A high-power intermediate frequency transformer
By adopting a four-water-circuit design and an aluminum shell structure in high-power intermediate frequency transformers, the problem of slow heat dissipation is solved, the transformer life is extended, the working efficiency and welding quality are improved, and the maintenance cost is reduced.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- SHANDONG CHENGTAI WELDING TECH CO LTD
- Filing Date
- 2025-07-25
- Publication Date
- 2026-07-14
AI Technical Summary
Existing high-power intermediate frequency transformers have slow heat dissipation, resulting in reduced transformer lifespan and high maintenance and replacement costs, which cannot meet the needs of high-power intermediate frequency transformers.
The rectifier and transformer are integrated into a four-water circuit design, which shortens the cooling water path and increases the flow rate. The four independent water circuits cool each part of the transformer separately, and the aluminum shell and dustproof protective cover are combined to improve heat dissipation efficiency.
It effectively solved the heat dissipation problem of high-power transformers, extended transformer life, improved working efficiency, reduced maintenance costs, and ensured welding quality and equipment stability.
Smart Images
Figure CN224501627U_ABST
Abstract
Description
Technical Field
[0001] This utility model belongs to the technical field of medium frequency transformer equipment, specifically high-power medium frequency transformer. Background Technology
[0002] With industrial development, the demand for resistance welding equipment is increasing in more and more factories. However, existing resistance welding equipment suffers from low efficiency, unstable welding quality, excessive weight, and difficulty in effectively and quickly dissipating and cooling the internal intermediate frequency transformer during long-term operation. Therefore, research on the design and control technology of resistance welding transformers is of great significance for improving the performance of welding equipment and ensuring welding quality.
[0003] In existing technologies, intermediate frequency transformers dissipate heat and cool down through water cooling. However, transformers are often configured with a single water circuit. The single water circuit for heat dissipation and cooling is long and has a complex change path, which increases the obstruction of water flow, reduces the water flow rate, and makes heat dissipation relatively slow. At the same time, due to the slow water flow speed, the internal water temperature rises rapidly, and the inside of the transformer becomes occupied by hot water, making it difficult to remove heat, thus slowing down the cooling of the transformer. The disadvantages of slow transformer cooling are that the transformer body and diodes are easily damaged, thereby reducing the life of the transformer and affecting the normal operation of automated production lines. The maintenance and replacement costs are high, resulting in economic and human resource waste, and it cannot be applied to high-power intermediate frequency transformers. Utility Model Content
[0004] To address the problems of slow heat dissipation, reduced transformer lifespan, high maintenance and replacement costs, and wasted manpower and resources associated with existing high-power intermediate frequency transformers, this utility model provides a high-power intermediate frequency transformer.
[0005] This utility model is achieved through the following technical solution:
[0006] A high-power intermediate frequency transformer includes a transformer body, which comprises a support plate, an iron core, and windings wound on the iron core. A fixing block is connected and installed on the support plate, and a rectifier assembly is connected and installed on the fixing block. A positive output block is connected and installed on the upper side of the rectifier assembly, and a negative output block is connected and installed on one side of the support plate. Four water inlets are provided on the side of the positive output block away from the negative output block, and two water outlets are provided on the side of the negative output block away from the water inlets and on the side of the support plate near the water inlets. A water passage for cooling water to flow is connected between the water inlets and the water outlets and is connected in series on the positive output block, negative output block, fixing plate, support plate, rectifier assembly, and iron core. Each water passage is connected to the fixing block and the support plate through two water-cooled pipes and is wrapped around the iron core in a U-shape.
[0007] A further improvement of this utility model is that an aluminum shell is installed on the outside of the transformer body, and a dustproof protective cover is installed on the upper part of the aluminum shell.
[0008] A further improvement of this utility model is that the bottom of the aluminum shell is provided with a cover plate, and the cover plate is equipped with U and V terminals.
[0009] A further improvement of this utility model is that the negative output block includes a bottom negative output block connected and mounted on a support plate, a side negative output block connected and mounted on the bottom negative output block, and a top negative output block connected and mounted on the side negative output block.
[0010] A further improvement of this utility model is that the positive output block, the top negative output block, the side negative output block, and the bottom negative output block are all connected and installed by bolt fasteners.
[0011] A further improvement of this invention is that the rectifier assembly has two sets and is centrally symmetrically arranged.
[0012] A further improvement of this utility model is that the rectifier assembly includes several pressure caps, disc springs, insulating partitions, side plates, pads, diodes, corner plates, and pressure cap insulating pads connected in a straight line series.
[0013] As can be seen from the above technical solutions, the beneficial effects of this utility model are:
[0014] 1. The rectifier assembly and transformer are integrated into a four-water circuit design for separate cooling, which shortens the water cooling path, increases the cooling water flow rate, and effectively solves the problem of heat dissipation and cooling of high-power transformers;
[0015] 2. The four water channels shorten the waterway, reduce water flow resistance, improve temperature control, and quickly remove heat, thus cooling down the high-power transformer quickly, extending its lifespan, and improving the stability of the transformer.
[0016] 3. It greatly improves the quality of high-power transformers, increases working efficiency, and reduces maintenance costs. Attached Figure Description
[0017] To more clearly illustrate the technical solution of this utility model, the drawings used in the description 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.
[0018] Figure 1 This is a schematic diagram of the overall structure of this utility model.
[0019] Figure 2 This is a schematic diagram of the exploded structure of this utility model.
[0020] Figure 3 This is a schematic diagram of the structure of this utility model from a bottom view.
[0021] Figure 4 This is a schematic diagram of the waterway structure of this utility model.
[0022] Figure 5 This is a structural schematic diagram of the waterway of this utility model from another angle.
[0023] Figure 6 This is a schematic diagram of the rectifier structure of this utility model.
[0024] In the attached diagram: 1. Transformer body, 11. Support plate, 111. Fixing block, 12. Winding, 13. Iron core, 2. Rectifier assembly, 20. Negative output block, 201. Bottom negative output block, 202. Side negative output block, 203. Top negative output block, 21. Positive output block, 22. Disc spring, 23. Insulating partition, 24. Side plate, 25. Pad, 26. Diode, 27. Angle plate, 28. Pressure cover insulating pad, 29. Pressure cover, 3. Water inlet, 4. Water outlet, 5. Water passage, 51. Cold water pipe, 6. Aluminum shell, 7. Dustproof protective cover, 8. Cover plate, 9. U and V terminals. Detailed Implementation
[0025] To make the objectives, features, and advantages of this utility model more apparent and understandable, the technical solutions of this utility model will be clearly and completely described below with reference to the accompanying drawings of the specific embodiments. Obviously, the embodiments described below are only some embodiments of this utility model, and not all embodiments. Based on the embodiments of this patent, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this patent.
[0026] like Figure 1-6As shown, a high-power intermediate frequency transformer includes a transformer body 1, which includes a support plate 11, an iron core 13, and a winding 12 wound on the iron core 13. A fixing block 111 is connected and installed on the support plate 11, and a rectifier assembly 2 is connected and installed on the fixing block 111. A positive output block 21 is connected and installed on the upper side of the rectifier assembly 2, and a negative output block 20 is connected and installed on one side of the support plate 11. Four water inlets 3 are provided on the positive output block 21 away from the negative output block 20, and two water inlets are provided on the negative output block 20 away from the water inlets 3 and on the support plate 11 near the water inlets 3. Each outlet 4 and inlet 3 is independently connected to a water path 5 that flows through the positive output block 21, negative output block 20, fixed plate 111, support plate 11, rectifier assembly 2, and transformer body 1. Each water path 5 is connected to the fixed block 111 and support plate 11 by two water-cooling pipes 51, forming a U-shape around the transformer body 1. Cooling water flows from the fixed block 111 into the water-cooling pipes 5 and out through the support plate 11. There are a total of eight water-cooling pipes 51, arranged in two rows with a certain gap. Two water-cooling pipes 51 on the same side of each row form one water path 5 (e.g., ...). Figure 4 , 5 As shown, due to the symmetrical structure of this device, only half of the waterway 5 is shown in the figure to clearly illustrate its specific pathway.
[0027] The rectifier assembly 2 forms a structure with water channels by alternating clamping of side plates and corner plates, which facilitates the passage of cooling water for cooling. The water channels on the side plates and corner plates are all connected by drilling, which has a good insulation effect. The open ends of the drilled holes are blocked by thread plugs to allow the cooling water to flow smoothly.
[0028] The negative output block 20, positive output block 21, rectifier assembly 2, fixing block 111 and support plate 11 are provided with a connected channel and water cooling pipe 51 to form a water circuit 5. The entire water circuit 5 is insulated and protected by an electrical grade insulation layer.
[0029] In use, a high-voltage AC power supply from the controller is supplied to the input terminal of the transformer body 1. The transformer body 1 performs voltage reduction processing, and the reduced voltage electricity is rectified by the rectifier assembly 2 to convert AC power into DC power. The DC power is then output through the positive output block 21 and the negative output block 20. Since power equals voltage multiplied by current, the current will increase after the voltage decreases when the power remains constant. The large current will generate a lot of heat. Cooling water flows in from the inlet 3 and flows through the positive output block 21, rectifier assembly 2, fixing block 111, water cooling pipe 51, support plate 11 and negative output block 20 in sequence, carrying away the heat generated by the current heating effect of the rectifier assembly 2, winding 12 and iron core 13. This device adopts a four-water-circuit design integrating the rectifier assembly and the transformer for separate cooling, which shortens the water cooling path, increases the cooling water flow rate, and effectively solves the problem of difficult heat dissipation and cooling of the transformer. The four water circuits shorten the waterway, reduce water flow resistance, have good temperature control, and quickly remove heat, making the transformer cool down quickly, extending the transformer's lifespan, and improving the stability of the transformer. It greatly improves the quality of the transformer, increases working efficiency, and also reduces maintenance costs.
[0030] The transformer body 1 includes windings 12 and an iron core 13. Windings 12 include primary windings and secondary windings. The number of turns in the primary winding and the number of turns in the secondary winding are positively correlated with the step-down ratio. The iron core 13 is embedded between U-shaped water-cooling pipes 51, and the windings 12 are wound around the iron core 13. This allows for a larger contact area between the transformer body 1 and the water-cooling pipes 51, enabling better heat dissipation from the windings 12 and the iron core 13, maintaining the normal operating temperature of the transformer body 1, and improving its operating efficiency.
[0031] The transformer body 1 is externally connected to an aluminum casing 6, and a dustproof protective cover 7 is installed on the upper part of the aluminum casing 6, which shields the rectifier assembly 2. This dustproof cover prevents dust from entering the rectifier assembly and the transformer, prevents dust from absorbing moisture, reducing insulation strength, increasing the risk of leakage and short circuits, and affecting the overall performance of the equipment. At the same time, the aluminum casing 6 has good heat dissipation capabilities, effectively dissipating heat and improving the transformer's operating efficiency and stability.
[0032] The aluminum outer casing 6 has a cover plate 8 installed at its bottom. The cover plate 8 has U and V terminals 9 that are electrically connected to the input terminal of the transformer body 1. A protective rear shell is installed on the cover plate 8. Wiring is connected to the terminals through a wire hole on the rear shell, which has good insulation properties. This facilitates input power connection, provides a stable electrical connection environment, and offers good electrical insulation to prevent leakage and power outages.
[0033] The negative output block 20 includes a bottom negative output block 201 connected and mounted on the support plate 11, a side negative output block 202 connected and mounted on the bottom negative output block 201, and a top negative output block 203 connected and mounted on the side negative output block 202. The bottom negative output block 201, side negative output block 202, and top negative output block 203 are all connected in parallel to the output terminal of the rectifier assembly 2, and have good insulation between each other. This provides sufficient electrical connection points and also shares the output power of the negative output block 20, preventing excessive current from causing heat to be unable to dissipate in time, thus providing a safe and stable working environment for the device.
[0034] The positive output block 21, the top negative output block 203, the side negative output block 202, and the bottom negative output block 201 are all connected and installed using bolts and fasteners. This facilitates assembly, reduces production difficulty, and allows for easy disassembly, maintenance, and replacement, thereby lowering operating costs.
[0035] The rectifier assembly 2 consists of two sets arranged in a centrally symmetrical configuration. This reduces the space occupied by the device, making the entire device more compact. The two sets of rectifier assemblies 2 can improve rectification efficiency, share the power of the rectifier assembly 2, and better control the temperature.
[0036] The rectifier assembly 2 is connected in a straight series via bolts and nuts, comprising two pressure caps 29, two disc springs 22, four insulating partitions 23, four side plates 24, one pad 25, four diodes 26, two corner plates 27, and two pressure cap insulating pads 28. Figure 6The diodes are connected and installed together as shown. This single-group rectifier consists of four diodes. By increasing the number of diodes, multiple phases of the AC current are rectified and superimposed, which can significantly reduce the ripple coefficient (i.e., "ripple") of the output DC current, making the current more stable. Welding equipment has high requirements for current stability (such as spot welding and seam welding which require precise heat control). The more diodes there are, the smoother the rectified current and the more stable the welding quality. At the same time, the transformer power also needs to be adapted accordingly. The transformer contains two groups of rectifiers, a total of eight diodes, with strong power adaptability and a wide duty cycle range. This wide range of power regulation capability allows it to cope with both continuous batch production (such as assembly line welding) and intermittent high-current welding tasks, with significant flexibility. It has outstanding high-current output capability, and its high-current characteristics are particularly suitable for welding highly conductive and thermally conductive materials (such as copper and aluminum) or thick plates and large parts, avoiding defects such as incomplete welding and lack of fusion caused by insufficient heat. This type of transformer fills the gap in the medium-frequency welding transformer market for thick plates, large parts, and long intermittent welding times. Compared to AC welding at industrial frequency, DC output reduces the "skin effect" caused by changes in current direction, resulting in a more uniform current distribution in the workpiece contact area and improving welding quality (such as reducing spatter and ensuring consistent weld nugget). It achieves energy conversion (AC to DC), stable output, adaptability to dynamic loads, and supports precise control of welding parameters.
[0037] The specific operating steps of this utility model are as follows: The high-power intermediate frequency transformer is cooled by four cooling water circuits to cool the rectifier assembly 2 and the transformer body 1. The transformer converts high voltage and low current into low voltage and high current. The high current is output from the positive output block 21 and the negative output block 20, and is heated to a melting or plastic state by the resistance heat effect generated by the contact surface of the welding torch electrode rod joint and the area near the workpiece, so as to form a metal-bonded welding method. The main water inlet is introduced from the outside, and the four cooling water circuits are introduced into the rectifier assembly 2 from the positive output block 21, and then introduced into the transformer body 1 through each part of the rectifier assembly. The cooling water circulates once and is then led out. The four water circuits 5 are independent and do not cross or interfere with each other. Through the above specific embodiments, the rectifier assembly 2 and transformer 1 are connected in series with a four-water circuit design, which cools them separately, shortens the water cooling path, and increases the cooling water flow rate. This effectively solves the problem of heat dissipation and cooling of high-power transformers and rectifier assemblies. The four water circuits shorten the waterway, reduce water flow resistance, have good temperature control, and quickly remove heat, making the high-power transformer cool down quickly, extending the transformer's lifespan, and improving the stability of the transformer. This greatly improves the quality of the transformer, increases working efficiency, and also reduces maintenance costs.
[0038] Corrosion-preventing substances need to be added to the cooling water to reduce its corrosive effect on the water channels of various components and extend the service life of each component. In order to enhance the heat dissipation effect and capacity, it is also necessary to add devices for cooling the external cooling water, such as heat sinks and matching cooling fans, to actively cool the cooling water, improve the heat dissipation effect, maintain a suitable temperature, and ensure the normal operation of the device.
[0039] The above description of the disclosed embodiments enables those skilled in the art to make or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.
Claims
1. A high-power intermediate frequency transformer, comprising a transformer body (1), characterized in that, The transformer body (1) includes a support plate (11), an iron core (13), and a winding (12) wound on the iron core (13). A fixing block (111) is connected and installed on the support plate (11). A rectifier assembly (2) is connected and installed on the fixing block (111). A positive output block (21) is connected and installed on the upper side of the rectifier assembly (2). A negative output block (20) is connected and installed on one side of the support plate (11). Four water inlets (3) are provided on the positive output block (21) away from the negative output block (20). Two outlets (4) are provided on the side away from the inlet (3) and on the side of the support plate (11) near the inlet (3). The inlet (3) and the outlet (4) are connected by a water path (5) for cooling water to flow, which is connected in series on the positive output block (21), negative output block (20), fixed block (111), support plate (11), rectifier assembly (2) and iron core (13). Each water path (5) is connected to the fixed block (111) and the support plate (11) through two water cooling pipes (51) and is wrapped around the iron core (13) in a U-shape.
2. The high-power intermediate frequency transformer according to claim 1, characterized in that, An aluminum shell (6) is installed on the outside of the transformer body (1), and a dustproof protective cover (7) is installed on the upper part of the aluminum shell (6).
3. The high-power intermediate frequency transformer according to claim 2, characterized in that, The aluminum casing (6) has a cover plate (8) at the bottom, and the cover plate (8) is equipped with U and V terminals (9).
4. The high-power intermediate frequency transformer according to claim 1, characterized in that, The negative output block (20) includes a bottom negative output block (201) connected and installed on a support plate (11), a side negative output block (202) connected and installed on the bottom negative output block (201), and a top negative output block (203) connected and installed on the side negative output block (202).
5. The high-power intermediate frequency transformer according to claim 4, characterized in that, The positive output block (21), the top negative output block (203), the side negative output block (202) and the bottom negative output block (201) are all connected and installed by bolt fasteners.
6. The high-power intermediate frequency transformer according to claim 1, characterized in that, The rectifier assembly (2) has two sets and is centrally symmetrically arranged.
7. The high-power intermediate frequency transformer according to claim 6, characterized in that, The rectifier assembly (2) includes several pressure caps (29), disc springs (22), insulating partitions (23), side plates (24), pads (25), diodes (26), corner plates (27), and pressure cap insulating pads (28) connected in a straight series.