Integrated single-phase ac voltage regulator

Abstract

The utility model provides a kind of integrated single-phase ac voltage regulator, it is related to power electronics field.The voltage regulator includes voltage regulator shell, its inside is provided with control area, power area and heat dissipation area;Control area integrated control terminal, OLED display screen, state indicating lamp and main control PCB, and the operating panel of OLED display screen and the display part of state indicating lamp are all through control area, and extend to the front side of voltage regulator shell, main control PCB is built-in microcontroller and communication interface;Power area is provided with a pair of antiparallel thyristor adapted to main control PCB, constitutes single-phase ac full-wave voltage regulating main circuit, and integrates voltage sensor and current sensor;Heat dissipation area is provided with radiator, and radiator and a pair of antiparallel thyristor directly contact.The voltage regulator of the application effectively solves the problem of large size caused by the structure dispersion of conventional voltage regulator, integrated layout greatly reduces the volume, reduces the installation space occupation, and the modularization integration of each functional area simplifies the installation process, reduces manpower and time cost.

Description

Technical Field

[0001] This utility model relates to the field of power electronics technology, and more specifically, to an integrated single-phase AC voltage regulator. Background Technology

[0002] A single-phase AC voltage regulator is a device used to regulate the voltage of a single-phase AC power supply. Its core function is to continuously regulate the effective value of the output voltage by controlling the conduction characteristics of power electronic devices. It is widely used in industrial resistance heating equipment, motor soft starters, laboratory adjustable power supplies and other scenarios, and can meet the needs of precise regulation and intelligent control of single-phase voltage.

[0003] Traditional single-phase AC voltage regulators have significant structural defects, most notably their dispersed structure. They are typically assembled from discrete components such as thyristor modules, control boards, and heat sinks. This modular structure results in a large overall size, which not only occupies a lot of installation space in practical applications but also increases the difficulty of equipment layout.

[0004] Because discrete components need to be installed and connected one by one, the installation process of traditional voltage regulators is quite complicated. It not only consumes a lot of manpower and time, but also makes it difficult to fully guarantee the reliability of the connection between the components. Poor contact and other problems may affect the normal operation of the equipment. At the same time, the dispersed structure also makes the maintenance and repair of the equipment more cumbersome. Utility Model Content

[0005] The purpose of this invention is to provide an integrated single-phase AC voltage regulator, which aims to solve the technical problems mentioned in the background.

[0006] The embodiments of this utility model are implemented as follows:

[0007] This application provides an integrated single-phase AC voltage regulator, including a regulator housing with a control area, a power area, and a heat dissipation area arranged sequentially along the same straight line inside. The control area integrates control terminals, an OLED display screen, status indicator lights, and a main control PCB. The operation panel of the OLED display screen and the display part of the status indicator lights both penetrate the control area and extend to the front side of the regulator housing. The main control PCB has a built-in microcontroller and a communication interface. The power area is provided with a pair of anti-parallel thyristors adapted to the main control PCB to form a single-phase AC full-wave voltage regulation main circuit, and integrates a voltage sensor and a current sensor. The heat dissipation area is provided with a heat sink, and the heat sink is in direct contact with the pair of anti-parallel thyristors.

[0008] Furthermore, based on the aforementioned scheme, the above-mentioned communication interface supports the RS485 physical layer and the Modbus-RTU protocol.

[0009] Furthermore, based on the aforementioned scheme, the material of the voltage regulator housing is plastic.

[0010] Furthermore, based on the aforementioned scheme, the voltage regulator housing is provided with an insulating structure.

[0011] Furthermore, based on the aforementioned scheme, the voltage regulator housing includes an annular shell, one port of which is detachably provided with a sealing cover, and the other port is used to detachably engage with the aforementioned radiator.

[0012] The aforementioned sealed top cover is provided with multiple mounting ports for assembling the aforementioned control terminals, the aforementioned OLED display screen, and the aforementioned status indicator lights.

[0013] Furthermore, based on the aforementioned scheme, the annular shell is provided with heat dissipation vents opposite to the aforementioned power area and the aforementioned heat dissipation area.

[0014] Furthermore, based on the aforementioned scheme, the thyristor is a welded thyristor.

[0015] Furthermore, based on the aforementioned scheme, the thyristor is equipped with a temperature sensor, and the microcontroller is configured to receive the temperature value A from the temperature sensor, and to shut down the voltage regulator when the temperature value is greater than or equal to 80 degrees Celsius.

[0016] Compared with the prior art, the embodiments of this utility model have at least the following advantages or beneficial effects:

[0017] The integrated single-phase AC voltage regulator provided in this application adopts a layered integrated design with independent control, power, and heat dissipation areas arranged sequentially along the same straight line within the regulator housing. Control modules such as control terminals, an OLED display, and the main control PCB are integrated into the control area, making the user interface intuitive and easy to interact with. The built-in microcontroller and communication interface enhance intelligent control and system compatibility. The power area integrates anti-parallel thyristors to form the main circuit, paired with voltage and current sensors for real-time sampling to ensure voltage regulation accuracy. The heat sink in the heat dissipation area is in direct contact with the thyristors, and the layered layout shortens the heat dissipation path, improving heat dissipation efficiency. This structural design effectively solves the problem of the large size caused by the dispersed structure of traditional voltage regulators. The integrated layout significantly reduces the size and installation space required. The modular integration of each functional area simplifies the installation process, reduces labor and time costs, while the integrated connection improves the reliability of connections between components, reduces the risk of poor contact, and the layered independent partitions facilitate later maintenance and repair, significantly improving the practicality and reliability of the equipment. Attached Figure Description

[0018] To more clearly illustrate the technical solutions of the embodiments of this utility model, the drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of this utility model and should not be regarded as a limitation on the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0019] Figure 1 An explosion of an integrated single-phase AC voltage regulator according to an embodiment of this utility model. Figure 1 ;

[0020] Figure 2 An explosion of an integrated single-phase AC voltage regulator according to an embodiment of this utility model. Figure 2 ;

[0021] Figure 3 This is an isometric view of an integrated single-phase AC voltage regulator according to an embodiment of the present invention;

[0022] Figure 4 This is a front view of an integrated single-phase AC voltage regulator according to an embodiment of the present invention.

[0023] Icons: 100-Voltage regulator housing, 101-Annular housing, 102-Sealed top cover, 200-Main control PCB, 300-Control terminal, 400-OLED display, 500-Status indicator light, 600-Thyristor, 700-Heat sink, 800-Heat outlet. Detailed Implementation

[0024] The embodiments of this application will now be described in detail with reference to the accompanying drawings.

[0025] Example

[0026] Please refer to Figures 1-4 This application provides an integrated single-phase AC voltage regulator, including a regulator housing 100, inside which are arranged independently of each other along the same straight line: a control area, a power area, and a heat dissipation area. The control area integrates a control terminal 300, an OLED display screen 400, a status indicator light 500, and a main control PCB 200. The operation panel of the OLED display screen 400 and the display part of the status indicator light 500 both penetrate the control area and extend to the front side of the regulator housing 100. The main control PCB 200 has a built-in microcontroller and a communication interface. The power area is provided with a pair of anti-parallel thyristors 600 adapted to the main control PCB 200 to form a single-phase AC full-wave voltage regulation main circuit, and integrates a voltage sensor and a current sensor. The heat dissipation area is provided with a heat sink 700, and the heat sink 700 is in direct contact with the pair of anti-parallel thyristors 600.

[0027] The integrated single-phase AC voltage regulator provided in this application embodiment features a layered integrated design within the regulator housing 100, sequentially arranging independent control, power, and heat dissipation zones along the same straight line. Control modules such as the control terminal 300, OLED display 400, and main control PCB 200 are integrated into the control zone, making the user interface intuitive and easy to interact with. The built-in microcontroller and communication interface enhance intelligent control and system compatibility. The power zone integrates anti-parallel thyristors 600 to form the main circuit, paired with voltage and current sensors for real-time sampling to ensure voltage regulation accuracy. The heat sink 700 in the heat dissipation zone directly contacts the thyristors 600, and the layered layout shortens the heat dissipation path, improving heat dissipation efficiency. This structural design effectively solves the problem of bulky size caused by the dispersed structure of traditional voltage regulators. The integrated layout significantly reduces size and installation space, while the modular integration of each functional zone simplifies the installation process, reduces labor and time costs, and the integrated connection improves the reliability of connections between components, reducing the risk of poor contact. The layered and independent partitions also facilitate later maintenance and repair, significantly improving the practicality and reliability of the equipment.

[0028] As a preferred implementation, the above-mentioned communication interface supports the RS485 physical layer and the Modbus-RTU protocol.

[0029] In the above embodiments, the communication interface supports the RS485 physical layer and the Modbus-RTU protocol, offering several advantages. The RS485 physical layer features strong anti-interference capabilities, long transmission distances (up to 1200 meters), and support for multi-device bus connections, enabling stable signal transmission in complex industrial electromagnetic environments and meeting the long-distance communication needs of voltage regulators in industrial settings. The Modbus-RTU protocol, as a universal communication standard in the industrial field, boasts excellent compatibility and can be easily integrated into mainstream industrial control devices such as PLCs and touchscreens without requiring the development of dedicated communication protocols, thus reducing system integration difficulty. Furthermore, this protocol offers high data transmission efficiency and a simple frame structure, enabling real-time data interaction between the voltage regulator and the host computer (such as voltage / current parameter setting, operating status monitoring, and fault alarm information transmission), facilitating the construction of intelligent monitoring networks and improving the automation control level and system compatibility of the equipment.

[0030] In a preferred embodiment, the material of the voltage regulator housing 100 is plastic.

[0031] In the above embodiments, the use of plastic material for the voltage regulator housing 100 has several advantages. Firstly, plastic is lightweight, significantly reducing the overall weight of the voltage regulator, facilitating handling, installation, and equipment layout, especially in scenarios requiring frequent movement or where weight is a constraint. Secondly, plastic is low-cost, reducing manufacturing costs, and its simple molding process allows it to be easily processed into various shapes to meet the internal structural layout and appearance design requirements of the voltage regulator. It also possesses a certain degree of corrosion resistance, maintaining stable housing performance in various environments and extending equipment lifespan.

[0032] In a preferred embodiment, the voltage regulator housing 100 is provided with an insulating structure.

[0033] In the above embodiments, the voltage regulator housing 100 is provided with an insulating structure, which can significantly improve the safety and reliability of the equipment. This insulating structure effectively blocks the electrical connection between the housing and internal live components, preventing electric shock accidents caused by accidental contact with the housing. Especially in complex environments such as humid or dusty conditions, it avoids the risk of short circuits due to insulation failure. Simultaneously, the insulating structure reduces the impact of external electromagnetic interference on the internal circuitry, ensuring the stable operation of control signals and power electronic devices, and preventing a decrease in voltage regulation accuracy or fault alarms due to interference. Furthermore, the combination of the insulating structure and the plastic housing material further enhances the equipment's protective performance, making the voltage regulator suitable for industrial scenarios with high insulation requirements (such as power equipment and laboratory power supplies), extending the device's lifespan and reducing maintenance costs.

[0034] In a preferred embodiment, the voltage regulator housing 100 includes an annular housing 101, one port of which is detachably provided with a sealing cover 102, and the other port is used for detachable engagement with the heat sink 700; wherein the sealing cover 102 is provided with multiple mounting ports for assembling the control terminal 300, the OLED display screen 400 and the status indicator light 500.

[0035] In the above embodiments, the voltage regulator housing 100 adopts a structural design with an annular housing 101, a detachable sealed cover 102, and a heat sink 700, which has significant practical advantages. The ports of the annular housing 101 are detachably connected to the sealed cover 102 and the heat sink 700, which facilitates the modular installation and maintenance of the internal control area, power area, and heat dissipation area. During maintenance, the corresponding port components can be quickly disassembled without overall disassembly, greatly improving maintenance efficiency. The multiple mounting ports on the sealed cover 102 are precisely adapted to the assembly of the control terminal 300, the OLED display 400, and the status indicator light 500, so that the operation interface is concentrated on the front side of the housing, which not only ensures the convenience of human-machine interaction, but also strengthens the protective performance of the housing through the sealed structure, preventing dust and moisture from entering the internal circuit. This detachable design also supports the independent replacement and upgrading of each functional module, such as the separate disassembly of the heat sink 700 for cleaning or replacement of the thyristor 600 module.

[0036] In a preferred embodiment, the annular shell 101 is provided with a heat dissipation port 800 opposite to the power area and the heat dissipation area.

[0037] In the above embodiments, the annular shell 101 is provided with a heat dissipation port 800 opposite to the power area and the heat dissipation area, which can significantly improve the heat dissipation efficiency and operational stability of the voltage regulator.

[0038] As a preferred embodiment, the thyristor 600 is a welded thyristor.

[0039] In the above embodiments, the welding process can directly fix the thyristor 600 onto the heat sink substrate, shortening the heat conduction path with the heat sink 700 and achieving efficient heat dissipation. Combined with the isolation design of the heat dissipation module, it can effectively control the operating temperature of the thyristor 600 (e.g., normal operation when ≤80℃), extend the device life and reduce the trigger frequency of overheat protection. Compared with traditional bolt or plug-in methods, the welding connection has higher mechanical strength, which can avoid contact problems caused by vibration and long-term operation, improve the reliability of the main circuit, and is especially suitable for frequent voltage regulation scenarios in industrial environments.

[0040] In a preferred embodiment, the thyristor 600 is equipped with a temperature sensor, and the microcontroller is configured to receive the temperature value A from the temperature sensor and to shut down the voltage regulator when the temperature value is greater than or equal to 80 degrees Celsius.

[0041] In the above embodiments, the thyristor 600 is equipped with a temperature sensor, and the microcontroller is designed based on a temperature value A (shutdown at ≥80℃) to construct a precise overheat protection mechanism. The temperature sensor can monitor the operating temperature of the thyristor 600 in real time, and the microcontroller achieves closed-loop control by dynamically acquiring temperature data. When the temperature reaches the 80℃ threshold, it immediately triggers shutdown protection to prevent the device from performance degradation or burnout due to overheating, effectively extending the service life of the thyristor 600. This mechanism, together with the axial flow fan and heat sink of the heat dissipation module, forms a collaborative heat dissipation system. The fan continues to dissipate heat when the temperature does not reach the threshold, and shuts down when the temperature exceeds the threshold, providing dual protection and improving the operational reliability of the equipment under high-power conditions. At the same time, the precise temperature protection strategy can reduce unexpected failures caused by overheating, reduce maintenance costs, and is especially suitable for long-term high-load scenarios such as industrial resistance heating, ensuring that the voltage regulator operates stably within the safe temperature range.

[0042] Furthermore, unless otherwise explicitly specified or limited, the terms "installation" and "connection" in this application embodiment should be interpreted broadly. For example, "connection" can be a detachable connection or a non-detachable connection; it can be a direct connection or an indirect connection through an intermediate medium. The terms "upper," "lower," "left," "right," "inner," "outer," and "side," etc., are merely for reference to the direction in the accompanying drawings or the usual placement of the product during use. They are only for clearly describing this application and do not indicate or imply that the device or component referred to must have a specific orientation, or be constructed and operated in a specific orientation. They should not be construed as limitations on this application. The terms "first," "second," etc., are only used for distinguishing descriptions and should not be construed as indicating or implying relative importance; "multiple" refers to at least two. In this application embodiment, the limitations on relative positional relationships such as parallel, perpendicular, and aligned are all relative to the current technological level and are not absolutely strict limitations. Slight deviations are allowed; approximations of parallel, perpendicular, and aligned are all acceptable. For example, "A and B are parallel" means that A and B are parallel or approximately parallel, and the angle between A and B can be between 0 degrees and 10 degrees.

[0043] The above are only some embodiments and implementation methods of this application. The protection scope of this application is not limited thereto. In the absence of conflict, the embodiments and features in the embodiments of this application can be combined with each other. Any combination of features in different embodiments is also within the protection scope of this application. Any changes or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in this application should be included within the protection scope of this application.

Claims

1. An integrated single-phase AC voltage regulator, characterized in that, The device includes a voltage regulator housing (100), inside which are arranged in a straight line a series of independent control areas, power areas and heat dissipation areas; The control area integrates control terminals (300), OLED display screen (400), status indicator lights (500) and main control PCB (200). The operation panel of the OLED display screen (400) and the display part of the status indicator lights (500) both penetrate the control area and extend to the front side of the voltage regulator housing (100). The main control PCB (200) has a built-in microcontroller and communication interface. The power area is equipped with a pair of anti-parallel thyristors (600) adapted to the main control PCB (200) to form a single-phase AC full-wave voltage regulating main circuit, and integrates a voltage sensor and a current sensor. The heat dissipation area is provided with a heat sink (700), and the heat sink (700) is in direct contact with the pair of anti-parallel thyristors (600).

2. The integrated single-phase AC voltage regulator according to claim 1, characterized in that, The communication interface supports RS485 physical layer and Modbus-RTU protocol.

3. The integrated single-phase AC voltage regulator according to claim 1, characterized in that, The regulator housing (100) is made of plastic.

4. An integrated single-phase AC voltage regulator according to claim 3, characterized in that, The voltage regulator housing (100) is provided with an insulating structure.

5. An integrated single-phase AC voltage regulator according to claim 1, characterized in that, The voltage regulator housing (100) includes an annular housing (101), one port of which is detachably provided with a sealing cover (102), and the other port is used to detachably engage with the radiator (700). The sealing cover (102) is provided with multiple mounting ports for assembling the control terminal (300), the OLED display screen (400), and the status indicator (500).

6. An integrated single-phase AC voltage regulator according to claim 5, characterized in that, The annular shell (101) is provided with a heat dissipation port (800) opposite to the power area and the heat dissipation area.

7. An integrated single-phase AC voltage regulator according to claim 1, characterized in that, The thyristor (600) is a welded thyristor.

8. An integrated single-phase AC voltage regulator according to claim 7, characterized in that, The thyristor (600) is equipped with a temperature sensor, and the microcontroller is configured to receive the temperature value A from the temperature sensor and to shut down the voltage regulator when the temperature value is greater than or equal to 80 degrees Celsius.

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