WO2022007706A1

WO2022007706A1 - Winding assembly, on-board charger, and vehicle

Info

Publication number: WO2022007706A1
Application number: PCT/CN2021/104076
Authority: WO
Inventors: 龙保川; 吴斌; 梁树林; 王超
Original assignee: 比亚迪股份有限公司
Priority date: 2020-07-09
Filing date: 2021-07-01
Publication date: 2022-01-13
Also published as: CN113921242A

Abstract

A winding assembly, an on-board charger, and a vehicle. The winding assembly (100) has a plurality of pin terminals and a plurality of connection terminals. The winding assembly (100) comprises: a transformer winding (110) and a converter winding (150) integrated with the transformer winding (110). At least one pin terminal is directly or indirectly and electrically connected to the transformer winding (110). The converter winding (150) and the transformer winding (110) nested into each other. The connection terminals are provided on the converter winding (150).

Description

Winding assemblies, on-board chargers and vehicles

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the priority of the application date of July 09, 2020, the application number of 202010658616.3, and the title of the patent application "winding assembly, on-board charger and vehicle", the entire contents of which are incorporated into the present disclosure by reference.

technical field

The present disclosure relates to the technical field of vehicles, and in particular, to a winding assembly, an on-board charger and a vehicle.

Background technique

In the related art, a high-voltage loop of an on-board charger (OBC) includes a resonant inductor L1, a main transformer T1 and a resonant inductor L2. Among them, L1, T1 and L2 are mutually independent devices. This method: the volume of the entire power supply system increases, which cannot meet the trend of miniaturization, integration and high power density of vehicle electronics; and the materials of each device cannot be shared, and the pins need to be additionally connected. Processing costs are high.

SUMMARY OF THE INVENTION

The present disclosure aims to solve at least one of the technical problems existing in the prior art. To this end, the present disclosure proposes a winding assembly of an on-board charger, and the winding assembly of the on-board charger has the advantages of high integration and low cost.

The present disclosure also proposes an on-board charger having the above-mentioned winding assembly of the on-board charger.

The present disclosure further provides a vehicle having the above-mentioned on-board charger.

According to a winding assembly of an on-board charger according to an embodiment of the present disclosure, the winding assembly has a plurality of pin terminals and a plurality of connection terminals, and includes a transformer winding, at least one of the pin terminals is directly or indirectly electrically connected to the transformer winding connection; a converter winding integrated with the transformer winding, the converter winding and the transformer winding are arranged nested with each other, and the connection terminal is arranged on the converter winding.

According to the winding assembly of the on-board charger according to the embodiment of the present disclosure, by constructing the transformer winding and the converter winding into an independent component in an integrated form for the on-board charger, the number of parts of the on-board charger can be reduced. It is easy to realize the miniaturization and high power density design of the on-board charger, which can save the production cost.

In some embodiments, the converter windings are formed by stamping and bending of copper foil.

In some embodiments, the converter winding is wrapped around the outer circumference of the transformer winding.

In some embodiments, the transformer winding includes a primary winding, a secondary winding and a transformer winding bobbin, the secondary winding and the primary winding are nested, the transformer winding has winding slots, and the Both the secondary winding and the primary winding are arranged in the winding slot.

In some embodiments, the winding assembly further includes a first magnetic circuit part and a second magnetic circuit part, the first magnetic circuit part includes a support part and a connection part connected with the support part, the support part is located in the The lower part of the transformer winding is used to support the transformer winding. The support part and the connecting part form an L-shaped structure. The surface of the connecting part facing the transformer winding is provided with a first transformer magnetic core. The transformer magnetic core is inserted into the transformer winding, the structure of the second magnetic circuit component is the same as that of the first magnetic circuit component, the first magnetic circuit component is located at one end of the transformer winding, and the The second magnetic circuit element is located at the other end of the transformer, and the first magnetic circuit element is bonded to the second magnetic circuit element to form a ring magnetic circuit.

In some embodiments, an air gap is provided between the first magnetic circuit member and the second magnetic circuit member to adjust the inductance.

In some embodiments, the winding assembly further includes: a first inductor winding, a first inductor bobbin and a first inductor core, at least one of the pin terminals is directly electrically connected to the first inductor winding, and the transformer winding is electrically connected to the first inductor winding. The first inductance winding is connected in series and electrically, the first magnetic circuit component is located between the first inductance winding and the transformer winding, the first inductance winding is wound around the first inductance skeleton, so The first inductance magnetic core is connected to the first inductance skeleton, and a part of the structure of the first inductance magnetic core is penetrated in the first inductance winding.

In some embodiments, the outer peripheral wall of the first inductor skeleton has a winding slot, and the first inductor winding is wound in the winding slot.

In some embodiments, the first inductive winding is located at one end of the transformer winding, the winding assembly further includes: a second inductive winding, at least one of the pin terminals is directly electrically connected to the second inductive winding, The second inductance winding is located at the other end of the transformer winding, and the second inductance winding is connected in series with the transformer winding and is electrically connected.

In some embodiments, the winding assembly further includes: a second inductor bobbin, the second inductor winding is wound around the second inductor bobbin, the transformer winding bobbin is connected to the second inductor bobbin; a second inductor bobbin A magnetic core, the second inductive magnetic core is connected with the second inductive skeleton, and a part of the structure of the second inductive magnetic core is penetrated in the second inductive winding.

An on-board charger according to an embodiment of the present disclosure includes the above-described winding assembly of the on-board charger.

According to the on-board charger according to the embodiment of the present disclosure, by constructing the transformer winding and the converter winding into an independent component in an integrated form for the on-board charger, the number of parts of the on-board charger can be reduced, and it is easy to Enables miniaturized, high-power-density designs for on-board chargers, which can save production costs.

According to the vehicle according to the embodiment of the present disclosure, by integrating the transformer winding and the converter winding into an independent component for use by the on-board charger, the number of parts of the on-board charger can be reduced, and the on-board charger can be easily used. The charger enables a miniaturized, high-power-density design that saves production costs.

Description of drawings

The above and additional aspects and advantages of the present disclosure will become apparent and readily understood from the following description of embodiments taken in conjunction with the accompanying drawings, wherein:

FIG. 1 is a circuit schematic diagram of a winding assembly according to an embodiment of the present disclosure;

2 is an exploded view of a winding assembly according to an embodiment of the present disclosure;

3 is a perspective view of a winding assembly according to an embodiment of the present disclosure;

4 is a schematic circuit diagram of a winding assembly according to an embodiment of the present disclosure;

5 is a perspective view of a winding assembly according to an embodiment of the present disclosure;

6 is a schematic circuit diagram of a winding assembly according to an embodiment of the present disclosure;

7 is a perspective view of a winding assembly according to an embodiment of the present disclosure;

8 is a block diagram of an on-board charger according to an embodiment of the present disclosure;

9 is a block diagram of a vehicle according to an embodiment of the present disclosure.

Reference number:

winding assembly 100,

Pin terminal, first terminal 101, second terminal 102, third terminal 103, fourth terminal 104,

Connection terminals, fifth terminal 105, sixth terminal 106, seventh terminal 107,

Transformer winding 110, primary winding 111, secondary winding 112,

Transformer winding bobbin 120, winding slot 121,

The first magnetic circuit member 130, the supporting portion 131, the connecting portion 132, the first transformer magnetic core 133,

The second magnetic circuit member 140,

converter winding 150,

the first inductor winding 160,

The first inductor bobbin 170, the winding slot 171,

the first inductor core 180,

The second inductor winding 181,

The second inductor bobbin 182,

The second inductor core 183,

Vehicle charger 200, vehicle 1000.

detailed description

The embodiments of the present disclosure will be described in detail below. The embodiments described with reference to the accompanying drawings are exemplary, and the embodiments of the present disclosure will be described in detail below.

The winding assembly 100 , the on-board charger, and the vehicle according to the embodiments of the present disclosure will be described below with reference to FIGS. 1 to 7 .

As shown in FIGS. 1-3 , according to the winding assembly 100 of the vehicle charger according to the embodiment of the present disclosure, the winding assembly 100 has a plurality of pin terminals and a plurality of connection terminals. As shown in FIG. 1 , there may be four pin terminals, which are a first terminal 101 , a second terminal 102 , a third terminal 103 and a fourth terminal 104 , wherein the first terminal 101 and the second terminal 102 may be connected with One group of bridge circuits of the vehicle (Q7, Q8, Q9, and Q10 in FIG. 1 are electrical components of the bridge circuit) are electrically connected, and the third terminal 103 and the fourth terminal 104 can be connected to another group of bridge circuits of the vehicle. The circuits (Q11, Q12, Q13, and Q14 in FIG. 1 are electrical components of the bridge circuit) are electrically connected. As shown in FIG. 1 , there may be three connection terminals, which are the fifth terminal 105 , the sixth terminal 106 and the seventh terminal 107 respectively. As shown in FIG. 1 , the fifth terminal 105 , the sixth terminal 106 and the seventh terminal 107 can be electrically connected to a rectifier filter circuit (Q17 , Q18 , Q19 , and Q20 in FIG. 1 are electrical components of the rectifier filter circuit).

As shown in FIGS. 2 and 3 , the winding assembly 100 includes a transformer winding 110 and a converter winding 150 integrated with the transformer winding 110 . It can be understood that the transformer winding 110 and the converter winding 150 are integrated into an independent component for use by the on-board charger, thereby reducing the number of parts of the on-board charger and making it easy to realize the on-board charger. Miniaturized, high power density design, which can save production costs.

Specifically, at least one pin terminal is directly or indirectly electrically connected to the transformer winding 110 . For example, as shown in FIG. 3 , the first terminal 101 to the fourth terminal 104 are directly electrically connected to the transformer winding 110 ; for another example, as shown in FIG. 5 , the first terminal 101 and the second terminal 102 are indirectly electrically connected to the transformer winding 110 . , that is, the first terminal 101 and the second terminal 102 are electrically connected to the transformer winding 110 through the first inductance winding 160, and the third terminal 103 and the fourth terminal 104 are directly electrically connected to the transformer winding 110; for another example, as shown in FIG. 7 , the first terminal 101 and the second terminal 102 are electrically connected to the transformer winding 110 indirectly, that is, the first terminal 101 and the second terminal 102 are electrically connected to the transformer winding 110 through the first inductor winding 160 , the third terminal 103 and the fourth terminal 104 is indirectly electrically connected to the transformer winding 110 , that is, the third terminal 103 and the fourth terminal 104 are electrically connected to the transformer winding 110 through the second inductive winding 181 .

As shown in FIG. 2 and FIG. 3 , the converter winding 150 and the transformer winding 110 are nested with each other, and the connection terminals are provided on the converter winding 150 . The "nested arrangement" here can be understood as: the converter winding 150 is sheathed on the transformer winding 110 , or the transformer winding 110 is sheathed on the converter winding 150 . For example, as shown in FIG. 3 , the converter winding 150 is wrapped around the outer circumference of the transformer winding 110 .

According to the winding assembly 100 of the on-board charger according to the embodiment of the present disclosure, by constructing the transformer winding 110 and the converter winding 150 into an independent component in an integrated form for the on-board charger, the on-board charger can be reduced. The number of parts is easy to achieve miniaturization and high power density design of the on-board charger, which can save production costs.

According to some embodiments of the present disclosure, as shown in FIG. 2, the converter winding 150 may be formed in a stamped and bent configuration of copper foil. It should be noted that the winding structure formed by stamping has the advantages of simple process and short production cycle. In addition, the thickness of the copper foil can be adjusted according to the current, so that the converter winding 150 can be easily applied to more types of on-board chargers. The converter winding 150 includes multiple layers of copper foils, and the multiple layers of copper foils are stacked. Here, the number of the copper foil layers is not specifically limited, and it is mainly enough to satisfy the magnitude of the current carried.

As shown in FIGS. 2 and 3 , according to some embodiments of the present disclosure, the transformer winding 110 includes a primary winding 111 and a secondary winding 112 , and the secondary winding 112 and the primary winding 111 are nested. The transformer winding 110 further includes a transformer winding bobbin 120 . The transformer winding 110 has a winding slot 121 , and both the secondary winding 112 and the primary winding 111 are arranged in the winding slot 121 . Thereby, the secondary winding 112 and the primary winding 111 can be stably mounted on the transformer bobbin 120 .

As shown in FIGS. 2 and 3 , the winding assembly 100 may further include a first magnetic circuit member 130 . The first magnetic circuit member 130 includes a support portion 131 and a connection portion 132 connected to the support portion 131 . The support portion 131 is located on the transformer winding 110 . The lower part is used to support the transformer winding 110. The support part 131 and the connecting part 132 form an L-shaped structure. The surface of the connecting part 132 facing the transformer winding 110 is provided with a first transformer core 133. The first transformer core 133 is inserted into the transformer. within winding 110 . The winding assembly 100 may further include a second magnetic circuit member 140, the structure of the second magnetic circuit member 140 is the same as that of the first magnetic circuit member 130, the first magnetic circuit member 130 is located at one end of the transformer winding 110, and the second magnetic circuit member 140 is located at the other end of the transformer, and the first magnetic circuit member 130 and the second magnetic circuit member 140 are bonded to form a ring magnetic circuit. An air gap is provided between the first magnetic circuit member 130 and the second magnetic circuit member 140, so that the inductance can be adjusted. It should be noted that the inductance can be adjusted by adjusting the size of the air gap.

As shown in FIG. 5 , the winding assembly 100 further includes a first inductance winding 160, at least one pin terminal is directly electrically connected to the first inductance winding 160, the transformer winding 110 is connected in series with the first inductance winding 160 and is electrically connected, the first magnetic circuit A portion of the component 130 is located between the first inductor winding 160 and the transformer winding 110 . It should be noted that, the part of the first magnetic circuit element 130 located between the first inductance winding 160 and the transformer winding 110 can be used as a common magnetic circuit structure, and the magnetic flux of this part of the structure is canceled.

It should be noted here that, as shown in FIG. 4 and FIG. 5 , the first inductor winding 160 , the transformer winding 110 and the converter winding 150 are integrated into an independent component, thereby reducing the number of components of the on-board charger. It is easy to realize the miniaturization and high power density design of the on-board charger; on the other hand, the number of external pins can also be reduced, which can save the production cost.

When the first inductance winding 160 and the transformer winding 110 are wound, two winding methods can be included: 1) directly and continuously wind the primary winding 111 of the transformer winding 110 after the coil of the first inductance winding 160 is wound; 2) the transformer winding After the primary winding 111 of 110 is wound, the coil of the first inductor winding 160 is directly wound continuously. Here, the positions of the pin terminals are not specifically limited. For example, as shown in FIG. 2 , there are four pin terminals, two of which are set on the first inductor winding 160 , and the other two are set on the first inductor winding 160 . on the transformer winding 110.

As shown in FIG. 5 , the winding assembly 100 includes a first inductor bobbin 170 and a first inductor core 180 , the first inductor winding 160 is wound around the first inductor bobbin 170 , and the first inductor core 180 is connected to the first inductor bobbin 170 . , a part of the structure of the first inductor core 180 is penetrated in the first inductor winding 160 . In order to facilitate the winding of the first inductance winding 160 on the first inductance bobbin 170, in some embodiments, as shown in FIG. Set in the winding slot 171 .

In order to further improve the integration degree of the winding assembly 100 , in some embodiments, as shown in FIGS. 6 and 7 , the winding assembly 100 further includes a second inductor winding 181 . The first inductive winding 160 is located at one end of the transformer winding 110 , the second inductive winding 181 is located at the other end of the transformer winding 110 , and the second inductive winding 181 is connected to the transformer winding 110 in series and electrically. Wherein, at least one pin terminal is directly electrically connected to the second inductance winding 181 .

It should be noted that the second magnetic circuit element 140 is sandwiched between the transformer winding 110 and the second inductance winding 181, and the structure in which the second magnetic circuit element 140 is located between the second inductance winding 181 and the transformer winding 110 can be used as a common magnetic circuit structure, the magnetic fluxes of this part of the structure cancel each other out.

It should also be noted here that, as shown in FIG. 6 and FIG. 7 , the first inductor winding 160 , the second inductor winding 181 , the transformer winding 110 and the converter winding 150 are integrated into an independent component, thereby reducing the cost of the on-board charger. On the one hand, it is easy to achieve miniaturization and high power density design of the on-board charger; on the other hand, it can also reduce the number of external pins, thereby saving production costs.

As shown in FIG. 7 , the winding assembly 100 further includes a second inductor bobbin 182 and a second inductor core 183 . The second inductor winding 181 is wound around the second inductor bobbin 182 , and the transformer winding bobbin 120 is connected to the second inductor bobbin 182 . The second inductor core 183 is connected to the second inductor bobbin 182 , and a part of the structure of the second inductor core 183 passes through the second inductor winding 181 .

For the first inductance winding 160, the second inductance winding 181 and the transformer winding 110, two winding methods can be included: 1) After the coil of the first inductance winding 160 is wound, the primary winding of the transformer winding 110 is directly and continuously wound 111, and then wind the coil of the second inductance winding 181; 2) After the coil of the second inductance winding 181 is wound, directly and continuously wind the primary winding 111 of the transformer winding 110, and then wind the first inductance winding 160. coil. Here, the positions of the pin terminals are not specifically limited. For example, as shown in FIG. 7 , there are four pin terminals, two of which are set on the first inductor winding 160 , and the other two are set on the first inductor winding 160 . on the second inductor winding 181 .

In order to simplify the winding assembly 100 of the on-board charger and reduce the number of inventory components of the winding assembly 100, in some embodiments, the second inductor bobbin 182 has the same structure as the first inductor bobbin 170, and the second magnetic circuit component 140 has the same structure as the first inductor bobbin 170. A magnetic circuit member 130 has the same structure. In addition, in some embodiments, the configurations of the first inductor core 180 and the second inductor core 183 may also be the same.

Referring to FIG. 8 , an on-board charger 200 according to an embodiment of the present disclosure includes the winding assembly 100 of the on-board charger as described above.

Referring to FIG. 9 , the vehicle 1000 according to the embodiment of the present disclosure includes the on-board charger 200 as described above.

According to the on-board charger and the vehicle according to the embodiments of the present disclosure, the transformer winding 110 and the converter winding 150 are integrated into an independent component for the on-board charger, thereby reducing the components of the on-board charger. It is easy to realize the miniaturization and high power density design of the on-board charger, so that the production cost can be saved.

In the description of this specification, reference to the terms "one embodiment," "some embodiments," "exemplary embodiment," "example," "specific example," or "some examples", etc., is meant to incorporate the embodiments A particular feature, structure, material, or characteristic described by an example or example is included in at least one embodiment or example of the present disclosure. In this specification, schematic representations of the above terms do not necessarily refer to the same embodiment or example.

Although embodiments of the present disclosure have been shown and described, it will be understood by those of ordinary skill in the art that various changes, modifications, substitutions, and alterations can be made in these embodiments without departing from the principles and spirit of the present disclosure, The scope of the present disclosure is defined by the claims and their equivalents.

Claims

A winding assembly of an on-board charger, characterized in that the winding assembly has a plurality of pin terminals and a plurality of connection terminals and includes:

a transformer winding, at least one of the pin terminals is directly or indirectly electrically connected to the transformer winding;

The converter winding is integrated with the transformer winding, the converter winding and the transformer winding are nested with each other, and the connection terminal is provided on the converter winding.
The winding assembly of the on-board charger according to claim 1, wherein the converter winding is formed by stamping and bending copper foil.
The winding assembly of the on-board charger according to claim 1 or 2, wherein the converter winding is wrapped around the outer circumference of the transformer winding.
The winding assembly of the on-board charger according to any one of claims 1-3, wherein the transformer winding includes a primary winding, a secondary winding and a transformer winding bobbin, and the secondary winding is the same as the primary winding. The side windings are nested, the transformer winding is wound with a winding slot, and both the secondary winding and the primary winding are arranged in the winding slot.
The winding assembly of the on-board charger according to any one of claims 1-4, further comprising a first magnetic circuit member and a second magnetic circuit member, the first magnetic circuit member comprising a support portion and a a connecting part connected to the supporting part, the supporting part is located below the transformer winding to support the transformer winding, the supporting part and the connecting part form an L-shaped structure, and the connecting part faces the transformer The surface of the winding is provided with a first transformer magnetic core, and the first transformer magnetic core is inserted into the transformer winding;

The structure of the second magnetic circuit element is the same as that of the first magnetic circuit element, the first magnetic circuit element is located at one end of the transformer winding, and the second magnetic circuit element is located at the other end of the transformer , the first magnetic circuit member is bonded with the second magnetic circuit member to form a ring magnetic circuit.
The winding assembly of the on-board charger according to claim 5, wherein an air gap is provided between the first magnetic circuit member and the second magnetic circuit member to adjust the inductance.
The winding assembly of the on-board charger according to claim 5 or 6, further comprising:

The first inductance winding, at least one of the pin terminals is directly electrically connected to the first inductance winding, the transformer winding is connected in series with the first inductance winding and is electrically connected, and the first magnetic circuit component is located in the first inductance winding. between an inductor winding and the transformer winding;

a first inductor skeleton, the first inductor winding is wound around the first inductor skeleton;

a first inductor core, the first inductor core is connected to the first inductor skeleton, and a part of the structure of the first inductor core is penetrated in the first inductor winding.
The winding assembly of the on-board charger according to claim 7, wherein the first inductor winding is located at one end of the transformer winding,

The winding assembly also includes:

The second inductor winding, at least one of the pin terminals is directly electrically connected to the second inductor winding, the second inductor winding is located at the other end of the transformer winding, and the second inductor winding is connected in series with the transformer winding and electrically connected.
The winding assembly of the on-board charger according to claim 8, further comprising:

a second inductor bobbin, the second inductor winding is wound around the second inductor bobbin, and the transformer winding bobbin is connected to the second inductor bobbin;

A second inductive magnetic core, the second inductive magnetic core is connected with the second inductive skeleton, and a part of the structure of the second inductive magnetic core is penetrated in the second inductive winding.
An on-board charger, characterized by comprising the winding assembly of the on-board charger according to any one of claims 1-9.
A vehicle, characterized by comprising the on-board charger according to claim 10 .