CN113077956B - High-power high-frequency five-phase magnetic integrated transformer - Google Patents
High-power high-frequency five-phase magnetic integrated transformer Download PDFInfo
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F27/00—Details of transformers or inductances, in general
- H01F27/08—Cooling; Ventilating
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F27/00—Details of transformers or inductances, in general
- H01F27/28—Coils; Windings; Conductive connections
- H01F27/32—Insulating of coils, windings, or parts thereof
- H01F27/321—Insulating of coils, windings, or parts thereof using a fluid for insulating purposes only
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F5/00—Coils
- H01F5/04—Arrangements of electric connections to coils, e.g. leads
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F5/00—Coils
- H01F5/06—Insulation of windings
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Abstract
The invention discloses a high-power high-frequency five-phase magnetic integrated transformer, and belongs to the technical field of high-frequency transformers. The transformer comprises five single-phase transformers, an upper magnetic cover, a lower magnetic cover and an insulation structure. The single-phase transformer comprises a magnetic core column, a primary coil and a secondary coil from inside to outside. Five single-phase transformers are arranged between the upper magnetic cover and the lower magnetic cover according to a regular pentagon staggered sequence, the input excitation phase difference of five primary coils is 72 degrees, the outgoing lines of the five primary coils are connected in a star shape, and the incoming lines of the five secondary coils are connected in a star shape. The insulation structure is arranged between the magnetic core column and the primary coil, between the primary coil and the secondary coil, between the five secondary coils and between the upper top cover and the lower top cover. The high-power high-frequency five-phase magnetic integrated transformer designed by the invention has the advantages of high power density, strong heat dissipation performance and high working stability, and has a large-range leakage inductance and excitation inductance adjusting interval.
Description
Technical Field
The invention relates to a high-power high-frequency five-phase magnetic integrated transformer, and belongs to the technical field of high-frequency transformers.
Background
The high-capacity new energy electric field is directly connected to the grid through the power frequency transformer, the occupied space is large, and the power density is low. With the rapid development of power electronic technology, modular power electronic transformers are receiving more attention, and comprise two major core elements: a high-power high-frequency transformer and a power electronic converter.
For the high-power high-frequency transformer, the volume of the high-power high-frequency transformer can be reduced and the power density can be improved by improving the working frequency. But also leads to the increase of the magnetic core loss and the winding loss of the high-power high-frequency transformer, and the miniaturization of the volume leads to the reduction of the heat conducting area, thus leading to the difficulty of heat dissipation of the high-power high-frequency transformer. Meanwhile, with the increase of working voltage and power capacity, the requirement of the high-power high-frequency transformer on insulation is further improved, so that the high-power high-frequency transformer is usually wrapped by an insulation material, the heat dissipation performance is further reduced, and the working reliability of the high-power high-frequency transformer is influenced.
Therefore, how to provide a high-power high-frequency transformer with good heat dissipation performance and operational reliability becomes a problem to be solved in the field.
In order to solve this problem, some researchers have proposed a high-power high-frequency multiphase magnetic integrated transformer starting from a multiphase DC/DC converter. The multiphase DC/DC converter is more suitable for high-power occasions due to the advantages of low current stress and low filter size requirement, but the traditional multiphase DC/DC converter contains a plurality of high-power high-frequency single-phase transformers, occupies a large volume, has low power density and urgently needs to be improved. The high-power high-frequency multi-phase magnetic integrated transformer integrates a plurality of single-phase transformers in the multi-phase DC/DC converter topology into the same multi-column magnetic core, the heat conducting area can be obviously increased under the condition of not reducing the power density, so that the heat dissipation performance is improved, the plurality of single-phase transformers work simultaneously, the high-power high-frequency multi-phase magnetic integrated transformer can be ensured to generate heat uniformly, and the local overheating phenomenon can not occur. Therefore, the high-power high-frequency multi-phase magnetic integrated transformer receives more attention. However, the research scope at present mainly focuses on medium-and-small-power high-frequency three-phase magnetic integrated transformers, for example, a university scholars of kyushu in 2018 researches the design and decoupling of the small-power high-frequency three-phase magnetic integrated transformers, and a university scholars of british columbia in canada in 2020 designs the high-frequency three-phase magnetic integrated transformers under medium power for application occasions of new energy automobile charging piles. However, in the research aspect of the high-frequency multi-phase magnetic integrated transformer with more phases and larger power, no explanation or report of the similar technology of the invention is found at present, and similar data at home and abroad are not collected yet.
Disclosure of Invention
Aiming at the defects of the prior art, the invention provides the high-power high-frequency five-phase magnetic integrated transformer in order to realize better heat dissipation capability of the high-power high-frequency transformer, further improve the working reliability of the high-power high-frequency transformer and the modular power electronic transformer, and research the high-frequency multi-phase magnetic integrated transformer with more phases and higher power.
The invention aims to realize the purpose, and provides a high-power high-frequency five-phase magnetic integrated transformer which comprises five same single-phase transformers, an upper magnetic cover S, a lower magnetic cover X and an insulating structure; the insulation structure comprises a main insulation structure J1 and a secondary insulation structure J2, and the center positions of the upper magnetic cover S and the lower magnetic cover X are both provided with the same wire passing hole K;
any one of the five single-phase transformers is marked as i-phase transformer G i I represents phases, i ═ a, B, C, D, E; the i-phase transformer G i From the inside to the outside by a core column Z i A primary coil Y1 i And a secondary coil Y2 i Formed of a primary coil Y1 i Secondary coil Y2 i Shape of (2) and core leg Z i The three are the same and concentric; at core column Z i And primary coil Y1 i A secondary insulation structure J2 is filled between the primary coil Y1 i And a secondary coil Y2 i The main insulating structure J1 is filled between the two layers;
the five single-phase transformers are arranged between the upper magnetic cover S and the lower magnetic cover X, and a certain space is reserved between the five single-phase transformers and the upper magnetic cover S and the lower magnetic cover X; the upper magnetic cover S and the lower magnetic cover X are concentrically arranged with the two wire passing holes K, a regular pentagon is drawn by taking the wire passing holes K as centers, the five single-phase transformers are arranged at five vertexes of the regular pentagon in a staggered mode, and specifically, the A-phase transformer G is arranged from the A-phase transformer G A Starting from the following and rotating clockwise, the method respectively comprises the following steps: phase-A transformer G A C phase transformer G C E phase transformer G E B-phase transformer G B And D phase transformer G D (ii) a At five core legs Z i A non-magnetic material with the same thickness is laid in a space opposite to the upper magnetic cover S, and the non-magnetic material forms an air gap layer Q; i-phase transformer G i Five secondary coils Y2 i And secondary insulation structures J2 are filled in the spaces between the upper magnetic cover S and the lower magnetic cover X.
Preferably, the core leg Z i The upper magnetic cover S and the lower magnetic cover X are all made of the same high-permeability materialThe high-permeability material is a material with initial permeability more than 2500, and the working frequency f of the high-permeability material is more than or equal to 20 kHz.
Preferably, the primary coil Y1 i And a secondary coil Y2 i The electromagnetic signal collector is formed by winding a plurality of stranded wires, wherein the wire diameter of a single-turn lead in the stranded wires is smaller than the skin depth of an electromagnetic signal under the working frequency.
Preferably, the primary coil Y1 A 、Y1 B 、Y1 C 、Y1 D 、Y1 E Are sequentially 72 deg. out of phase with each other.
Preferably, the five primary coils Y1 i The leading-in wire and the leading-out wire are wound by using an insulating tape, then penetrate out of the wire passing hole K of the upper magnetic cover, and are connected in a star shape; the five secondary coils Y2 i The leading-in wires and the leading-out wires are wound by using an insulating tape, then penetrate out of the wire passing holes K of the lower magnetic cover, and are connected in a star shape.
Preferably, the interiors of the main insulating structure J1 and the secondary insulating structure J2 are both filled with insulating materials, and the withstand temperature of each of the main insulating structure J1 and the secondary insulating structure J2 is greater than the maximum operating temperature of the transformer.
Preferably, the thickness of the main insulation structure J1 is 15mm-20mm, and the thickness of the secondary insulation structure J2 is 5mm-15 mm.
Compared with the prior art, the invention has the beneficial effects that:
1. the high-power high-frequency five-phase magnetic integrated transformer provided by the invention is a high-power high-frequency transformer with good heat dissipation performance, high working reliability and high power density.
2. The high-power high-frequency five-phase magnetic integrated transformer provided by the invention is characterized in that five primary coils Y1 are adopted i Lead-out and lead-in wires of (2), five secondary coils Y2 i The outgoing line and the incoming line are respectively led out from the wire passing hole K of the upper magnetic cover and the wire passing hole K of the lower magnetic cover, and high insulation strength can be realized.
3. The high-power high-frequency five-phase magnetic integrated transformer provided by the invention passes through five single-phase transformers G i In the wrong orderThe arrangement ensures that the magnetic flux in the upper magnetic cover S and the lower magnetic cover X is mainly concentrated on the edge part, thereby ensuring that the magnetic flux is not gathered near the wire passing hole K and is further supersaturated.
4. The high-power high-frequency five-phase magnetic integrated transformer provided by the invention is characterized in that five primary coils Y1 are adopted i The lead-out line of (2) and five secondary coils Y2 i The star-shaped connection of the lead-in wire, the upper magnetic cover S and the five magnetic core columns Z i Laying thin plates of non-magnetic material with the same thickness in opposite spaces ensures that five single-phase transformers G i Can work independently and normally without generating large interphase influence.
5. According to the high-power high-frequency five-phase magnetic integrated transformer, the sizes of the main insulation structure J1 and the air gap layer Q are adjusted according to the optimal matching of leakage inductance and excitation inductance, the large-range leakage inductance and excitation inductance adjusting range is provided, external inductance is not needed for an applied five-phase DC/DC converter, the zero-voltage soft switch can be guaranteed to be turned on, and the efficiency is improved.
Drawings
FIG. 1 is a schematic perspective view of a high-power high-frequency five-phase magnetic integrated transformer according to an embodiment of the present invention;
FIG. 2 is a schematic diagram of the position of five single-phase transformers in the embodiment of the present invention;
FIG. 3 is a front view of a high-power high-frequency five-phase magnetic integrated transformer according to an embodiment of the present invention;
FIG. 4 is a schematic cross-sectional view of a multi-strand wire used in an embodiment of the present invention with five primary coils and five secondary coils;
FIG. 5 is a schematic diagram of input excitation of five primary coils in an embodiment of the present invention;
FIG. 6 is a current simulation waveform of five primary windings in a high-power high-frequency five-phase magnetic integrated transformer obtained by magnetic-electric joint simulation in the embodiment of the invention;
fig. 7 is a simulation diagram of the magnetic flux distribution of the upper top cover at the moment when the excitation current in the primary coil of the a-phase in the high-power high-frequency five-phase magnetic integrated transformer reaches the maximum value, which is obtained by magnetoelectric joint simulation in the embodiment of the invention.
Detailed Description
The technical scheme of the invention is clearly and completely described below with reference to the accompanying drawings.
Fig. 1 is a schematic perspective view of a high-power high-frequency five-phase magnetic integrated transformer in the present embodiment, fig. 2 is a schematic diagram of a staggered arrangement position of five single-phase transformers in the present embodiment, and fig. 3 is a front view of the high-power high-frequency five-phase magnetic integrated transformer in the present embodiment. As can be seen from fig. 1 to 3, the high-power high-frequency five-phase magnetic integrated transformer in the present embodiment includes five identical single-phase transformers, an upper magnetic cover S, a lower magnetic cover X and an insulating structure; the insulation structure comprises a main insulation structure J1 and a secondary insulation structure J2, and the center positions of the upper magnetic cover S and the lower magnetic cover X are both provided with the same wire passing hole K.
Any one of the five single-phase transformers is marked as i-phase transformer G i I represents phases i ═ a, B, C, D, E; the i-phase transformer G i From the inside to the outside by a core column Z i A primary coil Y1 i And a secondary coil Y2 i Formed of a primary coil Y1 i Secondary coil Y2 i Shape of (2) and core leg Z i The three are the same and concentric; at core column Z i And a primary coil Y1 i A secondary insulation structure J2 is filled between the primary coil Y1 i And a secondary coil Y2 i The main insulating structure J1 is filled between the two.
Five single-phase transformers set up between upper magnetic cover S and lower magnetic cover X, and all keep certain space with upper magnetic cover S and lower magnetic cover X. The upper magnetic cover S and the lower magnetic cover X are concentrically arranged with the two wire passing holes K, a regular pentagon is drawn by taking the wire passing holes K as centers, the five single-phase transformers are arranged at five vertexes of the regular pentagon in a staggered mode, and specifically, the A-phase transformer G is arranged from the A-phase transformer G A Starting from the following and rotating clockwise, the method respectively comprises the following steps: phase-A transformer G A C phase transformer G C E phase transformer G E B-phase transformer G B And D phase transformer G D . At five core legs Z i A non-magnetic material with the same thickness is laid in a space opposite to the upper magnetic cover S, and the non-magnetic material forms an air gap layer Q; i-phase transformer G i Five secondary coils Y2 i And secondary insulation structures J2 are filled in the spaces between the upper magnetic cover S and the lower magnetic cover X.
As can be seen from fig. 2, in the present embodiment, the cross sections of the upper magnetic cover S and the lower magnetic cover X are both rounded regular pentagons, and the same position thereof has the wire through hole K with the same shape and size. Due to five magnetic core columns Z i The magnetic flux is mainly concentrated at the edge parts of the upper top cover S and the lower top cover X, namely the magnetic flux around the two wire passing holes K is very small, and the magnetic flux of the upper magnetic cover S and the magnetic flux of the lower magnetic cover X are not gathered and then supersaturated. The upper magnetic cover S and the lower magnetic cover X are respectively arranged on five magnetic core columns Z i Above and below, and at the upper magnetic lid S and five core legs Z i The non-magnetic material with the same thickness is filled in the joint to form an air gap layer Q for adjusting the excitation inductance, and the tolerance temperature of the non-magnetic material is required to be higher than the maximum working temperature of the transformer and is not easy to deform. The non-magnetic conductive material can be epoxy resin sheet, acrylic sheet, etc. During specific manufacturing, the non-magnetic-conductive material is adhered to the upper parts of the five magnetic core columns by AB glue, and is fixed by a clamp from the upper part of the upper magnetic cover S and the lower part of the lower magnetic cover X.
In this embodiment, the core leg Z i The upper magnetic cover S and the lower magnetic cover X are made of the same magnetic conductivity material, and the working frequency f of the magnetic conductivity material is more than or equal to 20 kHz. Specifically, five core legs Z i The upper magnetic cover S and the lower magnetic cover X are made of ferrite materials with initial magnetic conductivity larger than 2500, and the working frequency of the ferrite materials is larger than 20 kHz.
In the present embodiment, the primary coil Y1 i And a secondary coil Y2 i The electromagnetic signal collector is formed by winding a plurality of stranded wires, wherein the wire diameter of a single-turn lead in the stranded wires is smaller than the skin depth of an electromagnetic signal under the working frequency. Fig. 4 shows a state of a section of a stranded wire. During specific manufacture, the wire diameter of the single-turn wire is selected to be 0.15mm according to the working frequency, and the number of the single-turn wires in the stranded wire is selected to be 4A/mm 2 -6A/mm 2 The current density of the current sensor is flexibly selected.
In the present embodiment, the primary coil Y1 A 、Y1 B 、Y1 C 、Y1 D 、Y1 E Are sequentially 72 deg. out of phase with each other. The specific state can be seen in fig. 5.
In the present embodiment, the five primary coils Y1 i The leading-in wire and the leading-out wire are wound by using an insulating tape, then penetrate out of the wire passing hole K of the upper magnetic cover, and are connected in a star shape. The five secondary coils Y2 i The leading-in wires and the leading-out wires are wound by using an insulating tape, then penetrate out of the wire passing hole K of the lower magnetic cover, and are connected in a star shape.
In the implementation of the invention, the interiors of the main insulating structure J1 and the secondary insulating structure J2 are both filled with insulating materials, and the withstand temperature of the main insulating structure J1 and the secondary insulating structure J2 is greater than the maximum working temperature of the transformer. The thickness of the main insulation structure J1 is 15mm-20mm, and the thickness of the secondary insulation structure J2 is 5mm-15 mm.
Specifically, the main insulating structure J1 and the secondary insulating structure J2 are made of epoxy resin, electric ceramics, phenolic resin and the like. The main insulating structure J1 is used for bearing five primary coils Y1 i And five secondary coils Y2 i The thickness of the high isolation voltage is set to be 15mm-20mm, so that the high isolation voltage of more than 10kV can be realized by combining the insulating material. The secondary insulation structure J2 mainly bears five magnetic core columns Z i An upper magnetic cover S, a lower magnetic cover X and five primary coils Y1 i Five secondary coils Y2 i The thickness thereof is set to 5mm to 15 mm. In addition, since leakage magnetic flux mainly flows through the main insulation structure J1, the transformer provided by the invention can adjust the size of leakage inductance by using the parameters of a magnetic core and a coil, and has the possibility of adjusting the inductance by using the size of the main insulation structure J1, thereby effectively increasing the adjustment range of the inductance.
The sizes of the specific insulation structure and the air gap Q are adjusted according to the insulation requirement, the optimal matching of leakage inductance and excitation inductance, so that the applied five-phase LLC resonant converter does not need external inductance any more, and zero-voltage soft switching conduction of a switching device in the five-phase LLC resonant converter can be realized.
In order to verify the technical effect of the invention, the invention is subjected to magnetoelectric combined simulation to verify the effectiveness of the transformer, and the simulation result is shown in fig. 6 and 7.
Fig. 6 is a current simulation waveform of five primary windings in a high-power high-frequency five-phase magnetic integrated transformer obtained by magnetoelectric joint simulation in the embodiment of the invention. As shown in fig. 6, flows through five primary coils Y1 i The five integrated single-phase transformers G have the advantages of basically consistent current magnitude and stable phase, and indicate that the transformers work normally i Can work independently and normally without mutual influence.
Fig. 7 is a magnetic flux distribution simulation diagram of the upper top cover S at the time when the excitation current in the a-phase primary coil reaches the maximum in the high-power high-frequency five-phase magnetic integrated transformer, which is obtained by magnetoelectric joint simulation in this embodiment. As shown in fig. 7, the magnetic flux is mainly concentrated at the edge portion of the upper cover S, and the magnetic flux is extremely small near the wire passing hole K of the upper cover, so that the magnetic flux is not saturated.
The five-phase LLC resonant converter can solve the problem that the traditional high-power high-frequency transformer cannot give consideration to high insulation level, high power density, high heat conduction area and high working reliability at the same time. The five-phase LLC resonant converter does not need to be externally connected with an inductor and can keep the full-load soft switching characteristic by optimally matching the air gap height and the size of the insulating structure according to the leakage inductance and the excitation inductance, and the five-phase LLC resonant converter has the advantages of small current stress and small size of a filter compared with a traditional DC/DC converter with the same level of power capacity, so that the high heat dissipation capacity and the working reliability of the high-power high-frequency five-phase magnetic integrated transformer are further ensured.
Claims (5)
1. A high-power high-frequency five-phase magnetic integrated transformer is characterized by comprising five same single-phase transformers, an upper magnetic cover S, a lower magnetic cover X and an insulating structure; the insulation structure comprises a main insulation structure J1 and a secondary insulation structure J2, and the center positions of the upper magnetic cover S and the lower magnetic cover X are both provided with the same wire passing hole K;
any one of the five single-phase transformers is marked as i-phase transformer G i I represents a phase, i = a, B, C, D, E; the i-phase transformer G i From the inside to the outside by a core column Z i A primary coil Y1 i And a secondary coil Y2 i Formed of a primary coil Y1 i Secondary coil Y2 i Shape of (2) and core leg Z i The three are the same and concentric; at core column Z i And a primary coil Y1 i A secondary insulation structure J2 is filled between the primary coil Y1 i And a secondary coil Y2 i The main insulating structure J1 is filled between the two layers;
the five single-phase transformers are arranged between the upper magnetic cover S and the lower magnetic cover X, and a certain space is reserved between the five single-phase transformers and the upper magnetic cover S as well as the space between the five single-phase transformers and the lower magnetic cover X; the upper magnetic cover S and the lower magnetic cover X are concentrically arranged with the two wire passing holes K, a regular pentagon is drawn by taking the wire passing holes K as centers, the five single-phase transformers are arranged at five vertexes of the regular pentagon in a staggered mode, and specifically, the A-phase transformer G is arranged from the A-phase transformer G A Starting from the following and rotating clockwise, the method respectively comprises the following steps: phase-A transformer G A C phase transformer G C E phase transformer G E B-phase transformer G B And D phase transformer G D (ii) a At five core legs Z i A non-magnetic material with the same thickness is laid in a space opposite to the upper magnetic cover S, and the non-magnetic material forms an air gap layer Q; i-phase transformer G i Five secondary coils Y2 i Secondary insulation structures J2 are filled in the spaces between the upper magnetic cover S and the lower magnetic cover X;
the primary coil Y1 A 、Y1 B 、Y1 C 、Y1 D 、Y1 E The input excitation phases of (a) and (b) are sequentially different by 72 degrees;
the five primary coils Y1 i The leading-in wire and the leading-out wire are wound by using an insulating tape, then penetrate out of the wire passing hole K of the upper magnetic cover, and are connected in a star shape; the five secondary coils Y2 i The leading-in wires and the leading-out wires are wound by using an insulating tape, then penetrate out of the wire passing holes K of the lower magnetic cover, and are connected in a star shape.
2. The high-power high-frequency five-phase magnetic integrated transformer according to claim 1, wherein the core leg Z is i Upper magnetic cover S and lower magnetic cover X are all usedThe material is made of the same high-permeability material, the high-permeability material is a material with the initial permeability of more than 2500, and the working frequency f of the high-permeability material is more than or equal to 20 kHz.
3. The high-power high-frequency five-phase magnetic integrated transformer according to claim 1, wherein the primary coil Y1 i And a secondary coil Y2 i The electromagnetic signal collector is formed by winding a plurality of stranded wires, wherein the wire diameter of a single-turn lead in the stranded wires is smaller than the skin depth of an electromagnetic signal under the working frequency.
4. The high-power high-frequency five-phase magnetic integrated transformer according to claim 1, characterized in that the interiors of the main insulation structure J1 and the secondary insulation structure J2 are filled with insulation materials, and the withstand temperature of the main insulation structure J1 and the secondary insulation structure J2 is higher than the maximum working temperature of the transformer.
5. The high-power high-frequency five-phase magnetic integrated transformer according to claim 1, wherein the thickness of the main insulation structure J1 is 15mm-20mm, and the thickness of the secondary insulation structure J2 is 5mm-15 mm.
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