A transformer for a pulse power charger

Abstract

The application relates to a transformer of a pulse power charger, and relates to the technical field of transformers.The transformer comprises a shell and an iron core arranged in the shell, a winding is arranged on the iron core, a voltage stabilizing mechanism is arranged in the shell, and the voltage stabilizing mechanism is used for stabilizing inter-turn voltage.In the application, silicon stacks have unidirectional conduction characteristics, the reverse flow of current in the winding can be limited, reverse voltage superposition can be avoided, and inter-turn voltage can be prevented from rising; voltage equalization capacitors can balance the voltage at both ends of the silicon stacks, prevent a single silicon stack from being damaged due to voltage concentration, can absorb pulse peak voltage on the winding, and can further reduce inter-turn voltage fluctuation; and insulation partitions can enhance the insulation performance between adjacent windings, and can avoid the creeping phenomenon caused by too small winding spacing.Through the synergistic effect of the three, the stability of the inter-turn voltage is significantly improved, and the risk of insulation layer breakdown is reduced.

Description

Technical Field

[0001] This application relates to the technical field of transformers, and in particular to a transformer for a pulse power charger. Background Technology

[0002] Pulse power chargers are widely used in electric vehicles, energy storage devices, and other fields due to their advantages such as high charging efficiency and minimal damage to batteries. As the core energy conversion component in a pulse power charger, the transformer's performance directly affects the charger's overall efficiency, stability, and safety. During the operation of the pulse power charger, the transformer needs to operate under high-frequency pulse conditions. Due to the large voltage change rate of the pulse power supply, the existing transformer windings are prone to high voltage between turns, which can cause the winding insulation layer to break down, thereby affecting the service life of the transformer and even causing safety accidents. Utility Model Content

[0003] In order to improve the inter-turn voltage stability, heat dissipation efficiency, operating condition adaptability and operational safety of transformers used in pulse power chargers, and to extend the service life of the equipment, this application provides a transformer for a pulse power charger.

[0004] The transformer for a pulse power charger provided in this application adopts the following technical solution: A transformer for a pulse power charger includes a housing and an iron core disposed within the housing. Windings are disposed on the iron core. A voltage stabilizing mechanism is disposed within the housing to stabilize the inter-turn voltage. The voltage stabilizing mechanism includes: A silicon stack, wherein the silicon stack is connected in series with the winding; A voltage equalizing capacitor is connected in parallel across the silicon stack. An insulating partition is disposed inside the housing and located between two adjacent winding sections.

[0005] By adopting the above technical solutions, the silicon stack has unidirectional conductivity, which can limit the reverse flow of current in the winding and avoid the increase of inter-turn voltage caused by the superposition of reverse voltage; the voltage equalizing capacitor can balance the voltage across the silicon stack, prevent individual silicon stacks from being damaged due to voltage concentration, and absorb the pulse peak voltage on the winding, further reducing the fluctuation of inter-turn voltage; the insulating partition can enhance the insulation performance between adjacent windings and avoid creepage caused by the small spacing between windings. The three work together to significantly improve the stability of inter-turn voltage and reduce the risk of insulation layer breakdown.

[0006] Optionally, the number of silicon stacks is matched with the number of winding segments, each segment of the winding is connected in series with a silicon stack, and each of the silicon stacks is connected in parallel with a voltage equalizing capacitor at both ends.

[0007] By adopting the above technical solution, the winding is segmented, and each segment is equipped with an independent silicon stack and voltage-equalizing capacitor, enabling "segmented control" of the inter-turn voltage of the winding. Compared with the integrated voltage regulator design, segmented voltage regulation can more accurately balance the voltage of each winding segment, avoiding the problem of uneven voltage distribution caused by excessive overall winding length. It is especially suitable for scenarios with large voltage change rates under high-frequency pulses, further improving the reliability and specificity of the voltage regulation effect.

[0008] Optionally, the insulating partition is made of epoxy resin glass cloth tube with a thickness of 3-5mm, the winding is made of copper foil, and the surface of the winding is wrapped with a polyimide film insulation layer.

[0009] By adopting the above technical solutions, the epoxy resin glass cloth tube material has excellent insulation performance, high temperature resistance, and mechanical strength. The thickness of 3-5mm can ensure sufficient insulation and isolation effect without excessively increasing the internal volume of the transformer, which is suitable for the insulation requirements under high-frequency pulse conditions. Compared with traditional enameled wire, copper foil has a larger conductive cross-sectional area and better heat dissipation performance, which can reduce copper loss in the winding and reduce heat generation. The polyimide film insulation layer has the characteristics of high temperature resistance (long-term operating temperature can reach above 200℃), aging resistance, and chemical corrosion resistance, which can effectively protect the winding conductor, prevent the insulation layer from aging rapidly under high-frequency pulse and high-temperature environments, and further extend the service life of the winding.

[0010] Optionally, the outer casing is provided with a heat dissipation mechanism for dissipating heat from the internal space of the outer casing, the heat dissipation mechanism comprising: A cooling fan is provided, wherein a heat dissipation channel is provided on the outer casing, and the cooling fan is disposed within the heat dissipation channel; The heat dissipation fins are provided in a plurality of them, and the plurality of heat dissipation fins are evenly distributed on the outer side wall of the outer casing.

[0011] By adopting the above technical solution, the heat dissipation channel provides a flow path for heat inside the casing. When the cooling fan is working, it can accelerate air convection between the inside and outside of the casing, expelling internal heat through the heat dissipation channel. The heat dissipation fins evenly distributed on the outer wall of the casing can increase the contact area between the casing and the air, using the principle of heat conduction to quickly transfer the internal heat absorbed by the casing to the air, achieving passive heat dissipation. The combination of active heat dissipation (cooling fan) and passive heat dissipation (heat dissipation fins) significantly improves heat dissipation efficiency, effectively controls the operating temperature of the transformer under high-frequency pulse conditions, and avoids insulation aging and performance degradation caused by overheating.

[0012] Optionally, the housing may also include a temperature sensor and a temperature control module, wherein the temperature sensor is electrically connected to the temperature control module and the temperature control module is electrically connected to the cooling fan.

[0013] By adopting the above technical solution, the temperature sensor can collect the internal temperature data of the casing in real time and transmit the data to the temperature control module. The temperature control module analyzes and judges the temperature data. When the internal temperature reaches a preset threshold (e.g., 80℃), it automatically controls the cooling fan to start or increase the fan speed to enhance the heat dissipation effect. When the temperature drops to a safe range (e.g., below 50℃), it can control the fan to stop or reduce the speed, realizing intelligent start-stop and speed adjustment of the cooling fan. This design not only ensures the timeliness and effectiveness of heat dissipation, but also avoids energy waste and noise pollution caused by long-term full-load operation of the fan, improving the energy efficiency and user comfort of the equipment.

[0014] Optionally, the housing is also provided with a voltage detection interface, which is electrically connected to the winding, and a waterproof and dustproof plug is provided at the voltage detection interface.

[0015] By adopting the above technical solution, the voltage detection interface can be connected to external testing equipment (such as multimeters and oscilloscopes), which allows staff to periodically or in real-time test key parameters such as the output voltage and inter-turn voltage of the winding, promptly detect voltage anomalies, and provide convenience for equipment maintenance and troubleshooting. The waterproof and dustproof plug can seal the interface when it is not in use, preventing external dust and moisture from entering the interface and avoiding problems such as poor contact and short circuits caused by moisture or dust accumulation. This ensures the long-term reliable use of the detection interface and also improves the overall sealing and protection performance of the housing.

[0016] Optionally, the outer shell is made of aluminum alloy, and heat insulation cotton is pasted on the inner wall of the outer shell.

[0017] By adopting the above technical solutions, aluminum alloy, with its low density, good thermal conductivity, and high mechanical strength, can reduce the overall weight of the transformer, facilitating installation and transportation. Furthermore, it can quickly transfer internal heat to the outer casing surface, achieving efficient heat dissipation in conjunction with the heat sink fins. In addition, the corrosion resistance of aluminum alloy can extend the service life of the casing. The insulation cotton pasted on the inner wall provides thermal insulation, reducing heat loss during the initial startup phase and helping the equipment quickly reach a stable operating temperature. When the external ambient temperature is low, it also prevents condensation from forming on the inner wall of the casing, avoiding corrosion of internal electrical components. It also helps to isolate the internal operating conditions from fluctuations in external ambient temperature to a certain extent.

[0018] Optionally, the bottom of the housing is provided with a shock-absorbing pad, which is made of nitrile rubber.

[0019] By adopting the above technical solutions, nitrile rubber possesses excellent elasticity, wear resistance, and oil resistance. The shock-absorbing pads made from it can effectively absorb vibrations generated during transformer operation (such as magnetostriction of the iron core and vibrations generated by fan operation), as well as vibrations transmitted from the external environment (such as vibrations during charger operation and impacts during handling). This reduces the impact of vibrations on internal components such as the iron core, windings, and silicon stack, preventing loosening of components and wear of the insulation layer due to long-term vibration, thereby ensuring the structural stability and electrical performance stability of the equipment. At the same time, the shock-absorbing pads can also reduce the noise generated by vibration and improve the quietness of the equipment.

[0020] In summary, this application includes at least one of the following beneficial technical effects: 1. By setting up a silicon stack, the reverse current flow in the winding can be restricted due to the unidirectional conductivity of the silicon stack, thus avoiding the increase in inter-turn voltage caused by the superposition of reverse voltages. 2. By segmenting the windings and configuring each segment with an independent silicon stack and voltage-equalizing capacitor, "segmented control" of the inter-turn voltage can be achieved. Compared to an integrated voltage regulator design, segmented voltage regulation can more accurately balance the voltage of each winding segment, avoiding uneven voltage distribution caused by excessive winding length. It is especially suitable for scenarios with large voltage change rates under high-frequency pulses, further improving the reliability and specificity of the voltage regulation effect. 3. The heat insulation cotton pasted on the inner wall of the outer casing can play a role in heat insulation and heat preservation. In the early stage of transformer startup, it can reduce the loss of internal heat to the outside and help the equipment quickly reach a stable operating temperature. When the external ambient temperature is low, it can also prevent condensation from forming on the inner wall of the outer casing due to low temperature, avoid condensation from corroding the internal electrical components, and at the same time, it can also isolate the influence of external ambient temperature fluctuations on the internal operating conditions to a certain extent. Attached Figure Description

[0021] Figure 1 This is a three-dimensional structural diagram of this application; Figure 2 This is a schematic diagram of the heat dissipation mechanism and voltage detection interface in this application.

[0022] Reference numerals: 11. Outer shell; 12. Iron core; 13. Winding; 14. Shock-absorbing pad; 15. Thermal insulation cotton; 16. Voltage detection interface; 17. Waterproof and dustproof plug; 2. Voltage stabilizing mechanism; 21. Silicon stack; 22. Voltage equalizing capacitor; 23. Insulating partition; 3. Heat dissipation mechanism; 31. Cooling fan; 32. Heat dissipation fins; 33. Temperature sensor; 34. Temperature control module. Detailed Implementation

[0023] The following is in conjunction with the appendix Figure 1 -Appendix Figure 2 This application will be described in further detail.

[0024] This application discloses a transformer for a pulse power charger.

[0025] Reference Figure 1 The transformer of the pulse power charger includes a housing 11, an iron core 12, windings 13, and a voltage stabilizing mechanism 2. The housing 11 is integrally formed from aluminum alloy sheet, and four nitrile rubber shock-absorbing pads 14 are fixed to the bottom with bolts. The bottom surface of the shock-absorbing pads 14 has anti-slip texture. The inner wall of the housing 11 is lined with fiberglass insulation cotton 15.

[0026] Reference Figure 1 The iron core 12 is made of high-silicon steel sheets laminated together and is installed on the central support inside the housing 11. The winding 13 is divided into a primary winding 13 and a secondary winding 13. Both the primary winding 13 and the secondary winding 13 are made of oxygen-free copper foil and wound on the iron core 12. The surface of the copper foil is wrapped with a polyimide film insulation layer. The voltage stabilizing mechanism 2 is located inside the housing 11 and is used to stabilize the inter-turn voltage.

[0027] Reference Figure 1 The voltage regulator 2 includes a silicon stack 21, a voltage equalizing capacitor 22, and an insulating partition 23. The silicon stack 21 is a 1000V / 50A high-frequency silicon stack 21, which is connected in series between the lead-out terminal and the output terminal of the secondary winding 13. The voltage equalizing capacitor 22 is a 1000pF / 2000V ceramic capacitor, which is connected in parallel to both ends of the silicon stack 21 through wires. Both the silicon stack 21 and the voltage equalizing capacitor 22 are fixed inside the outer casing 11.

[0028] Reference Figure 1 The insulating partition 23 in the voltage stabilizing mechanism 2 is made of epoxy resin glass cloth tube, with a thickness of 3mm. Two partitions are provided, one between the primary winding 13 and the secondary winding 13, and the other on the outer side of both ends of the secondary winding 13. The epoxy resin glass cloth tube has excellent insulation performance, high temperature resistance, and mechanical strength, and can maintain stable insulation effect in the high temperature environment generated by high frequency pulses. The 3mm thickness can meet the insulation requirements between adjacent windings 13, and avoid the waste of internal space of the outer shell 11 due to excessive partition thickness, thus balancing insulation performance and structural compactness.

[0029] Reference Figure 2 The outer casing 11 is equipped with a heat dissipation mechanism 3 for dissipating heat from its internal space. The heat dissipation mechanism 3 includes a cooling fan 31 and heat dissipation fins 32. Heat dissipation channels are formed on the opposite outer side walls of the outer casing 11, connecting the inner and outer side walls. The cross-section of the heat dissipation channels is rectangular. The cooling fan 31 is installed within the heat dissipation channels. Several heat dissipation fins 32 are welded to the front and rear outer side walls of the outer casing 11 where the cooling fan 31 is not installed. The heat dissipation fins 32 are made of aluminum alloy and are integrally die-cast with the side walls of the outer casing 11.

[0030] Reference Figure 1 The housing 11 also houses a temperature sensor 33 and a temperature control module 34. The temperature control module 34 is fixedly mounted on a circuit board inside the housing 11, and its output is electrically connected to the cooling fan 31 via a relay. The temperature sensor 33 is fixedly mounted in the gap between the iron core 12 and the winding 13, and is connected to the temperature control module 34 via a wire. The temperature sensor 33 can collect real-time temperature data inside the housing 11 and transmit the data to the temperature control module 34. The temperature control module 34 analyzes and judges the temperature data; when the internal temperature reaches a preset threshold (e.g., 80℃), it automatically controls the cooling fan 31 to start or increase its speed to enhance heat dissipation.

[0031] Reference Figure 1 and Figure 2 The outer casing 11 is also equipped with a voltage detection interface 16, which is fixed to the front side wall of the outer casing 11. The interface is connected to the test points of the primary winding 13 and the secondary winding 13 through wires. The interface is fitted with a waterproof and dustproof plug 17 made of nitrile rubber. The dustproof plug is connected to the side wall of the outer casing 11 by a hanging rope to prevent loss.

[0032] The working principle of this application embodiment is as follows: When the transformer is connected to a pulse power supply, the primary winding 13 receives electrical energy and couples it to the secondary winding 13 through the iron core 12. In the voltage stabilizing mechanism 2, the silicon stack 21 limits the reverse current of the secondary winding 13, the voltage equalizing capacitor 22 absorbs the pulse peak voltage and equalizes the voltage across the silicon stack 21, and the insulating partition 23 isolates the creepage risk of adjacent windings 13, thus stabilizing the inter-turn voltage together. The temperature sensor 33 detects the internal temperature in real time. When the temperature reaches 80℃, the temperature control module 34 controls the cooling fan 31 to start, which, together with the heat dissipation fins 32, dissipates the internal heat through the heat dissipation channel. When the temperature drops to 50℃, the fan stops. The operator can remove the waterproof and dustproof plug 17, connect the detection equipment, and monitor the voltage of the winding 13 through the voltage detection interface 16. The shock-absorbing pad 14 absorbs vibration, and the heat insulation cotton 15 isolates the influence of external temperature and humidity, ensuring stable operation of the equipment.

[0033] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. A transformer for a pulse power charger, characterized in that: Includes a housing (11) and an iron core (12) disposed within the housing (11), wherein a winding (13) is disposed on the iron core (12), and a voltage stabilizing mechanism (2) is disposed within the housing (11). The voltage stabilizing mechanism (2) is used to stabilize the inter-turn voltage, and the voltage stabilizing mechanism (2) includes: A silicon stack (21) is connected in series with the winding (13); A voltage equalizing capacitor (22) is connected in parallel across the silicon stack (21); An insulating partition (23) is disposed inside the housing (11) and located between two adjacent windings (13).

2. The transformer of a pulse power charger according to claim 1, characterized in that: The number of silicon stacks (21) matches the number of segments of the winding (13). Each segment of the winding (13) is connected in series with a silicon stack (21), and each of the two ends of each silicon stack (21) is connected in parallel with a voltage equalizing capacitor (22).

3. A transformer for a pulse power supply charger according to claim 1, characterized in that: The insulating partition (23) is made of epoxy resin glass cloth tube material with a thickness of 3-5mm. The winding (13) is made of copper foil and the surface of the winding (13) is wrapped with a polyimide film insulation layer.

4. The transformer of a pulse power charger according to claim 1, characterized in that: The outer casing (11) is provided with a heat dissipation mechanism (3) for dissipating heat from the interior space of the outer casing (11), the heat dissipation mechanism (3) comprising: Cooling fan (31), the outer casing (11) has a heat dissipation channel, and the cooling fan (31) is installed in the heat dissipation channel; Heat dissipation fins (32) are provided in a plurality of them, and the plurality of heat dissipation fins (32) are evenly distributed on the outer side wall of the outer shell (11).

5. A transformer for a pulse power supply charger according to claim 4, characterized in that: The outer casing (11) is also equipped with a temperature sensor (33) and a temperature control module (34). The temperature sensor (33) is electrically connected to the temperature control module (34), and the temperature control module (34) is electrically connected to the cooling fan (31).

6. The transformer of a pulse power charger according to claim 1, characterized in that: The outer casing (11) is also provided with a voltage detection interface (16), which is electrically connected to the winding (13), and a waterproof and dustproof plug (17) is provided at the voltage detection interface (16).

7. The transformer of a pulse power charger according to claim 1, characterized in that: The outer shell (11) is made of aluminum alloy, and heat insulation cotton (15) is pasted on the inner wall of the outer shell (11).

8. The transformer of a pulse power charger according to claim 1, characterized in that: The bottom of the outer shell (11) is provided with a shock-absorbing pad (14), which is made of nitrile rubber.

Images