A megawatt-level outdoor PCS cabinet

Abstract

This invention relates to a megawatt-level outdoor PCS cabinet, belonging to the technical field of outdoor cabinet design for air-cooled units. The cabinet includes a sealed main protection area and an open secondary protection area, which are isolated from each other. The secondary protection area includes an upper air intake chamber located at the top of the cabinet and connected to the outside. A heat exchanger is located adjacent to the upper air intake chamber. The heat exchanger is connected to both the main protection area and the secondary protection area. This invention effectively balances the conflict between protection and heat dissipation, achieving high-power heat dissipation under high protection requirements with high cost-effectiveness. All key sensitive components are placed within a highly protected, enclosed area, facilitating temperature and humidity control and enabling the system to cope with extreme outdoor climate conditions. Through a special design of the heat exchanger's structure and installation location, the large airflow provided by the main cooling fan is cleverly utilized, saving on the number of external circulation fans while improving the heat exchanger's heat exchange capacity.

Description

Technical Field

[0001] This invention relates to a megawatt-level outdoor PCS (Power Conversion System) cabinet, belonging to the field of outdoor cabinet design technology for air-cooled units. Background Technology

[0002] The protection and heat dissipation of internal components in high-power megawatt-level PCS are crucial factors affecting equipment reliability. For strong air cooling, protection and heat dissipation are contradictory: high protection can hinder heat dissipation performance and increase costs, while smooth ventilation can negatively impact protection levels, especially in outdoor applications. Existing PCS rack designs range from fully open designs with relatively low protection levels to fully enclosed designs with high protection levels, as well as combinations of open and enclosed configurations. Fully open designs also have minimum protection requirements (usually not less than IP43). First, high protection and high resistance significantly complicate the selection of cooling fans and substantially increase manufacturing costs; second, open structures cannot effectively control internal humidity. While fully enclosed designs offer significantly improved environmental adaptability, the main heat dissipation relies on one or more heat exchangers to reach the external environment. High-capacity heat exchangers are often bulky and expensive, posing numerous engineering limitations. Given the limitations of the two solutions mentioned above, there is an urgent need in this technical field for a highly efficient combined solution that differs from the existing open and closed combination approach. This solution aims to balance and resolve the contradiction between protection and heat dissipation in large-capacity outdoor PCS cabinets at a high cost-performance ratio, thereby maximizing the application limits of air-cooled heat dissipation. Summary of the Invention

[0003] The purpose of this invention is to resolve the contradiction between protection and heat dissipation in large-capacity outdoor PCS cabinets, thereby improving the technical limit of air-cooled heat dissipation applications.

[0004] To address the aforementioned problems, the present invention provides a megawatt-level outdoor PCS cabinet. The cabinet has an upper air intake structure and a lower air outlet structure. The cabinet includes a sealed main protection area and an open secondary protection area that are isolated from each other. The secondary protection area includes an upper air intake chamber located at the top of the cabinet and connected to the outside. A heat exchanger is located adjacent to the upper air intake chamber. The heat exchanger is connected to both the main protection area and the secondary protection area.

[0005] Preferably, the secondary protection area includes an upper air inlet chamber, a heat exchanger, a fan cavity, a module heat sink duct, a reactor cavity, and an air outlet, which are connected sequentially from the top to the bottom of the cabinet; the fan cavity is equipped with a main cooling centrifugal fan.

[0006] Preferably, the main protection area includes a heat exchanger, a DC capacitor air chamber, a main protection section one, and a main protection section two connected in sequence; an auxiliary centrifugal fan is provided in the main protection area.

[0007] Preferably, an auxiliary centrifugal fan is provided adjacent to the heat exchanger; the air emitted from the auxiliary centrifugal fan flows back to the auxiliary centrifugal fan in sequence through the heat exchanger, the DC capacitor air chamber, the first main protection section, and the second main protection section.

[0008] Preferably, a control element area is provided between the auxiliary centrifugal fan and the DC capacitor air cavity; the air emitted from the auxiliary centrifugal fan flows back to the auxiliary centrifugal fan in sequence through the heat exchanger, the DC capacitor air cavity and the control element area.

[0009] Preferably, the upper air inlet chamber includes a top surface, a side surface with louvers, and a bottom surface connected in sequence; the top surface forms an angle with the horizontal plane; the bottom surface has a through hole for installing a heat exchanger, and a raised baffle plate perpendicular to the bottom surface is provided around the through hole; the louvers on the side surface have openings parallel to the bottom surface; and an air inlet baffle plate perpendicular to the bottom surface is provided on the top surface facing the bottom surface, with the air inlet baffle plate parallel to the opening of the louvers.

[0010] Preferably, the heat exchanger is provided with separate vertical direct current channels and horizontal flow channels; the vertical direct current channels connect to the secondary protection area, and the horizontal flow channels connect to the primary protection area.

[0011] Preferably, a main cooling centrifugal fan is provided below the heat exchanger, and a fan air cavity is provided around the main cooling centrifugal fan; a fan guide ring is provided between the main cooling centrifugal fan and the heat exchanger, and a certain gap is reserved between the fan guide ring and the bottom surface of the heat exchanger; a ventilation opening is provided at the bottom of the fan air cavity corresponding to the air outlet of the main cooling centrifugal fan; a space for air concealment is provided between the bottom of the fan air cavity and the main cooling centrifugal fan; the horizontal height of the edge of the ventilation opening is higher than the horizontal height of other parts of the bottom of the fan air cavity.

[0012] Preferably, the heat exchanger further includes a damping orifice plate, which has damping holes for adjusting the airflow through the vertical direct current channel.

[0013] Compared with the prior art, the present invention has the following beneficial effects:

[0014] 1) For air-cooled outdoor cabinets, this invention can effectively balance the contradiction between protection and heat dissipation, and achieve high power density heat dissipation under high protection level requirements with high cost performance.

[0015] 2) In this invention, all key sensitive components are placed in a highly protected enclosed area, which makes it easy to control the temperature and humidity and can cope with extreme outdoor climate conditions;

[0016] 3) This invention, through the special design of the heat exchanger structure and installation position, places its vertical direct current channel area in the secondary protection area, cleverly utilizing the large air volume provided by the main cooling fan, thus saving an external circulation fan and improving the heat exchanger's heat exchange capacity. Attached Figure Description

[0017] Figure 1 This is a front view structural diagram of a megawatt-level outdoor PCS cabinet according to the present invention;

[0018] Figure 2 for Figure 1 Sectional view of AA;

[0019] Figure 3 for Figure 2 Wind direction diagram;

[0020] Figure 4 This is a side view of a megawatt-level outdoor PCS cabinet according to the present invention, showing the wind direction.

[0021] Figure 5 This is a schematic diagram of the wind direction of a megawatt-level outdoor PCS cabinet heat exchanger according to the present invention;

[0022] Figure 6 This is a partial schematic diagram of the fan cavity of a megawatt-level outdoor PCS cabinet according to the present invention;

[0023] Reference numerals in the attached diagram: 1. Upper air inlet chamber; 11. Top surface; 12. Side surface; 121. Louver; 122. Plain panel; 13. Bottom surface; 14. Air inlet baffle; 15. Heightening enclosure; 2. Heat exchanger; 21. Vertical flow channel; 22. Horizontal flow channel; 23. Damping perforated plate; 3. Main cooling centrifugal fan; 4. Fan cavity; 41. Ventilation opening; 5. Module heat sink air duct; 6. Reactor cavity; 7. DC capacitor cavity; 81. Main protection area one; 82. Main protection area two; 9. Auxiliary centrifugal fan; 10. Control element area. Detailed Implementation

[0024] To make the present invention more apparent and understandable, preferred embodiments are described in detail below with reference to the accompanying drawings:

[0025] like Figure 1-6As shown, this invention provides a megawatt-level outdoor PCS cabinet. The cabinet has an upper air intake structure and a lower air outlet structure. The cabinet includes a sealed main protection area and an open secondary protection area that are isolated from each other. The secondary protection area includes an upper air intake chamber 1 located at the top of the cabinet and connected to the outside. A heat exchanger 2 is located adjacent to the upper air intake chamber 1. The heat exchanger 2 is connected to both the main protection area and the secondary protection area. The secondary protection area includes, from the top of the cabinet to the bottom, the upper air intake chamber 1, the heat exchanger 2, the fan cavity 4, the module heat sink duct 5, the reactor cavity 6, and the air outlet. The fan cavity 4 is equipped with a main cooling centrifugal fan 3. The main protection area includes, in sequence, the heat exchanger 2, the DC capacitor cavity 7, the first main protection area 81, and the second main protection area 82. An auxiliary centrifugal fan 9 is provided in the main protection area. An auxiliary centrifugal fan 9 is provided adjacent to the heat exchanger 2; the air emitted from the auxiliary centrifugal fan 9 flows back to the auxiliary centrifugal fan 9 after passing through the heat exchanger 2, the DC capacitor air chamber 7, the main protection section area 1 81, and the main protection section area 2 82. A control element area 10 is also provided between the auxiliary centrifugal fan 9 and the DC capacitor air chamber 7; the air emitted from the auxiliary centrifugal fan 9 flows back to the auxiliary centrifugal fan 9 after passing through the heat exchanger 2, the DC capacitor air chamber 7, and the control element area 10. The upper air inlet chamber 1 includes a top surface 11, a side surface 12 with louvers, and a bottom surface 13 connected in sequence. The top surface 11 forms an angle with the horizontal plane. The bottom surface 13 has a through hole for installing the heat exchanger 2, and a raised baffle 15 extending vertically upward from the bottom surface 13 is provided around the through hole. The louvers 121 of the side surface 12 have openings parallel to the bottom surface 13. An air inlet baffle 14 is provided on the top surface 11 facing the bottom surface 13, perpendicular to the bottom surface 13, and the air inlet baffle 14 is parallel to the opening of the louvers 121. The heat exchanger 2 has a separated vertical flow channel 21 and a horizontal flow channel 22. The vertical flow channel 21 connects to the secondary protection area, and the horizontal flow channel 22 connects to the main protection area. A main cooling centrifugal fan 3 is located below the heat exchanger 2, and fan cavities 4 are arranged around the main cooling centrifugal fan 3. A fan guide ring 31 is provided between the main cooling centrifugal fan 3 and the heat exchanger 2. A vent 41 is provided at the bottom of the fan cavity 4 corresponding to the air outlet of the main cooling centrifugal fan 3. A space for air concealment is provided between the bottom of the fan cavity 4 and the main cooling centrifugal fan 3. The horizontal height of the edge of the vent 41 is higher than the horizontal height of other parts of the bottom of the fan cavity 4. The heat exchanger 2 also includes a damping orifice plate 23, which has damping holes for adjusting the airflow through the vertical direct current channel 21.

[0026] Example

[0027] like Figure 1-6 The present invention provides a megawatt-level outdoor PCS cabinet. This outdoor PCS cabinet employs a welded frame and forced ventilation cooling. Taking into account both site conditions and its own structural characteristics, it adopts a top-intake, bottom-exhaust airflow design. The overall layout combines open and closed configurations.

[0028] Specifically, it is divided into a closed main protection area, including DC capacitor air cavity 7, main protection part area one 81 and main protection part area two 82; and an open secondary protection area, including upper air intake chamber 1, fan air cavity 4, module heat sink air duct 5 and reactor air cavity 6; the two areas are isolated from each other.

[0029] The main protection area is sealed and isolated from the outside, with a high protection level (IP65). In terms of heat dissipation function, it is defined as an auxiliary heat dissipation area. Most of the PCS components are placed in this area. An auxiliary centrifugal fan 9 drives the air circulation, and the heat exchanger 2 achieves efficient heat exchange with the outside.

[0030] The secondary protection area is connected to the outside world and has a low protection level (IP23). In terms of heat dissipation function, it is defined as the main heat dissipation area. Devices with high heat generation and low protection requirements, such as IGBT heat sink fins and reactors, are placed in this area. A main heat dissipation centrifugal fan 3 is provided to drive the overall design requirements, namely, air intake at the top and air exhaust at the bottom.

[0031] The secondary protection area, namely the upper air intake chamber 1, fan air cavity 4, module heat sink air duct 5, and reactor air cavity 6, is designed in the relatively central part of the cabinet and runs vertically through the entire cabinet height. The top side of the cabinet is the air inlet, and the bottom of the cabinet is the air outlet. The main protection area, namely the DC capacitor air cavity 7, main protection area one 81, and main protection area two 82, surrounds the secondary protection area. The two areas are completely isolated by necessary sealing measures and together form the entire cabinet space.

[0032] The top section of the cabinet is defined as the upper air intake chamber 1, consisting of a top surface 11, side surfaces 12, and a bottom surface 13. The top surface 11 consists of two inclined surfaces at a certain angle to prevent rain and snow accumulation. The side surfaces 12 consist of four removable side panels with drainage holes at the bottom. Three of the side panels have louvers 121, and one side panel is a smooth panel 122. The bottom surface 13 is a metal partition with square holes to isolate the upper air intake chamber from the main protected area. The square holes on the partition are used to connect to the lower secondary protected area. See also... Figure 2 ;

[0033] Inside the upper air intake chamber 1, air intake baffles 14 are provided at certain intervals corresponding to the side panels of the three louvers 121. These baffles 14 extend downwards from the top of the cabinet to a certain distance from the bottom surface 13. External air is drawn in through the louvers 121 and, guided by the baffles 14, changes its direction from horizontal to vertical. Then, influenced by the bottom surface 13, it changes back to horizontal and rises at a certain angle towards the inlet of the raised baffle 15 located at the edge of the opening on the bottom surface 13, flowing out of the upper air intake chamber 1 and into the lower secondary protection area. The raised baffle 15 is set along the edge of the square hole on the bottom surface 13, extending upwards to a certain distance from the top surface 11 of the cabinet. If the drawn-in external air contains rainwater, the deflection of the baffles 14, the variable speed design of the air outlet, and the height increase can achieve a certain degree of rainwater separation, preventing rainwater from entering the secondary protection area. See also... Figure 2 .

[0034] The lower part of the bottom surface 13 of the upper air inlet chamber 1 is a heat exchanger 2. The heat exchanger 2 is equipped with independent and intersecting vertical straight channels 21 and horizontal channels 22. The vertical straight channels 21 can be understood as being placed in the air duct of the secondary protection area, connecting the opening of the bottom surface 13 of the upper air inlet chamber 1 to the secondary protection area inside the cabinet; the horizontal channels 22 can be understood as being placed in the air duct of the main protection area, with both ends connected to the main protection area. The heat exchange between the closed main protection area and the outside is achieved through the heat exchange of the vertical and horizontal channels within the heat exchanger 2; see [link to relevant documentation]. Figure 3 , 5 .

[0035] A main cooling centrifugal fan 3 is installed at the bottom of the heat exchanger 2. The air inlet of the main cooling centrifugal fan 3 faces upward, and a certain gap is reserved between the fan guide ring 31 and the bottom surface of the heat exchanger 2 to facilitate the optimal performance of the fan and the heat exchanger. The main cooling centrifugal fan 3 is surrounded by a fan cavity, defined as the fan cavity 4, to create a dynamic effect of air intake at the top and air exhaust at the bottom. A certain height is reserved in the lower part of the fan cavity 4, with no obstructions, to form a sheltered air space and achieve a uniform airflow effect. The bottom of the fan cavity 4 has three rectangular ventilation openings 41, which connect to the lower module heat sink air duct 5. The lower part of the module heat sink air duct 5 connects to the reactor air cavity 6, and the reactor air cavity 6 connects to the air outlet of the secondary protection area of ​​the cabinet. See also Figure 2 , 3 .

[0036] Airflow direction in the secondary protection area: Air enters through the louvers 121 in the top air intake area of ​​the cabinet, passes through the square holes of the raised panel 15 and bottom surface 13 of the upper air intake chamber 1, enters the vertical direct current channel 21 of the heat exchanger 2 located directly below, then enters the centrifugal fan cavity 4, passes through the three ventilation ports 41 at the bottom of the fan cavity 4, enters the module heat sink air duct 5, then enters the reactor air cavity 6, and finally is exhausted to the outside of the cabinet through the bottom air outlet; see also Figure 3 A double arrow is used to indicate this.

[0037] Structural details in the secondary protection zone include: the vertical flow channel 21 of the heat exchanger 2 located in the secondary protection zone does not fill the entire cross-section of the air duct perpendicular to its flow direction. Instead, it leaves a certain gap on both sides parallel to its horizontal flow channel, where damping orifice plates 23 are installed to regulate the airflow through the vertical flow channel. In other words, part of the total ventilation volume in the secondary protection zone flows through the fins of the high-resistance heat exchanger vertical flow channel 21, and part flows through the low-resistance damping orifice plates 23 on its sides, to reduce the air resistance in this section; see also Figure 5 .

[0038] Structural details in the secondary protection area also include: three rectangular vents 41 at the bottom of the main cooling fan cavity, with their edges slightly higher than the bottom surface of the cavity to prevent rainwater separated from the sidewalls of the cavity from flowing into the lower module radiator duct 5; the connection between the rectangular vents 41 of the cavity and the module radiator duct 5 is equipped with a sealing measure that is not affected by disassembly or assembly; see also Figure 6 .

[0039] In the main protected area, driven by the auxiliary centrifugal fan 9, air circulates throughout the entire enclosed area. Hot air returns to the inlet of the circulating fan, and the fan outlet is connected to the horizontal flow channel 22 of the heat exchanger 2. After heat exchange within the horizontal flow channel 22, the air flows out as cold air. The cold air first enters the DC capacitor air chamber 7, and after exiting through the outlet of the DC capacitor air chamber 7, it flows sequentially through various heating elements, finally returning to the fan inlet to form a cycle; see also Figure 3 The single arrow in the diagram indicates the direction of wind flow.

[0040] The detailed features of the air duct structure in the main protection area include: the air duct after the DC capacitor air chamber 7 is divided into two parallel branches; branch one flows through the relatively enclosed rectangular space of the low-heat, temperature-sensitive control element area 10, with circulating air flowing along the diagonal path of the control element area 10 to achieve sufficient cooling; branch two connects to other spaces in the main protection area, sequentially passing through main protection section area one 81 and main protection section area two 82, and mainly contains heat-generating and secondary temperature-sensitive components such as switches, transformers, and copper busbars; finally, the downwind ends of the two parallel branches converge at the inlet of the auxiliary circulating fan 9. See also Figure 4 The hollow arrow indicates the airflow direction of branch one, and the solid arrow indicates the airflow direction of branch two.

[0041] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any form or substance. It should be noted that those skilled in the art can make various improvements and additions without departing from the present invention, and these improvements and additions should also be considered within the scope of protection of the present invention. Any modifications, alterations, and equivalent changes made by those skilled in the art based on the above-disclosed technical content without departing from the spirit and scope of the present invention are equivalent embodiments of the present invention. Furthermore, any modifications, alterations, and evolutions made to the above embodiments based on the essential technology of the present invention still fall within the scope of the technical solution of the present invention.

Claims

1. A megawatt outdoor PCS cabinet characterized by, The cabinet body is provided with an upper air inlet structure and a lower air outlet structure; the cabinet body comprises a closed main protection area and an open secondary protection area which are isolated from each other; the secondary protection area comprises an upper air inlet chamber which is in communication with the outside at the upper part of the cabinet body; a heat exchanger is arranged adjacent to the upper air inlet chamber; the heat exchanger is in communication with the main protection area and the secondary protection area respectively; The heat exchanger is provided with separated vertical flow channels and horizontal flow channels; the secondary protection area is in communication with the outside and the vertical flow channels, and is provided with a main heat dissipation centrifugal fan to provide driving force; the main protection area is in communication with the horizontal flow channels, the main protection area is closed and isolated from the outside, and is provided with an auxiliary centrifugal fan to drive air circulation, and heat exchange between the closed main protection area and the outside is realized through heat exchange of the horizontal flow channels and the vertical flow channels in the heat exchanger.

2. A megawatt outdoor PCS cabinet according to claim 1, characterized in that, The secondary protection area comprises, from top to bottom of the cabinet body, an upper air inlet chamber, a heat exchanger, a fan air cavity, a module radiator air duct, an electric reactor air cavity and an air outlet.

3. The megawatt outdoor PCS cabinet according to claim 1, characterized in that, The main protection area comprises, in sequence, a heat exchanger, a direct-current capacitor air cavity, a main protection part area one and a main protection part area two.

4. A megawatt outdoor PCS cabinet according to claim 3, characterized in that, An auxiliary centrifugal fan is arranged adjacent to the heat exchanger; air emitted from the auxiliary centrifugal fan flows back to the auxiliary centrifugal fan in sequence through the heat exchanger, the direct-current capacitor air cavity, the main protection part area one and the main protection part area two.

5. A megawatt outdoor PCS cabinet according to claim 4, characterized in that, A control element area is further arranged between the auxiliary centrifugal fan and the direct-current capacitor air cavity; air emitted from the auxiliary centrifugal fan flows back to the auxiliary centrifugal fan in sequence through the heat exchanger, the direct-current capacitor air cavity and the control element area.

6. A megawatt outdoor PCS cabinet according to claim 1, characterized in that, The upper air inlet chamber comprises, in sequence, a top surface, a side surface provided with louvers and a bottom surface; the top surface is provided with an included angle with a horizontal plane; the bottom surface is provided with a through hole for mounting the heat exchanger, and a raised coaming is arranged around the through hole and is perpendicular to the bottom surface; the louvers of the side surface are provided with openings parallel to the bottom surface; the top surface is provided with an air inlet partition plate which is perpendicular to the bottom surface and faces the bottom surface, and the air inlet partition plate is parallel to the openings of the louvers.

7. A megawatt outdoor PCS cabinet according to claim 1, characterized in that, A main heat dissipation centrifugal fan is arranged below the heat exchanger, and a fan air cavity is arranged around the main heat dissipation centrifugal fan; a fan air guide ring is arranged between the main heat dissipation centrifugal fan and the heat exchanger, and a gap is arranged between the fan air guide ring and the bottom surface of the heat exchanger; a ventilation opening is arranged at the bottom of the fan air cavity corresponding to the air outlet of the main heat dissipation centrifugal fan; a space for hiding air is arranged between the bottom of the fan air cavity and the main heat dissipation centrifugal fan; the horizontal height of the edge of the ventilation opening is higher than the horizontal height of other parts of the bottom of the fan air cavity.

8. A megawatt outdoor PCS cabinet according to claim 5, characterized in that, The heat exchanger further comprises a damping hole plate, and the damping hole plate is provided with damping holes for adjusting the air volume through the vertical flow channels.

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