A high-power high-efficiency air-gap-free isolation transformer

Abstract

The application belongs to the technical field of transformers, and particularly relates to a high-power high-efficiency air-gap-free isolation transformer, which comprises a mounting plate, the mounting plate is of an I-shaped structure, two mounting holes are formed at each corner of the mounting plate, two insulating frames are fixedly connected to the upper side walls of the mounting plate in a left-right symmetrical mode, the same magnetic core is placed in the two insulating frames, the magnetic core is of a mouth-shaped structure, and the side walls of the two insulating frames are provided with the same winding assembly. The prefabricated winding is spliced and welded on the outer side of the magnetic core, the problem that the magnetic core is easily broken due to a large pressure of equipment in the traditional large-diameter winding process is avoided, the service life of the equipment is improved, the integral magnetic core design is adopted, the traditional splicing structure is cancelled, the magnetic leakage phenomenon during equipment operation is reduced, and the magnetic circuit loss is effectively reduced.

Description

Technical Field

[0001] This invention belongs to the field of transformer technology, and in particular relates to a high-power, high-efficiency gapless isolation transformer. Background Technology

[0002] Transformers are important power conversion components inside switching power supplies, enabling voltage transformation and electrical isolation. In high-power, high-end equipment such as solid-state transformers in computing centers and data centers, the industry has high requirements for the energy conversion efficiency of transformers. Nanocrystalline materials have low magnetic core losses and are more suitable for high-power transformer products that pursue energy-saving effects. These materials are more suitable for making gapless, integral closed magnetic circuit structures, commonly in the shape of a square, which can reduce magnetic losses during energy transmission.

[0003] However, this type of air-gap-free integral magnetic core requires the primary and secondary windings to be wound directly on the core body. Under high-power conditions, the operating current is large, requiring the use of thicker wires. Due to processing limitations, it generally relies on high-power winding equipment to complete the winding. The nanocrystalline material itself is relatively brittle, and the pressure generated during the winding process can easily cause the magnetic core to break, resulting in a deterioration in product performance. If an air gap is added to the magnetic core to avoid the winding pressure, it will increase magnetic losses, reduce the conversion efficiency of the transformer, and be detrimental to the long-term energy-saving operation of the equipment.

[0004] To address these issues, a high-power, high-efficiency gapless isolation transformer is proposed. Summary of the Invention

[0005] The purpose of this invention is to address the above-mentioned problems by providing a high-power, high-efficiency gapless isolation transformer.

[0006] To achieve the above objectives, the present invention adopts the following technical solution: a high-power, high-efficiency gapless isolation transformer, comprising a mounting plate, wherein the mounting plate has an I-shaped structure, two mounting holes are provided at each of the four corners of the mounting plate, two insulating frames are symmetrically fixedly connected to the upper sidewall of the mounting plate, the same magnetic core is placed inside the two insulating frames, the magnetic core has a U-shaped structure, and the sidewall of the two insulating frames is provided with the same winding assembly;

[0007] The upper sealing assembly is disposed on the upper side wall of the insulating frame to protect the upper part of the winding assembly;

[0008] A fastening assembly is provided on the sidewall of the insulating frame to improve the tightness of the winding assembly.

[0009] Preferably, the insulating frame includes a lower frame portion and an upper frame portion, which are located on the upper and lower sides of the magnetic core, respectively. The lower frame portion and the upper frame portion are welded and fixed, and a first partition plate, a second partition plate, and a third partition plate are fixedly sleeved on the outer walls of the upper frame portion and the lower frame portion.

[0010] Preferably, the winding assembly includes four lower pre-wound sections, which are located below the left and right sides of the magnetic core, respectively. Multiple welding plates are welded to the upper end of each lower pre-wound section, and two lower pre-wound sections are connected by connecting plates. The lower pre-wound sections, welding plates, and connecting plates are all made of flat enameled wire, and the ends of the lower pre-wound sections are connected to terminals.

[0011] Preferably, the upper sealing assembly includes a limiting plate and a cover plate. The limiting plate is located above the two insulating frames. The side wall of the limiting plate has through holes adapted to the first partition, the second partition, the third partition, and the winding assembly. The cover plate is located above the limiting plate. The side wall of the cover plate has through holes adapted to the first partition, the second partition, the third partition, and the connector. Both the left and right sides of the cover plate are fixedly connected to protruding plates. One end of the connector extending out of the cover plate is fixed to the protruding plate by bolts.

[0012] Preferably, two side baffles are provided between the limiting plate and the mounting plate, with the upper end of the side baffles passing through the limiting plate, and the two side baffles are respectively located on both sides of the two insulating frames.

[0013] Preferably, the fastening assembly includes eight fixing plates. The side walls of the upper first partition, the second partition, and the lower second and third partitions are all provided with T-slots that match the fixing plates. The eight fixing plates are respectively inserted into the eight T-slots. The fixing plates are provided with limiting components. The side walls of the four lower fixing plates are all fixedly connected to lower positioning seats. The side walls of the four upper fixing plates are all connected to push seats. The side walls of the push seats are fixedly connected to two adjusting cylinders. Adjusting rods are slidably inserted into the two adjusting cylinders. The adjusting cylinders and adjusting rods are fixed by positioning bolts. The ends of the two adjusting rods on the same side that extend out of the adjusting cylinders are hinged to the same extrusion plate.

[0014] Preferably, the limiting assembly includes a limiting cavity formed inside the fixed plate. The inner wall of the limiting cavity is rotatably connected to two threaded cylinders via bearings. The internal threads of the two threaded cylinders have opposite directions and are fixedly connected at opposite ends. A threaded pin is connected to the internal thread of each threaded cylinder. A limiting pin is fixedly connected to the end of the threaded pin extending out of the threaded cylinder. The inner wall of the T-slot has a limiting groove that matches the limiting pin. The side wall of the limiting cavity has two through holes that match the limiting pin. A rotating rod is rotatably connected to the side wall of the limiting cavity. A rotating plate is fixedly connected to the end of the rotating rod extending out of the limiting cavity. The end of the rotating rod located inside the limiting cavity is connected to the lower threaded cylinder via a gear ring transmission mechanism.

[0015] Preferably, the sidewalls of the lower frame and the upper frame that are far apart from each other are connected to a separation plate, and the separation plate has a T-shaped structure.

[0016] Compared with existing technologies, the present invention has the following advantages:

[0017] 1. This invention adopts an integral magnetic core design, eliminating the traditional spliced ​​structure, which can reduce magnetic leakage during equipment operation, effectively reduce magnetic circuit loss, and with the integrated welded winding structure, the overall fit is high. It is not easily affected by electromagnetic vibration during operation, and can maintain stable working efficiency under long-term high-power operation, reducing unnecessary power consumption.

[0018] 2. This invention adopts a pre-wound flat enameled wire process. Compared with traditional non-pre-wound windings, the traditional winding process is more difficult and requires more sophisticated equipment. Furthermore, because the magnetic core is not circular, it cannot be completely fitted, making it more susceptible to crushing of nanocrystalline or amorphous ribbons under high-intensity winding pressure. Since the pre-wound winding is limited by the frame and plate holes, each turn has a fixed position, which greatly enhances product consistency, ensures uniform heat distribution, reduces the likelihood of localized heat accumulation, and improves product lifespan.

[0019] 3. This invention can adaptively fit and tighten the coil winding, avoiding the loosening and displacement of the coil caused by long-term vibration of the equipment. Combined with the reinforced wiring structure, it improves the wiring firmness, reduces equipment operating noise and the probability of failure, and makes the overall operation more stable. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the structure of a high-power, high-efficiency gapless isolation transformer provided by the present invention;

[0021] Figure 2 This is a schematic diagram of the surface structure of the limiting plate in this invention;

[0022] Figure 3 This is a schematic diagram showing the positional relationship between the welding plate and the connecting plate in this invention;

[0023] Figure 4 This is a schematic diagram showing the positions of the lower pre-fabricated winding section and the magnetic core in this invention;

[0024] Figure 5 This is a schematic diagram of the upper sealing component in this invention;

[0025] Figure 6 This is a schematic diagram of the winding assembly in this invention;

[0026] Figure 7 This is a schematic diagram of the insulating frame in this invention;

[0027] Figure 8 This is a schematic diagram showing the positions of the first partition, the second partition, and the third partition in this invention;

[0028] Figure 9 This is a schematic diagram of the fastening assembly in this invention;

[0029] Figure 10 This is a schematic diagram of the limiting component in this invention.

[0030] In the diagram: 1 Mounting plate, 2 Mounting hole, 3 Magnetic core, 4 Insulating frame, 41 Lower frame part, 42 Upper frame part, 5 First partition, 6 Second partition, 7 Third partition, 8 Winding assembly, 81 Lower pre-made winding part, 82 Welding plate, 9 Connecting plate, 10 Terminal, 11 Upper sealing assembly, 111 Limiting plate, 112 Cover plate, 12 Protruding plate, 13 Side baffle, 14 Fastening assembly, 141 Fixing plate, 142 Lower positioning seat, 15 Push seat, 16 Adjusting cylinder, 17 Adjusting rod, 18 Extrusion plate, 19 Limiting assembly, 191 Limiting cavity, 192 Threaded cylinder, 20 Threaded pin, 21 Limiting pin, 22 Rotating rod, 23 Rotating plate, 24 Separation plate. Detailed Implementation

[0031] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.

[0032] like Figures 1-4 , Figure 7 and Figure 8As shown, a high-power, high-efficiency gapless isolation transformer includes a mounting plate 1, which has an I-shaped structure. Two mounting holes 2 are opened at each of the four corners of the mounting plate 1. Two insulating frames 4 are symmetrically fixedly connected to the upper sidewall of the mounting plate 1. The same magnetic core 3 is placed inside the two insulating frames 4. The magnetic core 3 has a U-shaped structure. The sidewall of the two insulating frames 4 is provided with the same winding assembly 8. The insulating frame 4 includes a lower frame part 41 and an upper frame part 42. The sidewall of the lower frame part 41 and the upper frame part 42 that are far apart from each other is connected to a separation plate 24. The separation plate 24 has a T-shaped structure. The lower frame part 41 and the upper frame part 42 are located on the upper and lower sides of the magnetic core 3, respectively. The lower frame part 41 and the upper frame part 42 are welded and fixed. The outer walls of the upper frame part 42 and the lower frame part 41 are fixedly fitted with a first partition plate 5, a second partition plate 6 and a third partition plate 7.

[0033] During operation, an integral U-shaped magnetic core 3 is used to eliminate splicing air gaps from the structure, reduce magnetic flux leakage, reduce magnetic loss, adapt to high-power long-term continuous working conditions, and improve transformer working efficiency. The welded insulating skeleton 4 wraps the magnetic core 3, with good overall fit and high structural strength, which can resist electromagnetic vibration under high-power operation. Multiple sets of winding assemblies 8 are independently separated, allowing the coils to be arranged in layers, reducing electromagnetic coupling interference between layers, while improving the insulation performance between layers and reducing the risk of insulation breakdown under high-voltage conditions.

[0034] like Figure 4 and 6 As shown, the device also includes a winding assembly 8, which includes four lower pre-wound sections 81. The four lower pre-wound sections 81 are located on the lower left and right sides of the magnetic core 3, respectively. Multiple welding plates 82 are welded to the upper end of the lower pre-wound sections 81. The lower pre-wound sections 81 are welded together by connecting plates 9. After the welding plates 82 and connecting plates 9 are welded, they are fixed with epoxy resin and covered with insulation. The lower pre-wound sections 81, welding plates 82 and connecting plates 9 are all made of flat enameled wire (or round Litz enameled wire). The ends of the lower pre-wound sections 81 are connected to terminals 10.

[0035] During operation, a prefabricated flat enameled wire winding structure is adopted, which has a high degree of overall prefabrication, regular and uniform winding arrangement, and good winding consistency. This ensures a symmetrical and stable magnetic circuit distribution. Compared with traditional round wire, flat wire has a larger effective heat dissipation area, lower temperature rise during high-power current carrying, and better heat dissipation. This reduces the aging rate of the insulation layer, extends the service life of the equipment, and avoids the problem of core breakage caused by high pressure during winding. This ensures that the transformer has high energy conversion efficiency, reduces energy consumption and electricity costs, and also breaks through the bottleneck of large-diameter wire winding process, simplifying the production process.

[0036] like Figure 5As shown, the device also includes an upper sealing assembly 11, which is disposed on the upper side wall of the insulating frame 4 to protect the upper part of the winding assembly 8. The upper sealing assembly 11 includes a limiting plate 111 and a cover plate 112. The limiting plate 111 is located above the two insulating frames 4. The side wall of the limiting plate 111 has through holes adapted to the first partition 5, the second partition 6, the third partition 7, and the winding assembly 8. The cover plate 112 is located above the limiting plate 111. The side wall of the cover plate 112 has through holes adapted to the first partition 5, the second partition 6, the third partition 7, and the connector 10. The left and right sides of the cover plate 112 are fixedly connected with protruding plates 12. One end of the connector 10 extending out of the cover plate 112 is fixed to the protruding plate 12 by bolts. Two side baffles 13 are provided between the limiting plate 111 and the mounting plate 1. The upper end of the side baffles 13 passes through the limiting plate 111. The two side baffles 13 are located on both sides of the two insulating frames 4 respectively.

[0037] During operation, the limiting plate 111, together with the first partition 5, the second partition 6, and the third partition 7, are used for layered positioning to keep the winding assembly 8 neatly layered, prevent cross-contact of the wires between layers, and improve insulation safety. The protruding plate 12 mechanically fixes the terminal 10, improves the tensile strength of the wiring structure, and ensures stable connection of high-power circuits. The side baffles 13 on both sides laterally limit the insulation frame 4, restricting the left and right displacement of the frame, improving the seismic stability of the whole structure, and adapting to long-term high-frequency vibration working conditions.

[0038] like Figures 9-10As shown, the device also includes a fastening assembly 14, which is disposed on the side wall of the insulating frame 4 to improve the tightness of the winding assembly 8. The fastening assembly 14 includes eight fixing plates 141. The side walls of the upper first partition 5, the second partition 6, and the lower second partition 6 and the third partition 7 are all provided with T-slots that match the fixing plates 141. The eight fixing plates 141 are respectively inserted into the eight T-slots. The fixing plates 141 are provided with limiting components 19. The side walls of the four lower fixing plates 141 are all fixedly connected to lower positioning seats 142. The side walls of the four upper fixing plates 141 are all connected to push seats 15. The side walls of the push seats 15 are fixedly connected to two adjusting cylinders 16. The adjusting rods 17 are slidably inserted into the two adjusting cylinders 16. The adjusting cylinders 16 and the adjusting rods 17 are fixed by positioning bolts. The two adjusting rods 17 on the same side extend out of the adjusting cylinders. One end of 16 is hinged to the same extrusion plate 18. The limiting assembly 19 includes a limiting cavity 191 opened inside the fixed plate 141. The inner wall of the limiting cavity 191 is rotatably connected to two threaded cylinders 192 via bearings. The internal threads of the two threaded cylinders 192 have opposite directions. The two threaded cylinders 192 are fixedly connected to each other at one end. The internal threads of the threaded cylinders 192 are connected to threaded pins 20. The end of the threaded pins 20 extending out of the threaded cylinders 192 is fixedly connected to a limiting pin 21. The inner wall of the T-slot is provided with a limiting groove that matches the limiting pin 21. The side wall of the limiting cavity 191 is provided with two through holes that match the limiting pins 21. The side wall of the limiting cavity 191 is rotatably connected to a rotating rod 22. The end of the rotating rod 22 extending out of the limiting cavity 191 is fixedly connected to a rotating plate 23. The end of the rotating rod 22 located in the limiting cavity 191 is connected to the lower threaded cylinder 192 through a gear ring transmission mechanism.

[0039] During operation, the retractable adjusting cylinder 16 and adjusting rod 17 work together to finely adjust the clamping distance according to the actual thickness of the winding, allowing the pressing plate 18 to evenly fit against the side of the winding, achieving uniform clamping and fixing, improving the overall tightness of the winding, reducing winding vibration under high power operation, and reducing electromagnetic noise. In conjunction with the lower positioning seat 142 and pressing plate 18, the winding is laterally and omnidirectionally limited, preventing the winding from misaligning and loosening. Rotating the rotating plate 23 controls the limit pins 21 on both sides to engage with the limit groove, achieving mechanical self-locking of the fixing plate 141. The assembly is firm and not easy to loosen, with strong anti-vibration stability, which can keep the winding in a tight state for a long time, avoiding aging and loosening problems, and ensuring the long-term stable and efficient operation of the high-power transformer.

[0040] The operating principle of the present invention is explained as follows: The entire machine is stably installed by relying on the mounting plate 1 with the four corner mounting holes 2. The magnetic core 3 with the overall structure of the square is placed inside the two sets of insulating frames 4, which can eliminate the assembly air gap of the traditional spliced ​​magnetic core 3, reduce magnetic flux leakage, reduce magnetic loss, and adapt to high-power continuous working conditions.

[0041] The insulating frame 4, composed of a welded and fixed lower frame 41 and upper frame 42, is integrally fitted with the magnetic core 3, exhibiting high structural strength and resisting electromagnetic vibrations during high-power operation. Combined with T-shaped separation plates 24 on both sides, it enhances lateral insulation protection. Simultaneously, the first partition 5, second partition 6, and third partition 7 on the outer wall of the frame separate the winding assembly 8 into layers, reducing interlayer electromagnetic coupling interference and improving interlayer insulation. The winding assembly 8 consists of four sets of lower prefabricated winding sections 81, welding plates 82, and connecting plates 9 distributed on the left, right, and lower sides of the magnetic core 3. All are prefabricated using flat enameled wire, resulting in a neat winding arrangement and a larger heat dissipation area. This reduces temperature rise during high-power current flow, slows insulation aging, and avoids the difficulties of large-diameter wire winding processes and the risk of core 3 breakage. The terminal block 10 at the end is used for external circuit connection. To ensure stable conductivity, the upper sealing assembly 11 above the insulating frame 4, together with the limiting plate 111 and each partition, completes the layered limiting of the winding assembly 8, preventing the circuit from shifting and contacting. The cover plate 112 closes the exposed area at the top, and the terminal 10 is bolted to the protruding plates 12 on both sides of the cover plate 112 after it passes through, improving the tensile stability of the wiring. Together with the side baffles 13 on both sides of the limiting plate 111, the left and right displacement of the insulating frame 4 is limited, improving the overall shock resistance. The fastening assembly 14 on the side wall of the insulating frame 4 is assembled by inserting the fixing plate 141 into the T-slot of each partition. The extension and retraction of the adjusting cylinder 16 and the adjusting rod 17 are adapted to the actual thickness of the winding, driving the pressing plate 18 to fit against the side of the winding to achieve uniform tightening. Together with the lower positioning seat 142, the winding is limited in all directions, reducing working vibration and electromagnetic noise.

[0042] Rotating the rotating plate 23 drives the rotating rod 22 to rotate, which in turn drives the two sets of threaded cylinders 192 with opposite rotation directions to rotate via the gear ring transmission mechanism. This causes the threaded pin 20 and the limiting pin 21 to extend and retract into the limiting groove of the T-shaped groove, thereby achieving mechanical self-locking of the fixing plate 141. This maintains the tightness of the winding assembly 8 for a long time, ensuring the long-term stable and efficient operation of the transformer.

[0043] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A high-power, high-efficiency gapless isolation transformer, comprising a mounting plate (1), characterized in that, The mounting plate (1) has an I-shaped structure. Two mounting holes (2) are opened at each of the four corners of the mounting plate (1). Two insulating frames (4) are symmetrically fixed to the upper side wall of the mounting plate (1). The same magnetic core (3) is placed inside the two insulating frames (4). The magnetic core (3) has a square-shaped structure. The same winding assembly (8) is provided on the side wall of the two insulating frames (4). The upper sealing assembly (11) is disposed on the upper side wall of the insulating frame (4) to protect the upper part of the winding assembly (8); Fastening assembly (14) is provided on the side wall of the insulating frame (4) to improve the tightness of the winding assembly (8).

2. The high-power, high-efficiency gapless isolation transformer according to claim 1, characterized in that, The insulating frame (4) includes a lower frame part (41) and an upper frame part (42). The lower frame part (41) and the upper frame part (42) are located on the upper and lower sides of the magnetic core (3), respectively. The lower frame part (41) and the upper frame part (42) are welded and fixed. The outer walls of the upper frame part (42) and the lower frame part (41) are fixedly fitted with a first partition (5), a second partition (6) and a third partition (7).

3. A high-power, high-efficiency gapless isolation transformer according to claim 2, characterized in that, The winding assembly (8) includes four lower pre-wound sections (81), which are located on the left and right sides below the magnetic core (3). Multiple welding plates (82) are welded to the upper end of each lower pre-wound section (81), and two lower pre-wound sections (81) are connected by a connecting plate (9). The lower pre-wound sections (81), welding plates (82) and connecting plates (9) are all made of flat enameled wire, and the ends of the lower pre-wound sections (81) are connected to terminals (10).

4. A high-power, high-efficiency gapless isolation transformer according to claim 3, characterized in that, The upper sealing assembly (11) includes a limiting plate (111) and a cover plate (112). The limiting plate (111) is located above the two insulating frames (4). The side wall of the limiting plate (111) is provided with through holes that are compatible with the first partition (5), the second partition (6), the third partition (7), and the winding assembly (8). The cover plate (112) is located above the limiting plate (111). The side wall of the cover plate (112) is provided with through holes that are compatible with the first partition (5), the second partition (6), the third partition (7), and the connector (10). The left and right sides of the cover plate (112) are fixedly connected with protruding plates (12). One end of the connector (10) extending out of the cover plate (112) is fixed to the protruding plate (12) by bolts.

5. A high-power, high-efficiency gapless isolation transformer according to claim 4, characterized in that, Two side baffles (13) are provided between the limiting plate (111) and the mounting plate (1). The upper end of the side baffles (13) passes through the limiting plate (111), and the two side baffles (13) are located on both sides of the two insulating frames (4).

6. A high-power, high-efficiency gapless isolation transformer according to claim 4, characterized in that, The fastening assembly (14) includes eight fixing plates (141). The side walls of the first partition (5) and the second partition (6) on the upper side, as well as the second partition (6) and the third partition (7) on the lower side, are all provided with T-shaped grooves that match the fixing plates (141). The eight fixing plates (141) are respectively inserted into the eight T-shaped grooves. The fixing plates (141) are provided with limiting components (19). The side walls of the four fixing plates (141) on the lower side are all fixedly connected with lower positioning seats (142). The side walls of the four fixing plates (141) on the upper side are all connected with push seats (15). The side walls of the push seats (15) are fixedly connected with two adjusting cylinders (16). The two adjusting cylinders (16) are slidably inserted with adjusting rods (17). The adjusting cylinders (16) and the adjusting rods (17) are fixed by positioning bolts. The two adjusting rods (17) on the same side are hinged to the same pressing plate (18) at one end extending out of the adjusting cylinders (16).

7. A high-power, high-efficiency gapless isolation transformer according to claim 6, characterized in that, The limiting assembly (19) includes a limiting cavity (191) formed inside the fixed plate (141). The inner wall of the limiting cavity (191) is rotatably connected to two threaded cylinders (192) via bearings. The internal threads of the two threaded cylinders (192) have opposite directions and are fixedly connected at opposite ends. A threaded pin (20) is threadedly connected to the internal thread of each threaded cylinder (192). A limiting pin (21) is fixedly connected to one end of the threaded pin (20) extending out of the threaded cylinder (192). The inner wall of the T-slot is provided with a limiting groove that matches the limiting pin (21). The side wall of the limiting cavity (191) is provided with two through holes that match the limiting pin (21). The side wall of the limiting cavity (191) is rotatably connected to a rotating rod (22). One end of the rotating rod (22) extending out of the limiting cavity (191) is fixedly connected to a rotating plate (23). One end of the rotating rod (22) located in the limiting cavity (191) is connected to the lower threaded cylinder (192) through a gear ring transmission mechanism.

8. A high-power, high-efficiency gapless isolation transformer according to claim 2, characterized in that, The lower frame part (41) and the upper frame part (42) are connected to a separation plate (24) on the side wall of the side away from each other. The separation plate (24) is a T-shaped structure.

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