Liquid-cooled transformer
By using a liquid-cooled transformer structure, hollow copper tubes and coolant are used to cool the iron core and coils. Combined with insulation and current shunting structures, the problem of insufficient cooling efficiency of traditional cooling methods in high-power transformers is solved, and temperature control and reliability improvement of transformers under high loads are achieved.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2026-01-16
- Publication Date
- 2026-03-13
AI Technical Summary
Traditional cooling methods have limited cooling efficiency and heat dissipation capacity in high-power transformers, making it difficult to effectively control the transformer's operating temperature, which may lead to overheating and performance degradation.
The transformer adopts a liquid-cooled structure, using hollow copper tubes as the primary coil and cooling it with coolant. Combined with insulation and shunt structure, it achieves cooling of the iron core, primary coil and secondary coil. The single-inlet and single-outlet coolant pipeline design ensures electrical insulation and mechanical strength.
Under high power density and high load conditions, effectively control transformer temperature, reduce temperature rise, improve reliability, and meet system requirements for size and weight.
Smart Images
Figure CN121662564A_ABST
Abstract
Description
Technical Field
[0001] This invention belongs to the field of transformer technology, specifically a liquid-cooled transformer. Background Technology
[0002] In high-power transformer applications, the transformer coils and core generate a significant amount of heat due to the high current and high voltage operating conditions. Traditional cooling methods include natural air cooling, forced air cooling, and oil-immersed cooling, but these methods have limitations in terms of cooling efficiency and heat dissipation capacity.
[0003] Air cooling has limited cooling capacity and is not suitable for high-power applications; oil-immersed liquid cooling has problems such as exceeding the limits of equipment size and weight; especially under high power density and high load operating conditions, traditional cooling methods are difficult to effectively control the operating temperature of transformers, which may lead to transformer overheating, performance degradation or even damage. Summary of the Invention
[0004] To address the aforementioned problems, this invention proposes a liquid-cooled transformer that effectively reduces the transformer's operating temperature and improves its heat dissipation capacity and reliability through liquid cooling technology.
[0005] The technical solution of the present invention is as follows: a liquid-cooled transformer, the liquid-cooled transformer including several sets of iron cores, primary coils, secondary coils and cooling pipes, the primary coils are hollow copper tubes, coaxially installed between the iron cores and the secondary coils, the hollow copper tubes act as conductors through which primary current passes, and at the same time, coolant is introduced through the cooling pipes to achieve cooling of the iron cores, primary coils and secondary coils, the cooling pipes have several insulating sections to electrically isolate the primary coils from each set.
[0006] Furthermore, clamps are provided on both sides of the liquid-cooled transformer, and the clamps are used to install several sets of iron cores, primary coils and secondary coils into a whole through fixing rods.
[0007] Furthermore, the liquid-cooled transformer includes a main coolant pipeline, with a main inlet and a main outlet for the coolant.
[0008] Furthermore, diversion structures are installed on both sides of the clamping plate. One end of the diversion structure is connected to the main inlet or main outlet, and the other end is connected to the hollow copper tube.
[0009] Furthermore, several insulating structural components are installed on both sides of the clamping plate. The insulating structural components are hollow tubes, with cooling pipes connected to both sides of the hollow tubes, and the interior is a coolant channel.
[0010] Furthermore, a flexible connecting pipe is used between the insulating structural components and the hollow copper tube.
[0011] Furthermore, the primary power supply of the transformer is achieved by welding wires to the hollow copper tube of the primary coil to realize the power input of the transformer; the secondary coil is led out after being fixed by connectors to realize the power output of the transformer.
[0012] Furthermore, thermally conductive adhesive is used to fix the hollow copper tube of the primary coil to the iron core.
[0013] Compared with the prior art, the technical solution of the present invention has the following beneficial effects: This design uses hollow copper tubes as the primary coil of the transformer; the transformer coil and the external cooling pipes are isolated by insulating material; the external cooling of the transformer adopts a single-inlet and single-outlet configuration; and metal shunt structural components are used to distribute the cooling pipes. The primary coil for input and output is installed between the iron core and the secondary coil, using a coaxial mounting method, which allows the coolant flowing through the primary coil to simultaneously cool both the iron core and the coil. (3) Compared with air-cooled transformers and oil-immersed transformers, transformers with this structure can effectively control the size and weight of the transformer, reduce the operating temperature of the transformer, and improve the reliability of the transformer under high power density and high load operating conditions. Attached Figure Description
[0014] Figure 1 This is a schematic diagram of the primary coil and core of a transformer; Figure 2 It is the secondary coil of the transformer; Figure 3 This is a schematic diagram of the transformer clamp; Figure 4 This is a schematic diagram of the flow divider structure; Figure 5 It is an insulating structural component; Figure 6 This is a diagram of the transformer's external shape.
[0015] Among them, 1 is the primary coil, 2 is the iron core, 3 is the secondary coil, 4 is the clamping plate, 5 is the main cooling pipe, 6 is the connector, 7 is the shunt structure, 8 is the insulation structure, 9 is the cooling pipe, and 10 is the fixing rod. Detailed Implementation
[0016] As shown in the figure, the transformer consists of an iron core 2, a primary coil 1, a secondary coil 3, a fixing plate 4 and a fixing rod 10, and a cooling pipe 9, etc.; the iron core 2, the primary coil 1, and the secondary coil 3 are installed in a coaxial manner.
[0017] The primary coil 1 is made of hollow copper tube. The inner diameter and wall thickness of the copper tube are designed according to the requirements of coolant flow rate and mechanical strength. The hollow copper tube can be used as a conductor to carry primary current and as a cooling pipe to carry coolant. The primary coil 1 is installed between the iron core 2 and the secondary coil 3. Cooling of the iron core 2, primary coil 1 and secondary coil 3 can be achieved by the flow of coolant.
[0018] The primary coil 1, a hollow copper tube, is manufactured using precision machining technology to ensure excellent electrical conductivity and cooling performance. The hollow copper tube of the primary coil 1 is fixed to the iron core 2 using a high thermal conductivity adhesive to ensure rapid heat transfer. High-insulation materials are used for electrical insulation between the copper tube and the iron core 2, achieving electrical insulation without affecting thermal conductivity.
[0019] To ensure strength, the main coolant pipe 5 is made of metal with a single inlet and single outlet structure, and is distributed to each coil using a flow divider 7. Each primary coil 1's hollow copper tube is electrically insulated from the main coolant pipe 5 by a section of insulating material pipe (i.e., insulating structural component 8). A flexible connection is used between the insulating material and the hollow copper tube to prevent structural stress from causing cracks in the coolant pipe and thus leakage. The main coolant pipe 5 is located below the transformer and has a main inlet and main outlet for the coolant.
[0020] The primary power supply of the transformer is achieved by welding suitable wires to the coils; the secondary coil 3 is fixed by connector 6 and its lead-out is achieved by connector 6 to achieve the transformer output connection. The transformer core 2, primary coil 1, secondary coil 3, and cooling pipe 9 are assembled by clamping plates 4 and fixing rods 10 to achieve reliable structural assembly.
[0021] Take a medium-frequency high-voltage output transformer as an example. The transformer input is a 3-phase 400Hz AC power supply with a line voltage of 200V. The transformer output power is as high as tens of kVA. It is installed in a confined space, and there are high restrictions on temperature rise, volume, and weight. The system provides one liquid cooling channel, and the cooling medium is 65# aviation coolant.
[0022] If an air-cooled transformer is used, a heat exchanger and air-cooling equipment need to be added to the system. Furthermore, the heat dissipation capacity of an air-cooled dry-type transformer is limited, necessitating an increase in transformer size to meet system requirements. If an oil-immersed transformer is used, the transformer body size and weight can be miniaturized, but the increased size and weight of the oil tank still exceed limits and cannot meet system requirements. If a liquid-cooled cooling system with two side plates is used, the transformer temperature rise will be excessive. During rated load testing, the transformer coil temperature rises excessively, exceeding 100°C at room temperature, which does not meet system requirements.
[0023] After improvements to the design, the transformer with the adopted design has the following appearance: Figure 6As shown, the system uses three sets of silicon steel sheet cores 2. The primary coil 1 is installed around the core 2 using hollow copper tubing, then potted and cured. The secondary coil 3 is potted and cured separately, then coaxially installed with the primary coil 1. The transformer is fixed with stainless steel clamps 4 and fixing rods 10, achieving reliable structural assembly. The transformer liquid cooling circuit is a single-input, single-output type. The transformer structure is compact, and its size and weight meet the system requirements. Test results show that under rated operating conditions, the temperature rise of the core 2 and the primary and secondary coils 3 is controlled within 30℃, enabling long-term effective and reliable operation.
Claims
1. A liquid-cooled transformer, characterized in that, The liquid-cooled transformer includes several sets of iron cores, primary coils, secondary coils, and cooling pipes. The primary coil is made of hollow copper tubes and is coaxially installed between the iron cores and the secondary coils. The hollow copper tubes act as conductors through which the primary current passes. At the same time, coolant is introduced through the cooling pipes to cool the iron cores, primary coils, and secondary coils. The cooling pipes have several insulating sections to electrically isolate the primary coils from each other.
2. The liquid-cooled transformer according to claim 1, characterized in that, The liquid-cooled transformer is equipped with clamps on both sides, and the clamps are used to install several sets of iron cores, primary coils and secondary coils into a whole through fixing rods.
3. The liquid-cooled transformer according to claim 1, characterized in that, The liquid-cooled transformer includes a main coolant pipeline and is provided with a main inlet and a main outlet for the coolant.
4. The liquid-cooled transformer according to claim 2, characterized in that, Diverting structural components are installed on both sides of the clamping plate. One end of the diverting structural component is connected to the main inlet or main outlet, and the other end is connected to the hollow copper tube.
5. The liquid-cooled transformer according to claim 1, characterized in that, Several insulating structural components are installed on both sides of the clamping plate. The insulating structural components are hollow tubes, with cooling pipes connected to both sides of the hollow tubes, and coolant channels inside.
6. The liquid-cooled transformer according to claim 5, characterized in that, The insulating structural component and the hollow copper tube are connected by a flexible pipe.
7. The liquid-cooled transformer according to claim 1, characterized in that, The primary power supply of the transformer is achieved by welding wires to the hollow copper tube of the primary coil to realize the power input of the transformer; the secondary coil is led out after being fixed by connector to realize the power output of the transformer.
8. The liquid-cooled transformer according to claim 1, characterized in that, The primary coil hollow copper tube is fixed to the iron core using thermally conductive adhesive.