A six-phase current-sharing common-differential integrated reactor

Abstract

This invention discloses a six-phase current-sharing common-mode integrated reactor, belonging to the fields of power electronic magnetic components, electromagnetic interference suppression, and multi-path current-sharing filtering. The reactor includes three winding working columns and two magnetically integrated columns, which are connected to form a closed magnetic circuit. The top of each winding working column has a coil start-up terminal block and a coil end terminal block, while the bottom has a coil middle tap terminal block, with coils wound on all three terminal blocks. The three winding working columns are arranged at intervals, and the two magnetically integrated columns are respectively positioned between adjacent winding working columns, enabling magnetic integration of the three winding magnetic circuits through the magnetically integrated columns. An air gap is provided in each winding working column. This invention utilizes the opposite winding directions of the coils to cancel out the magnetomotive forces. When the current is balanced, it is in an inductive state; when the current is unbalanced, the common-mode inductor functions to force current sharing; the differential-mode inductor is used to filter out noise. This invention achieves six-phase common-mode integration with a single-coil scheme, resulting in small size and low cost.

Description

Technical Field

[0001] This invention relates to the fields of power electronic magnetic components, electromagnetic interference suppression, and multi-channel current sharing filtering technology, specifically to a six-phase current sharing common differential mode integrated reactor. Background Technology

[0002] In the energy storage and test power supply industry, system capacity upgrades are rapid. Limited by the development level of power electronic devices such as IGBTs, the industry commonly adopts multi-path parallel connection schemes to improve current and power levels. However, multi-path parallel connection brings the following problems in practical applications: First, it is difficult to maintain a balanced current across multiple branches. Due to differences in device parameters and inconsistent wiring impedances among parallel branches, circulating currents can easily occur between branches, leading to uneven heating, reduced system efficiency, and potentially shortened device lifespan.

[0003] Secondly, common-mode interference is a significant issue. High-frequency switching in multi-channel parallel systems generates substantial common-mode noise, adversely affecting the stability of the battery management system, sampling circuit, and communication link.

[0004] Third, the differential mode ripple amplitude is too large, making it difficult to meet the application requirements of high-precision test power supplies in terms of output accuracy.

[0005] Fourth, in traditional discrete inductor solutions, functions such as current sharing, common-mode rejection, and differential-mode filtering are usually implemented by separate magnetic components. This results in a large number of components, large size, high cost, and complex wiring, which is not conducive to high-density system integration.

[0006] Traditional current-sharing reactors in existing technologies typically employ a two-column core structure, with four coils interleaved and connected to counteract the effects of leakage magnetic fields. This approach not only incurs significant material and production costs but also only achieves current sharing across two paths. For applications with multiple parallel paths, multiple components are required, resulting in a relatively limited functionality that fails to meet the demands of the energy storage and test power industries for integration, high performance, and low cost. Summary of the Invention

[0007] The purpose of this invention is to provide a six-phase current-sharing common-mode integrated reactor. It utilizes the opposite winding directions of the coils to cancel out the magnetomotive forces, resulting in a non-inductive state when the current is balanced. When the current is unbalanced, the common-mode inductor functions to force current sharing; the differential-mode inductor is used to filter out noise. This invention achieves six-phase common-mode integration using a single-coil scheme, resulting in small size and low cost.

[0008] To achieve the above objectives, the technical solution adopted by the present invention is as follows: A six-phase current-sharing common-differential-mode integrated reactor includes: three wound working columns and two magnetic integrated columns, wherein the two magnetic integrated columns are connected to the three wound working columns to form a closed magnetic circuit; The top of the winding working column is provided with a coil start terminal busbar and a coil end terminal busbar, and the bottom of the winding working column is provided with a coil middle tap terminal busbar. A coil is wound on the coil start terminal busbar, the coil end terminal busbar and the coil middle tap terminal busbar.

[0009] Furthermore, the number of coil turns wound from the starting copper busbar to the middle tap busbar is the same as the number of coil turns wound from the middle tap busbar to the ending busbar.

[0010] Furthermore, the three winding working posts are arranged at intervals, and the two magnetic integration posts are respectively disposed between adjacent winding working posts, so that the magnetic circuits of the three sets of windings are magnetically integrated through the magnetic integration posts.

[0011] Furthermore, the winding work post is provided with an air gap, the total length of which is designed according to the required differential mode inductance.

[0012] Furthermore, the magnetic integrated column is an iron core column.

[0013] Furthermore, the common-mode inductance value is determined by simulation or theoretical calculation, jointly by the number of winding turns, the cross-sectional area of ​​the core column, and the winding spatial arrangement parameters.

[0014] In summary, the present invention has at least one of the following beneficial technical effects: Firstly, the present invention adopts a five-column iron core magnetic integrated structure and a center-tapped single-coil winding design, which integrates current sharing, common-mode suppression and differential-mode filtering functions into a single magnetic element, effectively reducing the number of system components, simplifying the wiring structure, and improving the system power density.

[0015] Secondly, this invention utilizes the working principle of opposite coil winding directions and canceling magnetic potentials. When the current is balanced, the winding is in an inductive state. When the current is unbalanced, the common-mode inductor automatically plays a role, and the impedance difference causes the circuit to tend to equalize the current, thus realizing the automatic current equalization function without the need for additional control circuits.

[0016] Thirdly, the single-coil design of this invention allows two currents in the same phase to share a single coil. Compared with the traditional method of interleaving multiple coils, the winding time and material usage are reduced, thus lowering production costs.

[0017] Fourth, in this invention, the magnetic potential can be naturally canceled out, reducing the sensitivity to the influence of leakage magnetic field. There is no need to specifically deal with the leakage magnetic field problem by arranging coils in an alternating manner, which improves the flexibility of structural design.

[0018] Fifth, by setting the air gap on the winding working column and rationally designing the winding space arrangement, the present invention can accurately control the parameters of differential mode inductance and common mode inductance. The differential mode inductance is used to filter out noise, making the output waveform smoother, which is conducive to meeting the ripple requirements of high-precision application scenarios. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the six-phase current-sharing common-differential-mode integrated reactor structure of the present invention; Figure 2 This is a schematic diagram of the differential mode inductor principle; Figure 3 This is a schematic diagram of the principle of a common-mode inductor.

[0020] Attached reference numerals: 1. Winding work post; 2. Magnetic integrated post; 3. Coil start terminal busbar; 4. Coil end terminal busbar; 5. Coil middle tap terminal busbar. Detailed Implementation

[0021] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention. Furthermore, the technical features involved in the various embodiments of this invention described below can be combined with each other as long as they do not conflict with each other.

[0022] like Figure 1 As shown, the present invention provides a six-phase current-sharing common differential mode integrated reactor, comprising: three wound working columns 1 and two magnetic integrated columns 2, wherein the two magnetic integrated columns 2 are connected to the three wound working columns 1 to form a closed magnetic circuit; The top of the winding working column 1 is provided with a coil start-up copper busbar 3 and a coil end-up copper busbar 4, and the bottom of the winding working column 1 is provided with a coil middle tap copper busbar 5. A coil is wound on the coil start-up copper busbar 3, the coil middle tap copper busbar 5 and the coil end-up copper busbar 4.

[0023] The three winding working posts 1 are arranged at intervals, and the two magnetic integration posts 2 are respectively disposed between adjacent winding working posts 1, so that the magnetic circuits of the three windings are magnetically integrated through the magnetic integration posts 2.

[0024] The winding work column 1 is provided with an air gap.

[0025] The magnetic integrated column 2 is an iron core column.

[0026] For the sake of clarity in the following explanation, it is necessary to... Figure 1For detailed explanation, the coil start terminal busbar 3, the coil end terminal busbar 4, and the coil middle tap terminal busbar 5 of the A winding working column are referred to as A1, A2, and A3, respectively. The coil start terminal busbar 3, coil end terminal busbar 4, and coil middle tap terminal busbar 5 of the B winding work column are abbreviated as B1, B2, and B3, respectively. The coil start terminal block 3, coil end terminal block 4, and coil middle tap terminal block 5 of the B winding work column are abbreviated as C1, C2, and C3, respectively.

[0027] The number of turns in A1-A3 is equal to the number of turns in A3-A2, both being W turns. The number of turns in A1-A2 is 2W turns. When winding, start by soldering copper foil from terminal block A1, winding W turns, then solder copper busbar A3 at W turns, continuing to wind W turns, and then soldering copper busbar A2. In actual use, for example, if the current in A1-A3 is 500A and the current in A2-A3 is 500A, you can see that the winding of A1-A3 is naturally opposite to that of A2-A3, which is much better than the traditional structure.

[0028] For example, another current, A1-A2, is 50A, which is a differential-mode current that needs to be filtered.

[0029] The number of turns in B1-B3 is equal to the number of turns in B3-B2, both being W turns. The number of turns in C1-C3 is equal to the number of turns in C3-C2, both being W turns.

[0030] like Figure 2 As shown, regarding differential mode inductors: A1-A2, B1-B2, C1-C2.

[0031] Let the total air gap length be d, then for differential mode inductors, the following applies: , can be obtained by unfolding, In the formula, B is the magnetic flux density, S is the cross-sectional area of ​​the iron core, and I is the current. is the vacuum permeability.

[0032] like Figure 3 As shown, regarding the common-mode inductors: A1A2 short-circuit -A3, B1B2 short-circuit -B3, C1C2 short-circuit -C3.

[0033] Method 1: Simulation using magnetic field energy. ; The common-mode current is 50uH, the differential-mode current is 4mH, the common-mode current is 550A, and the differential-mode current is 50A.

[0034] Method 2: Calculate using the formula, which is: ; In the formula, For relative leakage flux, Lochtein coefficient, This represents the winding height.

[0035] Where W is the number of turns, B is the magnetic flux density, S is the core cross-sectional area, I is the current, μ0 is the free permeability, and Hk is the winding height.

[0036] The common-mode current is the current that needs to be balanced in the circuit, requiring I(A1-A3) = I(A2-A3). This represents two relatively large currents, the specific values ​​of which depend on the design and can range from hundreds to tens of thousands of amperes. Ultimately, A3 outputs twice the current. As seen in the coil structure, the coils are wound in opposite directions, causing the magnetomotive forces to cancel each other out. When the currents are unbalanced (I(A1-A3) ≠ I(A2-A3)), the magnetomotive forces do not cancel each other out, and the common-mode inductor comes into play, forcing the circuit to share the current due to the different impedances. When the currents are balanced (I(A1-A3) = I(A2-A3)), the magnetomotive forces cancel each other out, resulting in a non-inductive state. The differential-mode inductor is used to filter out noise, making the waveform more perfect.

[0037] Therefore, the coil design is as follows: (A1-A3) and (A2-A3) have the same number of turns. Spatially, through theoretical calculation or simulation, a large distance is left to precisely control the common-mode inductance and balance the current.

[0038] Embodiments of the present invention may be provided as methods, systems, or computer program products. Therefore, the present invention may take the form of a completely hardware embodiment, a completely software embodiment, or an embodiment combining software and hardware aspects. Furthermore, the present invention may take the form of a computer program product embodied on one or more computer-usable storage media (including, but not limited to, disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.

[0039] This invention is described with reference to flowchart illustrations and / or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of the invention. It will be understood that each block of the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, special-purpose computer, embedded processor, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, generate instructions for implementing the flowchart illustrations and / or block diagrams. Figure 1 One or more processes and / or boxes Figure 1 A device that provides the functions specified in one or more boxes.

[0040] These computer program instructions may also be stored in a computer-readable storage medium that can direct a computer or other programmable data processing device to function in a particular manner, such that the instructions stored in the computer-readable storage medium produce an article of manufacture including instruction means, which are implemented in a process Figure 1 One or more processes and / or boxes Figure 1 The function specified in one or more boxes.

[0041] These computer program instructions may also be loaded onto a computer or other programmable data processing equipment to cause a series of operational steps to be performed on the computer or other programmable equipment to produce a computer-implemented process, thereby providing instructions that execute on the computer or other programmable equipment for implementing the process. Figure 1 One or more processes and / or boxes Figure 1 The steps of the function specified in one or more boxes.

[0042] Contents not described in detail in this specification are prior art known to those skilled in the art. It is hereby indicated that the above description is intended to help those skilled in the art understand this invention, but does not limit the scope of protection of this invention. Any equivalent substitutions, modifications, improvements, or simplifications of the above descriptions that do not depart from the essential content of this invention fall within the scope of protection of this invention.

Claims

1. A six-phase current-sharing common-differential mode integrated reactor, characterized in that, include: Three winding working posts and two magnetic integrated posts, wherein the two magnetic integrated posts are connected to the three winding working posts to form a closed magnetic circuit; The top of the winding working column is provided with a coil start terminal busbar and a coil end terminal busbar, and the bottom of the winding working column is provided with a coil middle tap terminal busbar. A coil is wound on the coil start terminal busbar, the coil end terminal busbar and the coil middle tap terminal busbar.

2. A six-phase current-sharing common-differential mode integrated reactor according to claim 1, characterized in that, The number of coil turns wound from the starting copper busbar to the middle tap busbar is the same as the number of coil turns wound from the middle tap busbar to the end busbar.

3. A six-phase current-sharing common-differential mode integrated reactor according to claim 1, characterized in that, The three winding working posts are arranged at intervals, and the two magnetic integration posts are respectively disposed between adjacent winding working posts, so that the magnetic circuits of the three windings are magnetically integrated through the magnetic integration posts.

4. A six-phase current-sharing common-differential mode integrated reactor according to claim 1, characterized in that, The winding work post is provided with an air gap, and the total length of the air gap is designed according to the required differential mode inductance.

5. A six-phase current-sharing common-differential mode integrated reactor according to claim 1, characterized in that, The magnetic integrated column is an iron core column.

6. A six-phase current-sharing common-differential mode integrated reactor according to claim 5, characterized in that, The common-mode inductance value is determined by simulation or theoretical calculation, and is jointly determined by the number of winding turns, the cross-sectional area of ​​the iron core column, and the winding spatial arrangement parameters.

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