Polycrystalline silicon converter transformer
By adopting a three-phase iron core structure and a single-phase secondary winding design in a polysilicon transformer, sub-winding is connected in series or parallel to solve the problems of local overheating and ampere-turn imbalance of the secondary winding, higher stability and lower losses are achieved, and the safety and reliability of the equipment are improved.
Patent Information
- Application Number
- CN202422306241.0
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-09-20
- Publication Date
- 2025-08-08
- Estimated Expiration
- 2034-09-20
AI Technical Summary
The existing polysilicon transformers have problems of local overheating of the secondary winding and ampere-turn imbalance, especially when the phase-deficient operation increases dramatically, affecting the safety, reliability and life of the equipment.
It adopts a three-phase iron core structure, each phase sub-edge winding is single-phase and electrically independent. The primary winding is set on the outer circumference of the secondary winding. Two sub-windings are connected in series or parallel to achieve different states, ensuring uniform current distribution and electromagnetic ampere turns balance.
It effectively avoids local overheating, improves the stability and production efficiency of the equipment, reduces manufacturing difficulty and cost, and reduces operating losses, ensuring electromagnetic ampere turns balance.
Smart Images
Figure CN223206093U_ABST
Abstract
Description
Technical Field
[0001] The utility model relates to the technical field of converter transformers, in particular to a polysilicon converter transformer. Background Art
[0002] With the rapid development of the polysilicon industry, electricity consumption has increased rapidly and load density has continued to increase. Polysilicon converter transformers are high-voltage electrical equipment and are key equipment in the production of polysilicon power supply systems. They are crucial to the safe, reliable operation and life of the entire polysilicon power supply system.
[0003] Currently, split-type converter transformers are mostly used in polysilicon converter transformers, which split the primary and secondary windings of each phase into upper and lower phases in the axial direction. The upper and lower phases operate independently to obtain different voltage and current outputs.
[0004] However, the above-mentioned polysilicon converter transformer has the following disadvantages:
[0005] First, existing secondary windings all use foil windings, which are made of extremely thin foil material. Their width is close to the height of the transformer window. Due to their structural characteristics, foil windings will produce extremely uneven current density and eddy current losses under the influence of the leakage magnetic field. When operating in some gear taps, the upper and lower secondary windings may not operate at the same time, that is, they operate in a phase-loss state. For polycrystalline silicon converter transformers, this is a semi-through operating state, resulting in serious load imbalance and a sharp increase in eddy current losses caused by leakage magnetic field. In particular, eddy current losses are more concentrated at the lower end of the upper secondary winding near the middle of the iron core and the upper end of the lower secondary winding, causing local overheating of the secondary winding of the polycrystalline silicon converter transformer.
[0006] 2. During the operation of the polysilicon converter transformer, the growth rate of the silicon rods in each phase may be inconsistent, which will lead to long-term unbalanced operation of the three phases of the polysilicon converter transformer, thereby superimposing the half-through operation state. The split primary winding leads to uneven current distribution, causing more serious ampere-turn imbalance. If a short-circuit fault occurs, the axial short-circuit electromotive force will cause damage to the polysilicon converter transformer, which will affect the overall safe operation. Utility Model Content
[0007] The main purpose of the utility model is to propose a polysilicon converter transformer, aiming to solve the problem in the prior art that the primary and secondary windings are divided into upper and lower parts in the axial direction, which leads to local overheating and ampere-turn imbalance during operation.
[0008] To achieve the above-mentioned purpose, the present invention provides a polysilicon converter transformer, comprising:
[0009] A three-phase iron core, wherein each phase of the iron core is provided with a secondary winding and a primary winding, wherein the primary winding of each phase is a single-phase primary winding, and the secondary winding of each phase is a single-phase secondary winding, and the secondary winding is sleeved on the outer periphery of the iron core, and the primary winding is sleeved on the outer periphery of the secondary winding;
[0010] The secondary windings of each phase are electrically independent and insulated from each other, and each phase secondary winding comprises two sub-windings spaced apart in the radial direction of the iron core;
[0011] When the two sub-windings are connected in series, the polysilicon converter transformer is in a first state; when the two sub-windings are connected in parallel, the polysilicon converter transformer is in a second state.
[0012] In one embodiment, both of the two sub-windings include a plurality of wire turn units arranged at radial intervals along the iron core; when all of the wire turn units in the two sub-windings are arranged in series in sequence, the polycrystalline silicon converter transformer is in a first state; when the wire turn units of the two sub-windings are arranged in parallel, the polycrystalline silicon converter transformer is in a second state.
[0013] In one embodiment, the output voltage of each of the winding turn units is arranged to decrease in sequence from a direction close to the iron core to a direction away from the iron core.
[0014] In one embodiment, each of the wire turn units has a conductor with multiple turns; the number of conductor turns of the wire turn unit decreases from close to the iron core to away from the iron core, so that the output voltage of the wire turn unit decreases.
[0015] In one embodiment, a gear tap is connected between any two adjacent turn units, and any combination of the two gear taps is used to output voltage and current.
[0016] In one embodiment, a heat dissipation channel is provided between any two adjacent wire turn units.
[0017] In one embodiment, one of the sub-windings is a foil winding, and the other sub-winding is a wire winding.
[0018] In one embodiment, the primary winding of each phase includes multiple layers of windings spaced apart in a radial direction of the core.
[0019] In one embodiment, the three-phase primary windings are connected in a delta connection manner.
[0020] In one embodiment, an insulating cylinder is provided on the outer circumference of the secondary winding of each phase, and the primary winding is provided on the outer circumference of the insulating cylinder.
[0021] The technical solution of the present invention is to set the secondary winding of each phase as a single-phase secondary winding and the primary winding of each phase as a single-phase primary winding. This structure has good processability and efficiency, and improves the overall stability of the polysilicon converter transformer. The difficulty of design and manufacturing process is greatly reduced, the production efficiency of the product is improved and the overall manufacturing difficulty and cost of the product are reduced. In addition, the single-phase secondary winding avoids the problem of local area overheating caused by phase-loss operation of the polysilicon converter transformer.
[0022] In addition, by connecting the two sub-windings in series or in parallel, the polysilicon converter transformer is placed in the first state or the second state accordingly, thereby outputting currents and voltages of different specifications, thereby utilizing all the turns in the two sub-windings, and at the same time evenly distributing the current of the single-phase primary winding, thereby obtaining a better electromagnetic ampere-turn balance, which is beneficial to reducing the loss during operation of the polysilicon converter transformer, thereby solving the problem of ampere-turn imbalance when the polysilicon converter transformer is operating in a phase-missing state in the prior art. BRIEF DESCRIPTION OF THE DRAWINGS
[0023] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on the structures shown in these drawings without paying any creative work.
[0024] Figure 1 This is a front structural diagram of an embodiment of a polysilicon converter transformer provided by the present utility model;
[0025] Figure 2 A side structural diagram of an embodiment of a polysilicon converter transformer provided by the present invention;
[0026] Figure 3 This is a schematic structural diagram of the secondary winding and the primary winding in the polysilicon converter transformer provided by the present invention.
[0027] Description of Figure Numbers:
[0028] 100. Polycrystalline silicon converter transformer; 1. Iron core; 2. Secondary winding; 2a. First sub-winding; 2b. Second sub-winding; 21. Gear tap; 3. Primary winding; 4. Insulation tube; 5. Heat dissipation duct.
[0029] The realization of the purpose, functional features and advantages of the present invention will be further explained in conjunction with embodiments and with reference to the accompanying drawings. DETAILED DESCRIPTION
[0030] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the embodiments described are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making any creative work are within the scope of protection of the present invention.
[0031] It should be noted that if the embodiments of the present invention involve directional indications (such as up, down, left, right, front, back, etc.), the directional indications are only used to explain the relative position relationship, movement status, etc. between the components in a certain specific posture. If the specific posture changes, the directional indications will also change accordingly.
[0032] In addition, if there are descriptions involving "first", "second", etc. in the embodiments of the present invention, the descriptions of "first", "second", etc. are only for descriptive purposes and cannot be understood as indicating or implying their relative importance or implicitly indicating the number of the indicated technical features. Therefore, the features limited to "first" and "second" may explicitly or implicitly include at least one of such features. In addition, if "and / or" or "and / or" appears in the full text, its meaning includes three parallel schemes. Taking "A and / or B" as an example, it includes scheme A, or scheme B, or a scheme in which A and B are satisfied at the same time. In addition, the technical solutions between the various embodiments can be combined with each other, but it must be based on the fact that ordinary technicians in this field can implement it. When the combination of technical solutions is mutually contradictory or cannot be implemented, it should be deemed that such a combination of technical solutions does not exist and is not within the scope of protection required by the present invention.
[0033] With the rapid development of the polysilicon industry, electricity consumption has increased rapidly and load density has continued to increase. Polysilicon converter transformers are high-voltage electrical equipment and are key equipment in the production of polysilicon power supply systems. They are crucial to the safe, reliable operation and life of the entire polysilicon power supply system.
[0034] Currently, split-type converter transformers are mostly used in polysilicon converter transformers, which split the primary and secondary windings of each phase into upper and lower phases in the axial direction. The upper and lower phases operate independently to obtain different voltage and current outputs.
[0035] However, the above-mentioned polysilicon converter transformer has the following disadvantages:
[0036] First, existing secondary windings all use foil windings, which are made of extremely thin foil material. Their width is close to the height of the transformer window. Due to their structural characteristics, foil windings will produce extremely uneven current density and eddy current losses under the influence of the leakage magnetic field. When operating in some gear taps, the upper and lower secondary windings may not operate at the same time, that is, they operate in a phase-loss state. For polycrystalline silicon converter transformers, this is a semi-through operating state, resulting in serious load imbalance and a sharp increase in eddy current losses caused by leakage magnetic field. In particular, eddy current losses are more concentrated at the lower end of the upper secondary winding near the middle of the iron core and the upper end of the lower secondary winding, causing local overheating of the secondary winding of the polycrystalline silicon converter transformer.
[0037] 2. During the operation of the polysilicon converter transformer, the growth rate of the silicon rods of each phase may be inconsistent, which will lead to long-term unbalanced operation of the three phases of the polysilicon converter transformer, thereby superimposing the half-through operation state. The current distribution is uneven due to the split primary winding, causing more serious ampere-turn imbalance. If a short circuit fault occurs, the axial short circuit electromotive force will cause damage to the polysilicon converter transformer, which will affect the overall safe operation.
[0038] The utility model provides a polycrystalline silicon converter transformer.
[0039] See also Figure 1-Figure 2 In one embodiment of the present invention, the polycrystalline silicon converter transformer 100 includes a three-phase iron core 1, and each phase iron core 1 is provided with a secondary winding 2 and a primary winding 3, wherein the primary winding 3 is a single-phase primary winding 3, and the secondary winding 2 is a single-phase secondary winding 2, the secondary winding 2 is sleeved on the outer periphery of the iron core 1, and the primary winding 3 is sleeved on the outer periphery of the secondary winding 2; the secondary windings 2 of each phase are electrically independent and insulated from each other, and the secondary winding 2 of each phase includes two sub-windings spaced apart along the radial direction of the iron core 1; when the two sub-windings are connected in series, the polycrystalline silicon converter transformer 100 is in a first state; when the two sub-windings are connected in parallel, the polycrystalline silicon converter transformer 100 is in a second state.
[0040] As can be understood, in this embodiment, neither the secondary winding 2 nor the primary winding 3 is split into multiple parts axially along the core 1. Instead, each phase's secondary winding 2 is a single-phase secondary winding 2, and each phase's primary winding 3 is a single-phase primary winding 3. This structure offers excellent manufacturability and efficiency, improves the overall stability of the polycrystalline silicon converter transformer 100, significantly reduces design and manufacturing complexity, improves product efficiency, and reduces overall manufacturing difficulty and cost. Furthermore, the single-phase secondary winding 2 avoids localized overheating caused by the polycrystalline silicon converter transformer operating with one phase missing.
[0041] By connecting the two sub-windings in series or in parallel, the polycrystalline silicon converter transformer is placed in a first state or a second state, thereby outputting different current and voltage specifications. In the series or parallel connection, all turns in the two sub-windings are utilized, while the current of the single-phase primary winding is evenly distributed, thereby achieving better electromagnetic ampere-turn balance. This helps reduce losses during operation of the polycrystalline silicon converter transformer 100, thereby solving the problem of ampere-turn imbalance in polycrystalline silicon converter transformers in the prior art when operating with a phase missing.
[0042] The secondary winding 2 is mounted on the three-phase iron core, and the primary winding 3 is mounted outside the secondary winding 2. The primary winding 3 is connected to the high-voltage power grid. Under the action of electromagnetic induction, the high voltage of the primary winding 3 is converted into the low voltage of the secondary winding 2 to meet the voltage requirements of the load.
[0043] It can be understood that the output voltage of the polysilicon converter transformer 100 is the largest when it is in the first state, and the output current of the polysilicon converter transformer 100 is the largest when it is in the second state.
[0044] The two sub-windings are wound separately inside and outside and then assembled, which can also solve the problem of difficulty and low efficiency in winding the secondary winding 2 due to the large capacity of the product.
[0045] Specifically, both sub-windings include a plurality of wire turn units arranged at radial intervals along the iron core 1; when all the wire turn units in the two sub-windings are arranged in series in sequence, the polycrystalline silicon converter transformer 100 is in a first state; when the wire turn units of the two sub-windings are arranged in parallel, the polycrystalline silicon converter transformer 100 is in a second state.
[0046] It can be understood that each sub-winding includes multiple wire turn units, and all the wire turn units are arranged in sequence along the radial direction of the iron core 1. Different wire turn units are connected in series or in parallel to output different voltages to meet different usage requirements. All the wire turn units are connected in series or in parallel, so that all the wire turn units are utilized and put into operation to obtain better electromagnetic ampere-turn balance and reduce losses during operation.
[0047] In one embodiment, the output voltage of each winding unit decreases from close to the iron core 1 to away from the iron core 1. It can be understood that the output voltage of each winding unit is different to form multiple output voltage levels to meet the power supply requirements of various loads.
[0048] Specifically, each wire turn unit has a conductor with multiple turns; the number of conductor turns of the wire turn unit decreases from close to the iron core 1 to far away from the iron core 1, so that the output voltage of the wire turn unit decreases.
[0049] It can be understood that each wire turn unit has a conductor with a different number of turns, the output voltage of the wire turn unit with a large number of conductor turns is high, and the output voltage of the wire turn unit with a small number of conductor turns is low. The combination of different wire turn units constitutes different gears of the transformer, forming a multi-capacity output to meet power demand, and has good short-circuit resistance and anti-system power harmonics capability.
[0050] In some embodiments, a support structure may be provided between two adjacent layers of adjacent turn units to enhance the stability of the neat structure of the polysilicon converter transformer 100. The support structure may be a support bar provided along the axial direction of the core 1.
[0051] In one embodiment, a gear tap 21 is connected between any two adjacent turn units, and any combination of two gear taps 21 is used to output voltage and current.
[0052] It can be understood that any two gear taps 21 are combined to output different levels of voltage and current. The wire turn unit between any two gear taps 21 is wound into a capacity segment, and the combination of two different gear taps 21 forms a capacity segment with different output voltages, thereby being able to meet the power supply needs of various loads, so as to more accurately adjust the range of current and voltage required for the electric heating output. The gear tap 21 can be a copper busbar tap. The copper busbar is also called a copper busbar or a copper busbar. It is made of copper material and has a long conductor with a rectangular or chamfered rectangular cross-section. Rounded copper busbars are generally used now to avoid tip discharge. It plays the role of transmitting current and connecting electrical equipment in the circuit.
[0053] Specifically, if Figure 3 As shown, in this embodiment, for the convenience of explanation, one of the sub-windings is the first sub-winding 2a, and the other sub-winding is the second sub-winding 2b; the first sub-winding 2a includes two gear taps 21, which are 1u5 and 1u4 in the figure, and the second sub-winding 2b includes four gear taps 21, which are 1u3, 1u2, 1u1 and 1u; when the first sub-winding 2a and the second sub-winding 2b are connected in series, 1u5 and 1u4 in the first sub-winding 2a are connected in series, and 1u3, 1u2, 1u1 and 1u in the second sub-winding 2b are connected in series in sequence, and 1u4 and 1u3 are connected in series, so as to output the required current and voltage, and the output voltage at this time is the highest; when the first sub-winding 2a and the second sub-winding 2b are connected in parallel, 1u5 is connected to 1u3 and 1u1, and 1u4 is connected to 1u2 and 1u, and the output current is the largest at this time. From the above operation mode, it can be seen that after the secondary winding 2 of each phase is designed as a modular relationship, that is, the voltage and current are in a multiple relationship, there are no idle turns when outputting in series or parallel, which can obtain the best electromagnetic ampere-turn balance and reduce the corresponding loss during operation.
[0054] In one embodiment, one of the sub-windings is a foil winding, and the other sub-winding is a wire winding.
[0055] It can be understood that the foil-wire mixed winding structure adopted by the secondary winding 2 makes the secondary winding 2 have both the advantages of the foil winding and the advantages of the wire winding. Specifically, the foil winding uses a flat metal foil as a conductor, usually copper foil or aluminum foil. Due to the large cross-sectional area of the foil, it can carry a larger current while having a lower resistance, which helps to dissipate heat and improve the heat dissipation performance; while the wire winding uses the wire as the conductor, which can provide better mechanical strength, optimize the current distribution, and allow the lateral leakage magnetic field to penetrate the winding smoothly. The eddy current loss generated on the wire is small, thereby solving the problem of local eddy current loss concentration caused by the leakage magnetic field when passing through the end of the secondary winding 2, resulting in local heating.
[0056] Specifically, in this embodiment, the first sub-winding 2a is a wire winding, and the second sub-winding 2b is a foil winding. Compared with the first sub-winding 2a, the second sub-winding 2b is closer to the iron core 1, which is conducive to heat dissipation.
[0057] In one embodiment, a heat dissipation channel 5 is provided between any two adjacent winding turn units. It is understood that the heat dissipation channel 5 extends axially along the core 1 and is connected to the outside world. This connection facilitates heat dissipation within the transformer. External air can enter the primary winding 3 and secondary winding 2 of the polycrystalline silicon converter transformer 100 through the heat dissipation channel 5. During operation of the polycrystalline silicon converter transformer 100, heat generated by the coils can be discharged through the heat dissipation channel 5, effectively improving the transformer's heat dissipation capability.
[0058] In other embodiments, a cooling mechanism, such as a fan, may be provided at the end of the polysilicon converter transformer 100 to blow air into the heat dissipation duct 5 to cool the polysilicon converter transformer 100 .
[0059] In one embodiment, each phase primary winding 3 includes multiple layers of windings spaced apart along the radial direction of the core 1. It is understood that the multiple layers of windings are spaced apart to increase the heat dissipation area and facilitate heat dissipation, and each layer of winding can also be provided with a different number of turns of conductor to meet different power requirements.
[0060] In one embodiment, the three-phase primary windings 3 are connected in a delta connection manner.
[0061] It can be understood that the triangle connection method enables the primary winding 3 of each phase to carry the corresponding load respectively, and the secondary windings 2 of each phase operate independently and are insulated from each other. Therefore, the output voltage of the secondary winding 2 of each phase is different to adapt to different loads, and the change of the load of one phase will not affect the other two phases. In addition, when a fault occurs, the triangle connection can more easily isolate the faulty part, thereby reducing interference with the entire polycrystalline silicon converter transformer 100; and the primary windings 3 of each phase are connected in a triangle connection method. The triangle connection method is to connect the ends of the three primary windings 3 to each other to form a closed triangle, and the head end of each winding is respectively connected to the power supply or load, and in the triangle connection, the line voltage is equal to the phase voltage, that is, the voltage at both ends of the line is the same as the voltage at both ends of the winding, but the line current is not equal to the phase current, and the line current is √3 times the phase current.
[0062] In one embodiment, an insulating cylinder 4 is sheathed on the outer circumference of the secondary winding 2 of each phase, and a primary winding 3 is sheathed on the outer circumference of the insulating cylinder 4 .
[0063] It can be understood that the insulating tube 4 is used to electrically isolate the primary winding 3 from the secondary winding 2 to prevent current from flowing through undesigned paths, thereby avoiding short circuit or leakage accidents. Through physical isolation, it is ensured that the voltages between the primary winding 3 and the secondary winding 2 do not interfere with each other, thereby ensuring the stability of electrical performance; in addition, the insulating tube 4 also plays a role of mechanical support, which can maintain a fixed distance between the primary winding 3 and the secondary winding 2, preventing the primary winding 3 and the secondary winding 2 from being displaced or deformed due to vibration during transportation or operation, and improving the overall mechanical strength of the polysilicon converter transformer 100 by enhancing the structural stability of the winding and reducing the impact of mechanical stress on the winding.
[0064] In some embodiments, a heat dissipation duct 5 is provided between the primary winding 3, the insulating cylinder 4, and the secondary winding 2. The heat dissipation duct 5 is connected to the outside world, facilitating air circulation and improving heat dissipation efficiency. The above description is merely an exemplary embodiment of the present invention and does not limit the scope of the present invention. Any equivalent structural transformation based on the technical concept of the present invention and the contents of the present invention specification and drawings, or any direct or indirect application in other related technical fields, is included within the scope of the present invention.
Claims
1. A polycrystalline silicon converter transformer, characterized in that: include: A three-phase iron core, wherein each phase of the iron core is provided with a secondary winding and a primary winding, wherein the primary winding of each phase is a single-phase primary winding, and the secondary winding of each phase is a single-phase secondary winding, and the secondary winding is sleeved on the outer periphery of the iron core, and the primary winding is sleeved on the outer periphery of the secondary winding; The secondary windings of each phase are electrically independent and insulated from each other, and each phase secondary winding comprises two sub-windings spaced apart in the radial direction of the iron core; When the two sub-windings are connected in series, the polysilicon converter transformer is in a first state; when the two sub-windings are connected in parallel, the polysilicon converter transformer is in a second state.
2. The polysilicon converter transformer according to claim 1, wherein: The two sub-windings each include a plurality of wire turn units spaced apart along the radial direction of the iron core; when all the wire turn units in the two sub-windings are arranged in series in sequence, the polycrystalline silicon converter transformer is in a first state; when the wire turn units of the two sub-windings are arranged in parallel, the polycrystalline silicon converter transformer is in a second state.
3. The polysilicon converter transformer according to claim 2, wherein: The output voltage of each of the winding turn units is arranged to decrease in sequence from a direction close to the iron core to a direction away from the iron core.
4. The polysilicon converter transformer according to claim 3, wherein: Each of the wire turn units has a conductor with multiple turns. The number of conductor turns of the wire turn units decreases in sequence from close to the iron core to far away from the iron core, so that the output voltage of the wire turn units decreases in sequence.
5. The polysilicon converter transformer according to claim 2, wherein: A gear tap is connected between any two adjacent turn units, and any combination of the two gear taps is used to output voltage and current.
6. The polysilicon converter transformer according to claim 2, wherein: There is a heat dissipation channel between any two adjacent wire turn units.
7. The polycrystalline silicon converter transformer according to any one of claims 1 to 6, characterized in that: One of the sub-windings is a foil winding, and the other sub-winding is a wire winding.
8. The polycrystalline silicon converter transformer according to any one of claims 1 to 6, characterized in that: The primary winding of each phase includes multiple layers of windings arranged at intervals along the radial direction of the iron core.
9. The polycrystalline silicon converter transformer according to any one of claims 1 to 6, characterized in that: The three-phase primary windings are connected in a delta connection manner.
10. The polycrystalline silicon converter transformer according to any one of claims 1 to 6, characterized in that: An insulating cylinder is provided on the outer circumference of the secondary winding of each phase, and the primary winding is provided on the outer circumference of the insulating cylinder.