EP2294591A1 - Water-cooled reactor - Google Patents

Water-cooled reactor

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Publication number
EP2294591A1
EP2294591A1 EP09753402A EP09753402A EP2294591A1 EP 2294591 A1 EP2294591 A1 EP 2294591A1 EP 09753402 A EP09753402 A EP 09753402A EP 09753402 A EP09753402 A EP 09753402A EP 2294591 A1 EP2294591 A1 EP 2294591A1
Authority
EP
European Patent Office
Prior art keywords
component according
disc
coils
flat
cooler
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP09753402A
Other languages
German (de)
French (fr)
Other versions
EP2294591B1 (en
Inventor
Alexander Stoev
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Woodward Switzerland GmbH
Original Assignee
IDS HOLDING AG
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Filing date
Publication date
Application filed by IDS HOLDING AG filed Critical IDS HOLDING AG
Publication of EP2294591A1 publication Critical patent/EP2294591A1/en
Application granted granted Critical
Publication of EP2294591B1 publication Critical patent/EP2294591B1/en
Active legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • 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
    • H01F27/10—Liquid cooling
    • H01F27/16—Water cooling
    • 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
    • H01F27/2871—Pancake coils
    • 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
    • H01F27/2876—Cooling

Definitions

  • the invention relates to an electromagnetic component (throttle, transformer) according to claim 1, uses thereof according to claims 16 and 17 and a method according to claim 18.
  • throttles In rectifier-fed plants, throttles often have to be used for smoothing and filtering purposes which produce high losses, are difficult to cool and have comparatively high weights and volumes. This is particularly unpleasant when such components are to be installed in cabinets.
  • inductive power components In the lower industrial power range up to about 1MW plant power, inductive power components often become natural, for reasons of economy, i. cooled with ambient air, usually with forced air circulation. In this case, air is e.g. pressed by special recessed in the winding air channels. These measures increase the throttle weight and volume, and unfavorably also the copper demand. A good specific cooling effect can also be achieved only by increasing the winding temperature, which is very disturbing for the installation environment.
  • Inductive components for medium frequency operation eg transformers for inductive heating systems, which work in the kHz range, generate high losses, which are dissipate practically only by means of water cooling.
  • a cooling liquid Since this cooling liquid has the electrical potential of the surrounding conductor, it must be insulating, for example, when using water, the water must be deionized. Construction and cooling are costly in direct conductor cooling and therefore in conventional industrial plants hardly used.
  • a medium and high frequency transformer which has split or undivided disc windings, wherein alternating primary and secondary disc coils are stacked.
  • the disc windings are only partially cooled directly with water, oil or a gaseous coolant, while the heat loss in the remaining parts is dissipated by heat conduction to the directly cooled parts.
  • the secondary winding has a cooling channel in which the coolant flows.
  • a disadvantage of this arrangement is that the coolant is in direct contact with the Cu winding, which is undesirable and should be avoided.
  • the object of the invention is to propose a design or technology for magnetic components and their cooling, with the following results:
  • Another object of the invention is to provide a method for producing the component.
  • Fig. 1 principle of a simple, single-phase choke
  • FIG. 1A side view of Fig. 1st
  • FIG. 1 B top view of FIG. 1
  • Fig. 2 water-cooled three-phase running filter choke for a power converter plant
  • FIG. 2A side view of FIG. 2.
  • FIG. 2B is a plan view of FIG. 2.
  • FIG. 4 winding package with 8 disk coils FIG. 4A side view of FIG. 4
  • FIG. 5 shows a side view of a component according to the invention with water-cooled iron core.
  • the invention relates to a design, or a technology for electromagnetic components (chokes, transformers), which consist of one or more disc-shaped coils with directly adjacent, electrically insulated, plate-shaped cooling elements, which are flowed through by a cooling medium.
  • electromagnetic components chokes, transformers
  • Fig. 1 shows the principle of a simple, single-phase choke.
  • a throttle 10 consists of a core sheet package 1 with two legs 2, 2 'and 2 yokes 3, 3'.
  • the thighs wear e.g. each 2 coils 4, 4 ', which are formed as single-layer disc coils, directly in between is a specially designed, double-acting flat cooler 5.
  • the Einlagnier the disc coil causes each turn of the winding is directly connected to a cooling surface.
  • a double-sided cooler can thus always cool 2 disc coils per leg, which has proven to be particularly advantageous.
  • FIGS. 1A and 1B show the side view and the plan view of FIG. 1.
  • the yokes 3, 3 ', the coils 4, 4', the flat cooler 5 and the leg 2 in FIG. 1B can be seen.
  • the flat cooler 5 must be made insulating.
  • a cooler in VoII plastic technology can be used, wherein the cooling medium or the cooling liquid is completely surrounded by plastic and the adjacent windings are electrically isolated.
  • a metal cooler which is provided with an insulating layer.
  • the flat cooler 5 may be formed as a multilayer metal construction with internal cooling structure and external plastic insulation, said plastic layer completely enclosing the radiator.
  • metals aluminum and steel as well as their alloys are particularly well suited. It has surprisingly been found that the use of stainless, Non-magnetic steel is particularly advantageous, since thereby the harmful and undesirable eddy current losses are reduced compared to aluminum by a factor greater than 4.
  • a thermally conductive plastic film of low hardness and yielding properties of a few tenths mm thickness is used.
  • the heat contact surfaces must be contacted plane-parallel and with sufficient pressure.
  • the electrical conductor and cooler insulations involved must have the highest possible thermal conductivity with simultaneous dielectric strength. These requirements can only be met by careful selection of modern materials, such as by ceramic-filled polymers or plastics in general.
  • the construction of flat coolers and disk coils generally has air gaps, in which there are specially designed air-gap inserts.
  • the coil can also be glued to the radiator surface elastic and heat-conducting.
  • the number of flat cooler units in a component must be kept as low as possible for reasons of expense.
  • this is achieved in that a horizontally continuous flat cooler cools the coils of both legs.
  • a cooler cools a total of 4 coils, in a 3-phase arrangement with 3 legs even coils. This saves external connections and thus additional connection material for the cooling medium, since these connections are located inside the flat cooler.
  • Fig. 2 shows a water-cooled filter throttle for a power converter plant.
  • a 3-phase running, water-cooled filter choke for a converter plant in the power range 2 MW an embodiment of the inventive throttle with a total of 24 coil sections is described, which are arranged on 8 levels.
  • the choke has an iron core with 3 wound legs 2, 2 ', 2 "Each leg has in this example 8 single-pancake coils 4, 4' (disks) .In each case 2 coil disks of each leg which sit on the same installation plane is a flat cooler 5.
  • Fig. 3 shows the geometry of the flat cooler.
  • the shape is S-shaped and thus has 3 recesses A, thus ensuring that the cooler does not work as a short-circuit winding due to the transformer coupling.
  • the series connections between the respective above and below the flat cooler 5 coil discs can run.
  • the flat coolers consist of several welded together aluminum or steel plates, which together have a thickness of less than 8 mm.
  • the middle, water-carrying plates in this layer structure are structured to increase the heat transfer surface by means of knobs.
  • the radiator plates are continuous, ie over the entire surface covered with an insulating layer of a few tenths of a mm.
  • the insulating material used has a high insulation strength with sufficient thermal conductivity and mechanical pressure resistance.
  • To equalize the contact pressure of the coils on the cooling surfaces latter with a special, relative soft, heat-conducting plastic film occupied, which also has a thickness of a few tenths of mm.
  • 3A and 3B show the side view and the plan view to Fig. 3. Visible are the inlet and outlet nozzles 9, 9 'of the cooling medium of the flat cooler 5 and the recesses A.
  • the mentioned 8 coils of a leg can be wound as single coils and then have to be switched individually - in the example in series -. With the choke executed these disturbing series connections were avoided by a special winding technique. In this case, stacked coils are partially wound in the opposite direction in the stack, whereby every second series connection is shifted into the coil interior. This makes it possible to place the series connections exactly in the above-mentioned recesses of the flat cooler.
  • a flat cooler 5 may carry a plurality of coils 4, 4 'of a winding arrangement, e.g. 2 coils each phase of a multi-phase arrangement, the flat cooler is designed by the shape and the choice of material so that it has the lowest possible eddy current losses.
  • suitable as a flat cooler insulation is a plastic with filling, for which a thermally conductive, insulating metal oxide such.
  • a thermally conductive, insulating metal oxide such as Aluminum oxide or a carbide between 20 - 50% is added to the plastic.
  • a thermally conductive plastic film with thicknesses of 0.1 - 0.4 mm can be used or a bond with a thermally conductive adhesive.
  • Fig. 4 shows the winding package 11 with 8 disc coils. 4A and 4B, the corresponding side view and top view.
  • the single disc coil 4 is shown with its outwardly leading terminal 12.
  • the inner terminal 13 leads to the next adjacent disc coil.
  • the disk coils 4, 4 1 of a phase or a build-up stack are wound so that external connections lying in the region of the flat cooler are avoided and that the internal series connections 13 fit into the recesses of the associated radiator plate provided for this purpose.
  • the executed throttle shows as a result of the cooling measures taken both a weight reduction, as well as a volume reduction by about a factor of 2.5 compared to a forced air-cooled throttle equal construction capacity and conventional design with tubular layer winding.
  • cooling arrangement according to the invention to other electromagnetic components, such as ironless chokes and transformers in general, and in particular to medium frequency transformers.
  • FIG. 5 shows the side view of a component according to the invention with water-cooled iron core.
  • two metal plates 14, 14 'preferably aluminum plates are attached, each end-welded tubes 16, preferably aluminum tubes has.
  • the cooling medium is now also passed, whereby the iron core is additionally cooled efficiently.
  • the cooling medium is first passed through the disc coils and then through the tubes 16.
  • a method for producing the component is characterized in that the flat cooler 5 is glued to the disk coil 4 in a thermally conductive manner. As a result, the flat cooler and the disc coil form a modular unit.
  • Uses find such components in water-cooled power converter systems and medium-frequency systems, in particular for inductive heating.

Landscapes

  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Coils Of Transformers For General Uses (AREA)
  • Transformer Cooling (AREA)

Abstract

A liquid-cooled electromagnetic component (reactor, transformer) is comprised of a plurality of disc-shaped coils (4, 4') with one or more turns and flat radiators (5) located between them, wherein at least two disc coils (4, 4') are assigned to a flat radiator (5), and in which all the winding elements (turns of the coil) are in direct thermal contact with the surfaces of the flat radiators (5). This component is used in power converter installations and in midfrequency installations.

Description

Wassergekühlte Drossel Water-cooled throttle
Die Erfindung betrifft eine elektromagnetische Komponente (Drossel, Transformator) gemäss Patentanspruch 1 , Verwendungen derselben gemäss den Patentansprüchen 16 und 17 sowie ein Verfahren gemäss Patentanspruch 18.The invention relates to an electromagnetic component (throttle, transformer) according to claim 1, uses thereof according to claims 16 and 17 and a method according to claim 18.
In stromrichtergespeisten Anlagen müssen für Glättungs- und Filterzwecke oft in erheblichem Umfang Drosseln eingesetzt werden, die hohe Verluste produzieren, schwierig zu kühlen sind und vergleichsweise hohe Gewichte und Volumina aufweisen. Dies ist besonders unangenehm, wenn solche Bauteile in Schränke eingebaut werden sollen.In rectifier-fed plants, throttles often have to be used for smoothing and filtering purposes which produce high losses, are difficult to cool and have comparatively high weights and volumes. This is particularly unpleasant when such components are to be installed in cabinets.
Im unteren industriellen Leistungsbereich bis etwa 1MW Anlagenleistung werden induktive Leistungskomponenten aus Aufwandgründen oft natürlich, d.h. mit Umgebungsluft gekühlt, darüber meist mit forcierter Luftumwälzung. Dabei wird Luft z.B. durch besondere in derWicklung ausgesparte Luftkanäle gedrückt. Durch diese Massnahmen steigt das Drosselgewicht und Volumen an, sowie ungünstigerweise auch der Kupferbedarf. Eine gute spezifische Kühlwirkung kann ausserdem nur durch Erhöhen der Wicklungstemperatur erreicht werden, was für die Einbauumgebung sehr störend ist.In the lower industrial power range up to about 1MW plant power, inductive power components often become natural, for reasons of economy, i. cooled with ambient air, usually with forced air circulation. In this case, air is e.g. pressed by special recessed in the winding air channels. These measures increase the throttle weight and volume, and unfavorably also the copper demand. A good specific cooling effect can also be achieved only by increasing the winding temperature, which is very disturbing for the installation environment.
Induktive Bauteile für Mittelfrequenzbetrieb, z.B. Transformatoren für induktive Erwärmungsanlagen, die im kHz-Bereich arbeiten, erzeugen hohe Verluste, die praktisch nur mittels Wasserkühlung abzuführen sind. Hier ist Stand der Technik, die Wicklung aus Rohren oder speziellen Hohlleitern zu bilden, wobei diese Rohre von einer Kühlflüssigkeit durchströmt werden. Da diese Kühlflüssigkeit das elektrische Potential des umgebenden Leiters aufweist, muss sie isolierend sein, z.B. bei Verwendung von Wasser muss das Wasser entionisiert werden. Aufbau und Kühlung sind bei direkter Leiterkühlung aufwendig und werden bei konventionellen Industrieanlagen deshalb kaum eingesetzt.Inductive components for medium frequency operation, eg transformers for inductive heating systems, which work in the kHz range, generate high losses, which are dissipate practically only by means of water cooling. Here is state of the art to form the winding of tubes or special waveguides, these tubes are flowed through by a cooling liquid. Since this cooling liquid has the electrical potential of the surrounding conductor, it must be insulating, for example, when using water, the water must be deionized. Construction and cooling are costly in direct conductor cooling and therefore in conventional industrial plants hardly used.
Nach dem Patentdokument DE 1057219 ist ein Mittel- und Hochfrequenztransformator bekannt, der geteilte oder ungeteilte Scheibenwicklungen aufweist, wobei abwechselnd primäre und sekundäre Scheibenspulen übereinandergeschichtet vorliegen. Die Scheibenwicklungen sind nur teilweise direkt mit Wasser, Öl oder einem gasförmigen Kühlmittel gekühlt, während die Verlustwärme in den übrigen Teilen durch Wärmeleitung an die direkt gekühlten Teile abgeführt wird. Die Sekundärwicklung weist einen Kühlkanal auf, in dem das Kühlmittel fliesst. Ein Nachteil dieser Anordnung ist, dass das Kühlmittel in direktem Kontakt zur Cu-Wicklung ist, was unerwünscht ist und vermieden werden soll.According to the patent document DE 1057219 a medium and high frequency transformer is known, which has split or undivided disc windings, wherein alternating primary and secondary disc coils are stacked. The disc windings are only partially cooled directly with water, oil or a gaseous coolant, while the heat loss in the remaining parts is dissipated by heat conduction to the directly cooled parts. The secondary winding has a cooling channel in which the coolant flows. A disadvantage of this arrangement is that the coolant is in direct contact with the Cu winding, which is undesirable and should be avoided.
Aufgabe der Erfindung ist es, eine Bauform bzw. eine Technologie für magnetische Komponenten und deren Kühlung vorzuschlagen, mit der Folgendes erreicht wird:The object of the invention is to propose a design or technology for magnetic components and their cooling, with the following results:
- Erhebliche Reduktion von Gewicht und Volumen um mindestens einen Faktor zwei;- Substantial reduction in weight and volume by at least a factor of two;
- insbesondere eine Reduktion des spezifischen Kupferanteiles für die Wicklung;- In particular, a reduction of the specific copper content for the winding;
- freie Wahl des Kühlmittels insbesondere die Möglichkeit einer Brauchwasserkühlung;- Free choice of coolant, in particular the possibility of domestic water cooling;
- Betrieb der Wicklungen bei Oberflächentemperaturen bis 100 0C, wodurch sich die Komponente für einen Schrankeinbau eignet.- Operation of the windings at surface temperatures up to 100 0 C, making the component suitable for cabinet installation.
Eine weitere Aufgabe der Erfindung ist es, ein Verfahren zur Herstellung der Komponente anzugeben.Another object of the invention is to provide a method for producing the component.
Die Erfindung wird im Folgenden anhand der Figuren näher erläutert. Es zeigen:The invention will be explained in more detail below with reference to FIGS. Show it:
Fig. 1 Prinzip einer einfachen, einphasigen DrosselFig. 1 principle of a simple, single-phase choke
Fig. 1A Seitenansicht zu Fig. 1Fig. 1A side view of Fig. 1st
Fig. 1 B Draufsicht zu Fig. 1FIG. 1 B top view of FIG. 1
Fig. 2 wassergekühlte dreiphasig ausgeführte Filter-Drossel für eine StromrichteranlageFig. 2 water-cooled three-phase running filter choke for a power converter plant
Fig. 2A Seitenansicht zu Fig. 2FIG. 2A side view of FIG. 2. FIG
Fig. 2B Draufsicht zu Fig. 2FIG. 2B is a plan view of FIG. 2. FIG
Fig. 3 Geometrie des FlachkühlersFig. 3 geometry of the flat cooler
Fig. 3A Seitenansicht zu Fig. 3 Fig. 3B Draufsicht zu Fig. 3 Fig. 4 Windungpaket mit 8 Scheibenspulen Fig. 4A Seitenansicht zu Fig. 4 Fig. 4B Draufsicht zu Fig. 4Fig. 3A side view of Fig. 3rd FIG. 3B top view of FIG. 3 FIG. 4 winding package with 8 disk coils FIG. 4A side view of FIG. 4 FIG. 4B top view of FIG. 4
Fig.5 Seitenansicht einer erfindungsgemässen Komponente mit wassergekühltem Eisenkern.5 shows a side view of a component according to the invention with water-cooled iron core.
Die Erfindung betrifft eine Bauform, bzw. eine Technologie für elektromagnetische Bauteile (Drosseln, Transformatoren), die aus einer oder mehreren scheibenförmigen Spulen bestehen mit unmittelbar anliegenden, elektrisch isolierten, plattenförmigen Kühlelementen, die von einem Kühlmedium durchströmt werden.The invention relates to a design, or a technology for electromagnetic components (chokes, transformers), which consist of one or more disc-shaped coils with directly adjacent, electrically insulated, plate-shaped cooling elements, which are flowed through by a cooling medium.
Fig. 1 zeigt das Prinzip einer einfachen, einphasigen Drossel. Eine solche Drossel 10 besteht aus einem Kernblech-Paket 1 mit zwei Schenkeln 2, 2' und 2 Jochen 3, 3'. Die Schenkel tragen z.B. je 2 Spulen 4, 4', die als einlagige Scheibenspulen ausgebildet sind, dazwischen direkt anliegend liegt ein speziell ausgebildeter, beidseitig wirkender Flachkühler 5. Die Einlagigkeit der Scheibenspule bewirkt, dass jede einzelne Windung der Wicklung direkt mit einer Kühlfläche in Verbindung steht. Ein doppelseitiger Kühler kann pro Schenkel somit stets 2 Scheibenspulen kühlen, was sich besonders vorteilhaft erwiesen hat.Fig. 1 shows the principle of a simple, single-phase choke. Such a throttle 10 consists of a core sheet package 1 with two legs 2, 2 'and 2 yokes 3, 3'. The thighs wear e.g. each 2 coils 4, 4 ', which are formed as single-layer disc coils, directly in between is a specially designed, double-acting flat cooler 5. The Einlagigkeit the disc coil causes each turn of the winding is directly connected to a cooling surface. A double-sided cooler can thus always cool 2 disc coils per leg, which has proven to be particularly advantageous.
Fig. 1A und 1 B zeigen die Seitenansicht und die Draufsicht zu Fig. 1. Erkennbar sind die Joche 3, 3', die Spulen 4, 4', der Flachkühler 5, sowie der Schenkel 2 in Fig. 1 B.FIGS. 1A and 1B show the side view and the plan view of FIG. 1. The yokes 3, 3 ', the coils 4, 4', the flat cooler 5 and the leg 2 in FIG. 1B can be seen.
Der Flachkühler 5 muss isolierend ausgeführt sein. Dafür kann ein Kühler in VoII- Kunststofftechnik verwendet werden, wobei das Kühlmedium bzw. die Kühlflüssigkeit vollkommen von Kunststoff umgeben ist und die anliegenden Windungen elektrisch isoliert werden. Möglich ist auch die Verwendung eines Metallkühlers, der mit einer Isolierschicht versehen ist. Der Flachkühler 5 kann als mehrschichtige Metall- Konstruktion mit innenliegender Kühlstruktur und aussenliegender Kunststoffisolation ausgebildet sein, wobei diese Kunststoffschicht den Kühler vollständig umschliesst. Als Metalle eignen sich Aluminium und Stahl sowie deren Legierungen besonders gut. Es hat sich überraschernder Weise gezeigt, dass die Verwendung von rostfreiem, nichtmagnetischem Stahl besonders vorteilhaft ist, da dadurch die schädlichen und unerwünschten Wirbelstromverluste im Vergleich zu Aluminium um einen Faktor grösser als 4 herabgesetzt werden.The flat cooler 5 must be made insulating. For this, a cooler in VoII plastic technology can be used, wherein the cooling medium or the cooling liquid is completely surrounded by plastic and the adjacent windings are electrically isolated. It is also possible to use a metal cooler, which is provided with an insulating layer. The flat cooler 5 may be formed as a multilayer metal construction with internal cooling structure and external plastic insulation, said plastic layer completely enclosing the radiator. As metals aluminum and steel as well as their alloys are particularly well suited. It has surprisingly been found that the use of stainless, Non-magnetic steel is particularly advantageous, since thereby the harmful and undesirable eddy current losses are reduced compared to aluminum by a factor greater than 4.
Zur Verbesserung des Wärmeüberganges zwischen Spulenscheibe (Scheibenspule) und angrenzender Oberfläche des Flachkühlers wird eine thermisch leitende Kunststofffolie geringer Härte und nachgiebigen bzw. nachgebenden Eigenschaften von einigen Zehntel mm Dicke eingesetzt. Damit der Wärmetransport maximiert werden kann, müssen die Wärmekontaktflächen planparallel und mit genügend Druck kontaktiert werden. Die beteiligten elektrischen Leiter- und Kühlerisolationen müssen eine möglichst hohe Wärmeleitfähigkeit bei gleichzeitiger Spannungsfestigkeit aufweisen. Diese Anforderungen können nurdurch sorgfältige Auswahl moderner Werkstoffe erfüllt werden, wie z.B. durch keramikgefüllte Polymere bzw. Kunststoffe allgemein. Der Aufbau von Flachkühlem und Scheibenspulen weist in der Regel Luftspälte auf, in denen sich speziell ausgebildete Luftspalteinlagen befinden.To improve the heat transfer between the coil disc (disk coil) and the adjacent surface of the flat cooler, a thermally conductive plastic film of low hardness and yielding properties of a few tenths mm thickness is used. In order to maximize the heat transfer, the heat contact surfaces must be contacted plane-parallel and with sufficient pressure. The electrical conductor and cooler insulations involved must have the highest possible thermal conductivity with simultaneous dielectric strength. These requirements can only be met by careful selection of modern materials, such as by ceramic-filled polymers or plastics in general. The construction of flat coolers and disk coils generally has air gaps, in which there are specially designed air-gap inserts.
Die Spule kann auch mit der Kühleroberfläche elastisch und wärmeleitend verklebt werden.The coil can also be glued to the radiator surface elastic and heat-conducting.
Zur Verbesserung des Wärmetransportes von der Kühlflüssigkeit auf die Kühlfläche ist der Kühler inwendig zur Vergrösserung der Innenfläche strukturiert.To improve the heat transfer from the cooling liquid to the cooling surface of the cooler is internally structured to increase the inner surface.
Die Anzahl der Flachkühler-Einheiten in einem Bauteil muss aus Aufwandsgründen möglichst niedrig gehalten werden. Im Beispiel gemäss Fig. 1 wird das dadurch erreicht, dass ein waagerecht durchgehender Flachkühler die Spulen beider Schenkel kühlt. Somit kühlt ein Kühler insgesamt 4 Spulen, in einer 3-phasigen Anordnung mit 3 Schenkeln sogarß Spulen. Damit werden externe Verbindungen und damit zusätzliches Anschlussmaterial für das Kühlmedium eingespart, da sich diese Verbindungen innerhalb des Flachkühlers befinden.The number of flat cooler units in a component must be kept as low as possible for reasons of expense. In the example according to FIG. 1, this is achieved in that a horizontally continuous flat cooler cools the coils of both legs. Thus, a cooler cools a total of 4 coils, in a 3-phase arrangement with 3 legs even coils. This saves external connections and thus additional connection material for the cooling medium, since these connections are located inside the flat cooler.
Ausführungsbeispiel:Embodiment:
Fig. 2 zeigt eine wassergekühlte Filter-Drossel für eine Stromrichteranlage. Anhand einer 3-phasig ausgeführten, wassergekühlten Filter-Drossel für eine Stromrichteranlage im Leistungsbereich 2 MW wird eine Ausführung der erfindungsgemässen Drossel mit insgesamt 24 Teilspulen beschrieben, die auf 8 Ebenen angeordnet sind. Die Drossel besitzt einen Eisenkern mit 3 bewickelten Schenkeln 2, 2', 2". Jeder Schenkel besitzt in diesem Beispiel 8 einlagige Flachspulen 4, 4' (Scheiben). Zwischen jeweils 2 Spulenscheiben jedes Schenkels, die auf gleicher Einbauebene sitzen, ist ein Flachkühler 5 vorgesehen. Dieser Flachkühler ist somit 3-teiIig und kühlt insgesamt 8 Spulen. Gesamthaft werden in dieser Anordnung 4 Flachkühler benötigt, wobei erfin- dungsgemäss jede einzelne Windung der gesamten Wicklung der Drossel mit einer Kühlerfläche in direktem Kontakt steht und so optimal gekühlt werden kann. Der gesamte Stapelaufbau wird über eine Pressvorrichtung 6 zusammengehalten, die den Anpressdruck zwischen Spulenscheiben und den Oberflächen der Flachkühler aufrecht erhält.Fig. 2 shows a water-cooled filter throttle for a power converter plant. Based on a 3-phase running, water-cooled filter choke for a converter plant in the power range 2 MW, an embodiment of the inventive throttle with a total of 24 coil sections is described, which are arranged on 8 levels. The choke has an iron core with 3 wound legs 2, 2 ', 2 "Each leg has in this example 8 single-pancake coils 4, 4' (disks) .In each case 2 coil disks of each leg which sit on the same installation plane is a flat cooler 5. In this arrangement, four flat coolers are required in total, with each individual turn of the entire winding of the throttle being in direct contact with a cooler surface and thus optimally cooled The entire stack structure is held together by a pressing device 6 which maintains the contact pressure between the coil disks and the surfaces of the flat coolers.
In diesem Beispiel sind alle Spulenscheiben, die zu einem Schenkel gehören, elektrisch in Serie geschaltet und werden somit vom gleichen elektrischen Strom durchflössen. Alternativ sind die Spulenscheiben parallel geschaltet. Die Kühlflüssigkeit wird dagegen zur Verbesserung der Kühlwirkung und zur Kleinhaltung des Druckabfalles über einen Wasserverteiler parallel in alle 4 Flachkühler ein- und ausgeleitet. Fig.2A und 2B zeigen die Seitenansicht und die Draufsicht zu Fig. 2. Erkennbar sind die Einlauf- bzw. Auslaufstutzen 7, T des Kühlmediums sowie die elektrischen Anschlüssen 8, 8' für das erste Windungspaket der drei Phasen.In this example, all the coil disks that belong to a leg, electrically connected in series and are thus flowed through by the same electric current. Alternatively, the coil disks are connected in parallel. On the other hand, the cooling liquid is introduced and discharged in parallel into all four flat coolers via a water distributor in order to improve the cooling effect and keep the pressure drop small. 2A and 2B show the side view and the plan view to Fig. 2. Visible are the inlet and outlet nozzles 7, T of the cooling medium and the electrical terminals 8, 8 'for the first winding packet of the three phases.
Fig. 3 zeigt die Geometrie des Flachkühlers. Die Form ist S-förmig und besitzt damit 3 Aussparungen A, womit sichergestellt wird, dass der Kühler infolge der transformatorischen Kopplung nicht als Kurzschlusswindung arbeitet. In diesen Aussparungen können zudem die Serieverbindungen zwischen der jeweils über und der unter dem Flachkühler 5 liegenden Spulenscheiben verlaufen.Fig. 3 shows the geometry of the flat cooler. The shape is S-shaped and thus has 3 recesses A, thus ensuring that the cooler does not work as a short-circuit winding due to the transformer coupling. In addition, in these recesses, the series connections between the respective above and below the flat cooler 5 coil discs can run.
Die Flachkühler bestehen aus mehreren zusammengeschweissten Aluminium- oder Stahlplatten, die zusammen eine Dicke von weniger als 8 mm haben. Die mittleren, wasserführenden Platten in diesem Lagenaufbau sind zurVergrösserung der Wärmeübergangsfläche mittels Noppen strukturiert.The flat coolers consist of several welded together aluminum or steel plates, which together have a thickness of less than 8 mm. The middle, water-carrying plates in this layer structure are structured to increase the heat transfer surface by means of knobs.
Aus isolationstechnischen Gründen sind die Kühlerplatten durchgehend, d.h. gesamtflächig mit einer Isolierschicht von einigen Zehntel mm überzogen. Das verwendete Isoliermaterial hat eine hohe Isolationsfestigkeit bei ausreichender Wärmeleitfähigkeit und mechanischer Druckfestigkeit. Zur Vergleichmässigung des Auflagedruckes der Spulen auf die Kühlflächen sind letztere mit einer speziellen, relativ weichen, wärmeleitenden Kunststofffolie belegt, die ebenfalls eine Dicke von einigen Zehntel mm aufweist.For insulation reasons, the radiator plates are continuous, ie over the entire surface covered with an insulating layer of a few tenths of a mm. The insulating material used has a high insulation strength with sufficient thermal conductivity and mechanical pressure resistance. To equalize the contact pressure of the coils on the cooling surfaces latter with a special, relative soft, heat-conducting plastic film occupied, which also has a thickness of a few tenths of mm.
Fig. 3A und 3B zeigen die Seitenansicht und die Draufsicht zu Fig. 3. Erkennbar sind die Einlauf- bzw. Auslaufstutzen 9, 9' des Kühlmediums des Flachkühlers 5 sowie die Aussparungen A.3A and 3B show the side view and the plan view to Fig. 3. Visible are the inlet and outlet nozzles 9, 9 'of the cooling medium of the flat cooler 5 and the recesses A.
Die erwähnten 8 Spulen eines Schenkels können als Einzelspulen gewickelt werden und müssten dann alle einzeln - im Beispiel in Serie - geschaltet werden. Bei der ausgeführten Drossel wurden diese störenden Serieverbindungen durch eine spezielle Wickeltechnik vermieden. Dabei werden im Stapel übereinander liegende Spulen teilweise im Gegensinn gewickelt, wodurch jede zweite Serieverbindung ins Spuleninnere verlagert wird. Dadurch wird es möglich, die Serieverbindungen genau in die oben erwähnten Aussparungen des Flachkühlers zu legen.The mentioned 8 coils of a leg can be wound as single coils and then have to be switched individually - in the example in series -. With the choke executed these disturbing series connections were avoided by a special winding technique. In this case, stacked coils are partially wound in the opposite direction in the stack, whereby every second series connection is shifted into the coil interior. This makes it possible to place the series connections exactly in the above-mentioned recesses of the flat cooler.
Ein Flachkühler 5 kann mehrere Spulen 4, 4' einer Wicklungsanordnung tragen, z.B. jeweils 2 Spulen jeder Phase einer mehrphasigen Anordnung, wobei der Flachkühler durch die Formgebung und die Materialwahl so gestaltet ist, dass er möglichst geringe Wirbelstromverluste aufweist.A flat cooler 5 may carry a plurality of coils 4, 4 'of a winding arrangement, e.g. 2 coils each phase of a multi-phase arrangement, the flat cooler is designed by the shape and the choice of material so that it has the lowest possible eddy current losses.
Vorteilhafterweise eignet sich als Flachkühlerisolation ein Kunststoff mit Füllung, wofür ein wärmeleitendes, isolierendes Metalloxid wie z.B. Aluminiumoxid oder ein Karbid zwischen 20 - 50% dem Kunststoff beigefügt wird.Advantageously, suitable as a flat cooler insulation is a plastic with filling, for which a thermally conductive, insulating metal oxide such. Aluminum oxide or a carbide between 20 - 50% is added to the plastic.
Zur Verbesserung des Wärmeüberganges zwischen Spulenscheibe (Scheibenspule) und angrenzender Oberfläche des Flachkühlers kann eine thermisch leitende Kunststofffolie mit Dicken von 0,1 - 0,4 mm eingesetzt werden oder eine Verklebung mit einem wärmeleitenden Kleber.To improve the heat transfer between the coil disc (disc coil) and adjacent surface of the flat cooler, a thermally conductive plastic film with thicknesses of 0.1 - 0.4 mm can be used or a bond with a thermally conductive adhesive.
Fig. 4 zeigt das Windungpaket 11 mit 8 Scheibenspulen. Fig. 4A und 4B die entsprechenden Seitenansicht bzw. Draufsicht. In Fig. 4A ist die einzelne Scheibenspule 4 mit ihrem nach aussen führenden Anschluss 12 dargestellt. Der innen liegende Anschluss 13 führt zur nächsten benachbarten Scheibenspule. Die Scheibenspulen 4, 41 einer Phase bzw. eines Aufbaustapels werden so gewickelt, dass aussenliegende, im Bereich des Flachkühlers liegende Verbindungen vermieden werden und dass die innenliegenden Serieverbindungen 13 in die hierfür vorgesehenen Aussparungen der zugeordneten Kühlerplatte passen. Die ausgeführte Drossel zeigt infolge der getroffenen Kühlmassnahmen sowohl eine Gewichtsreduktion, als auch eine Volumenreduktion um etwa Faktor 2,5 gegenüber einer forciert luftgekühlten Drossel gleicher Bauleistung und konventioneller Bauart mit röhrenförmiger Lagenwicklung.Fig. 4 shows the winding package 11 with 8 disc coils. 4A and 4B, the corresponding side view and top view. In Fig. 4A, the single disc coil 4 is shown with its outwardly leading terminal 12. The inner terminal 13 leads to the next adjacent disc coil. The disk coils 4, 4 1 of a phase or a build-up stack are wound so that external connections lying in the region of the flat cooler are avoided and that the internal series connections 13 fit into the recesses of the associated radiator plate provided for this purpose. The executed throttle shows as a result of the cooling measures taken both a weight reduction, as well as a volume reduction by about a factor of 2.5 compared to a forced air-cooled throttle equal construction capacity and conventional design with tubular layer winding.
Es ist grundsätzlich möglich, die erfindungsgemässe Kühlanordnung auch bei anderen elektromagnetischen Komponenten anzuwenden, wie etwa bei eisenlosen Drosseln und Transformatoren im Allgemeinen und im Besonderen bei Mittelfrequenztransformatoren.It is basically possible to apply the cooling arrangement according to the invention to other electromagnetic components, such as ironless chokes and transformers in general, and in particular to medium frequency transformers.
Fig. 5 zeigt die Seitenansicht einer erfindungsgemässen Komponente mit wassergekühltem Eisenkern. Erkennbar sind wiederum das aus einem Eisenkern bestehende Joch 3, die Scheibenspulen 4, 4' und der Flachkühler 5. Auf beiden Seiten des Joches 3 sind zwei Metallplatten 14, 14' vorzugsweise Aluminiumplatten angebracht, die jede endseitig aufgeschweisste Rohre 16, vorzugsweise Aluminiumrohre aufweist. Durch die Rohre 16 wird nun ebenfalls das Kühlmedium geleitet, wodurch der Eisenkern zusätzlich effizient gekühlt wird. Sinnvollerweise, aber nicht zwingend, handelt es sich um das gleiche Kühlmedium wie für die Scheibenspulen. Vorteilhafterweise, aber nicht zwingend wird das Kühlmedium zuerst durch die Scheibenspulen geführt und danach noch durch die Rohre 16. Durch eine derartige Kombination der Kühlung des Kupfers und des Eisens mit einem einzigen Kühlmedium ergibt sich ein überaus effizienter Kühlkreislauf bzw. eine überaus effiziente Kühlung der Komponente.5 shows the side view of a component according to the invention with water-cooled iron core. On both sides of the yoke 3, two metal plates 14, 14 'preferably aluminum plates are attached, each end-welded tubes 16, preferably aluminum tubes has. Through the tubes 16, the cooling medium is now also passed, whereby the iron core is additionally cooled efficiently. Usefully, but not necessarily, it is the same cooling medium as for the disc coils. Advantageously, but not necessarily, the cooling medium is first passed through the disc coils and then through the tubes 16. Such a combination of cooling the copper and the iron with a single cooling medium results in a very efficient cooling circuit or an extremely efficient cooling of the component ,
Ein Verfahren zur Herstellung der Komponente zeichnet sich dadurch aus, dass der Flachkühler 5 mit der Scheibenspule 4 wärmeleitend verklebt wird. Dadurch bilden der Flachkühler und die Scheibenspule eine modulare Einheit.A method for producing the component is characterized in that the flat cooler 5 is glued to the disk coil 4 in a thermally conductive manner. As a result, the flat cooler and the disc coil form a modular unit.
Verwendungen finden derartige Komponenten in wassergekühlten Stromrichteranlagen und in Mittelfrequenzanlagen, insbesondere zur induktiven Erwärmung. Uses find such components in water-cooled power converter systems and medium-frequency systems, in particular for inductive heating.

Claims

Patentansprüche: P471-09.IDS/07.05.09 Claims: P471-09.IDS / 07.05.09
1. Flüssigkeitsgekühlte elektromagnetische Komponente (Drossel, Transformator) bestehend aus mehreren scheibenförmigen Spulen mit einer oder mehreren Windungen und dazwischen liegenden Flachkühlern, dadurch gekennzeichnet, dass mindestens 2 Scheibenspulen (4, 4') einem Flachkühler (5) zugeordnet sind, wobei jede Scheibenspule aus Wicklungselementen (Windungen der Spule) aufweist, von denen sich jede über eine wärmeleitende Isolierschicht in direktem thermischen Kontakt zu den Oberflächen der Flachkühler befindet und dass zur Kühlung ein Kühlmedium vorgesehen ist, das durch die Isolierschicht vom Kühlmedium potentialgetrennt ist.1. Liquid-cooled electromagnetic component (throttle, transformer) consisting of several disc-shaped coils with one or more windings and intervening flat coolers, characterized in that at least 2 disc coils (4, 4 ') are associated with a flat cooler (5), each disc coil Winding elements (turns of the coil), each of which is located over a thermally conductive insulating layer in direct thermal contact with the surfaces of the flat cooler and that a cooling medium is provided for cooling, which is electrically isolated by the insulating layer of the cooling medium.
2. Komponente nach Anspruch 1 , dadurch gekennzeichnet, dass als Flachkühler (5) eine Kunststoff-Anordnung gewählt wird derart, dass die flüssigkeitsführende Schicht vom Kunststoff vollständig umgeben vorliegt.2. Component according to claim 1, characterized in that as a flat cooler (5) a plastic arrangement is selected such that the liquid-conducting layer is completely surrounded by the plastic.
3. Komponente nach Anspruch 1 oder2, dadurch gekennzeichnet, dass als Flachkühler (5) eine mehrschichtige Metall-Konstruktion mit innenliegender Kühlstruktur und aussenliegender Kunststoffisolation verwendet wird, wobei diese Kunststoffschicht den Kühler vollständig umschliesst.3. Component according to claim 1 or 2, characterized in that as flat cooler (5) a multilayer metal construction with internal cooling structure and external plastic insulation is used, said plastic layer completely enclosing the radiator.
4. Komponente nach Anspruch 3, dadurch gekennzeichnet, dass die Metall- Konstruktion aus Aluminium, aus rostfreiem Stahl oder aus deren Legierungen besteht.4. Component according to claim 3, characterized in that the metal construction made of aluminum, stainless steel or their alloys.
5. Komponente nach Anspruch 3 oder 4, dadurch gekennzeichnet, dass die Metall- Konstruktion aus rostfreiem, nichtmagnetischem Stahl besteht.5. Component according to claim 3 or 4, characterized in that the metal construction consists of stainless, non-magnetic steel.
6. Komponente nach einem der Ansprüche 2 - 5, dadurch gekennzeichnet, dass bei einer Metall-Konstruktion aus rostfreiem, nichtmagnetischem Stahl die Wirbelstromverluste im Vergleich zu Aluminium mehr als um einen Faktor 4 kleiner sind.6. Component according to one of claims 2-5, characterized in that in a metal construction of stainless, non-magnetic steel, the eddy current losses are smaller than by a factor of 4 compared to aluminum.
7. Komponente nach einem der Ansprüche 1 - 6, dadurch gekennzeichnet, dass der Kunststoff eine Füllung enthält, die den thermischen Leitwert verbessert.7. Component according to one of claims 1-6, characterized in that the Plastic contains a filling, which improves the thermal conductance.
8. Komponente nach einem der Ansprüche 1 - 7, dadurch gekennzeichnet, dass zur Verbesserung des Wärmeüberganges zwischen Spulenscheibe (Scheibenspule) und angrenzender Oberfläche des Flachkühlers eine thermisch leitende Kunststofffolie geringer Härte und nachgiebigen bzw. nachgebenden Eigenschaften von einigen Zehntel mm Dicke eingesetzt wird.8. Component according to one of claims 1-7, characterized in that to improve the heat transfer between the coil disc (disc coil) and adjacent surface of the flat cooler, a thermally conductive plastic film low hardness and yielding or yielding properties of a few tenths mm thickness is used.
9. Komponente nach einem der Ansprüche 1 - 8, dadurch gekennzeichnet, dass die Scheibenspulen (4, 4') einer Wicklungsanordnung durch eine mechanische Pressanordnung (6) zu engem Kontakt mit den Oberflächen des Flachkühlers (5) gezwungen werden.9. Component according to one of claims 1-8, characterized in that the disc coils (4, 4 ') of a winding assembly by a mechanical pressing arrangement (6) to close contact with the surfaces of the flat cooler (5) are forced.
10. Komponente nach einem der Ansprüche 1 - 9, dadurch gekennzeichnet, dass die Scheibenspulen (4, 4') direkt mit der Kühleroberfläche wärmeleitend verklebt vorliegen.10. Component according to one of claims 1-9, characterized in that the disc coils (4, 4 ') are bonded directly to the radiator surface heat-conducting.
11. Komponente nach einem der Anspruch 1 - 10, dadurch gekennzeichnet, dass die Scheibenspulen (4, 4') einer Phase bzw. eines Aufbaustapels so gewickelt werden, dass aussenliegende, im Bereich des Flachkühlers liegende Verbindungen vermieden werden und die innenliegenden Serieverbindungen (13) in die hierfür vorgesehenen Aussparungen der zugeordneten Kühlerplatte passen.11. Component according to one of claims 1-10, characterized in that the disc coils (4, 4 ') of a phase or a buildup stack are wound in such a way that external connections lying in the region of the flat cooler are avoided and the internal series connections (13 ) fit into the recesses provided for the associated radiator plate.
12. Komponente nach einem der Anspruch 1 - 11 , dadurch gekennzeichnet, dass ein Flachkühler (5) mehrere Spulen (4, 41) einer Wicklungsanordnung trägt, vorzugsweise jeweils 2 Spulen jeder Phase einer mehrphasigen Anordnung, wobei der Flachkühler durch die Formgebung und die Materialwahl so gestaltet ist, dass er möglichst geringe Wirbelstromverluste aufweist.12. Component according to any one of claims 1-11, characterized in that a flat cooler (5) carries a plurality of coils (4, 4 1 ) of a winding arrangement, preferably in each case 2 coils of each phase of a multi-phase arrangement, wherein the flat cooler by the shaping and the Choice of material is designed so that it has the lowest possible eddy current losses.
13. Komponente nach einem der Anspruch 1 - 12, dadurch gekennzeichnet, dass das Joch (3) mit Metallplatten (14, 14'), vorzugsweise Aluminiumplatten umgeben ist, die endseitig aufgeschweisste Metallrohre (16), vorzugsweise Aluminiumrohre aufweist, und dass durch die Metallrohre das gleiche oder ein verschiedenes Kühlmedium geleitet wird, wodurch sich eine effiziente Kühlung von Kupfer und Eisen ergibt. 13. Component according to any one of claims 1-12, characterized in that the yoke (3) with metal plates (14, 14 '), preferably aluminum plates is surrounded, the end-welded metal tubes (16), preferably aluminum tubes, and that by the Metal tubes the same or a different cooling medium is passed, resulting in an efficient cooling of copper and iron.
14. Komponente nach Anspruch 13, dadurch gekennzeichnet, dass das Kühlmedium zuerst den Flachkühler (5) passiert und erst danach die Metallrohre (16).14. Component according to claim 13, characterized in that the cooling medium first passes through the flat cooler (5) and only then the metal tubes (16).
15. Komponente nach einem der Anspruch 1 - 14, dadurch gekennzeichnet, dass sowohl eine Gewichtsreduktion, als auch eine Volumenreduktion der Komponente um einen Faktor 2, vorzugsweise um einen Faktor 3 gegenüber einer forciert luftgekühlten Drossel in vergleichbarer Bauart und Anwendung erzielbar ist.15. Component according to one of claims 1-14, characterized in that both a weight reduction and a volume reduction of the component by a factor of 2, preferably by a factor of 3 over a forced air-cooled throttle in a comparable design and application can be achieved.
16. Verwendung der Komponente nach einem der Ansprüche 1 - 15 in wassergekühlten Stromrichteranlagen.16. Use of the component according to one of claims 1 - 15 in water-cooled converter systems.
17. Verwendung der Komponente nach einem der Ansprüche 1 - 15 in Mittelfrequenzanlagen insbesondere zur induktiven Erwärmung.17. Use of the component according to one of claims 1 - 15 in medium frequency systems, in particular for inductive heating.
18. Verfahren zur Herstellung der Komponente nach einem der Ansprüche 1 - 15, dadurch gekennzeichnet, dass der Flachkühler (5) mit der Scheibenspule (4) wärmeleitend verklebt wird und dass dadurch eine modulare Einheit gebildet wird. 18. A method for producing the component according to any one of claims 1-15, characterized in that the flat cooler (5) with the disc coil (4) is glued thermally conductive and that thereby a modular unit is formed.
EP09753402.8A 2008-05-27 2009-05-25 Water-cooled reactor Active EP2294591B1 (en)

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