Industrial frequency transformer with double-iron-core integrated winding

Abstract

The utility model discloses an industrial frequency transformer with a double-iron-core integrated winding, and belongs to the technical field of power equipment. The transformer comprises two parallel independent iron cores and an integrated conductor winding, wherein windows of the two independent iron cores are coplanar and aligned, and the integrated conductor winding is formed by winding a single continuous wire in a breakpoint-free mode. The winding sequentially penetrates and winds the two iron cores according to a specific path, penetrates in from the lower portion of the first iron core window and winds turns upwards, crosses over the upper portion of the second iron core window and then winds turns downwards, and finally turns back to form a closed loop. The bridging extension section of the winding is of a straight or rounded-corner continuous bending structure, and the outer diameter of a wire is kept uniform. Through bidirectional symmetrical winding and turn number matching design, double-iron-core magnetic flux superposition is realized; central columns of the E-shaped iron cores are wound intensively to reduce magnetic leakage; and an insulating sheath and a plurality of layers of U-shaped gaskets are additionally arranged on the extension section for layered winding, so that the heat dissipation and pressure resistance are improved. The structure cancels traditional welding or segmented connection, eliminates contact resistance loss and welding spot failure risks, ensures winding mechanical strength and magnetic field coupling efficiency, and is suitable for power frequency voltage conversion scenes with high reliability requirements.

Description

Technical Field

[0001] This utility model relates to the field of power equipment, specifically to a power frequency transformer with a double-core integrated winding. Background Technology

[0002] Traditional twin-core transformers often use two independent windings connected by welding or terminals to achieve magnetic flux coupling. This has the following drawbacks: welding introduces contact resistance, resulting in additional losses and reduced efficiency; segmented winding leads to complex structure, increased insulation risk, and complicated manufacturing process; and solder joints are prone to failure under high-frequency vibration, affecting long-term reliability.

[0003] To address the aforementioned issues, this invention proposes a weld-free, single-conductor continuously wound, double-core integrated transformer structure. Through a unique winding path and mechanical optimization, connection points are eliminated while ensuring magnetic field coupling efficiency. Utility Model Content

[0004] In view of the above situation, it is necessary to provide a power frequency transformer with a dual-core integrated winding that solves at least one of the above problems, comprising:

[0005] Two separate iron cores (1), each of which is provided with a rectangular window (2);

[0006] The axes of the windows (2) of the two iron cores (1) are parallel to each other and their central planes are aligned.

[0007] The conductor winding (3) is integrally formed without any breaks. It is made by continuously winding the two iron cores (1) windows (2) in a single direction, and is wound along the following path:

[0008] Enter from the lower part of the first iron core window (2), wind X turns along the iron core upwards and then exit from the upper part of the window (2), extend vertically to the upper part of the second iron core window (2), enter from the lower part of the second iron core window (2), wind Y turns along the lower part of the second iron core window (2), then exit from the lower part of the second iron core window (2) and fold back vertically to the lower part of the first iron core window (2) to form a closed loop.

[0009] The two extensions (31) of the conductor winding (3) between the two iron cores (1) are straight lines or continuous curved sections with rounded corners, and the outer diameter of the conductor of the extension (31) is consistent with the outer diameter of the conductor of the winding area inside the iron core window (2).

[0010] Preferably, the conductor winding (3) is wound in counterclockwise and clockwise directions on the two iron cores (1), and the number of turns in the winding area inside the window (2) of the two iron cores (1) is equal.

[0011] Preferably, the iron core (1) has an E-type structure, including a central post (11) and two side posts, and the conductor winding (3) is only wound around the surface of the central post (11) of the two iron cores.

[0012] Preferably, the outer side of the extension section (31) is covered with a groove-shaped insulating sheath (4).

[0013] Preferably, the conductor winding (3) has three or more layers in the winding area within the core window (2), and a U-shaped insulating pad (5) is provided between each layer. The pad (5) is bonded to the surface of the central column (11).

[0014] Preferably, the angle between the centerline of the extension section (31) and the central axis of the core window (2) is 0° or 5° to 15°.

[0015] Preferably, the iron core (1) is formed by stacking silicon steel sheets, and the conductor winding (3) is made of flat copper wire, with the long side of its cross-section parallel to the stacking direction of the silicon steel sheets of the iron core (1). Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the planar structure of a power frequency transformer with a double-core integrated winding according to an embodiment of the present invention.

[0017] Figure 2 This is a schematic diagram of the iron core structure according to an embodiment of the present invention.

[0018] Figure 3 This is a schematic diagram of the structure of the central column in an embodiment of this utility model.

[0019] Figure 4 This is a schematic diagram of the structure of a power frequency transformer with a double-core integrated winding according to an embodiment of this utility model. Detailed Implementation

[0020] To make the objectives, technical solutions, and advantages of this utility model clearer, the following detailed description of the power frequency transformer with a double-core integrated winding, in conjunction with the accompanying drawings and embodiments, is provided. It should be understood that the specific embodiments described herein are merely illustrative of the utility model and are not intended to limit the scope of the utility model.

[0021] In the description of this utility model, unless otherwise stated, "a plurality of" means two or more; the terms "center," "longitudinal," "lateral," "upper," "lower," "left," "right," "inner," "outer," "front end," "rear end," "head," "tail," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying 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. Furthermore, the terms "first," "second," "third," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0022] In the description of this utility model, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "joining" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; 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; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model based on the specific circumstances.

[0023] Please see Figures 1 to 4 This utility model discloses a power frequency transformer with a dual-core integrated winding, comprising two separate iron cores (1), each of which has a rectangular window (2); the axes of the windows (2) of the two iron cores (1) are parallel to each other and their center planes are aligned; an integrally formed conductor winding (3) without any breaks is formed by a continuous conductor that passes through the windows (2) of the two iron cores (1) in a single direction and is wound along the following path: it enters from the lower part of the first iron core window (2) and moves upward along the iron core. After winding X turns, it passes through the upper part of the window (2), extends vertically to the upper part of the second iron core window (2), passes through it, winds Y turns downwards along it, and then passes through the lower part of the window (2) and folds back vertically to the lower part of the first iron core window (2) to form a closed loop; the two extension sections (31) of the conductor winding (3) between the two iron cores (1) are straight lines or continuous curved sections with rounded corners, and the outer diameter of the conductor of the extension section (31) is consistent with the outer diameter of the conductor of the winding area inside the iron core window (2). The conductor winding is integrally formed through a continuous "bottom in, top out → bridging → top in, bottom out → loop" path, avoiding the contact resistance and mechanical failure risk of traditional welding points; the continuous geometric shape of the extension section (straight or rounded corner bend) ensures that the conductor is subjected to uniform force, avoids the breakage caused by local stress concentration, thereby improving the overall reliability of the winding.

[0024] Claim: The conductor winding (3) is wound in counterclockwise and clockwise directions on the two iron cores (1), and the number of turns in the winding area inside the window (2) of the two iron cores (1) is equal. The symmetrical and opposite winding directions of the two iron cores make the magnetic flux generated by the two iron cores opposite in direction and superimposed through a shared loop, which significantly enhances the total magnetic flux; the equal number of turns on both sides further coordinates the magnetic field balance, suppresses leakage magnetic flux and improves energy transmission efficiency.

[0025] Please see Figures 1 to 4 In another embodiment, the iron core (1) has an E-type structure, including a central post (11) and two side posts, and the conductor winding (3) is only wound around the surface of the central post (11) of the two iron cores. By concentrating the winding on the central post of the E-type iron core, its magnetic cross-sectional area is fully utilized, and leakage magnetic loss caused by the side post shunting is reduced; at the same time, the window space utilization rate is improved and the overall volume is reduced.

[0026] Please see Figures 1 to 4 In another embodiment, the outer side of the extension section (31) is covered with a groove-shaped insulating sheath (4). The insulating sheath wraps around the exposed conductor of the extension section, effectively isolating it from dust and moisture in the environment and preventing insulation deterioration; the groove-shaped structure has a high degree of fit with the conductor, preventing the sheath from loosening and falling off.

[0027] Please see Figures 1 to 4 In another embodiment, the conductor winding (3) has three or more layers in the winding area within the core window (2), with U-shaped insulating pads (5) provided between each layer. The pads (5) are bonded to the surface of the center post (11). The multi-layer winding combined with the U-shaped pads optimizes the heat dissipation channels between layers and increases the thickness of the insulation layer, thereby improving the withstand voltage. The pads are fixed by bonding to prevent misalignment between layers during the winding process.

[0028] Please see Figures 1 to 4 In another embodiment, the angle between the centerline of the extension section (31) and the center axis of the core window (2) is 0° or 5° to 15°. When the extension section is parallel to the window axis (0°), the occupancy of the bridging section on the surrounding space is reduced; the inclined layout (5° to 15°) leaves a buffer gap between the extension section and the edge of the core, avoiding assembly interference and dispersing electromagnetic vibration stress.

[0029] Please see Figures 1 to 4 In another embodiment, the iron core (1) is formed by stacking silicon steel sheets, and the conductor winding (3) is made of flat copper wire, the long side of which is parallel to the stacking direction of the silicon steel sheets of the iron core (1). The long side of the flat copper wire is consistent with the stacking direction of the silicon steel sheets, which reduces hysteresis loss by utilizing the magnetic orientation of the silicon steel sheets; at the same time, the wide surface of the flat wire contacts the surface of the iron core, increasing the heat dissipation area and improving the winding stability.

[0030] The above description is merely a preferred embodiment of the present utility model and is not intended to limit the present utility model in any way. Although the present utility model has been disclosed above with reference to a preferred embodiment, it is not intended to limit the present utility model. Any person skilled in the art can make some modifications or alterations to the above-disclosed technical content to create equivalent embodiments without departing from the scope of the present utility model. Any simple modifications, equivalent changes, and alterations made to the above embodiments based on the technical essence of the present utility model without departing from the scope of the present utility model shall still fall within the scope of the present utility model.

Claims

1. A power frequency transformer of the double-iron-core integrated winding type, characterized in that, include: Two separate iron cores (1), each of which is provided with a rectangular window (2); The axes of the windows (2) of the two iron cores (1) are parallel to each other and their central planes are aligned. The conductor winding (3) is integrally formed without any breaks. It is made by continuously winding the two iron cores (1) windows (2) in a single direction, and is wound along the following path: Enter from the lower part of the first iron core window (2), wind X turns along the iron core upwards and then exit from the upper part of the window (2), extend vertically to the upper part of the second iron core window (2), enter from the lower part of the second iron core window (2), wind Y turns along the lower part of the second iron core window (2), then exit from the lower part of the second iron core window (2) and fold back vertically to the lower part of the first iron core window (2) to form a closed loop. The two extensions (31) of the conductor winding (3) between the two iron cores (1) are straight lines or continuous curved sections with rounded corners, and the outer diameter of the conductor of the extension (31) is consistent with the outer diameter of the conductor of the winding area inside the iron core window (2).

2. The power frequency transformer with a dual-core integrated winding according to claim 1, characterized in that: The conductor winding (3) is wound in counterclockwise and clockwise directions on the two iron cores (1), and the number of turns in the winding area inside the window (2) of the two iron cores (1) is equal.

3. The power frequency transformer with a dual-core integrated winding according to claim 1, characterized in that: The iron core (1) has an E-type structure, including a central post (11) and two side posts. The conductor winding (3) is only wound around the surface of the central post (11) of the two iron cores.

4. The power frequency transformer with a double-core integrated winding according to claim 1, characterized in that: The outer side of the extension section (31) is covered with a groove-shaped insulating sheath (4).

5. The power frequency transformer with a double-core integrated winding according to claim 1, characterized in that: The conductor winding (3) has more than 3 layers in the winding area within the iron core window (2), and a U-shaped insulating pad (5) is provided between each layer. The pad (5) is bonded to the surface of the central column (11).

6. The power frequency transformer with a double-core integrated winding according to claim 1, characterized in that: The angle between the centerline of the extension section (31) and the center axis of the core window (2) is 0° or 5° to 15°.

7. The power frequency transformer with a double-core integrated winding according to claim 1, characterized in that: The iron core (1) is formed by stacking silicon steel sheets, and the conductor winding (3) is made of flat copper wire, with the long side of its cross-section parallel to the stacking direction of the silicon steel sheets of the iron core (1).

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