OBC vehicle-mounted fast-charging three-phase common-mode inductor

Abstract

The utility model discloses an OBC vehicle-mounted fast-charging three-phase common-mode inductor, which belongs to the technical field of new energy electric vehicle charging modules and is characterized in that the outer end of an insulating sheath is provided with a tin-plated terminal, a fixed base is respectively provided with a leading-out end limiting hole, the tin-plated terminal is arranged in the leading-out end limiting hole and is fixedly connected with the leading-out end limiting hole, and the tin-plated terminal is arranged in the leading-out end limiting hole. Six limiting holes are designed in the left bottom and the right bottom of the fixed base, so that pins of the coil can smoothly pass through the limiting holes, and the coil and the control key are dispensed to further fix the coil; the magnetic ring is designed to be of a runway-shaped structure, the overall height of the inductor can be reduced, the leakage inductance of the three-phase common-mode inductor is small, the nanocrystalline magnetic ring which is smaller in loss and higher in saturation characteristic is selected as a magnetic core material, the loss is smaller under the large-current condition, a flat wire vertical winding mode is adopted for a coil of the inductor, and automation is deviated. And the three groups of coils can be arranged in parallel in a straight line shape, so that compared with an annular horizontal three-phase common mode inductor, the occupied space area on an integrated board is reduced, and more space can be provided for optimizing the circuit design.

Description

Technical Field

[0001] This utility model relates to an OBC on-board fast charging three-phase common mode inductor, belonging to the technical field of new energy electric vehicle charging module. Background Technology

[0002] Currently, silicon carbide is the preferred material for high-frequency high-voltage inductors, which reduces the size and cost of inductors and transformers, thereby addressing the cost increases brought about by the introduction of high-voltage devices. However, with the development of electric vehicle technology, the high-frequency design also places higher demands on magnetic components, namely smaller size and higher frequency, requiring improved loss performance and heat dissipation performance of magnetic components. If the frequency is further increased, there will be a strong demand for new high-frequency magnetic materials. For example, a 11KW supercharger is generally a three-phase single-channel PFC and a single or two-channel isolated DC-DC converter.

[0003] For example, CN216353718U discloses a spliced ​​horizontal three-phase common-mode inductor, including a square ring magnetic core, three sets of inductor coils, and a frame; the square ring magnetic core is square-shaped with a U-shaped side and a bottom side; the U-shaped side has a locking protrusion, and the bottom side has a locking groove; the beneficial effects of this utility model are: this design divides the square ring magnetic core into a U-shaped side and a bottom side; it solves the problem of slow production caused by manually winding the coils to form the inductor coils; it can also be produced mechanically and automatically; the frame has pins, coil grooves, magnetic core grooves, and wire end grooves, making its structure more compact; the structure is simple and easy to produce.

[0004] Based on retrieval and analysis, it is concluded that existing technologies still have shortcomings:

[0005] The high-frequency design also places higher demands on magnetic components, namely smaller size and higher frequency. Magnetic components need to improve loss performance and heat dissipation performance. Traditional iron-silicon powder core materials are difficult to achieve the required performance and have high losses. Therefore, an OBC vehicle fast charging three-phase common-mode inductor is needed to improve the above-mentioned shortcomings. Utility Model Content

[0006] The main purpose of this invention is to provide an OBC vehicle fast charging three-phase common mode inductor.

[0007] The objective of this utility model can be achieved by adopting the following technical solution:

[0008] An OBC (On-Board Charger) vehicle fast charging three-phase common mode inductor includes a fixing base for limiting position;

[0009] The fixed base has limit grooves at both ends, and a magnetic ring is placed in the limit groove. A flat copper coil is wound on the magnetic ring. An insulating sleeve is installed on the outer end of the flat copper coil, and a tin-plated terminal is installed on the outer end of the insulating sleeve. The fixed base has lead-out limit holes, and the tin-plated terminal is inserted into the lead-out limit holes for fixed connection.

[0010] Preferably, the flat copper coils on the magnetic ring are arranged in a straight line side by side.

[0011] Preferably, the lead-out portion of the flat copper coil is covered by an insulating sheath.

[0012] Preferably, the flat copper coil has a circular ring structure, and the outer end of the flat copper coil is tin-plated and soldered with tin-plated terminals.

[0013] Preferably, the bottom of the fixed base is designed with at least six lead-out end limiting holes.

[0014] Preferably, the magnetic ring has a racetrack structure, and the fixing base is made of insulating epoxy resin.

[0015] The beneficial technical effects of this utility model are as follows:

[0016] This utility model provides an OBC (On-Board Charger) three-phase common-mode inductor.

[0017] 1. The inductor can be quickly positioned by means of the limiting slot between the fixed base and the magnetic ring, which has high stability.

[0018] 2. Circular flat wires can be quickly wound vertically on the same racetrack-shaped magnetic ring by machine. Three uniform coils share a single magnetic core, resulting in high inductance consistency, high structural symmetry, low leakage inductance of the common-mode inductor, and efficient use of thick flat wires to make good use of space. Thick flat wires can also carry large currents, making them suitable for applications with high current requirements in vehicles.

[0019] 3. Using nanocrystals as the magnetic core, it features low loss and high magnetic saturation strength, and can be used at higher frequencies.

[0020] 4. In summary, this three-phase common mode inductor design is simple, has good consistency, is suitable for automated production, and can reduce product costs. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the overall three-dimensional structure of a preferred embodiment of an OBC vehicle fast charging three-phase common mode inductor according to the present invention;

[0022] Figure 2 This is a schematic diagram of the coil connection structure of a preferred embodiment of an OBC vehicle fast charging three-phase common mode inductor according to the present invention;

[0023] Figure 3 This is a schematic diagram of the limiting structure of a preferred embodiment of an OBC (On-Board Charger) three-phase common-mode inductor according to the present invention.

[0024] In the diagram: 1. Magnetic ring; 2. Fixing base; 3. Tin-plated terminal; 4. Insulating sleeve; 5. Flat copper coil; 6. Limiting groove; 7. Lead-out end limiting hole. Detailed Implementation

[0025] To enable those skilled in the art to understand the technical solution of this utility model more clearly, the present utility model will be further described in detail below with reference to the embodiments and accompanying drawings, but the implementation of this utility model is not limited thereto.

[0026] like Figure 1 - Figure 3 As shown, this embodiment provides an OBC vehicle fast charging three-phase common mode inductor, including a fixed base 2 for limiting the position;

[0027] The fixed base 2 has limit grooves 6 at both ends, and a magnetic ring 1 is placed in the limit groove 6. A flat copper coil 5 is wound on the magnetic ring 1. An insulating sleeve 4 is installed on the outer end of the flat copper coil 5. A tin-plated terminal 3 is installed on the outer end of the insulating sleeve 4. A lead-out limit hole 7 is opened on the fixed base 2. The tin-plated terminal 3 is inserted into the lead-out limit hole 7 for fixed connection.

[0028] The flat copper coils 5 on the magnetic ring 1 are arranged in a straight line.

[0029] The lead-out portion of the flat copper coil 5 is covered by an insulating sheath 4.

[0030] The flat copper coil 5 has a circular structure, and the outer end of the flat copper coil 5 is tin-plated and soldered with a tin-plated terminal 3.

[0031] The bottom of the fixed base 2 is designed with at least six lead-out end limiting holes 7.

[0032] The magnetic ring 1 has a racetrack structure, and the fixed base 2 is made of insulating epoxy resin.

[0033] like Figure 1 - Figure 3As shown in the figure, the working process of the OBC vehicle fast charging three-phase common mode inductor provided in this embodiment is as follows: It includes three parallel inductor coils, a magnetic ring 1, a fixed base 2, and an insulating sleeve 4. The bottom end of the inductor body is fixed by the base and limiting holes, and is connected to three sets of side-by-side support feet. The coil has a circular ring structure. The lead-out ends of the coils are tin-plated to enhance the solderability of the copper wires, and the lead-out ends of the copper wires are covered with insulating thermoplastic tubes to increase the withstand voltage and leakage distance between the copper wires. The base is designed with a slot to fix the position of the magnetic ring. By adopting the above technical solution, the copper coils and the base, as well as the magnetic ring 1 and the base, are connected. It is also easy to assemble, effectively improving installation efficiency. The base is made of insulating epoxy resin. Six limiting holes are designed on the left and right bottom of the base so that the coil pins can pass through smoothly and to fix the coil position. The coil is further fixed by applying glue to the coil and control key. The magnetic ring 1 is designed with a racetrack-shaped structure, which can reduce the overall height of the inductor. The leakage inductance of this three-phase common mode inductor is small. The magnetic core material is a nanocrystalline magnetic ring with lower loss and higher saturation characteristics, resulting in lower loss under high current conditions. The inductor coil adopts a flat wire vertical winding method, which is more automated. The three sets of coils can be arranged in a straight line, compared with the toroidal horizontal three-phase common mode inductor.

[0034] Examples; such as Figure 1 - Figure 3 As shown, the inductor includes three parallel inductor coils, a magnetic ring 1, a fixed base 2, and an insulating sleeve 4. The bottom end of the inductor body is fixed by the base and limiting holes, and is connected to three sets of side-by-side support feet. The coils have a circular ring structure. The coil lead-out ends are tin-plated to enhance the solderability of the copper wires, and the copper wire lead-out ends are covered with insulating thermoplastic tubing to increase the withstand voltage and leakage distance between the copper wires. The base is designed with slots to fix the position of the magnetic ring. By adopting the above technical solutions, the copper coils and the base, as well as the magnetic ring 1 and the base, are easy to assemble, effectively improving installation efficiency. The base is made of insulating epoxy resin. The base has six limiting holes on the left and right bottom to allow the coil pins to pass through smoothly and to fix the coil position. The coil is further fixed by applying glue to the coil and control key. The magnetic ring 1 is designed with a racetrack-shaped structure, which can reduce the overall height of the inductor. The leakage inductance of this three-phase common mode inductor is small. The magnetic core material is a nanocrystalline magnetic ring with lower loss and higher saturation characteristics, resulting in lower loss under high current conditions. The inductor coil adopts a flat wire vertical winding method, which is more suitable for automation. The three sets of coils can be arranged in a straight line. Compared with the toroidal horizontal three-phase common mode inductor, the space occupied on the integrated board is reduced, which provides more space for optimizing circuit design.

[0035] The above description is only a further embodiment of the present utility model, but the protection scope of the present utility model is not limited thereto. Any equivalent substitutions or changes made by those skilled in the art within the scope disclosed by the present utility model, based on the technical solution and concept of the present utility model, shall fall within the protection scope of the present utility model.

Claims

1. An OBC vehicle fast charging three-phase common mode inductor, including a fixed base (2) for limiting the position; Its features are: The fixed base (2) has limit grooves (6) at both ends. A magnetic ring (1) is placed in the limit groove (6). A flat copper coil (5) is wound on the magnetic ring (1). An insulating sleeve (4) is installed on the outer end of the flat copper coil (5). A tin-plated terminal (3) is installed on the outer end of the insulating sleeve (4). A lead-out limit hole (7) is opened on the fixed base (2). The tin-plated terminal (3) is inserted into the lead-out limit hole (7) and fixedly connected.

2. The OBC vehicle fast charging three-phase common-mode inductor according to claim 1, characterized in that: The flat copper coils (5) on the magnetic ring (1) are arranged in a straight line.

3. The OBC vehicle fast charging three-phase common-mode inductor according to claim 2, characterized in that: The lead-out portion of the flat copper coil (5) is covered by an insulating sheath (4).

4. The OBC vehicle fast charging three-phase common-mode inductor according to claim 3, characterized in that: The flat copper coil (5) has a circular ring structure, and the outer end of the flat copper coil (5) is tin-plated and soldered with a tin-plated terminal (3).

5. The OBC vehicle fast charging three-phase common-mode inductor according to claim 4, characterized in that: The bottom of the fixed base (2) is designed with at least six lead-out end limiting holes (7).

6. The OBC vehicle fast charging three-phase common-mode inductor according to claim 5, characterized in that: The magnetic ring (1) has a racetrack structure, and the fixed base (2) is made of insulating epoxy resin.

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