Power source and method for cooling such a power source

Patent metadata

Field	Value
Publication number	US-9641093-B2
Application number	US-201214354987-A
Country	US
Kind code	B2
Filing date	Oct 31, 2012
Priority date	Oct 31, 2011
Publication date	May 2, 2017
Grant date	May 2, 2017

Abstract

The invention relates to a power source ( 10 ) for providing a direct current, comprising a heavy-current transformer ( 12 ) with at least one primary winding ( 13 ) and at least one secondary winding ( 14 ) with center tapping, a synchronous rectifier ( 16 ) connected with the at least one secondary winding ( 14 ) of the heavy-current transformer ( 12 ) and comprising circuit elements ( 24 ), and a circuit ( 17 ) for actuating the circuit elements ( 24 ) of the synchronous rectifier ( 16 ), and a supply circuit ( 48 ) for supplying the synchronous rectifier ( 16 ) and the actuation circuit ( 17 ), and to a method for cooling such a power source ( 10 ). For reduction of losses and improvement of efficiency, the synchronous rectifier ( 16 ) and the actuation circuit ( 17 ) and the supply circuit ( 48 ) thereof are integrated in the heavy-current transformer ( 12 ).

First claim

The invention claimed is:

1. A power source ( 10 ) for providing a direct current, comprising a heavy-current transformer ( 12 ) with at least one primary winding ( 13 ) and at least one secondary winding ( 14 ) with center tapping, a synchronous rectifier ( 16 ) connected with the at least one secondary winding ( 14 ) of the heavy-current transformer ( 12 ) and comprising circuit elements ( 24 ), and an actuation circuit for actuating the circuit elements ( 24 ) of the synchronous rectifier ( 16 ), and a supply circuit ( 48 ) for supplying the synchronous rectifier ( 16 ) and the actuation circuit ( 17 ), wherein the synchronous rectifier ( 16 ) and the actuation circuit ( 17 ) and the supply circuit ( 48 ) thereof are integrated in the heavy-current transformer ( 12 ) wherein, in order to form a multi-point contacting, at least four contacts ( 20 , 21 , 22 , 23 ) are provided at the heavy-current transformer ( 12 ) for providing the direct current, whereby the direct current is at least halved and the contact losses are thus reduced, and wherein two first contacts ( 20 , 21 ) of one polarity and two additional contacts ( 22 , 23 ) of opposite polarity are each arranged opposite each other, wherein the two additional contacts ( 22 , 23 ) are substantially arranged offset to each other by 90° compared to the two first contacts ( 20 , 21 ).

2. The power source ( 10 ) according to claim 1 , wherein the circuit elements ( 24 ) of the synchronous rectifier ( 16 ) are connected without lines with the at least one secondary winding ( 14 ) of the heavy-current transformer ( 12 ).

3. The power source ( 10 ) according to claim 1 , wherein the heavy-current transformer ( 12 ) comprises a plurality of, preferably at least 10, primary windings ( 13 ) connected in series, and a plurality of, preferably at least 10, secondary windings ( 14 ) with center tapping connected in parallel.

4. The power source ( 10 ) according to claim 1 , wherein the heavy-current transformer ( 12 ) comprises an I-beam ( 25 ) of electrically conductive material, in recesses ( 25 a ) of which at least one respective ring core ( 15 ) is arranged, wherein one respective connection of each secondary winding ( 13 ) is directly contacted with one inner surface of the I-beam ( 25 ), and wherein the outer surfaces ( 28 ) of the I-beam ( 25 ) form the two first contacts ( 20 , 21 ), and wherein the center tapping of the at least one secondary winding ( 14 ) of the heavy-current transformer ( 12 ) is connected with the I-beam ( 25 ) without lines.

5. The power source ( 10 ) according to claim 4 , wherein the at least one primary winding ( 13 ) of the heavy-current transformer ( 12 ) is arranged to run through the at least one ring core ( 15 ).

6. The power source ( 10 ) according to claim 4 , wherein respective contact plates ( 29 ) are located above the recesses ( 25 a ) of the I-beam ( 25 ), said contact plates ( 29 ) being of electrically conductive material and connected with the respectively other connections of each secondary winding ( 14 ) via the synchronous rectifier ( 16 ) and the actuation circuit ( 17 ), wherein the outer surfaces of the contact plates ( 29 ) form the two additional contacts ( 22 , 23 ) of the power source ( 10 ).

7. The power source ( 10 ) according to claim 1 , wherein one secondary winding ( 14 ) with center tapping is each formed by two metal sheets ( 44 , 45 ) insulated from each other and being of electrically conductive material and having a substantially S-shaped mirror-inverted course around the cross-section of the ring core ( 15 ) and through the ring core ( 15 ), wherein the exterior surfaces ( 47 ) of the metal sheets ( 44 , 45 ) form the contacts for the connection with the circuit elements ( 24 ) of the synchronous rectifier ( 16 ) or electrodes ( 7 ).

8. The power source ( 10 ) according to claim 6 , wherein the I-beam ( 25 ) and the contact plates ( 29 ) of the heavy-current transformer ( 12 ) form a cube or ashlar-shaped unit, wherein cover plates ( 31 ) are arranged at the front faces of the I-beam ( 25 ), and wherein the cover plates ( 31 ) are formed of electrically conductive material and are adapted to be screwed to the contact plates ( 29 ), so that the contact plates ( 29 ) are connected electrically.

9. The power source ( 10 ) according to claim 4 , wherein the I-beam ( 25 ) and/or contact plates ( 29 ) or the cover plates ( 31 ) and/or the metal sheets ( 44 , 45 ) for forming the secondary winding ( 14 ) of the heavy-current transformer ( 12 ) are formed of copper or a copper alloy, preferably with a silver coating.

10. The power source ( 10 ) according to claim 1 , wherein at the connections of a secondary winding ( 14 ) a current transducer ( 18 ) each is arranged for measuring the current through this secondary winding ( 14 ), said current transducers ( 18 ) being connected with the actuation circuit ( 17 ).

11. The power source ( 10 ) according to claim 10 , wherein the current transducers ( 18 ) are arranged to be oriented substantially 90° to the direction of the direct current.

12. The power source ( 10 ) according to claim 10 , wherein the actuation circuit ( 17 ) is designed to activate the circuit elements ( 24 ) of the synchronous rectifier ( 16 ) at a preset point in time prior to reaching zero crossing of the current in the secondary winding ( 14 ).

13. The power source ( 10 ) according to claim 4 , wherein channels ( 39 ) for feeding a cooling fluid are arranged in the I-beam ( 25 ) and contact plates ( 29 ), wherein two inlets ( 32 ) for feeding the cooling fluid and one outlet ( 33 ) for discharging the cooling fluid are arranged at an outer surface ( 28 ) of the I-beam ( 25 ), wherein the cooling channels ( 39 ) are arranged to extend from each inlet ( 32 ) to the contact plates ( 29 ) and via the I-beam ( 25 ) to the outlet ( 33 ).

14. The power source ( 10 ) according to claim 6 , wherein the actuation circuit ( 17 ) and the synchronous rectifier ( 16 ) are arranged on at least one circuit board ( 35 ) which is arranged on the inner surface of at least one contact plate ( 29 ), and wherein each circuit board ( 35 ) of the synchronous rectifier ( 16 ) and of the actuation circuit ( 17 ) comprises openings ( 37 ) above which the circuit elements ( 24 ) are arranged, and wherein the inner surface of the contact plates ( 29 ), in the places of the openings ( 37 ) in the circuit board ( 35 ) of the synchronous rectifier ( 16 ), comprises protrusions ( 36 ), in particular pinnacle-shaped protrusions, so that the circuit elements ( 24 ) can be contacted without lines via the protrusions ( 36 ) protruding into the openings ( 37 ) on the circuit board ( 35 ) on the inner surface of the contact plates ( 29 ).

15. A method for cooling a power source ( 10 ) for providing a direct current, comprising a heavy-current transformer ( 12 ) with at least one primary winding ( 13 ) and at least one secondary winding ( 14 ) with center tapping, a synchronous rectifier ( 16 ) connected with the at least one secondary winding ( 14 ) of the heavy-current transformer ( 12 ) and comprising circuit elements ( 24 ), and a circuit ( 17 ) for actuating the circuit elements ( 24 ) of the synchronous rectifier ( 16 ), by means of a cooling fluid, wherein the cooling fluid is guided in a contact plate and an I-beam of the heavy-current transformer such that first the at least one actuation circuit ( 17 ) and the synchronous rectifier ( 16 ) and then the at least one secondary winding ( 14 ) of the heavy-current transformer ( 12 ) are cooled.

16. The cooling method according to claim 15 , wherein the cooling fluid is

Assignees

• Fronius Int Gmbh

Inventors

• Artelsmair Bernhard
• Schultschik Christoph
• Neuboeck Johannes
• Wolfsgruber Stefan

Classifications

• B23K11/241 Primary

  Electric supplies (B23K11/248 takes precedence) · CPC title

• Y02P70/181

  Cross-Sectional Technologies · mapped topic

• H02M7/12

  using discharge tubes with control electrode or semiconductor devices with control electrode · CPC title

• H01F38/085

  Welding transformers · CPC title

• H02M7/003 Primary

  Constructional details, e.g. physical layout, assembly, wiring or busbar connections · CPC title