High-power new energy integrated transformer

Abstract

The utility model discloses a high-power new energy integrated transformer which comprises a box body structure, a split type iron core assembly, a power assembly, a composite cooling system and an intelligent monitoring system, wherein the split type iron core assembly, the power assembly and the composite cooling system are arranged in the box body structure, and the intelligent monitoring system is connected with the composite cooling system. The iron core structure formed by alternately laminating the nanocrystalline alloy strips and the amorphous strips is adopted, and the splicing design of the wedge type locking blocks and the pretightening force adjustable bolt sets is combined, so that the loss of the iron core is remarkably reduced. The distributed temperature sensor array realizes accurate temperature measurement of an iron core joint surface and a winding layer, ensures that monitoring data is reliably transmitted to a processor, and realizes early-stage pre-judgment and active protection of a fault. The bidirectional circulating cooling system realizes the integrated design of heat dissipation and insulation functions. And the reliability of the transformer in a severe environment is remarkably improved by combining a multi-protection structure.

Description

Technical Field

[0001] This utility model relates to the field of transformer technology, specifically a high-power new energy integrated transformer. Background Technology

[0002] In the fields of new energy power generation, energy storage, and power conversion, high-power transformers, as core equipment for energy conversion, directly affect system performance due to their efficiency, reliability, and integration. Traditional transformers generally use silicon steel sheet laminated cores, which suffer from problems such as high high-frequency losses and poor magnetic circuit closure. Furthermore, the winding layout is mostly a planar laminated structure, resulting in low electromagnetic coupling efficiency and insufficient harmonic suppression. Meanwhile, traditional cooling systems rely on a single axial or radial airflow path, leading to localized overheating of the core and windings, making it difficult to meet the heat dissipation requirements of high-power operation. In addition, existing monitoring systems are mostly single-point temperature measurement or simple vibration sensing, lacking distributed and precise monitoring of core joint surface temperature, winding interlayer temperature rise, and mechanical vibration, thus failing to provide early warning of faults. Utility Model Content

[0003] In order to overcome the shortcomings of existing technical solutions, this utility model provides a high-power new energy integrated transformer, which can effectively solve the problems mentioned in the background technology.

[0004] The technical solution adopted by this utility model to solve its technical problem is:

[0005] A high-power integrated transformer for new energy includes a housing structure, a split core assembly, a power assembly, a composite cooling system, and an intelligent monitoring system connected to the composite cooling system. The composite cooling system includes a bidirectional circulation path composed of an axial air duct and a radial air duct. The intelligent monitoring system includes a processor, a distributed temperature sensor array, and a vibration monitoring module. The distributed temperature sensor array and the vibration monitoring module are connected to the processor via a wireless transmission node.

[0006] The split-type iron core assembly includes a splicing and locking mechanism and at least three E-type iron core components. The iron core components are combined by the splicing and locking mechanism to form a closed annular magnetic circuit. The iron core components are a structure of alternating stacked nanocrystalline alloy strips and amorphous strips.

[0007] The power unit includes a high-voltage winding, a low-voltage winding, and a medium-frequency filter winding, which are arranged in a three-dimensional staggered pattern.

[0008] As a further description of the above technical solution, the splicing locking mechanism includes a wedge-shaped locking block and a bolt group with adjustable preload.

[0009] As a further description of the above technical solution, the bidirectional circulation path is arranged around the inner wall of the box structure, and the box structure is a multi-layer composite shielding shell, which is provided with an electromagnetic shielding layer, a buffer layer and a protective layer respectively.

[0010] As a further description of the above technical solution, the high-voltage winding and the low-voltage winding are arranged alternately, an insulating air guide baffle is provided between the high-voltage winding and the low-voltage winding, and the intermediate frequency filter winding is wound in a double helix structure and embedded in the interlayer gap of the high-voltage winding.

[0011] As a further description of the above technical solution, the axial air duct is installed through the central column of the iron core, the radial air duct is distributed along the radial direction of the winding to form a tree-like branch, and the inlet of the axial air duct is provided with guide vanes.

[0012] As a further description of the above technical solution, the electromagnetic shielding layer includes alternating layers of permalloy mesh and conductive polymer composite material, and the buffer layer includes honeycomb aluminum-based shock-absorbing adhesive and silicone damping pad.

[0013] As a further description of the above technical solution, the temperature sensor array includes a thin-film thermocouple embedded in the iron core joint surface and an optical fiber temperature measurement unit disposed between the winding layers, and the vibration monitoring module includes a vibration sensor and a buzzer connected to the vibration sensor.

[0014] As a further description of the above technical solution, the outer surface of the box structure is also provided with a transparent window for easy maintenance, and the transparent window is sealed to the box structure.

[0015] Compared with the prior art, the beneficial effects of this utility model are:

[0016] This utility model discloses a high-power integrated transformer for new energy, which has at least one of the following beneficial effects during use:

[0017] The core structure employs alternating layers of nanocrystalline alloy strips and amorphous strips, combined with a wedge-type locking block and adjustable preload bolt assembly, significantly reducing core losses. A distributed temperature sensor array enables precise temperature measurement of the core mating surfaces and winding layers, ensuring reliable data transmission to the processor for early fault prediction and proactive protection. The bidirectional circulating cooling system, through the synergistic effect of axial and radial tree-branched air ducts, along with insulating baffles, achieves integrated heat dissipation and insulation. Combined with a multi-layered protective structure, this significantly improves the transformer's reliability in harsh environments. Overall, it meets the development requirements of new energy equipment for high integration and lightweight design. Attached Figure Description

[0018] Figure 1This is a schematic diagram of the overall structure of a high-power integrated transformer for new energy according to this utility model;

[0019] Figure 2 This is a first perspective structural schematic diagram of a high-power integrated transformer for new energy according to this utility model;

[0020] Figure 3 This is a second perspective structural schematic diagram of a high-power new energy integrated transformer according to the present invention.

[0021] Numbering on the map:

[0022] 1. Housing structure; 101. Transparent window; 102. Intelligent monitoring system; 103. Iron core components; 2. Power components; 201. Intermediate frequency filter winding; 202. High voltage winding; 203. Low voltage winding; 3. Splicing and locking mechanism; 301. Locking block; 302. Bolt group; 4. Composite cooling system; 401. Guide vane; 402. Iron core center column. Detailed Implementation

[0023] 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 of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0024] like Figure 1-3 As shown, this utility model provides a high-power integrated transformer for new energy, including a housing structure 1, a split core assembly, a power assembly 2, a composite cooling system 4, and an intelligent monitoring system 102 connected to the composite cooling system 4. The composite cooling system 4 includes a bidirectional circulation path composed of an axial air duct and a radial air duct. The intelligent monitoring system 102 includes a processor, a distributed temperature sensor array, and a vibration monitoring module. The distributed temperature sensor array and the vibration monitoring module are connected to the processor through a wireless transmission node.

[0025] This embodiment consists of a housing structure 1, a split-type iron core assembly, a power assembly 2, a composite cooling system 4, and an intelligent monitoring system 102. Its core working principle is to achieve efficient electromagnetic energy conversion, reliable heat dissipation and cooling, and accurate operational status monitoring through the coordinated operation of each component. The integrated design organically combines the key components, achieving a high degree of functional integration. Compared to traditional transformers, it reduces external connection parts, improves system compactness and reliability, and lowers installation and maintenance costs.

[0026] The split-type iron core assembly includes a splicing and locking mechanism 3 and at least three E-type iron core components 103. The iron core components 103 are combined by the splicing and locking mechanism 3 to form a closed annular magnetic circuit. The iron core components 103 are alternating stacked structures of nanocrystalline alloy strip and amorphous strip.

[0027] During the electromagnetic energy conversion process, the split-type iron core assembly forms a closed-loop magnetic circuit. When an input voltage is applied to the high-voltage winding 202, an alternating magnetic flux is generated in the iron core. According to the principle of electromagnetic induction, the alternating magnetic flux induces corresponding voltages in the low-voltage winding 203 and the intermediate-frequency filter winding 201, thereby realizing voltage conversion and power transmission. The bidirectional circulation path of the composite cooling system 4 removes the heat generated by the iron core and windings in a timely manner through the flow of air in the axial and radial air ducts during transformer operation, maintaining the transformer operating within a reasonable temperature range. The intelligent monitoring system 102 collects data from the distributed temperature sensor array and vibration monitoring module in real time. After analysis and processing by the processor, it realizes the monitoring and early warning of the transformer's temperature and vibration status.

[0028] The power unit includes a high-voltage winding 202, a low-voltage winding 203, and a medium-frequency filter winding 201, which are arranged in a three-dimensional staggered pattern.

[0029] The split-type iron core assembly includes a splicing and locking mechanism 3 and at least three E-type iron core components 103. The iron core components 103 are assembled by the splicing and locking mechanism 3 (a wedge-shaped locking block 301 and a bolt group 302 with adjustable preload) to form a closed annular magnetic circuit. The iron core components 103 adopt an alternating laminated structure of nanocrystalline alloy strip and amorphous strip. During electromagnetic induction, the alternating magnetic field generated when the alternating current passes through the winding causes the magnetic domains in the iron core to repeatedly orient, forming an alternating magnetic flux. The nanocrystalline alloy strip and amorphous strip have the characteristics of low coercivity and high permeability. The alternating laminated structure can effectively reduce the hysteresis loss and eddy current loss of the iron core, improve the magnetic permeability of the iron core, and make the magnetic flux flow more concentratedly in the closed annular magnetic circuit, reducing leakage flux and thus ensuring efficient energy transmission.

[0030] The alternating stacked structure of nanocrystalline alloy strip and amorphous strip fully leverages the low-loss advantages of the two materials at different frequencies. Compared with traditional silicon steel cores, it significantly reduces core loss and improves transformer efficiency, making it particularly suitable for high-power new energy scenarios with high energy conversion efficiency requirements.

[0031] Furthermore, the splicing locking mechanism 3 includes a wedge-shaped locking block 301 and a bolt group 302 with adjustable preload.

[0032] The splicing and locking mechanism 3, consisting of the wedge-type locking block 301 and the bolt group 302 with adjustable preload, makes the splicing of the iron core 103 more flexible and convenient, and can be combined according to different power requirements and space dimensions. At the same time, the adjustable preload ensures tight contact at the splicing points of the iron core, reduces air gaps in the magnetic circuit, avoids the problems of increased magnetic resistance and leakage magnetic field caused by the presence of air gaps, ensures the stability and integrity of the annular closed magnetic circuit, and further improves the efficiency and stability of electromagnetic induction.

[0033] Furthermore, the bidirectional circulation path is arranged around the inner wall of the box structure 1, and the box structure 1 is a multi-layer composite shielding shell, which is provided with an electromagnetic shielding layer, a buffer layer and a protective layer respectively.

[0034] The enclosure structure 1 is a multi-layer composite shielded shell, including an electromagnetic shielding layer, a buffer layer, and a protective layer. The electromagnetic shielding layer is composed of alternating layers of permalloy mesh and conductive polymer composite material, which can effectively shield the electromagnetic radiation generated inside the transformer, prevent interference to surrounding electronic equipment, and reduce the impact of external electromagnetic interference on the electronic components inside the transformer.

[0035] Furthermore, the high-voltage winding 202 and the low-voltage winding 203 are arranged in an alternating manner, and an insulating air guide baffle is provided between the high-voltage winding 202 and the low-voltage winding 203. The intermediate frequency filter winding 201 is wound in a double helix structure and embedded in the interlayer gap of the high-voltage winding 202.

[0036] Power component 2 includes a high-voltage winding 202, a low-voltage winding 203, and a medium-frequency filter winding 201, arranged in a three-dimensional staggered pattern. The high-voltage winding 202 and low-voltage winding 203 are staggered and separated by an insulating air-guiding baffle. The medium-frequency filter winding 201 is wound with a double-helix structure and embedded in the interlayer gaps of the high-voltage winding 202. When an alternating current is applied to the high-voltage winding 202, the generated alternating magnetic field induces a low-voltage alternating current in the low-voltage winding 203, achieving voltage conversion. The medium-frequency filter winding 201, through its double-helix structure, filters the medium-frequency harmonics in the circuit, improving power quality. The insulating air-guiding baffle serves two purposes: firstly, it provides insulation to prevent electrical breakdown between the high-voltage winding 202 and the low-voltage winding 203; secondly, it guides the cooling air in the composite cooling system 4 to flow between the windings, enhancing heat dissipation. The design of the three-dimensional staggered arrangement and double helix structure optimizes the electromagnetic coupling relationship between the windings, reduces electromagnetic interference between the windings, makes the magnetic field distribution more uniform, and improves the energy conversion efficiency.

[0037] The staggered arrangement of high-voltage and low-voltage windings 203 and the double-helix intermediate-frequency filter winding 201 embedded in the interlayer gaps ensures a rational spatial distribution of the windings, shortens the magnetic circuit distance between windings, enhances electromagnetic coupling strength, and improves energy transfer efficiency. Simultaneously, this layout effectively reduces electromagnetic interference between windings, lowers harmonic distortion, and improves the quality of output power, meeting the stringent power quality requirements of new energy power generation systems.

[0038] The placement of the air guide baffle ensures insulation safety between windings while providing a clear flow channel for cooling air. This allows the cooling air to more effectively remove heat generated by the windings, reducing winding temperature and extending winding lifespan. The double-helix structure of the intermediate frequency filter winding 201 increases the winding surface area, further improving heat dissipation. Simultaneously, its compact design fully utilizes the interlayer space of the high-voltage winding 202, making the layout of the power components 2 more compact and increasing the transformer's power density.

[0039] Furthermore, the axial air duct is provided through the iron core center column 402, the radial air duct is distributed along the winding radially to form a tree-like branch, and the axial air duct inlet is provided with guide vanes 401.

[0040] The composite cooling system 4 consists of a bidirectional circulation path formed by axial and radial air ducts, surrounding the inner wall of the housing structure 1. The axial air duct runs through the core center column 402, with guide vanes 401 at the inlet. The radial air ducts are distributed radially along the windings, forming a tree-like branch. When the transformer is running, the heat generated by the core and windings raises the temperature of the surrounding air. The hot air flows under the action of buoyancy and a fan (if present). The guide vanes 401 guide the external cool air evenly into the axial air ducts, flowing upwards along the core center column 402, carrying away the heat generated by the core. At the same time, the tree-like branch structure of the radial air ducts allows the cooling air to be evenly distributed radially along the windings, penetrating into the interlayer gaps of the windings and carrying away the heat from the windings. The hot air is discharged through the outlets on the housing structure 1, forming a bidirectional circulation flow of air, achieving effective cooling of the transformer interior.

[0041] The bidirectional circulation design of axial and radial air ducts forms a three-dimensional heat dissipation channel that can comprehensively cover the core and windings, ensuring that heat can be removed in a timely and effective manner. The design of the guide vanes 401 optimizes the air inlet flow field, reduces flow resistance, and improves air intake efficiency. The tree-branched radial air ducts allow cooling air to be evenly distributed to all parts of the windings, avoiding localized overheating, ensuring the uniformity of the internal temperature field of the transformer, and improving the reliability and service life of the equipment.

[0042] A bidirectional circulation path is arranged around the inner wall of the enclosure structure 1, making full use of the internal space of the transformer. This allows the cooling system to be organically integrated with the enclosure structure 1 without occupying excessive additional space, ensuring the compactness of the transformer. This cooling system is suitable for high-power operation scenarios, effectively addressing high heat generation issues and ensuring that the transformer maintains a stable operating temperature under different load conditions.

[0043] Furthermore, the electromagnetic shielding layer comprises alternating layers of permalloy mesh and conductive polymer composite material, and the buffer layer comprises honeycomb aluminum-based shock-absorbing adhesive and silicone damping pad.

[0044] The buffer layer consists of honeycomb aluminum-based shock-absorbing rubber and silicone damping pads. When the transformer is subjected to external vibration or impact, the buffer layer can absorb and dissipate vibration energy, reduce the transmission of vibration to internal components, and protect critical components such as the core and windings from mechanical damage. The protective layer is located on the outermost layer of the enclosure and has functions such as moisture-proof, dust-proof, and corrosion-proof, protecting the internal structure of the enclosure from the influence of external environmental factors.

[0045] Furthermore, the temperature sensor array includes a thin-film thermocouple embedded in the iron core joint surface and an optical fiber temperature measurement unit disposed between the winding layers, and the vibration monitoring module includes a vibration sensor and a buzzer connected to the vibration sensor.

[0046] The intelligent monitoring system 102 includes a processor, a distributed temperature sensor array, and a vibration monitoring module. The distributed temperature sensor array consists of thin-film thermocouples embedded in the core joint surface and fiber optic temperature measurement units positioned between the winding layers, collecting temperature data from the core joint surface and the winding layers in real time. The vibration monitoring module includes vibration sensors and buzzers connected to them. The vibration sensors are installed on key parts of the transformer, such as the core, windings, and tank, to monitor vibration signals during transformer operation in real time. Temperature and vibration data are transmitted to the processor via wireless transmission nodes, where the processor performs real-time analysis and processing. When the temperature exceeds a set threshold or an abnormal vibration signal occurs, the processor triggers the buzzer to sound an alarm and simultaneously transmits the abnormal information to a remote monitoring platform so that maintenance personnel can take timely measures.

[0047] The distributed temperature sensor array can accurately monitor local temperature changes in the core and windings. The fiber optic temperature measurement unit features strong anti-electromagnetic interference capabilities and high measurement accuracy, making it suitable for the complex electromagnetic environment inside transformers. The vibration monitoring module can capture abnormal mechanical vibrations during transformer operation, such as vibration signal changes caused by faults like core loosening or winding deformation. Through real-time monitoring and data analysis, the intelligent monitoring system 102 can issue alarms in the early stages of a fault, reminding maintenance personnel to conduct inspections and maintenance, preventing the fault from escalating, and reducing downtime and maintenance costs.

[0048] Wireless transmission nodes enable wireless transmission of monitoring data, avoiding the complexity and reliability issues associated with wired connections, making the monitoring system more flexible and easier to install. The processor can integrate advanced fault diagnosis algorithms to comprehensively analyze monitoring data, determine the type and location of faults, and provide accurate fault information to maintenance personnel. Simultaneously, connection to a remote monitoring platform enables remote real-time monitoring of the transformer's operating status, facilitating centralized management and scheduling, and improving maintenance efficiency and intelligence.

[0049] Furthermore, the outer surface of the enclosure structure 1 is also provided with a transparent window 101 for easy maintenance, and the transparent window 101 is sealed to the enclosure structure 1. The transparent window 101 on the outer surface of the enclosure structure 1, which is sealed to the enclosure structure 1, allows maintenance personnel to directly observe the internal operating status of the transformer through the transparent window 101 without opening the enclosure, thus facilitating daily inspections and maintenance.

[0050] It will be apparent to those skilled in the art that this invention is not limited to the details of the exemplary embodiments described above, and that it can be implemented in other specific forms without departing from the spirit or essential characteristics of this invention. Therefore, the embodiments should be considered illustrative and non-limiting in all respects, and the scope of this invention is defined by the appended claims rather than the foregoing description. Thus, it is intended that all variations falling within the meaning and scope of equivalents of the claims be included within this invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

Claims

1. A high-power integrated transformer for new energy, characterized in that: It includes a housing structure, a split iron core assembly, a power assembly, a composite cooling system, and an intelligent monitoring system connected to the composite cooling system. The composite cooling system includes a bidirectional circulation path composed of an axial air duct and a radial air duct. The intelligent monitoring system includes a processor, a distributed temperature sensor array, and a vibration monitoring module. The distributed temperature sensor array and the vibration monitoring module are connected to the processor through a wireless transmission node. The split-type iron core assembly includes a splicing and locking mechanism and at least three E-type iron core components. The iron core components are combined by the splicing and locking mechanism to form a closed annular magnetic circuit. The iron core components are a structure of alternating stacked nanocrystalline alloy strips and amorphous strips. The power unit includes a high-voltage winding, a low-voltage winding, and a medium-frequency filter winding, which are arranged in a three-dimensional staggered pattern.

2. The high-power integrated transformer for new energy as described in claim 1, characterized in that: The splicing and locking mechanism includes a wedge-shaped locking block and a bolt group with adjustable preload.

3. The high-power integrated transformer for new energy as described in claim 1, characterized in that: The bidirectional circulation path surrounds the inner wall of the box structure, which is a multi-layer composite shielding shell, with an electromagnetic shielding layer, a buffer layer, and a protective layer respectively.

4. A high-power integrated transformer for new energy sources according to claim 1, characterized in that: The high-voltage winding and the low-voltage winding are arranged alternately, and an insulating air guide baffle is provided between the high-voltage winding and the low-voltage winding. The intermediate frequency filter winding is wound in a double helix structure and embedded in the interlayer gap of the high-voltage winding.

5. A high-power integrated transformer for new energy sources according to claim 1, characterized in that: The axial air duct is installed through the central column of the iron core, the radial air duct is distributed along the radial direction of the winding to form a tree-like branch, and the inlet of the axial air duct is provided with guide vanes.

6. A high-power integrated transformer for new energy sources according to claim 3, characterized in that: The electromagnetic shielding layer comprises alternating layers of permalloy mesh and conductive polymer composite material, and the buffer layer comprises honeycomb aluminum-based shock-absorbing adhesive and silicone damping pad.

7. A high-power integrated transformer for new energy sources according to claim 1, characterized in that: The temperature sensor array includes a thin-film thermocouple embedded in the iron core joint surface and an optical fiber temperature measurement unit disposed between the winding layers. The vibration monitoring module includes a vibration sensor and a buzzer connected to the vibration sensor.

8. A high-power integrated transformer for new energy sources according to claim 1, characterized in that: The outer surface of the enclosure structure is also provided with a transparent window for easy maintenance, and the transparent window is sealed to the enclosure structure.

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