Low-voltage horizontal large-current single-phase transformer
By optimizing the core structure and winding design, and combining high-magnetic silicon steel sheets and high-temperature resistant insulation materials, the problems of high loss and insufficient stability of horizontal transformers in low-voltage and high-current scenarios have been solved, achieving efficient and stable power output.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- GUANGDONG NRE TECH CO LTD
- Filing Date
- 2025-08-20
- Publication Date
- 2026-07-21
AI Technical Summary
Existing horizontal transformers suffer from problems such as high losses, insufficient regulation performance, and inadequate mechanical strength and insulation reliability in low-voltage, high-current scenarios, making it difficult to meet the high precision and stability requirements of industrial applications.
The iron core adopts an interleaved laminated three-column EI sheet structure, with optimized winding arrangement and insulation design, combined with high magnetic induction silicon steel sheets and high temperature resistant insulation materials, optimized heat dissipation path, and suitable for high current output.
It improves the heat dissipation efficiency and insulation reliability of transformers, reduces current density and power loss, enhances the stability and adaptability of equipment, and meets the accuracy and reliability requirements of low-voltage, high-current scenarios.
Smart Images
Figure CN224536843U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of transformer technology, specifically to a horizontal high-current single-phase transformer with low output voltage. Background Technology
[0002] Horizontal transformers are a type of transformer used in power electronic equipment for specific scenarios. In industrial production, scientific research and other fields, there are many devices that require low voltage and high current output, such as electrochemical processes like electrolysis and electroplating, which require low voltage (e.g., a few volts to tens of volts) and high current (hundreds to thousands of amperes) to provide stable power. Scenarios such as motor testing and battery charging require this type of transformer for voltage conversion and current regulation.
[0003] Compared with traditional vertical transformers, horizontal transformers have the following advantages in high-current scenarios: current can cause severe heating of the windings, the heat dissipation path design of vertical structures is more complicated and can easily affect the stability of the equipment, while horizontal structures are more convenient for arranging large cross-section windings (reducing current density), and can also reduce the height of the equipment and adapt to specific installation environments.
[0004] With the development of industrial automation, new energy, and other fields, the requirements for the accuracy, reliability, and energy efficiency of low-voltage, high-current power supplies are constantly increasing. Existing horizontal transformers may have problems such as high losses and insufficient regulation performance, which need to be improved by optimizing core materials (such as high-magnetic-induction silicon steel sheets) and winding structures (such as foil windings). In addition, horizontal transformers also need to solve technical challenges such as mechanical strength (such as stability during transportation and installation) and insulation reliability (partial discharge control under high current). Utility Model Content
[0005] The purpose of this invention is to overcome the shortcomings of the prior art and provide a horizontal high-current single-phase transformer with low output voltage. Through the optimization of structure and performance, this horizontal transformer has significant advantages in adapting to high current, ensuring stability, and improving energy efficiency, and can better meet the core needs of specific industrial scenarios.
[0006] The technical solution of this utility model is as follows:
[0007] A horizontal high-current single-phase transformer with low output voltage includes an iron core, an upper support, a lower support, an input conductor bus, an input winding, and an output winding.
[0008] The core adopts an interleaved laminated three-column EI plate structure, which includes column A, column B, column C, two columns D and column E. Columns A, B and C are arranged vertically at intervals. Column E is arranged horizontally at the top of column B and its two ends are connected to columns A and C respectively. Columns D are arranged horizontally at the bottom of columns A and C respectively and are connected to column B.
[0009] The input winding and the output winding are wound inside and outside on the B-pillar, and the output winding and the input winding are tightened by several spaced heat dissipation support bars. The output winding is tightened by an epoxy plate between itself and the A-pillar and the C-pillar, respectively.
[0010] The upper bracket is disposed on the upper side of the A-pillar, C-pillar, D-pillar, and E-pillar, and the input conductive busbar is disposed on the upper bracket;
[0011] The lower bracket is disposed on the lower side of the A-pillar, C-pillar, D-pillar, and E-pillar, and the lower bracket has several mounting holes.
[0012] The iron core is made of high magnetic silicon steel sheets.
[0013] Wherein, the thickness of column A is equal to the thickness of column C, equal to the thickness of column D, equal to the thickness of column E, and equal to 1 / 2 the thickness of column B.
[0014] The input winding has an input voltage of 220V and is made of enameled copper wire.
[0015] The output winding has an output voltage of 8V and two rows of output copper busbars extend upwards.
[0016] The upper support and the lower support are connected by several connecting rods.
[0017] Compared with the prior art, the beneficial effects of this utility model are as follows:
[0018] 1. Its structural design is more suitable for high-current scenarios.
[0019] - High heat dissipation efficiency: The horizontal layout facilitates a tight fit between the windings, oil tank, and heat sink. The heat generated by the large current can be more directly conducted to the cooling system, reducing the temperature rise and avoiding overheating that could affect the equipment's lifespan.
[0020] - Reasonable winding arrangement: Suitable for winding with large cross-section conductors (such as copper foil and flat copper wire), reducing current density and winding loss; at the same time, the horizontal structure can shorten the distance between the winding ends, reducing the risk of leakage flux and local overheating.
[0021] - High installation flexibility: Compared with vertical transformers, it is lower in height and can adapt to industrial environments with limited space (such as low-ceilinged areas in workshops and laboratories). Moreover, the horizontal center of gravity is low, resulting in better stability during operation and transportation.
[0022] 2. More stable and reliable performance
[0023] - High accuracy in low voltage output: By optimizing the core magnetic circuit design (using high magnetic silicon steel sheets) and winding process (uniform winding, reducing distributed capacitance), voltage fluctuations are reduced to meet the requirements of electrolysis, electroplating and other scenarios with high requirements for low voltage stability.
[0024] - Superior insulation performance: Partial discharge under high current can easily lead to insulation aging. The horizontal design can reduce the insulation temperature and improve insulation reliability by properly arranging the insulation materials (such as thickening the end insulation and using high-temperature resistant insulation paper) and coordinating with heat dissipation.
[0025] 3. Improved energy efficiency and economy
[0026] - Lower losses: Combining low-loss core materials and optimized winding structure reduces iron and copper losses, improves operating efficiency, and reduces energy waste and energy costs in the long term.
[0027] -Low maintenance cost: The structural design facilitates disassembly and maintenance, and the maintenance or replacement of core components such as windings and iron cores is more convenient, reducing downtime.
[0028] 4. Specifically meet the needs of different scenarios
[0029] - Designed specifically for low-voltage, high-current, single-phase scenarios, it eliminates the need for redundant design compared to general-purpose transformers. Its size and weight are better suited to actual loads, avoiding the waste of resources by using a large transformer for a small load. It is more practical in fields such as industrial testing and battery charging and discharging. Attached Figure Description
[0030] To more clearly illustrate the technical solutions in the embodiments of this utility model, the drawings used in the description of the embodiments or the prior art 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.
[0031] Figure 1 A schematic diagram of the external structure of a horizontal high-current single-phase transformer with low output voltage provided by this utility model;
[0032] Figure 2 A schematic diagram of the internal structure of a horizontal high-current single-phase transformer with low output voltage provided by this utility model;
[0033] Figure 3 This is a schematic diagram of the iron core described in this utility model. Detailed Implementation
[0034] To make the objectives, technical solutions, and advantages of this utility model clearer, the present utility model will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the present utility model and are not intended to limit the present utility model.
[0035] To illustrate the technical solution described in this utility model, specific embodiments are described below.
[0036] Example
[0037] Please see Figure 1 , Figure 2 This embodiment provides a horizontal high-current single-phase transformer with low output voltage, including an iron core 1, an upper support 2, a lower support 3, an input conductor bus 4, an input winding 5, and an output winding 6. The iron core 1 is composed of high-magnetic-induction silicon steel sheets. To save on the cost and weight of the silicon steel sheets, it employs... Figure 3 The staggered laminated three-column EI plate structure shown has a core 1 comprising columns A, B, C, two D columns, and an E column. Columns A, B, and C are vertically spaced, while column E is horizontally positioned at the top of column B, with its two ends connected to columns A and C respectively. The two D columns are horizontally positioned opposite each other at the bottom of columns A and C, and connected to column B. The thickness of column A is equal to the thickness of column C, column D, column E, and half the thickness of column B. Input winding 5 and output winding 6 are wound internally and externally on column B. Input winding 5 has an input voltage of 220V and is made of enameled copper wire. Output winding 6 has an output voltage of 8V and extends upwards with two rows of output copper busbars 61. Output winding 6 is tensioned to input winding 5 by several spaced heat dissipation support bars 7, and output winding 6 is tensioned to columns A and C by epoxy plates 8 respectively. The upper bracket 2 is set on the upper side of the A-pillar, C-pillar, D-pillar, and E-pillar. The input conductive busbar is set on the upper bracket 2. The lower bracket 3 is set on the lower side of the A-pillar, C-pillar, D-pillar, and E-pillar. The lower bracket 3 has several mounting holes 31. The upper bracket 2 and the lower bracket 3 are connected by several connecting rods 9.
[0038] Through structural and performance optimization, this horizontal transformer offers significant advantages in adapting to high currents, ensuring stability, and improving energy efficiency, thus better meeting the core needs of specific industrial scenarios.
[0039] Its advantages are reflected in the following aspects, including structural adaptability, performance stability, energy efficiency, and practicality:
[0040] 1. Its structural design is more suitable for high-current scenarios.
[0041] - High heat dissipation efficiency: The horizontal layout facilitates a tight fit between the windings, oil tank, and heat sink. The heat generated by the large current can be more directly conducted to the cooling system, reducing the temperature rise and avoiding overheating that could affect the equipment's lifespan.
[0042] - Reasonable winding arrangement: Suitable for winding with large cross-section conductors (such as copper foil and flat copper wire), reducing current density and winding loss; at the same time, the horizontal structure can shorten the distance between the winding ends, reducing the risk of leakage flux and local overheating.
[0043] - High installation flexibility: Compared with vertical transformers, it is lower in height and can adapt to industrial environments with limited space (such as low-ceilinged areas in workshops and laboratories). Moreover, the horizontal center of gravity is low, resulting in better stability during operation and transportation.
[0044] 2. More stable and reliable performance
[0045] - High accuracy in low voltage output: By optimizing the core magnetic circuit design (using high magnetic silicon steel sheets) and winding process (uniform winding, reducing distributed capacitance), voltage fluctuations are reduced to meet the requirements of electrolysis, electroplating and other scenarios with high requirements for low voltage stability.
[0046] - Superior insulation performance: Partial discharge under high current can easily lead to insulation aging. The horizontal design can reduce the insulation temperature and improve insulation reliability by properly arranging the insulation materials (such as thickening the end insulation and using high-temperature resistant insulation paper) and coordinating with heat dissipation.
[0047] 3. Improved energy efficiency and economy
[0048] - Lower losses: Combining low-loss core materials and optimized winding structure reduces iron and copper losses, improves operating efficiency, and reduces energy waste and energy costs in the long term.
[0049] -Low maintenance cost: The structural design facilitates disassembly and maintenance, and the maintenance or replacement of core components such as windings and iron cores is more convenient, reducing downtime.
[0050] 4. Specifically meet the needs of different scenarios
[0051] - Designed specifically for low-voltage, high-current, single-phase scenarios, it eliminates the need for redundant design compared to general-purpose transformers. Its size and weight are better suited to actual loads, avoiding the waste of resources by using a large transformer for a small load. It is more practical in fields such as industrial testing and battery charging and discharging.
[0052] The above are merely preferred embodiments of the present utility model and are not intended to limit the present utility model. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.
Claims
1. A horizontal, high-current single-phase transformer with low output voltage, characterized in that: It includes the iron core, upper support, lower support, input conductor bus, input winding, and output winding; The core adopts an interleaved laminated three-column EI plate structure, which includes column A, column B, column C, two columns D and column E. Columns A, B and C are arranged vertically at intervals. Column E is arranged horizontally at the top of column B and its two ends are connected to columns A and C respectively. Columns D are arranged horizontally at the bottom of columns A and C respectively and are connected to column B. The input winding and the output winding are wound inside and outside on the B-pillar, and the output winding and the input winding are tightened by several spaced heat dissipation support bars. The output winding is tightened by an epoxy plate between itself and the A-pillar and the C-pillar, respectively. The upper bracket is disposed on the upper side of the A-pillar, C-pillar, D-pillar, and E-pillar, and the input conductive busbar is disposed on the upper bracket; The lower bracket is disposed on the lower side of the A-pillar, C-pillar, D-pillar, and E-pillar, and the lower bracket has several mounting holes.
2. The horizontal high-current single-phase transformer with low output voltage according to claim 1, characterized in that: The iron core is composed of high magnetic silicon steel sheets.
3. The horizontal high-current single-phase transformer with low output voltage according to claim 1, characterized in that: The thickness of column A is equal to the thickness of column C, the thickness of column D, the thickness of column E, and half the thickness of column B.
4. A horizontal high-current single-phase transformer with low output voltage according to claim 1, characterized in that: The input voltage of the input winding is 220V, and it is made of enameled copper wire.
5. A horizontal high-current single-phase transformer with low output voltage according to claim 1, characterized in that: The output voltage of the output winding is 8V, and it extends upwards with two rows of output copper busbars.
6. A horizontal high-current single-phase transformer with low output voltage according to claim 1, characterized in that: The upper support and the lower support are connected by several connecting rods.