Integrated drive unit and power unit suitable for high altitudes

Abstract

This invention relates to the field of power unit technology, specifically to an integrated drive unit and power unit suitable for high-altitude applications. The integrated drive unit for high-altitude applications includes: a first drive plate, a first insulating plate, a second drive plate, and a second insulating plate. The first insulating plate is separated from the first drive plate by at least two first spacers. The second drive plate is separated from the first insulating plate by at least two spacers, and the second drive plate is separated from the second insulating plate by a second spacer. The first drive plate, first insulating plate, second drive plate, and second insulating plate are all relatively fixed. The integrated drive unit for high-altitude applications provided by this invention effectively realizes the layout of the drive unit within a local space, while also meeting electrical clearance and creepage distance requirements, thus constituting a drive unit that can be used in high-altitude environments.

Description

Technical Field

[0001] This invention relates to the field of power unit technology, and in particular to an integrated drive unit and power unit suitable for high altitudes. Background Technology

[0002] Power units, which convert AC to DC power, are widely used in rail transportation and industrial fields. As the application carrier for power devices such as IGBTs, the power unit realizes the voltage-to-current conversion function. The control system sends control signals from the TCU, which are then converted into photoelectric signals by the driver board to control the on / off switching of the IGBTs, completing the power conversion. Therefore, the switching action of the IGBTs depends on the transmission of control signals from the driver unit, which acts as an intermediate signal transmission unit between the control system and the power module. Simultaneously, its short-circuit protection and undervoltage protection functions ensure the normal operation of the IGBTs and the protection of the power module under abnormal operating conditions.

[0003] In some existing power units, there are four IGBT devices, and one driver board drives two IGBT devices, with a total of two driver boards. However, due to the space limitations of the composite busbar and capacitors, the installation space of the driver unit is severely compressed, making it impossible to use the traditional composite busbar back-side mounting "isolation base plate + driver board" structure to complete the electrical isolation between high and low voltages. The driver unit can only be placed on the side wall of the power unit.

[0004] With this type of power unit, both drive boards are mounted on the side wall of the power unit. When the altitude is greater than 2500mm, it is extremely difficult to meet the requirements of electrical clearance and creepage distance so as to adapt to operation at high altitudes. Summary of the Invention

[0005] To overcome the shortcomings of existing power units with drive boards mounted on side walls that cannot meet the technical requirements for high-altitude operation, this invention provides an integrated drive unit and power unit suitable for high-altitude environments.

[0006] The integrated drive unit suitable for high-altitude environments provided by this invention includes:

[0007] First drive board;

[0008] A first insulating plate is arranged parallel to and directly opposite the first driving plate, and the first insulating plate and the first driving plate are separated by at least two first pads.

[0009] The second drive plate is arranged parallel to and directly opposite the first insulating plate. The second drive plate and the first drive plate are located on opposite sides of the first insulating plate. The second drive plate and the first insulating plate are separated by at least two isolation pads.

[0010] The second insulating plate is parallel to the second driving plate and has an extension portion opposite to the second driving plate. The second insulating plate and the first insulating plate are located on opposite sides of the second driving plate. The second driving plate and the second insulating plate are separated by a second pad. The extension portion is provided with mounting holes suitable for connecting to the side wall of the power unit.

[0011] The first drive board, the first insulating board, the second drive board, and the second insulating board are all fixed relative to each other.

[0012] Optional, also includes:

[0013] The U-shaped insulating frame includes a web and two wing plates. The web is parallel to the second insulating plate and is placed between the second pad and the second insulating plate. A connecting hole is opened on the web corresponding to the position of the mounting hole. The first drive plate, the second drive plate and the first insulating plate are all placed within the area enclosed by the U-shaped insulating frame.

[0014] Optionally, the first pad, the isolation pad, and the second pad are set together and correspondingly provided. Both ends of the isolation pad are provided with protruding screws. Both the first pad and the second pad are provided with threaded grooves. The two protruding screws pass through the first insulating plate and the second driving plate respectively and are screwed into the two threaded grooves. The first pad is locked by an insulating screw that passes through the first driving plate, and the second pad is locked by an insulating screw that passes through the web plate.

[0015] Optionally, the surface of the second insulating plate that is attached to the web plate is provided with a receiving groove suitable for accommodating the head of the insulating screw.

[0016] Optionally, the insulating screw is a nylon cylindrical head insulating screw.

[0017] Optionally, the U-shaped insulating frame is made of polycarbonate material.

[0018] Optionally, the first pad, the isolation pad, and the second pad are all nylon pads.

[0019] Optionally, both the first and second insulating boards are made of epoxy resin rigid glass cloth FR-5 material.

[0020] The power unit provided by the present invention includes:

[0021] Main framework;

[0022] The air-cooled radiator is fixed to the upper part of the main frame;

[0023] A composite busbar is installed on the main frame;

[0024] The aforementioned integrated drive unit suitable for high altitudes is fixed to the side wall of the main frame through the mounting holes.

[0025] The technical solution provided by this invention has the following advantages compared with the prior art:

[0026] The integrated drive unit provided by this invention is suitable for high-altitude environments. The two drive boards are arranged in a stacked structure, and a first insulating plate and an isolation pad are arranged between the two drive boards to complete the isolation. The second drive board is isolated from the side wall by the second pad and the second insulating plate. This effectively realizes the layout of the drive unit in a local space, while also meeting the requirements for electrical clearance and creepage distance, thus forming a drive unit that can be used in high-altitude environments.

[0027] The power unit provided by the present invention has the aforementioned advantages because it has the aforementioned integrated drive unit suitable for high altitudes. Attached Figure Description

[0028] The accompanying drawings, which are incorporated in and form part of this specification, illustrate embodiments consistent with the invention and, together with the description, serve to explain the principles of the invention.

[0029] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, for those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0030] Figure 1 This is a three-dimensional structural diagram of the integrated drive unit suitable for high altitudes as described in an embodiment of the present invention;

[0031] Figure 2 This is a side view of the integrated drive unit suitable for high altitudes as described in an embodiment of the present invention;

[0032] Figure 3 This is a schematic diagram of the power unit described in an embodiment of the present invention.

[0033] in:

[0034] 1. First drive board; 2. First insulating board; 3. First pad; 4. Second drive board; 5. Isolation pad; 6. Second insulating board; 61. Extension; 7. Second pad; 8. U-shaped insulating frame; 81. Web plate; 811. Connecting hole; 82. Wing plate; 9. Nylon cylindrical head insulating screw; 100. Main frame; 200. Air-cooled radiator; 300. Composite busbar. Detailed Implementation

[0035] To better understand the above-mentioned objectives, features, and advantages of the present invention, the solutions of the present invention will be further described below. It should be noted that, unless otherwise specified, the embodiments of the present invention and the features thereof can be combined with each other.

[0036] Many specific details are set forth in the following description in order to provide a full understanding of the invention, but the invention may also be practiced in other ways different from those described herein; obviously, the embodiments in the specification are only some embodiments of the invention, and not all embodiments.

[0037] In one embodiment, refer to Figure 1 and Figure 2 The integrated drive unit suitable for high-altitude applications includes a first drive plate 1, a first insulating plate 2, a second drive plate 4, and a second insulating plate 6. The first insulating plate 2 is parallel to and directly opposite the first drive plate 1, separated from it by at least two first spacers 3. The second drive plate 4 is parallel to and directly opposite the first insulating plate 2, located on opposite sides of the first drive plate 2, separated from it by at least two isolation spacers 5. The second insulating plate 6 is parallel to and opposite the second drive plate 4, with an extension 61. The second insulating plate 6 is located on opposite sides of the second drive plate 4, separated from it by a second spacer 7. The extension 61 has mounting holes suitable for connecting to the sidewall of the power unit. The first drive plate 1, first insulating plate 2, second drive plate 4, and second insulating plate 6 are all fixed relative to each other.

[0038] As is easily understood, "directly facing arrangement" means that the two plates are of equal size and their projections coincide in the direction perpendicular to the plates. For example, the first insulating plate 2 and the first driving plate 1 are directly facing each other, meaning that the first insulating plate 2 and the first driving plate 1 have the same size and their projections coincide in the direction perpendicular to the first insulating plate 2; the second driving plate 4 and the first insulating plate 2 are directly facing each other, meaning that the second insulating plate 6 and the first insulating plate 2 have the same size and their projections coincide in the direction perpendicular to the second insulating plate 6.

[0039] Specifically, such as Figure 1 As shown, both the first drive plate 1 and the first insulating plate 2 are rectangular. There are six first support pillars 3, which are located at the four corners of the rectangle and the middle of the two long sides, respectively, providing more stable support. Of course, as an alternative implementation, there can also be four first support pillars 3, located at the four corners of the rectangle; or there can be two first support pillars 3, located at a pair of opposite corners of the rectangle.

[0040] Specifically, such as Figure 1As shown, both the second drive plate 4 and the first insulating plate 2 are rectangular, and there are six isolation pads 5, which are located at the four corners of the rectangle and the middle of the two long sides, respectively, providing more stable support. Of course, as an alternative implementation, there can also be four isolation pads 5, located at the four corners of the rectangle; or there can be two isolation pads 5, located at a pair of opposite corners of the rectangle.

[0041] Specifically, such as Figure 1 As shown, the second drive plate 4 is rectangular, and there are six second support pillars 7, which are located at the four corners and the middle of the two long sides of the second drive plate 4, respectively, providing more stable support. Of course, as an alternative implementation, there can also be four second support pillars 7, located at the four corners of the rectangle; or there can be two second support pillars 7, located at a pair of opposite corners of the rectangle.

[0042] It should be noted that in this embodiment, the first pad 3, the isolation pad 5, and the second pad 7 are arranged in a set corresponding to each other, with the purpose of fixing the various plates relatively through the connection of the three. However, in other embodiments, the three may not be arranged correspondingly, that is, the number and position may not correspond, and they can be connected separately. For example, there are four first pads 3 located at the four corners, and two isolation pads 5 located in the middle of the two long sides. The first pads 3 and the isolation pads 5 can be locked with insulating screws.

[0043] Specifically, both the first insulating board 2 and the second insulating board 6 are made of epoxy resin rigid glass cloth board FR-5 material, which can withstand a withstand voltage of 10KV. Of course, as an alternative implementation, polycarbonate material can also be used.

[0044] Specifically, the first pad 3, the insulating pad 5, and the second pad 7 are all nylon pads, which can meet the insulation characteristics while ensuring rigidity requirements. Of course, as an alternative implementation, other insulating materials such as rigid silicone can also be used for the pads.

[0045] Specifically, such as Figure 1 As shown, the second insulating plate 6 has two extensions 61 relative to the second driving plate 4, and each extension 61 has two mounting holes. Of course, as an alternative embodiment, the extensions 61 may also have only one or three; the number of mounting holes on each extension 61 may also be one or three.

[0046] The integrated drive unit of this embodiment, suitable for high-altitude applications, has two drive boards arranged in a stacked structure. A first insulating plate 2, an isolation pad 5, and a first pad 3 are arranged between the two drive boards to achieve isolation. The second drive board 4 is isolated from the side wall by a second pad 7 and a second insulating plate 6. This effectively realizes the layout of the drive unit in a local space, while also meeting the requirements for electrical clearance and creepage distance, thus forming a drive unit that can be used in high-altitude environments.

[0047] In some embodiments, reference is made to Figure 1 and Figure 2 The integrated drive unit suitable for high altitudes also includes a U-shaped insulating frame 8. The U-shaped insulating frame 8 includes a web plate 81 and two wing plates 82. The web plate 81 is parallel to the second insulating plate 6 and is placed between the second pad 7 and the second insulating plate 6. A connection hole 811 is opened on the web plate 81 at the position corresponding to the mounting hole. The first drive plate 1, the second drive plate 4 and the first insulating plate 2 are all placed in the area enclosed by the U-shaped insulating frame 8.

[0048] Specifically, the U-shaped insulation frame 8 is made of polycarbonate material, i.e., PC board material, which can withstand a withstand voltage of 10KV. Of course, as an alternative implementation, the U-shaped insulation frame 8 can also be made of epoxy resin rigid glass cloth board FR-5 material.

[0049] Easy to understand, such as Figure 1 As shown, a connecting hole 811 is provided on the web plate 81 at the position corresponding to the mounting hole, that is, the web plate 81 also has an extension area relative to the second drive plate 4.

[0050] In these embodiments, since the drive unit is mounted on the side wall of the power unit, the two wings of the U-shaped insulating frame 8 can protect the inner drive board and prevent external cables from contacting the drive board and causing accidents.

[0051] As an improved embodiment of the above embodiments, refer to Figure 1 The first pad 3, the isolation pad 5, and the second pad 7 are set together and correspondingly arranged. Both ends of the isolation pad 5 are provided with extended screws. The first pad 3 and the second pad 7 are provided with threaded grooves. The two extended screws pass through the first insulating plate 2 and the second driving plate 4 respectively and are screwed to the two threaded grooves. The first pad 3 is locked by an insulating screw that passes through the first driving plate 1, and the second pad 7 is locked by an insulating screw that passes through the web plate 81.

[0052] Specifically, the insulating screw is a nylon cylindrical head insulating screw 9. For ease of installation, a slotted nylon cylindrical head insulating screw 9 is selected. Of course, as an alternative implementation, insulating screws of other materials can be used.

[0053] In practical implementation, two extended screws are screwed into two threaded grooves, enabling relative fixation of the first pad 3, the first insulating plate 2, the isolation pad 5, the second drive plate 4, and the second pad 7. The first pad 3 is locked by an insulating screw penetrating the first drive plate 1, achieving relative fixation between the first pad 3 and the first drive plate 1. The second pad 7 is locked by an insulating screw penetrating the web plate 81, achieving relative fixation between the second pad 7 and the U-shaped insulating frame 8. A connecting hole 811 is provided on the web plate 81 at the position corresponding to the mounting hole, enabling relative fixation between the second insulating plate 6 and the U-shaped insulating frame 8 when assembled onto the side wall. In this way, the relative fixation of the entire drive unit is achieved.

[0054] In this improved embodiment, an integrated drive unit is adopted, which can be disassembled and assembled in one piece, realizing the lightweight structural design concept of small components. During assembly, the drive unit can be assembled from small parts such as drive board and insulation board and then assembled on the frame component. If a fault occurs and disassembly is required, it can be disassembled as a whole and then the small parts can be disassembled. The structure is convenient and easy to operate, and meets the requirements of lean production.

[0055] As a further improvement to the above-described improved embodiment, the surface of the second insulating plate 6 that is attached to the web plate 81 is provided with a receiving groove suitable for accommodating the head of the insulating screw.

[0056] In this further improved design, the head of the insulating screw can be placed in the receiving groove so that the surface of the second insulating plate 6 that is in contact with the side wall is flat, thus making the installation more convenient and reliable.

[0057] In another embodiment, refer to Figure 3 The power unit includes a main frame 100, an air-cooled radiator 200, a composite busbar 300, and the aforementioned integrated drive unit suitable for high altitudes. The air-cooled radiator 200 is fixed to the upper part of the main frame 100; the composite busbar 300 is mounted on the main frame 100; and the integrated drive unit suitable for high altitudes is fixed to the side wall of the main frame 100 through mounting holes.

[0058] It should be noted that this list only includes some of the components of the power unit. In addition to these components, it should also include essential components of the power unit such as IGBTs and power board assemblies.

[0059] The power unit in this embodiment has the aforementioned integrated drive unit suitable for high altitudes, so it can meet the requirements for electrical clearance and creepage distance, and thus can be used in high-altitude environments.

[0060] The above are merely specific embodiments of the present invention, enabling those skilled in the art to understand or implement the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the invention. Therefore, the present invention is not to be limited to the embodiments described herein, but is to be accorded the widest scope consistent with the principles and novel features of the invention herein.

Claims

1. An integrated drive unit suitable for high-altitude environments, characterized in that, include: First drive board (1); The first insulating plate (2) is arranged parallel to and directly opposite the first driving plate (1), and the first insulating plate (2) and the first driving plate (1) are separated by at least two first pads (3); The second drive plate (4) is arranged parallel to and directly opposite the first insulating plate (2). The second drive plate (4) and the first drive plate (1) are located on opposite sides of the first insulating plate (2). The second drive plate (4) and the first insulating plate (2) are separated by at least two isolation pads (5). The second insulating plate (6) is parallel to the second driving plate (4) and has an extension (61) opposite to the second driving plate (4). The second insulating plate (6) and the first insulating plate (2) are located on opposite sides of the second driving plate (4). The second driving plate (4) and the second insulating plate (6) are separated by a second pad (7). The extension (61) has mounting holes suitable for connecting to the side wall of the power unit. The first drive board (1), the first insulating board (2), the second drive board (4), and the second insulating board (6) are all fixed relative to each other; The U-shaped insulating frame (8) includes a web (81) and two wing plates (82). The web (81) is parallel to the second insulating plate (6) and is placed between the second pad (7) and the second insulating plate (6). A connecting hole (811) is opened on the web (81) at the position corresponding to the mounting hole. The first drive plate (1), the second drive plate (4) and the first insulating plate (2) are all placed in the area enclosed by the U-shaped insulating frame (8).

2. The integrated drive unit suitable for high altitudes according to claim 1, characterized in that, The first pad (3), the isolation pad (5), and the second pad (7) are set together and correspondingly provided. Both ends of the isolation pad (5) are provided with extended screws. The first pad (3) and the second pad (7) are provided with threaded grooves. The two extended screws pass through the first insulating plate (2) and the second driving plate (4) respectively and are screwed to the two threaded grooves. The first pad (3) is locked by an insulating screw that passes through the first driving plate (1), and the second pad (7) is locked by an insulating screw that passes through the web plate (81).

3. The integrated drive unit suitable for high altitudes according to claim 2, characterized in that, The second insulating plate (6) has a receiving groove on the surface of the web plate (81) that is suitable for accommodating the head of the insulating screw.

4. The integrated drive unit suitable for high altitudes according to claim 3, characterized in that, The insulating screw is a nylon cylindrical head insulating screw (9).

5. The integrated drive unit suitable for high altitudes according to any one of claims 1 to 4, characterized in that, The U-shaped insulating frame (8) is made of polycarbonate material.

6. The integrated drive unit suitable for high altitudes according to claim 1, characterized in that, The first pad (3), the isolation pad (5), and the second pad (7) are all nylon pads.

7. The integrated drive unit suitable for high altitudes according to claim 1, characterized in that, Both the first insulating plate (2) and the second insulating plate (6) are made of epoxy resin rigid glass cloth FR-5 material.

8. A power unit, characterized in that, include: Main framework (100); An air-cooled radiator (200) is fixed to the upper part of the main frame (100); A composite busbar (300) is installed on the main frame (100); The integrated drive unit suitable for high altitude as described in any one of claims 1 to 7, wherein the integrated drive unit suitable for high altitude is fixed to the side wall of the main frame (100) through the mounting hole.

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