Transformer structure with distributed air gaps

Abstract

The utility model relates to the technical field of transformers, in particular to a transformer structure with distributed air gaps, which comprises an upper magnetic core, a lower magnetic core and a framework. The upper magnetic core and the lower magnetic core are respectively sleeved on the upper part and the lower part of the framework, and a plurality of air gaps are formed between the lower surface of the upper magnetic core and the upper surface of the lower magnetic core; therefore, the leakage flux and eddy current effect of the air gap are reduced, the loss of the transformer is reduced, and the conversion efficiency and heat dissipation efficiency of the transformer are improved.

Description

Technical Field

[0001] The utility model relates to the technical field of transformers, in particular to a transformer structure with a dispersed air gap. Background Art

[0002] With the continuous development of transformer technology, transformers are not only used as core components in power transmission and distribution systems in the power industry, but also used in power equipment, lighting circuits, electrical transmission, electric furnace heat treatment and other aspects in the industrial field to provide stable and reliable power supply for various industrial equipment. As the application scenarios become more and more complex, the requirements for transformer energy consumption, heat dissipation, insulation and installation convenience are getting higher and higher.

[0003] Current transformers all use a centralized air gap design, with the air gap set in the center of the magnetic core. This will result in large leakage flux in the central core, large eddy current effect, and increased loss of the coil near the air gap, which will cause heating in the concentrated area, overheating damage, performance degradation, or insulation breakdown in the concentrated area. In addition, the centralized air gap design results in a relatively fixed air gap size, and the design of the magnetic core is relatively limited. When the transformer is used in a complex mechanical structure environment, it is difficult to make the air gap setting meet both electrical performance requirements and mechanical structure requirements. Utility Model Content

[0004] In view of the above-mentioned defects, the purpose of the utility model is to propose a transformer structure with a distributed air gap, so as to reduce the leakage flux and eddy current effect of the air gap, thereby reducing the loss of the transformer and improving the conversion efficiency and heat dissipation efficiency of the transformer.

[0005] To achieve this purpose, the utility model adopts the following technical solutions:

[0006] A transformer structure with a distributed air gap comprises an upper magnetic core, a lower magnetic core and a frame; the upper magnetic core and the lower magnetic core are respectively sleeved on the upper part and the lower part of the frame, and a plurality of air gaps are formed between the lower part of the upper magnetic core and the upper part of the lower magnetic core.

[0007] Furthermore, the air gap includes a side column air gap and a middle column air gap; the middle column air gap is arranged at the center of the frame, the side column air gap is arranged at the edge of the frame, and the winding area is between the middle column air gap and the side column air gap.

[0008] Furthermore, the upper magnetic core and the lower magnetic core are each provided with at least one middle column and at least one side column, the middle column and side columns of the upper magnetic core respectively correspond to the middle column and side columns of the lower magnetic core and are symmetrically arranged, a middle column air gap is formed between the bottom of the middle column of the upper magnetic core and the top of the middle column of the lower magnetic core, and a side column air gap is formed between the bottom of the side column of the upper magnetic core and the top of the side column of the lower magnetic core.

[0009] Furthermore, an upper magnetic core limiting groove is provided at the upper part of the frame, a lower magnetic core limiting groove is provided at the lower part of the frame, and a magnetic core through groove is provided inside the frame from the upper magnetic core limiting groove to the lower magnetic core limiting groove;

[0010] The middle column of the upper magnetic core is embedded in the magnetic core through groove, the side columns of the upper magnetic core are arranged outside the upper magnetic core limiting groove, and the upper magnetic core is limited in the upper magnetic core limiting groove;

[0011] The middle column of the lower magnetic core is embedded in the magnetic core through groove, the side columns of the lower magnetic core are arranged outside the lower magnetic core limiting groove, and the lower magnetic core is limited in the lower magnetic core limiting groove.

[0012] Furthermore, the middle columns of the upper magnetic core and the lower magnetic core are both set to be cylindrical.

[0013] Furthermore, the outer wall and the slot wall of the cross section of the magnetic core slot are both circular, and the outer wall of the magnetic core slot is used for winding.

[0014] Furthermore, an upper insulating groove is provided on the outer surface of the upper magnetic core, and a lower insulating groove is provided on the outer surface of the lower magnetic core symmetrically to the upper insulating groove, and the upper insulating groove and the lower insulating groove are combined to form an insulating winding area.

[0015] Furthermore, the side columns of the upper magnetic core and the lower magnetic core are arranged on the left and right sides of the frame, and the front and rear sides of the lower part of the frame are provided with pins.

[0016] The technical solution provided by the utility model can include the following beneficial effects: by freely designing the shape and structure of the upper magnetic core and the lower magnetic core, after the upper magnetic core and the lower magnetic core are respectively sleeved on the upper and lower parts of the skeleton, the supporting force of the skeleton for the upper magnetic core and the lower magnetic core is used to form multiple air gaps between the bottom of the upper magnetic core and the top of the lower magnetic core, so that more transformers with different shapes and structures can be designed to adapt to the installation of different mechanical structures; at the same time, the current centralized air gap is dispersed into multiple freely set air gaps, so that the leakage flux of a single air gap is reduced, the eddy current effect is reduced, the wire package loss close to the air gap is reduced, and the conversion efficiency of the transformer is improved; more importantly, the heat generation of a single air gap will be very small, and under the cooling of the cooling system, there will be basically no local heating phenomenon, which effectively protects the performance and insulation of the transformer. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 It is a structural schematic diagram of a distributed air-gap transformer structure in one embodiment of the utility model.

[0018] Figure 2 Yes Figure 1 A front view of a transformer structure with a distributed air gap is shown.

[0019] Figure 3 Yes Figure 1 Schematic diagram of the structure of the skeleton shown.

[0020] Among them: upper magnetic core 1, lower magnetic core 2, skeleton 3, air gap 4, side column air gap 41, middle column air gap 42, winding area 5, upper magnetic core limiting groove 31, lower magnetic core limiting groove 32, magnetic core through groove 33, upper insulating groove 11, lower insulating groove 21, pin 6. DETAILED DESCRIPTION

[0021] The embodiments of the present invention are described in detail below, and examples of the embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals throughout represent the same or similar elements or elements having the same or similar functions. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and cannot be understood as limiting the present invention.

[0022] In the description of the present invention, it should be understood that the terms "longitudinal", "transverse", "upper", "lower", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside" and the like indicate positions or positional relationships based on the positions or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on the present invention. In addition, features defined as "first" or "second" may explicitly or implicitly include one or more of the features, and are used to distinguish and describe features, without distinction of order or importance.

[0023] In the description of the present invention, unless otherwise specified, “plurality” means two or more.

[0024] In the description of the embodiments of the present invention, it should be noted that, unless otherwise clearly specified and limited, the terms "installed", "connected", and "connected" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be directly connected, or indirectly connected through an intermediate medium, it can be the internal connection of two elements or the interaction relationship between two elements. For ordinary technicians in this field, the specific meanings of the above terms in the embodiments of the present invention can be understood according to specific circumstances.

[0025] Combine the following Figures 1 to 3 , describing a distributed air-gap transformer structure of an embodiment of the utility model.

[0026] A distributed air-gap transformer structure includes an upper magnetic core 1, a lower magnetic core 2 and a skeleton 3; the upper magnetic core 1 and the lower magnetic core 2 are respectively sleeved on the upper and lower parts of the skeleton 3, and a plurality of air gaps 4 are formed between the lower side of the upper magnetic core 1 and the upper side of the lower magnetic core 2.

[0027] The utility model proposes a preferred embodiment of a transformer structure with a distributed air gap, such as Figures 1 to 3 As shown, by freely designing the shape and structure of the upper magnetic core 1 and the lower magnetic core 2, the upper magnetic core 1 and the lower magnetic core 2 are respectively sleeved on the upper and lower parts of the skeleton 3, and the support force of the skeleton 3 for the upper magnetic core 1 and the lower magnetic core 2 is used to form multiple air gaps 4 between the lower part of the upper magnetic core 1 and the upper part of the lower magnetic core 2, so that more transformers with different shapes and structures can be designed and adapted to the installation of different mechanical structures; at the same time, the current centralized air gap is dispersed into multiple freely set air gaps 4, so that the leakage flux of a single air gap 4 is reduced, the eddy current effect is reduced, the wire package loss near the air gap 4 is reduced, and the conversion efficiency of the transformer is improved; more importantly, the heat generation of a single air gap 4 will be very small, and under the cooling of the cooling system, there will be basically no local heating phenomenon, which effectively protects the performance and insulation of the transformer. It should be noted that the total air gap amount of multiple air gaps 4 should meet the design inductance requirements of the transformer and realize the original function of the transformer.

[0028] Furthermore, the air gap 4 includes a side column air gap 41 and a middle column air gap 42; the middle column air gap 42 is arranged at the center of the skeleton 3, and the side column air gap 41 is arranged at the edge of the skeleton 3, and the winding area 5 is between the middle column air gap 42 and the side column air gap 41.

[0029] In this embodiment, the air gap 4 is preferably configured to be composed of a side column air gap 41 and a middle column air gap 42; wherein the middle column air gap 42 is arranged at the center of the skeleton 3, and the side column air gap 41 is arranged at the edge of the skeleton 3, and the hollow area between the middle column air gap 42 and the side column air gap 41 is used as the winding area 5, so that the air gap 4 avoids the winding, which facilitates the winding to be wound around the skeleton 3 in the winding area 5 to form a winding.

[0030] Furthermore, the upper magnetic core 1 and the lower magnetic core 2 are each provided with at least one middle column and at least one side column. The middle column and the side column of the upper magnetic core 1 correspond to the middle column and the side column of the lower magnetic core 2 one by one and are symmetrically arranged. A middle column air gap 42 is formed between the bottom of the middle column of the upper magnetic core 1 and the top of the middle column of the lower magnetic core 2, and a side column air gap 41 is formed between the bottom of the side column of the upper magnetic core 1 and the top of the side column of the lower magnetic core 2.

[0031] In the present embodiment, at least one middle column and at least one side column are provided on both the upper magnetic core 1 and the lower magnetic core 2, and the middle column and the side column of the upper magnetic core 1 correspond to the middle column and the side column of the lower magnetic core 2 one by one and are symmetrically arranged, so that after the upper magnetic core 1 and the lower magnetic core 2 are buckled on the upper and lower parts of the skeleton 3, the gap between the bottom of the middle column of the upper magnetic core 1 and the top of the middle column of the lower magnetic core 2 forms the desired middle column air gap 42, and the gap between the bottom of the side column of the upper magnetic core 1 and the top of the side column of the lower magnetic core 2 forms the desired side column air gap 41.

[0032] Furthermore, an upper magnetic core limiting groove 31 is formed at the upper part of the frame 3, a lower magnetic core limiting groove 32 is formed at the lower part of the frame 3, and a magnetic core through groove 33 is formed inside the frame 3 from the upper magnetic core limiting groove 31 to the lower magnetic core limiting groove 32;

[0033] The middle column of the upper magnetic core 1 is embedded in the magnetic core through groove 33, and the side columns of the upper magnetic core 1 are arranged outside the upper magnetic core limiting groove 31, and the upper magnetic core 1 is limited in the upper magnetic core limiting groove 31;

[0034] The middle column of the lower magnetic core 2 is embedded in the magnetic core through groove 33 , and the side columns of the lower magnetic core 2 are arranged outside the lower magnetic core limiting groove 32 . The lower magnetic core 2 is limited in the lower magnetic core limiting groove 32 .

[0035] In this embodiment, an upper magnetic core limiting groove 31 is opened at the upper part of the skeleton 3, a lower magnetic core limiting groove 32 is opened at the lower part of the skeleton 3, and a magnetic core through groove 33 is opened inside the skeleton 3 from the upper magnetic core limiting groove 31 to the lower magnetic core limiting groove 32; so that one or more middle columns of the upper magnetic core 1 can be embedded in the magnetic core through groove 33, and one or more side columns of the upper magnetic core 1 are arranged outside the upper magnetic core limiting groove 31, so that the upper magnetic core 1 is limited to the upper magnetic core limiting groove 31, so that the upper magnetic core 1 and the skeleton 3 form a fixed relationship; at the same time, one or more middle columns of the lower magnetic core 2 are embedded in the magnetic core through groove 33, and one or more side columns of the lower magnetic core 2 are arranged outside the lower magnetic core limiting groove 32, so that the lower magnetic core 2 is limited to the lower magnetic core limiting groove 32, so that the lower magnetic core 3 and the skeleton 3 form a fixed relationship; finally, the upper magnetic core 1 and the lower magnetic core 2 form a middle column air gap 42 inside (center) of the skeleton 3, and a side column air gap 41 is formed at the edge of the skeleton 3.

[0036] Furthermore, the middle columns of the upper magnetic core 1 and the lower magnetic core 2 are both set to be cylindrical.

[0037] In this embodiment, since the middle column of the upper magnetic core 1 and the lower magnetic core 2 is arranged in the center of the skeleton 3, it is the core air gap and has the greatest impact on the performance of the transformer, especially when there is only one middle column of the upper magnetic core 1 and the lower magnetic core 2. Therefore, it is preferred to set the middle column of the upper magnetic core 1 and the lower magnetic core 2 to be cylindrical, because the magnetic field distribution inside the cylindrical magnetic core is more uniform, which helps to reduce flux leakage and energy loss, and improve the transmission efficiency and performance of the transformer.

[0038] Furthermore, the outer wall and the slot wall of the cross section of the magnetic core slot 33 are both circular, and the outer wall of the magnetic core slot 33 is used for winding.

[0039] In this embodiment, when the middle column of the upper magnetic core 1 and the lower magnetic core 2 is preferably cylindrical, the outer wall and the slot wall of the cross section of the core slot 33 should be set to be circular accordingly, wherein the circular slot wall is convenient for the embedding of the cylindrical middle column; the circular outer wall is beneficial for winding, with good processing performance and easy winding, and the oil path between the wound winding layers has high heat dissipation efficiency, which helps the transformer maintain good heat dissipation performance when operating at high load, prevents overheating and prolongs its service life.

[0040] Furthermore, an upper insulating groove 11 is provided on the outer surface of the upper magnetic core 1 , and a lower insulating groove 21 is provided on the outer surface of the lower magnetic core 2 symmetrically to the upper insulating groove 11 , and the upper insulating groove 11 and the lower insulating groove 21 are combined to form an insulating winding area.

[0041] In this embodiment, an upper insulating groove 11 is provided on the outer surface of the upper magnetic core 1, and a lower insulating groove 21 is provided on the outer surface of the lower magnetic core 2 symmetrically to the upper insulating groove 11. The upper insulating groove 11 and the lower insulating groove 21 are combined to form an insulating winding area. The transformer core insulation layer can be wound around the insulating winding area by insulating material (such as insulating paper). At the same time, the upper magnetic core 1 and the lower magnetic core 2 are bound on the outer surface by insulating material to fix the positional relationship between the upper magnetic core 1, the lower magnetic core 2 and the skeleton 3, thereby preventing the side column air gap 41 and the middle column air gap 42 from shifting, resulting in a change in the total amount of the air gap.

[0042] Furthermore, the side columns of the upper magnetic core 1 and the lower magnetic core 2 are arranged on the left and right sides of the frame 3 , and the front and rear sides of the lower part of the frame 3 are provided with pins 6 .

[0043] In this embodiment, the side columns of the upper magnetic core 1 and the lower magnetic core 2 are arranged on the left and right sides of the frame 3, so that the winding wire can be inserted and wound from the front and rear sides of the frame 3, and the input and output wires of the winding are conveniently electrically connected to the pins 6 on the front and rear sides of the lower part of the frame 3.

[0044] Other structures and operations of the distributed air-gap transformer structure according to the embodiment of the utility model are known to ordinary technicians in the field and will not be described in detail here.

[0045] In the description of this specification, the description with reference to the terms "embodiment", "example", etc. means that the specific features, structures, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the utility model. In this specification, the schematic representation of the above terms does not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described can be combined in any one or more embodiments or examples in a suitable manner.

[0046] Although the embodiments of the present invention have been shown and described, those skilled in the art will appreciate that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the claims and their equivalents.

Claims

1. A distributed air-gap transformer structure, characterized in that: It comprises an upper magnetic core, a lower magnetic core and a frame; the upper magnetic core and the lower magnetic core are respectively sleeved on the upper part and the lower part of the frame, and a plurality of air gaps are formed between the lower part of the upper magnetic core and the upper part of the lower magnetic core; The air gaps include side column air gaps and middle column air gaps; the middle column air gap is arranged at the center of the frame, the side column air gap is arranged at the edge of the frame, and the winding area is between the middle column air gap and the side column air gap.

2. A distributed air-gap transformer structure according to claim 1, characterized in that: The upper magnetic core and the lower magnetic core are both provided with at least one middle column and at least one side column. The middle column and side columns of the upper magnetic core correspond to the middle column and side columns of the lower magnetic core respectively and are symmetrically arranged. A middle column air gap is formed between the bottom of the middle column of the upper magnetic core and the top of the middle column of the lower magnetic core, and a side column air gap is formed between the bottom of the side column of the upper magnetic core and the top of the side column of the lower magnetic core.

3. A distributed air-gap transformer structure according to claim 2, characterized in that: An upper magnetic core limiting groove is formed at the upper part of the frame, a lower magnetic core limiting groove is formed at the lower part of the frame, and a magnetic core through groove is formed inside the frame from the upper magnetic core limiting groove to the lower magnetic core limiting groove; The middle column of the upper magnetic core is embedded in the magnetic core through groove, the side columns of the upper magnetic core are arranged outside the upper magnetic core limiting groove, and the upper magnetic core is limited in the upper magnetic core limiting groove; The middle column of the lower magnetic core is embedded in the magnetic core through groove, the side columns of the lower magnetic core are arranged outside the lower magnetic core limiting groove, and the lower magnetic core is limited in the lower magnetic core limiting groove.

4. The distributed air-gap transformer structure according to claim 3, characterized in that: The middle columns of the upper magnetic core and the lower magnetic core are both set to be cylindrical.

5. The distributed air-gap transformer structure according to claim 4, characterized in that: The outer wall and the slot wall of the cross section of the magnetic core slot are both circular, and the outer wall of the magnetic core slot is used for winding wires.

6. The distributed air-gap transformer structure according to claim 1, characterized in that: An upper insulating groove is provided on the outer surface of the upper magnetic core, and a lower insulating groove is provided on the outer surface of the lower magnetic core symmetrically to the upper insulating groove. The upper insulating groove and the lower insulating groove are combined to form an insulating winding area.

7. The distributed air-gap transformer structure according to claim 2, characterized in that: The side columns of the upper magnetic core and the lower magnetic core are arranged on the left and right sides of the frame, and the front and rear sides of the lower part of the frame are provided with pins.

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