采用氮化铝材料的水冷变压器的热管理方法

doi:10.19595/j.cnki.1000-6753.tces.231685

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摘要干式高频变压器结构紧凑且损耗较高,而低导热系数的灌封材料使得热量易在变压器内部累积,从而导致温升成为限制大功率变压器容量与功率密度提升的重要因素。该文以环形水冷变压器为研究对象,建立了考虑中心圆柱热阻的变压器集总参数热路模型,并通过有限元仿真验证了所建模型的准确性。基于所建热路模型,解释了变压器温度降幅随着水流量的提高趋于稳定的现象。为了进一步增强散热效果,该文提出了一种基于高导热绝缘材料氮化铝的新型散热结构。该结构在热源与水冷板之间建立起低热阻通道,增强了变压器与水冷板之间的传热,变压器的容量和功率密度可进一步提高。最后,通过有限元仿真与25 kHz/160 kV·A高频变压器样机实验验证了所提散热结构的有效性。

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关键词 ：大功率高频变压器, 环形水冷变压器, 等效热路模型, 氮化铝材料

Abstract：Dry-type high-frequency transformers typically have compact structures and significant losses. The use of potting materials with low thermal conductivity can lead to heat accumulation within the large-capacity transformer, resulting in temperature rise becoming a limiting factor in increasing the power density of high-frequency transformers. Due to the significant advantages of toroidal cores and water-cooling heat dissipation method, this paper focuses on the thermal management issue of toroidal water-cooling transformers.
Because of the axisymmetric structure of the toroidal transformer, the thermal circuit of the transformer can be equivalently described using a two-dimensional model. In order to calculate the temperature rise, this paper establishes a lumped parameter two-dimensional equivalent thermal circuit model of the toroidal transformer based on the thermoelectric analogy theory, with the center and the four surfaces of the magnetic core as temperature nodes. Compared with existing models, the proposed model takes into account the thermal resistance of the central cylinder formed after sealing. The modeling of the thermal resistance between the side and bottom surfaces of the central cylinder is based on the analysis of heat flow path. This heat flow path is a curve, but solving the thermal resistance along the curve is difficult. This paper simplifies it by dividing the heat flow path into horizontal and vertical sections. The thermal resistances of these two sections are in series, so the thermal resistance of the cylinder is the sum of them. The accuracy of the simplification method is verified by finite element simulation.
With the established thermal circuit model, the phenomenon that the temperature decrease of the transformer tends to remain constant as the water flow rate increases is explained. The cause of this phenomenon is the relatively high thermal resistance between the heat source and the water-cooling plate, resulting in less heat reaching the water-cooling plate and limited cooling effect. Therefore, it is necessary to find an insulation material with strong thermal conductivity to meet the heat dissipation requirements of potting transformers.
Taking inspiration from the packaging materials of high-power semiconductor module, Aluminum Nitride material with both insulation and heat dissipation capabilities is suggested and applied in high-power transformers. Based on this high thermal conductivity insulation material, this paper proposes a new heat dissipation structure.
This structure provides a low thermal resistance channel between the heat source and the water-cooling plate, and allows further increase in capacity and power density of high-frequency transformers. In addition, due to the larger core loss in the inner circle of the toroidal core and the denser winding on the inner side of the core, the thermal density in the inner direction of the transformer is higher than that in the outer direction, and the proposed heat dissipation structure enhances the thermal conductivity in the inner direction, so it is highly suitable for the toroidal transformers.
Finite element simulation and experiments conducted on the 25 kHz/160 kV·A high-frequency transformer prototype prove that the temperature rise of the transformer using aluminum nitride heat dissipation structure is lower than that of the fully epoxy resin potted transformer, verifying the effectiveness of the proposed heat dissipation structure.

Key words： High-power high-frequency transformer toroidal water-cooling transformer equivalent thermal circuit model aluminum nitride material

收稿日期: 2023-10-12

PACS:

TM433

基金资助:国家自然科学基金资助项目（52177191）

通讯作者: 宫金武, 男,1981年生,副教授,博士生导师,研究方向为高效率高功率密度电力电子变换技术、宽禁带半导体器件应用、电能质量分析与治理。E-mail：gongjinwu@whu.edu.cn

作者简介: 王开国, 男,1998年生,硕士研究生,研究方向为大功率高频变压器精细化设计。E-mail：wangkaiguo@whu.edu.cn

引用本文:

王开国, 宫金武, 石子帅, 田杰, 潘尚智, 查晓明. 采用氮化铝材料的水冷变压器的热管理方法[J]. 电工技术学报, 2024, 39(21): 6614-6625. Wang Kaiguo, Gong Jinwu, Shi Zishuai, Tian Jie, Pan Shangzhi, Zha Xiaoming. Thermal Management Method for Toroidal Water-Cooling Transformer Using Aluminum Nitride Material. Transactions of China Electrotechnical Society, 2024, 39(21): 6614-6625.

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