductor according to the present invention. Detailed Implementation

[0024] To make the above-mentioned objects, features, and advantages of the present invention more apparent and understandable, specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings. Many specific details are set forth in the following description to provide a thorough understanding of the present invention. However, the present invention can be practiced in many other ways different from those described herein, and those skilled in the art can make similar modifications without departing from the spirit of the present invention. Therefore, the present invention is not limited to the specific embodiments disclosed below.

[0025] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," and "circumferential" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0026] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this invention, "a plurality of" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0027] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise explicitly limited. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0028] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "over," and "on top" of the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0029] It should be noted that when an element is referred to as being "fixed to" or "set on" another element, it can be directly on the other element or there may be an intervening element. When an element is considered to be "connected to" another element, it can be directly connected to the other element or there may be an intervening element. The terms "vertical," "horizontal," "upper," "lower," "left," "right," and similar expressions used herein are for illustrative purposes only and do not represent the only possible implementation.

[0030] Please see Figure 1 The present invention provides an AI four-in-one PV inductor, comprising: The base plate 1 is made of circuit board or load-bearing structural material. If it is a circuit board, it is made of FR-4 epoxy glass cloth substrate. If it is a load-bearing structure, it is made of aluminum alloy and a 0.1mm thick polytetrafluoroethylene insulating layer is sprayed on the surface of the aluminum alloy material. Five isolation sections 2 are evenly distributed on the base plate 1. The distance between two adjacent isolation sections 2 can be 15 to 20 mm. The isolation sections 2 are used for insulation and isolation and to adjust the spacing between components to ensure magnetic circuit alignment and structural accuracy. Four U-shaped magnetic cores 3 and one magnetic core end 4 are provided. Each of the four isolation parts 2 is connected to a U-shaped magnetic core 3 by a high-temperature resistant adhesive with a temperature range of -40 degrees Celsius to 200 degrees Celsius. The remaining isolation part 2 is connected to the magnetic core end 4. The four U-shaped magnetic cores 3 are connected end to end in sequence. The U-shaped opening end of the U-shaped magnetic core 3 at the very end is closed by the magnetic core end 4 to form a closed magnetic circuit frame. Four coil windings 5 ​​are provided. One coil winding 5 is wound on one of the U-shaped arms of each U-shaped magnetic core 3. The coil winding 5 is located on the arm of the U-shaped magnetic core 3 closest to the base plate 1. The ratio of the winding length of the coil winding 5 to the length of the corresponding arm of the U-shaped magnetic core 3 is 0.8 to 1. The leads at both ends of each coil winding 5 are inserted into the pre-drilled openings in the base plate 1. The diameter of the openings is 0.2 mm larger than the diameter of the leads.

[0031] For details, please refer to Figure 2 The isolation part 2 is made of a magnetic insulating composite material, which is composed of epoxy resin, nanocrystalline soft magnetic powder and alumina ceramic powder mixed in a mass ratio of 5:3:2. The nanocrystalline soft magnetic powder has a particle size of 50 to 100 nm, and the alumina ceramic powder has a particle size of 20 to 50 μm. It is formed by hot pressing at 150 degrees Celsius with a pressure of 5 MPa and a holding time of 30 minutes. The isolation part 2 has a height of 8 to 10 mm and a square cross-section with a side length of 10 mm. The top of the isolation part 2 is provided with a positioning groove 201 that is adapted to the bottom of the U-shaped magnetic core 3 and the end of the magnetic core 4. The positioning groove 201 has a depth of 2 mm and its inner wall is provided with a silicone rubber buffer layer 202. The silicone rubber buffer layer 202 has a thickness of 0.1 to 0.2 mm and a Shore hardness of 50 ± 5 HA.

[0032] For further details, please refer to the following: Figure 2 and Figure 3 In one embodiment, the U-shaped magnetic core 3 can be made of ferrite core, model PC44. The cross-section of the U-shaped arm of the U-shaped magnetic core 3 is rectangular, with a width of 8mm and a thickness of 5mm, and the spacing between the U-shaped openings is 12mm. Each of the two U-shaped arms of the U-shaped magnetic core 3 has a magnetically conductive groove 301 extending along its length. The width of the magnetically conductive groove 301 is one-third of the width of the U-shaped arm, i.e., 2.67mm, and the depth is half the thickness of the U-shaped arm, i.e., 2.5mm. The magnetically conductive groove 301 is filled with soft magnetic paste, with a permeability of 2000 ± 200μH / m. The gap between the connecting ends of two adjacent U-shaped magnetic cores 3 is 0.3 to 0.5mm, and the gap is filled with a permeability matching agent 302. This matching agent is a mixture of silicone resin and carbonyl iron powder in a mass ratio of 4:6, with a permeability of 1500 ± 150μH / m.

[0033] Specifically, in this embodiment, in order to reduce the leakage flux of the four-in-one PV inductor, improve the magnetic circuit coupling efficiency, and adapt to the high-voltage operating conditions of the photovoltaic system, the present invention makes targeted designs on the structure and connection method of the U-shaped magnetic core 3, as follows: The U-shaped magnetic core has a magnetically conductive groove 301 and a soft magnetic paste filling structure: Each U-shaped magnetic core 3 has a magnetically conductive groove 301 extending along the arm length direction on the inner side of each of the two U-shaped arms. The magnetically conductive groove 301 must meet the following requirements: Size matching: The width of the magnetic groove 301 is 1 / 3 of the width of the U-shaped arm, such as 2.67mm, based on the total width of the U-shaped arm of 8mm. The depth is 1 / 2 of the thickness of the U-shaped arm, such as 2.5mm, based on the total thickness of the U-shaped arm of 5mm. This size ratio can maximize the coverage of the main magnetic flux transmission area while ensuring the mechanical strength of the magnetic core, that is, avoiding the breakage of the arm body due to excessive thinness. Material filling: The magnetic groove 301 is filled with soft magnetic paste. The magnetic permeability of the soft magnetic paste is 2000±200μH / m, which is close to the magnetic permeability of the U-shaped magnetic core body, which is made of PC44 ferrite and has a magnetic permeability of 3000-5000μH / m. This can guide the magnetic flux to concentrate in the core area inside the U-shaped arm, reduce the leakage magnetic flux that diffuses to the outside of the arm, and reduce the magnetic circuit transmission resistance.

[0034] More specifically, the magnetically guided groove 301 extends continuously along the length of the U-shaped arm, with its two ends extending to 0.1 mm from the bottom end and the open end of the U-shaped arm, respectively. This avoids chipping at the edge of the arm during processing and ensures that the magnetic flux can be guided by the soft magnetic paste along the entire path from the bottom of the magnetic core to the open end, without any magnetic flux dispersion blind spots.

[0035] Furthermore, to address the issues of excessive magnetic reluctance and thermal expansion / contraction deformation at the joint of adjacent magnetic cores, this invention makes the following improvements to the connection gap of the U-shaped magnetic core: Gap setting: A gap of 0.3-0.5mm is reserved at the connection ends of two adjacent U-shaped magnetic cores 3, namely the open arm end of the previous U-shaped magnetic core 3 and the bottom arm end of the next U-shaped magnetic core 3, and the mating end of the rightmost U-shaped magnetic core 3 and the magnetic core end 4. This gap size can accommodate the thermal expansion and contraction of the magnetic core during operation and avoid compression deformation; at the same time, it can also prevent the air magnetic resistance from increasing sharply due to excessively wide gaps. Matching agent filling: The above gaps are filled with magnetic permeability matching agent 302. This matching agent is made by mixing silicone resin and carbonyl iron powder in a mass ratio of 4:6. Its magnetic permeability is 1500±150μH / m. The silicone resin can achieve a firm fit between the matching agent and the end of the magnetic core arm and has elasticity to buffer deformation. The carbonyl iron powder can improve the magnetic permeability of the matching agent, so that its magnetic permeability is between 2000±200μH / m of the soft magnetic paste in the magnetic groove 301 and about 1μH / m of air. This achieves a smooth transition of magnetic flux from soft magnetic paste to matching agent to soft magnetic paste and avoids magnetic flux reflection loss caused by sudden change in magnetic permeability.

[0036] In summary, in this embodiment, the magnetically conductive groove 301 and the gap matching agent design create a synergistic effect: the magnetic flux starts from the bottom arm of a U-shaped magnetic core, is guided to the open arm through the soft magnetic paste in the inner magnetically conductive groove 301, and then is transmitted losslessly to the bottom arm of the next U-shaped magnetic core through the magnetic permeability matching agent 302 in the gap, and finally circulates along the closed magnetic circuit. This can control the inductance leakage rate to below 5%, reduce the inductance fluctuation range to ±5%, and meet the magnetic circuit stability requirements of the photovoltaic system in an environment of -40℃ to 85℃.

[0037] Furthermore, the coil winding 5 is wound in a double-layer lap winding manner, with the inner layer being oxygen-free copper wire with a diameter of 0.2 to 0.3 mm and a resistivity of [missing information]. The outer layer is wrapped with polyimide insulating varnish with a thickness of 15 to 20 μm, a temperature resistance rating of H, and a breakdown voltage of not less than 3 kV / mm. The winding direction of the coil winding 5 is uniformly set clockwise along the arm of the U-shaped magnetic core 3. The difference in the number of layers between adjacent coil windings 5 ​​does not exceed 2 layers. For example, the first coil winding has 10 layers, the second has 11 layers, the third has 12 layers, and the fourth has 10 layers. The inductance deviation of the coil winding 5 is not greater than ±5% to adapt to the 96V and above high voltage conditions of PV systems.

[0038] Furthermore, in one embodiment (not shown in the figure), the magnetic core end 4 can be detachably connected to the U-shaped magnetic core 3 at the outermost end via a snap-fit ​​structure. The snap-fit ​​structure includes elastic claws on both sides of the magnetic core end 4 and a slot at the open end of the U-shaped magnetic core 3. The elastic claws are made of phosphor bronze with an elastic deformation range of no more than 1 mm, and the slot has a depth of 3 mm and a width of 2 mm. The magnetic core end 4 adopts a split structure, including a magnetic conductive body and an insulating shell. The magnetic conductive body is made of the same material as the U-shaped magnetic core 3, and the insulating shell is made of flame-retardant PA66 material with an oxygen index of no less than 28%. The insulating shell covers the outer side of the magnetic conductive body and has a thickness of 1.5 mm.

[0039] Furthermore, in one embodiment, when the base plate 1 is an integrated circuit board, the base plate 1 is equipped with a temperature sensor and a current sensor. The temperature sensor is an NTC10kΩ sensor with an accuracy of ±1 degree Celsius, and the current sensor is an ACS712 sensor with a range of 0 to 5A and an accuracy of ±3%. The temperature sensor is positioned close to the bottom of the coil winding 5, with a spacing of no more than 1mm. The current sensor is connected in series in the connection circuit between the lead of the coil winding 5 and the base plate 1. The base plate 1 has a reserved interface for an AI control module, which adopts the I²C communication protocol. It can collect the inductor operating temperature and winding current data in real time through the sensor and transmit the data to the AI ​​control module to realize intelligent overload protection and status warning. When the temperature is greater than 120 degrees Celsius or the current is greater than 120% of the rated value, protection is triggered, and a warning signal is output through RS485 communication.

[0040] Specifically, in the above embodiments, when the base plate 1 adopts an integrated circuit board, it achieves real-time monitoring and intelligent protection of the inductor's operating status through integrated sensors and a standardized AI interface. The specific design is as follows: a. Circuit Board and Sensor Layout: The base plate 1 is preferably an FR-4 epoxy glass cloth substrate, 1.6 mm thick, with a double-layer copper foil wiring structure. The board is divided into a coil connection area, a sensor area, and an AI interface area. The coil connection area has openings and pads for fixing coil leads; the sensor area is located outside the coil connection area and is used to arrange monitoring components; the AI ​​interface area is located at the edge of the circuit board to avoid power loop interference.

[0041] b. Temperature Monitoring Implementation: The temperature sensor is an NTC 10kΩ thermistor, using a surface-mount package. It is mounted flush against the bottom of the corresponding coil winding, with a spacing of 0.5 to 1 mm. Thermal grease is filled between the sensor and the coil to improve heat conduction efficiency. The sensor signal is transmitted using differential wiring, supplemented by a grounding shield design to ensure acquisition accuracy and interference resistance.

[0042] c. Current Monitoring Implementation: The preferred current sensor is the ACS712-5A Hall effect current sensor, which is connected in series in the loop between the coil leads and the circuit board pads to ensure that the current flowing through the coil is fully detected. The sensor body is kept at a certain distance from the coil winding to reduce magnetic field interference, and its output signal is processed by a filtering circuit before being connected to the control module.

[0043] d. AI Control Interface and Logic: The AI ​​control module connects to the baseboard via a standardized multi-pin interface. This interface is compatible with communication protocols such as I²C and is used to transmit sensor data such as temperature and current, and can receive external control commands. The AI ​​control module incorporates intelligent protection logic. When the temperature exceeds 120 degrees Celsius or the current exceeds 120% of the rated value for a certain period, a tiered protection mechanism is triggered: first, a warning signal is output through the communication interface; if the fault persists, the main circuit is disconnected, thus achieving fast and reliable overload and overheat protection.

[0044] Furthermore, after the lead wire of the coil winding 5 is inserted into the opening of the base plate 1, it is connected by a double connection method of welding fixation and elastic buckle 501 limiting; the space between the lead wire and the inner wall of the opening is filled with conductive silver paste, the volume resistivity of which is... The curing temperature is 80 degrees Celsius for 30 minutes; the elastic buckle 501 is made of phosphor bronze with a thickness of 0.3mm. It has a C-shaped structure, wraps around the root of the lead wire, and has a wrapping length of 5mm. It is then engaged and fixed with the buckle seat on the base plate 1. The buckle seat and the base plate 1 are integrally formed.

[0045] For further information, please refer to [link / reference]. Figure 4 The bottom of the positioning groove of the isolation part 2 is provided with a circular through hole 203 with a diameter of 2mm. A high-temperature resistant wire 204 with a temperature resistance of 200 degrees Celsius is inserted through the through hole. The two ends of the wire are respectively connected to the grounding end of the U-shaped magnetic core 3 or the magnetic core end 4 and the base plate 1 to form a magnetic core grounding circuit to suppress electromagnetic interference (EMI).

[0046] Furthermore, the outer side of the U-shaped arm of the U-shaped magnetic core 3 is wrapped with a 0.5mm thick glass fiber cloth with a temperature resistance rating of H. The surface of the glass fiber cloth is coated with thermally conductive silicone grease with a thermal conductivity of not less than 1.5W / m·K, which is used to conduct the heat generated by the magnetic core to the isolation part 2 to achieve heat dissipation optimization.

[0047] Furthermore, the base plate 1 is also provided with a voltage detection circuit, which is connected in parallel across the two ends of the coil winding 5 to collect the terminal voltage of the coil winding 5; the AI ​​control module can dynamically adjust the working parameters of the coil winding 5 based on temperature, current and voltage data through a PID algorithm to adapt to the power fluctuations of the photovoltaic system, such as the input power changes caused by changes in light intensity.

[0048] Furthermore, the lead root of the coil winding 5 is fitted with a heat shrink tubing made of polyolefin, with a shrinkage rate of not less than 50%, a temperature resistance of 125 degrees Celsius, and a length of 8 to 10 mm, covering the connection between the lead and the elastic buckle, further improving the insulation reliability.

[0049] Furthermore, taking the AI ​​four-in-one PV inductor suitable for a 10kW photovoltaic inverter as an example, the parameters of each component are as follows: The base plate 1 is made of FR-4 epoxy glass cloth substrate with a thickness of 1.6 mm. The surface is coated with a 0.1 mm thick polytetrafluoroethylene insulation layer. It has 5 isolation part mounting holes with a hole spacing of 18 mm and 8 coil lead holes with a diameter of 0.5 mm.

[0050] The isolation section 2 is made of a magnetic insulating composite material, which is formed by hot pressing a mixture of 50 grams of epoxy resin, 30 grams of nanocrystalline soft magnetic powder, and 20 grams of alumina ceramic powder. The isolation section is 9 mm high and has a cross-section of 10 mm by 10 mm. The top positioning groove is 2 mm deep and has a silicone rubber buffer layer with a thickness of 0.15 mm on the inner wall.

[0051] The U-shaped magnetic core 3 uses a PC44 ferrite core, with a U-shaped arm cross-section of 8 mm x 5 mm and a U-shaped opening spacing of 12 mm. A magnetically conductive groove, 2.67 mm x 2.5 mm in size, is provided on the inner side of the U-shaped arm and is filled with soft magnetic grease. The gap between adjacent U-shaped magnetic core connection ends is 0.4 mm, and the gap is filled with a permeability matching agent. The outer side of the magnetic core is wrapped with a 0.5 mm thick glass fiber cloth, the surface of which is coated with thermally conductive silicone grease.

[0052] The magnetic core end 4 consists of a PC44 ferrite magnetic conductor and a flame-retardant PA66 insulating shell. The magnetic conductor measures 8 mm x 5 mm x 12 mm, and the insulating shell is 1.5 mm thick. Its elastic claws are made of phosphor bronze with a thickness of 0.3 mm.

[0053] Coil winding 5 is made of 0.25 mm diameter oxygen-free copper wire wound in a double-layer overlapping manner, with 10 turns in the inner layer and 10 turns in the outer layer, for a total of 20 layers. The outer layer of the wire is wrapped with polyimide insulating varnish with a thickness of 18 micrometers. The root of the lead is covered with a heat shrink tubing with a length of 8 mm.

[0054] The AI ​​monitoring module includes an NTC temperature sensor with a resistance of 10 kΩ; an ACS712 current sensor with a range of 0 to 5 amps; and a voltage detection circuit with an accuracy of ±2%. The AI ​​control module uses an STM32L476 microcontroller, supports the I²C communication protocol, and has an RS485 warning output function.

[0055] The assembly process of this embodiment of the AI ​​four-in-one PV inductor suitable for a 10kW photovoltaic inverter is as follows: First, the base plate 1 is positioned. Then, the isolation part 2 is fixed to the base plate with high-temperature resistant adhesive. Next, the U-shaped magnetic core 3 and the magnetic core end 4 are installed in the positioning groove of the isolation part 2, wherein the magnetic core end 4 is fixed by snap-fit. After that, the coil winding 5 is wound on the arm of the U-shaped magnetic core 3, and its lead wire is inserted into the opening of the base plate 1. The hole is filled with conductive silver paste and welded to fix it. Finally, the root of the lead wire is snapped with elastic buckle. The sensor and the AI ​​control module are welded to the base plate 1. The magnetic circuit performance, including leakage flux and inductance, is tested. Finally, the casing is encapsulated. The casing is made of aluminum alloy and has heat dissipation holes with a diameter of 3 mm.

[0056] The performance test results of the AI ​​four-in-one PV inductor suitable for a 10kW photovoltaic inverter are as follows: inductance is 100 microhenries with a deviation of ±5%; withstand voltage up to 120V DC for 1 minute without breakdown; leakage flux is 4.2%; operating temperature range is -40°C to 120°C, and it can operate at full load; AI monitoring response time is 80 milliseconds; and the power conversion efficiency is 96.5% at 10kW.

[0057] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0058] The embodiments described above are merely illustrative of several implementations of the present invention, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the invention patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these all fall within the protection scope of the present invention. Therefore, the protection scope of this invention patent should be determined by the appended claims.

Claims

1. An AI four-in-one PV inductor, characterized in that, It includes: Base plate; Five isolation sections are evenly spaced on the base plate; Four U-shaped magnetic cores and one core end, wherein the four U-shaped magnetic cores are respectively disposed on the four isolation parts and connected end to end in sequence; the core end is disposed on the remaining isolation part and is used to close the opening of the outermost U-shaped magnetic core to form a closed magnetic circuit frame. Four coil windings are respectively wound on the arms of the four U-shaped magnetic cores closest to the base plate, and the leads of the coil windings are inserted into the pre-set openings in the base plate.

2. The AI ​​four-in-one PV inductor according to claim 1, characterized in that: The isolation part is made of magnetic insulating composite material, which is formed by hot pressing epoxy resin, nanocrystalline soft magnetic powder and alumina ceramic powder mixed in a mass ratio of 5:3:

2.

3. The AI ​​four-in-one PV inductor according to claim 1, characterized in that: The top of the isolation section is provided with a positioning groove, and the inner wall of the positioning groove is provided with a silicone rubber buffer layer.

4. The AI ​​quad-in-one PV inductor according to claim 1, characterized in that: The U-shaped magnetic core has a magnetically conductive groove extending along its length on the inner side of the U-shaped arm, and the groove is filled with soft magnetic paste; a gap is provided between the connecting ends of two adjacent U-shaped magnetic cores, and the gap is filled with a magnetic permeability matching agent.

5. The AI ​​quad-in-one PV inductor according to claim 4, characterized in that: The magnetic permeability matching agent is composed of silicone resin and carbonyl iron powder mixed in a mass ratio of 4:

6.

6. The AI ​​quad-in-one PV inductor according to claim 1, characterized in that: The end of the magnetic core is detachably connected to the U-shaped magnetic core via a snap-fit ​​structure, and the end of the magnetic core is a split structure, comprising a magnetically conductive body and an insulating outer shell wrapped around the magnetically conductive body.

7. The AI ​​quad-in-one PV inductor according to claim 1, characterized in that: The base plate is equipped with a temperature sensor, a current sensor, and a voltage detection circuit, and has a reserved interface for an AI control module for intelligent monitoring and overload protection.

8. The AI ​​quad-in-one PV inductor according to claim 1, characterized in that: The leads of the coil winding are fixed to the base plate by a combination of welding and elastic clips, and heat shrink tubing is fitted at the root of the leads.

9. The AI ​​quad-in-one PV inductor according to claim 1, characterized in that: The bottom of the positioning groove of the isolation part is provided with a through hole, and a high-temperature resistant wire is inserted through the through hole. The high-temperature resistant wire is used to ground the magnetic core to suppress electromagnetic interference.

10. The AI ​​four-in-one PV inductor according to claim 1, characterized in that: The outer side of the U-shaped arm of the U-shaped magnetic core is wrapped with glass fiber cloth, and the surface of the glass fiber cloth is coated with thermally conductive silicone grease.

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