Integrated 60KW three-phase high-frequency transformer for charger

Abstract

The utility model discloses an integrated 60KW three-phase high-frequency transformer for a charger, which comprises two groups of transformer banks connected in series and a shell, each transformer bank comprises three single transformers, each single transformer comprises a magnetic core, a framework, a primary winding, a secondary winding and a wiring terminal, the primary winding and the secondary winding are wound on the framework, and the primary winding and the secondary winding are wound on the framework. The primary winding and the secondary winding are arranged on the framework, the magnetic cores are arranged from the two ends of the framework and are aligned, the wire starting end of the primary winding and the wire starting end of the secondary winding are both provided with wiring terminals, and the take-up end of the adjacent primary winding and the take-up end of the adjacent secondary winding are in short-circuit connection. The transformer is of a combined structure and is distributed in a flat mode, the height problem of a product is well solved, leakage inductance of a single transformer is used for replacing a resonant inductor, and the cost of a device is reduced.

Description

Technical Field

[0001] This utility model relates to the field of high-frequency transformer technology, specifically an integrated 60KW three-phase high-frequency transformer for a charger. Background Technology

[0002] A charger is a device used to charge electric vehicles such as electric cars, electric bicycles, and electric buses. With the increasing prevalence of electric vehicles, the demand for chargers is also constantly growing. Charger power typically ranges from 3kW to 400kW, and charging time varies depending on the power output.

[0003] High-frequency transformers are an important component of chargers, converting the high-voltage AC power from the power grid into the low-voltage DC power required by the charger. Traditional transformers are large, heavy, inefficient, and require a large amount of magnetic material, which limits their application in chargers.

[0004] In recent years, with the development of power electronics technology and magnetic materials, high-frequency transformers have gradually become the mainstream choice for transformers in chargers.

[0005] However, existing integrated 60KW high-frequency transformers still have some problems in practical applications. In addition, the single soft ferrite core that can meet such a high power capacity of 60KW cannot be produced on the market. The height of such a high-power single transformer cannot be controlled, and flat installation is not possible. Utility Model Content

[0006] The purpose of this invention is to provide an integrated 60KW three-phase high-frequency transformer for chargers to solve the above-mentioned technical problems.

[0007] To achieve the above objectives, this utility model provides the following technical solution: an integrated 60KW three-phase high-frequency transformer for a charger, comprising two sets of transformer groups connected in series and a housing. Each transformer group includes three individual transformers, each individual transformer including a magnetic core, a frame, a primary winding, a secondary winding, and terminals. The primary and secondary windings are both wound on the frame. The magnetic core is inserted into and aligned from both ends of the frame. Terminals are provided on the starting ends of the primary winding and the secondary winding. The take-off ends of adjacent primary windings and secondary windings are short-circuited.

[0008] Preferably, the housing is an aluminum housing, and the aluminum housing is provided with thermally conductive potting compound.

[0009] Preferably, the thermally conductive potting compound is a thermally conductive silicone with a thermal conductivity of 2.0W.

[0010] Preferably, an air gap sheet is provided at the joint of the magnetic core and fixed by adhesive dispensing.

[0011] Preferably, the output power of each of the individual transformers is 10KW.

[0012] Preferably, the starting ends of the primary winding and the secondary winding are led out from the same side.

[0013] Preferably, the primary winding and the secondary winding are wound in layers.

[0014] Compared with the prior art, the beneficial effects of this utility model are as follows:

[0015] By coordinating the connection between transformer groups and individual transformers, there is no need to customize 60KW individual magnetic cores. The transformers adopt a combined structure and a flat distribution, which effectively solves the height problem of the product. Furthermore, the leakage inductance of the individual transformers is used to replace the resonant inductor, reducing the cost of the components. Attached Figure Description

[0016] To more clearly illustrate the technical solutions of the embodiments of this utility model, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0017] Figure 1 This is a schematic diagram of the overall structure of an integrated 60KW three-phase high-frequency transformer for a charger according to this embodiment;

[0018] Figure 2 This is a schematic diagram of the structure of a single transformer in this embodiment;

[0019] Figure 3 This is a schematic diagram of the transformer group in this embodiment;

[0020] Figure 4 This is a schematic diagram showing the connection of the two transformer groups in this embodiment.

[0021] Figure 5 This is a bottom view of the individual transformer in this embodiment.

[0022] The attached diagram lists the components represented by each number as follows:

[0023] 1. Transformer set; 2. Shell; 3. Individual transformer; 4. Magnetic core; 5. Frame; 6. Primary winding; 7. Secondary winding; 8. Terminal block; 9. Thermally conductive potting compound; 10. Air gap plate. Detailed Implementation

[0024] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of the present utility model.

[0025] Please see Figure 1-5 This utility model provides a technical solution: an integrated 60KW three-phase high-frequency transformer for a charger, comprising two sets of transformer groups 1 connected in series and a housing 2. The transformer group 1 includes three individual transformers 3. Each individual transformer 3 includes a magnetic core 4, a frame 5, a primary winding 6, a secondary winding 7, and terminals 8. The primary winding 6 and the secondary winding 7 are both wound on the frame 5. The magnetic core 4 is inserted into and aligned from both ends of the frame 5. Terminals 8 are provided on the starting end of the primary winding 6 and the starting end of the secondary winding 7. The take-off ends of adjacent primary windings 6 and secondary windings 7 are short-circuited.

[0026] Specifically, the housing 2 is made of aluminum, and thermally conductive potting compound 9 is installed inside the aluminum housing. Furthermore, the thermally conductive potting compound 9 is a thermally conductive silicone with a thermal conductivity of 2.0W. Through the above settings, the entire product is encapsulated with silicone with a thermal conductivity of 2.0W, which conducts the heat of the transformer to the aluminum housing, thereby improving the overall heat dissipation effect of the transformer and solving the heat dissipation problem of the transformer.

[0027] Specifically, an air gap 10 is provided at the joint of the magnetic core 4 and fixed by adhesive. By providing the air gap 10, the heat generated by the magnetic core 4 during operation can be more effectively dispersed, avoiding local overheating. The air gap 10 can also reduce the saturation of the magnetic core 4 and improve the efficiency of the transformer.

[0028] Specifically, each individual transformer 3 has an output power of 10KW, and the total output power of transformer group 1 reaches 30KW. When two transformer groups 1 are connected in series, the power can reach 60KW. Through the integrated design, it is also more convenient to repair when a single individual transformer 3 is damaged.

[0029] Specifically, the starting ends of the primary winding 6 and the secondary winding 7 are led out from the same side. This arrangement makes the winding lead layout more compact, reduces interference between leads, and improves the stability and reliability of the transformer.

[0030] Specifically, the primary winding 6 and the secondary winding 7 are wound in a layered manner. This layered winding method ensures the insulation performance between the primary winding 6 and the secondary winding 7. At the same time, the layered winding method helps to improve the heat dissipation efficiency of the primary winding 6 and the secondary winding 7, thereby further improving the performance and lifespan of the transformer.

[0031] A specific application example of this embodiment is as follows:

[0032] See Figure 2 During assembly, the individual transformers 3 are installed first. The primary winding 6 and secondary winding 7 are wound on the frame 5 in layers. The magnetic core 4 is inserted into and aligned from both ends of the frame 5. Air gap plates 10 are installed at the joints of the magnetic core 4 and fixed with epoxy glue. The starting end A of the primary winding 6 and the starting end A1 of the secondary winding 7 are connected to terminals 8, respectively. The taking end a of the primary winding 6 and the taking end a1 of the secondary winding 7 are not connected to terminals 8. Similarly, the other individual transformers 3 are installed. After the six individual transformers 3 are prepared, three individual transformers 3 are grouped together to form transformer group 1. (See reference...) Figure 3 The take-up terminal a of the left-hand transformer 3 is short-circuited with the take-up terminal b of the middle transformer 3. The take-up terminal a1 of the left-hand transformer 3 is short-circuited with the take-up terminal b1 of the middle transformer 3. The take-up terminal b of the middle transformer 3 is short-circuited with the take-up terminal c of the right-hand transformer 3. The take-up terminal b1 of the middle transformer 3 is short-circuited with the take-up terminal c1 of the right-hand transformer 3. After installation, transformer group 1 is installed. Refer to... Figure 4 Install the two assembled transformer groups 1 into the aluminum shell. Set the starting ends of the primary winding 6 and the secondary winding 7 of the six individual transformers 3 outwards on the same side of the aluminum shell. That is, the starting ends A of the primary winding 6 and A1 of the secondary winding 7, B of the primary winding 6 and B1 of the secondary winding 7, C of the primary winding 6 and C1 of the secondary winding 7, D of the primary winding 6 and D1 of the secondary winding 7, E of the primary winding 6 and E1 of the secondary winding 7, and F of the primary winding 6 and F1 of the secondary winding 7 are all set on the same side. Then pour 2.0W thermally conductive silicone into the aluminum shell and dry the 2.0W thermally conductive silicone.

[0033] In the description of this utility model, it should be understood that the terms "coaxial", "bottom", "one end", "top", "middle", "other end", "upper", "side", "top", "inner", "front", "center", "both ends", etc., indicate the orientation or positional relationship based on the drawings, and are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this utility model.

[0034] In this utility model, unless otherwise explicitly specified and limited, the terms "installation", "setting", "connection", "fixing", "screw connection", etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal connection of two components or the interaction between two components. Unless otherwise explicitly limited, those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.

[0035] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that modifications may be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. An integrated 60kW three-phase high-frequency transformer for a charger, characterized in that: The transformer assembly includes two sets of transformer groups (1) connected in series and a housing (2). The transformer group (1) includes three individual transformers (3). Each individual transformer (3) includes a magnetic core (4), a frame (5), a primary winding (6), a secondary winding (7), and terminals (8). The primary winding (6) and the secondary winding (7) are both wound on the frame (5). The magnetic core (4) is inserted from both ends of the frame (5) and aligned. Terminals (8) are provided on the starting end of the primary winding (6) and the starting end of the secondary winding (7). The take-off ends of adjacent primary windings (6) and secondary windings (7) are short-circuited.

2. The integrated 60kW three-phase high-frequency transformer for a charger according to claim 1, characterized in that: The housing (2) is made of aluminum, and thermally conductive potting compound (9) is provided inside the aluminum housing.

3. The integrated 60kW three-phase high-frequency transformer for a charger according to claim 2, characterized in that: The thermally conductive potting compound (9) is a thermally conductive silicone with a thermal conductivity of 2.0W.

4. The integrated 60kW three-phase high-frequency transformer for a charger according to claim 1, characterized in that: An air gap plate (10) is provided at the joint of the magnetic core (4) and fixed by adhesive dispensing.

5. The integrated 60kW three-phase high-frequency transformer for a charger according to claim 1, characterized in that: Each of the individual transformers (3) has an output power of 10KW.

6. The integrated 60kW three-phase high-frequency transformer for a charger according to claim 1, characterized in that: The starting end of the primary winding (6) and the starting end of the secondary winding (7) are led out from the same side.

7. An integrated 60kW three-phase high-frequency transformer for a charger according to claim 1, characterized in that: The primary winding (6) and the secondary winding (7) are wound in a layered manner.

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