Integrated single-phase power unit

Abstract

The application relates to the technical field of power units, in particular to an integrated single-phase power unit. The integrated single-phase power unit comprises a main frame, a radiator, a single-phase power module and a driving board assembly; the radiator is fixed to the top of the main frame, the bottom of the radiator is provided with a radiating base plate; the single-phase power module is fixed to the lower surface of the radiating base plate; and the driving board assembly is fixed to the main frame and is in communication connection with the single-phase power module. The integrated single-phase power unit provided by the application independently installs the single-phase power module in the main frame, forms a standardized module for use, three single-phase power units can be assembled for use, and the application flexibility is higher compared with the existing high-integration power module.

Description

Technical Field

[0001] This invention relates to the field of power unit technology, and more particularly to an integrated single-phase power unit. Background Technology

[0002] With the rapid development of high-speed trains, locomotives and EMUs are placing increasingly higher demands on the power of their electric drive systems.

[0003] In order to effectively utilize the internal space of the train converter, existing power units often integrate multiple power conversion functions into a single power module during design, thereby increasing power density. However, this highly integrated power module, forming a single unit, has relatively low application flexibility. Summary of the Invention

[0004] To overcome the technical shortcomings of existing power modules in terms of application flexibility, this invention provides an integrated single-phase power unit.

[0005] This invention provides an integrated single-phase power unit, comprising:

[0006] Main framework;

[0007] A radiator is fixed to the top of the main frame, and a heat dissipation base plate is provided at the bottom of the radiator;

[0008] A single-phase power module is fixed to the lower surface of the heat dissipation substrate;

[0009] The drive board assembly is fixed to the main frame and is communicatively connected to the single-phase power module.

[0010] Optionally, the drive plate assembly includes a cover plate and at least two vertically stacked drive assemblies, the cover plate being fixed to the uppermost drive assembly, the drive assembly comprising:

[0011] A strip-shaped base plate is fixed to the main frame;

[0012] Two side plates are fixed to the two sides of the strip base plate along its length, and the side plates are perpendicular to the strip base plate.

[0013] Four reinforcing columns are arranged vertically and fixed to the inner sides of both ends of the two side plates. The top of the reinforcing column is flush with the upper edge of the side plate and is fixed with a vertically arranged stud. The stud is adapted to penetrate the strip bottom plate of the adjacent upper drive assembly and be locked with a nut. A gap is left between the bottom of the reinforcing column and the strip bottom plate to avoid the stud of the adjacent lower drive assembly.

[0014] The drive plate is fixed to the strip base plate.

[0015] Optionally, the strip base plate, side plate, reinforcing column and stud of the drive assembly are integrally formed.

[0016] Optionally, the strip base plate is also integrally formed with a support column, and a threaded blind hole is provided in the middle of the support column. The drive plate is pressed onto the support column by a bolt that passes through it and is screwed into the threaded blind hole.

[0017] Optionally, the main frame includes a front baffle, a rear panel, a left side panel, and a right side panel. The rear panel protrudes from the front baffle in the left-right direction to form an extension. The extension has a first bolt mounting hole arranged horizontally. The left and right sides of the front baffle are provided with brackets, and the bottom of the brackets has a second bolt mounting hole arranged vertically.

[0018] Optionally, both the left and right side plates are provided with horizontal and vertical reinforcing ribs on their outer sides. The cross-section of the horizontal reinforcing ribs is U-shaped and the depth gradually increases from front to back. The horizontal and vertical reinforcing ribs form a cross-shaped reinforcing rib structure.

[0019] Optionally, the front baffle, rear panel, left side panel, right side panel, bracket, horizontal reinforcing ribs, and vertical reinforcing ribs are all welded together.

[0020] Optionally, a left rear bracket and a right rear bracket are fixed to the top of the main frame. The left rear bracket and the right rear bracket are both located on the rear side of the main frame and on the left and right sides of the radiator, respectively. The left rear bracket and the right rear bracket are both provided with horizontally arranged third bolt mounting holes.

[0021] Optionally, the radiator is an air-cooled radiator, and the number of fins of the air-cooled radiator decreases along the airflow direction.

[0022] Optionally, the single-phase power module includes two sets of IGBTs, each set of IGBTs includes two IGBTs connected in parallel, the two sets of IGBTs share one end as the AC end, and the remaining two ends of the two sets of IGBTs are respectively used as the DC positive end and the DC negative end, and each set of IGBTs shares one driver board.

[0023] The technical solution provided by this invention has the following advantages compared with the prior art:

[0024] The integrated single-phase power unit provided by this invention installs the single-phase power module independently within the main frame to form a standardized module for use. When in use, the three single-phase power units can be assembled. Compared with existing highly integrated power modules, it offers greater application flexibility. Attached Figure Description

[0025] 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.

[0026] 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.

[0027] Figure 1 This is a perspective view of the overall structure of the integrated single-phase power unit according to an embodiment of the present invention;

[0028] Figure 2 This is a front view of the overall structure of the integrated single-phase power unit according to an embodiment of the present invention;

[0029] Figure 3 This is a schematic diagram of the assembly structure of the integrated single-phase power module according to an embodiment of the present invention;

[0030] Figure 4 This is a schematic diagram of the drive board assembly described in an embodiment of the present invention;

[0031] Figure 5 This is an exploded view of the drive board assembly described in an embodiment of the present invention;

[0032] Figure 6 This is a partial structural diagram of the drive assembly described in an embodiment of the present invention (with the drive board removed).

[0033] Figure 7 This is a schematic diagram of the main frame structure according to an embodiment of the present invention;

[0034] Figure 8 This is a circuit diagram of the single-phase power module described in an embodiment of the present invention.

[0035] in:

[0036] 1. Main frame; 11. Front baffle; 12. Rear panel; 121. Extension; 1211. First bolt mounting hole; 13. Left side panel; 14. Right side panel; 15. Bracket; 151. Second bolt mounting hole; 16. Horizontal reinforcing rib; 17. Vertical reinforcing rib; 2. Radiator; 21. Heat sink base plate; 22. Air duct; 3. Single-phase power module; 4. Drive board assembly; 41. Cover plate; 42. Drive assembly; 421. Strip base plate; 422. Side panel; 423. Reinforcing column; 424. Stud; 425. Drive board; 426. Support column; 51. Left rear bracket; 52. Right rear bracket; 53. Third bolt mounting hole; 6. Support capacitor; 7. Composite busbar; 8. Power board; 9. Lifting ring. Detailed Implementation

[0037] 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.

[0038] 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.

[0039] In one embodiment, such as Figures 1 to 3 As shown, the integrated single-phase power unit includes a main frame 1, a heat sink 2, a single-phase power module 3, and a drive board assembly 4; the heat sink 2 is fixed to the top of the main frame 1, and a heat dissipation substrate 21 is provided at the bottom of the heat sink 2; the single-phase power module 3 is fixed to the lower surface of the heat dissipation substrate 21; the drive board assembly 4 is fixed to the main frame 1 and is communicatively connected to the single-phase power module 3.

[0040] Specifically, the main frame 1 can be a structure assembled from multiple parts, or it can be a one-piece structure.

[0041] Specifically, radiator 2 can be either an air-cooled radiator or a water-cooled radiator. For example... Figure 2 As shown, the radiator 2 is an air-cooled radiator, and the air duct 22 of the air-cooled radiator is opened in the front-to-back direction.

[0042] Specifically, the specific circuit layout of the single-phase power module 3 is not limited; a mature structure in this field can be adopted.

[0043] Specifically, the drive board assembly 4 includes a drive board 425 and an insulating support device. The drive board 425 and the insulating support device can adopt existing mature structures, but it is easy to understand that they need to meet the electrical clearance and creepage distance requirements to ensure electrical performance.

[0044] As is readily understood, in addition to the components mentioned above, the integrated single-phase power unit should also include a supporting capacitor 6 and a composite busbar 7. These components are mature in this field, and their installation method is not limited. Here, a preferred installation structure is provided: Refer to Figure 1 The supporting capacitor 6 is located at the bottom of the device, surrounded and supported by the main frame 1, and mainly plays the role of voltage stabilization and filtering; the composite busbar 7 is installed between the single-phase power module 3 and the supporting capacitor 6, and the DC terminals of the composite busbar 7 are respectively installed and fastened to the corresponding terminals of the supporting capacitor 6.

[0045] In practice, the single-phase power module 3 is installed independently in the main frame 1 to form a standardized module. When in use, the three single-phase power units can be assembled. Compared with the existing highly integrated power modules, it has greater application flexibility.

[0046] In some embodiments, reference is made to Figures 4 to 6 The drive plate assembly 4 includes a cover plate 41 and at least two vertically stacked drive assemblies 42. The cover plate 41 is fixed to the uppermost drive assembly 42. The drive assembly 42 includes a strip base plate 421, two side plates 422, four reinforcing columns 423, and a drive plate 425. The strip base plate 421 is fixed to the main frame 1. The two side plates 422 are respectively fixed to the two sides of the strip base plate 421 along its length, and the side plates 422 are perpendicular to the strip base plate 421. The four reinforcing columns 423 and 424 are respectively fixed to the two sides of the strip base plate 421 along its length. 23 are vertically arranged and fixed to the inner sides of both ends of the two side plates 422. The top of the reinforcing column 423 is flush with the upper edge of the side plate 422 and is fixed with a vertically arranged stud 424. The stud 424 is adapted to penetrate the strip base plate 421 of the adjacent upper drive assembly 42 and be locked with a nut. A gap is left between the bottom of the reinforcing column 423 and the strip base plate 421 to avoid the stud 424 of the adjacent lower drive assembly 42. The drive plate 425 is fixed on the strip base plate 421.

[0047] Specifically, refer to Figure 5 The cover plate 41 can be fixed to the uppermost drive assembly 42 by using the stud 424 of the drive assembly 42, so that the stud 424 passes through the cover plate 41, and then the cover plate 41 is fixed to the uppermost drive assembly 42 with the help of nuts and washers; it can also be fixed to the uppermost drive assembly 42 by other common methods such as snap-fit.

[0048] Specifically, in the drive assembly 42, the fixing between the strip base plate 421, side plate 422, reinforcing column 423, and stud 424 can be achieved by bonding or bolting, or by integral molding. The latter is preferred, as integral molding provides both excellent insulation and stable mechanical strength, ensuring both electrical and mechanical performance. It should be noted that existing drive plate assemblies often consist of a single-layer drive plate 425 mounted on an insulating plate via insulating pads, or multiple insulating plates connected in series with insulating pads. The limitation is that the series connection strength of the insulating pads is relatively low, serving only a supporting function. This is only suitable for displacement-free installations in wind power or State Grid products, and not for products operating at high speeds such as locomotives and EMUs. This integrally molded insulating support device can address the impacts and vibrations from different directions and accelerations generated during the operation of locomotives and EMUs.

[0049] It is easy to understand that the strip base plate 421, side plate 422, reinforcing column 423 and stud 424 used to support and fix the drive plate 425 should all be made of insulating material.

[0050] Specifically, the drive plate 425 can be fixed to the strip base plate 421 by means of clips, bolts, adhesive, etc. A preferred fixing structure is provided here: Refer to... Figure 5 The strip-shaped base plate 421 also has an integrally formed support column 426. The support column 426 has a threaded blind hole in the middle. The drive plate 425 is pressed onto the support column 426 by bolts that pass through it and are screwed into the threaded blind hole. This preferred fixing structure makes installation and disassembly more convenient, and the blind hole can isolate the electrical gaps between the drive plates 425 of each layer, which is more conducive to ensuring electrical performance.

[0051] In practice, this drive board assembly 4 assembles the drive board 425 into a small component, which facilitates overall disassembly and maintenance, and can achieve the isolation and insulation assembly of multiple drive boards 425 according to different needs.

[0052] In some embodiments, reference is made to Figure 7 The main frame 1 includes a front baffle 11, a rear back panel 12, a left side panel 13, and a right side panel 14. The rear back panel 12 protrudes from the front baffle 11 in the left-right direction to form an extension 121. The extension 121 has a horizontally arranged first bolt mounting hole 1211. The left and right sides of the front baffle 11 are provided with brackets 15. The bottom of the brackets 15 has a vertically arranged second bolt mounting hole 151.

[0053] Specifically, waist-shaped holes are provided on the left side plate 13, the right side plate 14 and the back plate 12, which serve to reduce weight and dissipate heat, and can also be used for binding and fixing wire harnesses.

[0054] Specifically, refer to Figure 3 The power board 8 is fixed on the left side plate 13. Therefore, a clearance groove and grounding post are provided at the power supply fixing position to ensure electrical clearance and grounding safety of the power board 8. The power board 8 is suitable for AC and DC power supply and mainly consists of a rectifier circuit and a filter circuit. It converts the AC or DC power input from the single-phase power unit into DC power after full-bridge rectification. After passing through the LC filter circuit, the output DC voltage supplies power to the driver board 425. The power board 8 has a soft-start function, which can protect against overcurrent generated during heavy-load startup and prevent impact on corresponding components.

[0055] In practical implementation, the main frame 1 of this solution abandons the long screw installation method commonly used in the industry. The first bolt mounting hole 1211 is used to fix the main frame 1 in the horizontal direction, and the second bolt mounting hole 151 is used to fix the main frame 1 in the vertical direction. The bolts are directly tightened, making assembly and disassembly more convenient, and overcoming the defect of easy loosening that exists in the existing long screw installation.

[0056] Furthermore, refer to Figure 7Both the left side plate 13 and the right side plate 14 are provided with horizontal stiffeners 16 and vertical stiffeners 17 on their outer sides. The cross section of the horizontal stiffener 16 is U-shaped and the depth gradually increases from front to back. The horizontal stiffener 16 and the vertical stiffener 17 form a cross-shaped stiffener structure. Through the design of the gradually changing stiffener structure, the main frame 1 can meet the strength and modal requirements and meet the Class B impact vibration requirements of GB / T 21563.

[0057] Furthermore, the front baffle 11, rear panel 12, left side panel 13, right side panel 14, bracket 15, horizontal reinforcing rib 16, and vertical reinforcing rib 17 are all welded together. Welding allows the front baffle 11, rear panel 12, left side panel 13, right side panel 14, bracket 15, horizontal reinforcing rib 16, and vertical reinforcing rib 17 to form an integrated welded structure, which better ensures structural strength.

[0058] Furthermore, refer to Figure 2 The main frame 1 is fixed to the top with a left rear bracket 51 and a right rear bracket 52. Both the left and right rear brackets 51 and 52 are located at the rear of the main frame 1 and on the left and right sides of the radiator 2, respectively. Both the left and right rear brackets 51 and 52 have horizontally arranged third bolt mounting holes 53. These third bolt mounting holes 53 secure the main frame 1 horizontally, and together with the first bolt mounting holes 1211, make the main frame 1 more firmly fixed. Furthermore, the left and right rear brackets 51 and 52 also contribute to strengthening the structural integrity of the main frame 1.

[0059] Furthermore, refer to Figure 2 The top of the main frame 1 is fixed with a lifting ring 9 for hoisting and moving the entire single-phase power unit.

[0060] In some embodiments, the radiator 2 is an air-cooled radiator, and the number of fins in the air-cooled radiator decreases along the airflow direction. In this heat dissipation structure, the radiator 2 fins adopt a gradient design, with the number of fins decreasing sequentially from the air inlet to the air outlet, which avoids heat accumulation and improves heat dissipation capacity.

[0061] In some embodiments, reference is made to Figure 8 The single-phase power module 3 includes two sets of IGBTs. Each set of IGBTs includes two IGBTs connected in parallel. The two sets of IGBTs share one end as the AC end. The remaining two ends of the two sets of IGBTs are used as the DC positive end and the DC negative end, respectively. Each set of IGBTs shares one driver board 425.

[0062] Specifically, the driver board 425 uses a programmable intelligent chip for driver design, and the driver parameters and fault protection thresholds can be flexibly set by the program.

[0063] In practical implementation, single-phase power module 3 can be used as one phase of an inverter circuit, performing DC / AC conversion, with P being the positive DC input terminal, N the negative DC input terminal, and AC the AC output terminal; or it can be used as one phase of a rectifier circuit, performing AC / DC conversion, with P the positive DC output terminal, N the negative DC output terminal, and AC the AC input terminal. In other words, this phase power module can achieve bidirectional energy flow.

[0064] 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 single-phase power unit, characterized in that, include: Main framework (1); The radiator (2) is fixed to the top of the main frame (1), and the bottom of the radiator (2) is provided with a heat dissipation base plate (21). A single-phase power module (3) is fixed to the lower surface of the heat dissipation substrate (21); A drive board assembly (4) is fixed to the main frame (1) and is communicatively connected to the single-phase power module (3). The drive board assembly (4) includes a cover plate (41) and at least two vertically stacked drive assemblies (42). The cover plate (41) is fixed to the uppermost drive assembly (42). The drive assembly (42) includes a strip base plate (421), two side plates (422), four reinforcing columns (423), and a drive plate (425). The strip base plate (421) is fixed to the main frame (1). The two side plates (422) are respectively fixed to the two sides of the strip base plate (421) in the length direction. 22) Perpendicular to the strip base plate (421), four reinforcing columns (423) are arranged vertically and fixed to the inner sides of the two side plates (422) respectively. The top of the reinforcing column (423) is flush with the upper edge of the side plate (422) and is fixed with a vertically arranged stud (424). The stud (424) is adapted to penetrate the strip base plate (421) of the adjacent upper drive assembly (42) and be locked with a nut. The bottom of the reinforcing column (423) and the strip base plate (421) are left with a gap suitable for avoiding the stud (424) of the adjacent lower drive assembly (42). The drive plate (425) is fixed on the strip base plate (421).

2. The integrated single-phase power unit according to claim 1, characterized in that, The strip base plate (421), side plate (422), reinforcing column (423) and stud (424) of the drive assembly (42) are integrally formed.

3. The integrated single-phase power unit according to claim 2, characterized in that, The strip base plate (421) is also integrally formed with a support column (426). The support column (426) has a threaded blind hole in the middle. The drive plate (425) is pressed onto the support column (426) by a bolt that passes through it and is screwed into the threaded blind hole.

4. The integrated single-phase power unit according to claim 1, characterized in that, The main frame (1) includes a front baffle (11), a rear back plate (12), a left side plate (13) and a right side plate (14). The rear back plate (12) protrudes from the front baffle (11) in the left-right direction to form an extension (121). The extension (121) has a horizontally arranged first bolt mounting hole (1211). The front baffle (11) has brackets (15) on both the left and right sides. The bottom of the brackets (15) has a vertically arranged second bolt mounting hole (151).

5. The integrated single-phase power unit according to claim 4, characterized in that, The outer sides of the left side plate (13) and the right side plate (14) are provided with horizontal reinforcing ribs (16) and vertical reinforcing ribs (17). The cross section of the horizontal reinforcing rib (16) is U-shaped and the depth gradually increases from front to back. The horizontal reinforcing ribs (16) and vertical reinforcing ribs (17) form a cross-shaped reinforcing rib structure.

6. The integrated single-phase power unit according to claim 5, characterized in that, The front baffle (11), rear back plate (12), left side plate (13), right side plate (14), bracket (15), horizontal reinforcing rib (16) and vertical reinforcing rib (17) are all welded together.

7. The integrated single-phase power unit according to claim 4, characterized in that, The top of the main frame (1) is fixed with a left rear bracket (51) and a right rear bracket (52). The left rear bracket (51) and the right rear bracket (52) are both located on the rear side of the main frame (1) and on the left and right sides of the radiator (2), respectively. The left rear bracket (51) and the right rear bracket (52) are both provided with horizontally arranged third bolt mounting holes (53).

8. The integrated single-phase power unit according to claim 1, characterized in that, The radiator (2) is an air-cooled radiator, and the number of fins of the air-cooled radiator decreases along the airflow direction.

9. The integrated single-phase power unit according to any one of claims 1 to 8, characterized in that, The single-phase power module (3) includes two sets of IGBTs. Each set of IGBTs includes two IGBTs connected in parallel. The two sets of IGBTs share one end as the AC end. The remaining two ends of the two sets of IGBTs are respectively the DC positive end and the DC negative end. Each set of IGBTs shares one driver board (425).

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