A converter device

Abstract

The application belongs to the technical field of converter, and particularly relates to a converter device. The converter device comprises a cabinet body and a charging machine module installed in the cabinet body; a vacuum DC contactor is arranged in the charging machine module; the vacuum DC contactor comprises a shell, a contactor main body arranged in the shell and an arc extinguishing cover; the opening and closing end of the contactor main body is located in the arc extinguishing cover; and the shell is filled with inert gas. The cabinet body comprises a top plate, a bottom plate, two side plates, two door frame plates, two inner partition plates and a plurality of lifting lugs; the bottom plate is arranged opposite to the top plate; the two side plates are arranged opposite to each other at the longitudinal ends of the bottom plate and are connected with the top plate through a frame mounting beam; the two door frame plates are arranged opposite to each other at the transverse ends of the bottom plate and are connected with the top plate, the bottom plate, the side plates and the frame mounting beam; the two inner partition plates are arranged in parallel and spaced apart between the two door frame plates; and the lifting lugs are fixedly arranged on the frame mounting beam. The application optimizes the structural design of the converter and meets the development trend of lightweight and compactness of the converter.

Description

Technical Field

[0001] This invention belongs to the field of converter technology, and specifically relates to a converter device. Background Technology

[0002] As a core component of locomotives and rolling stock, converters play a crucial role in regulating electrical energy and controlling power output during vehicle operation. With increasing customer demands for lightweight and compact converters, existing converters need to be optimized to meet this growing trend.

[0003] Currently, the charger modules inside the converter cabinet are usually equipped with traditional contactors. These contactors are heavy and bulky, and the arc generated between the moving and stationary contacts is relatively strong and has a long arcing time when breaking the circuit. A considerable arc extinguishing space is also required to ensure the working safety of the traditional contactor inside the converter. Therefore, they occupy a large space and reduce the volume ratio of the converter cabinet. It can be seen that traditional contactors are not conducive to the development of lightweight and compact converters.

[0004] In addition, the converter cabinet is currently mainly assembled using two methods: welding and riveting. For example... Figures 1-4As shown, the commonly used converter cabinet mainly consists of a main unit assembly 1a, two secondary unit assemblies 2a, and two lifting lug assemblies 3a. Specifically, a magnetic element mounting beam 17a is installed on each of the two transverse sides inside the main unit assembly 1a; a secondary unit assembly 2a is installed on each of the two transverse sides outside the main unit assembly 1a, forming a unit body; the two lifting lug assemblies 3a are respectively installed on the two longitudinal sides outside the unit body, and each lifting lug assembly 3a is connected to both the main unit assembly 1a and the two secondary unit assemblies 2a. The main unit component 1a includes a main welded frame 11a and multiple main frame skins covering the main welded frame 11a. The main welded frame 11a is mainly welded from 12 angle aluminum profiles. The main frame skins include a main top plate 12a, a first side plate 13a, a second side plate 14a, a main air duct plate 15a, and two branch air duct plates 16a. Each branch air duct plate 16a is provided with an air duct 161a, and the main top plate 12a is provided with an air inlet 121a corresponding to the position of each air duct 161a. To ensure airtightness, the main frame skins and the main welded frame 11a need to be glued together before riveting. The secondary unit assembly 2a includes a secondary welded frame 21a and multiple secondary frame skins covering the secondary welded frame 21a. The secondary welded frame 21a is mainly welded from 12 angle aluminum profiles. The secondary frame skins include a secondary top plate 22a, a secondary bottom plate 23a, a third side plate 24a, a fourth side plate 25a, a fifth side plate 26a, and a door frame plate 27a. To ensure sealing, the secondary frame skins and the secondary welded frame 21a need to be glued together before riveting. The lifting lug assembly 3a includes an angle aluminum profile 31a and multiple lifting lugs 32a installed on the angle aluminum profile 31a. However, the above-mentioned commonly used converter cabinets have the following disadvantages:

[0005] 1) The converter cabinet has a large number of parts, a complex structure, and many links in the dimensional chain, making it difficult to ensure machining accuracy;

[0006] 2) There are issues of overlapping skin and overlapping angle aluminum profiles between the main unit component 1a and the secondary unit component 2a. Specifically, the air duct plate 16a overlaps with the fifth side plate 26a, the angle aluminum profiles 111a and 211a overlap, the angle aluminum profiles 112a and 212a overlap, the angle aluminum profiles 113a and 213a overlap, and the angle aluminum profiles 114a and 214a overlap. This results in a heavier converter cabinet, more complex manufacturing process, and higher cost.

[0007] 3) When the main frame skin is connected to the main welded frame 11a, and when the secondary frame skin is connected to the secondary welded frame 21a, a large number of rivets are required; when the secondary unit assembly 2a is installed with the main unit assembly 1a, screws are required; the use of rivets and screws results in higher cost and heavier weight for the converter cabinet.

[0008] 4) The converter cabinet uses a large amount of angle aluminum profiles, and the lifting lugs 32a are manufactured by machining, resulting in high cost, long processing time and serious waste of materials; and although the angle aluminum profiles 111a of the main welded frame 11a reduce the structural dimensions of the corresponding air duct 161a, the size of the air inlet 121a on the main top plate 12a of the converter cabinet is still small due to this, which leads to an increase in system air resistance.

[0009] 5) The main welded frame 11a and the secondary welded frame 21a are each welded from 12 angle aluminum profiles. The welds are located at a position of geometric discontinuity, which leads to severe stress concentration and low fatigue strength.

[0010] 6) If rivet holes are pre-drilled on the angle aluminum profile before welding the main welded frame 11a, the rivet holes on the main welded frame 11a are prone to mismatch with the rivet holes on the main frame skin due to deformation after welding, making installation impossible. Similarly, the same problem will exist between the secondary welded frame 21a and the secondary frame skin. Therefore, the rivet holes on the main welded frame 11a and the secondary welded frame 21a need to be drilled to match the rivet holes on the main frame skin and the secondary frame skin respectively after welding, which is labor-intensive.

[0011] 7) Before the main frame skin is connected to the main welded frame 11a, and before the secondary frame skin is connected to the secondary welded frame 21a, glue treatment is required. The glue application work is extensive and costly.

[0012] 8) The magnetic component mounting beam 17a is made of carbon steel square tube. It usually has a large cross-sectional area and thick wall to ensure the stiffness required when it bears the load. Therefore, the magnetic component mounting beam 17a is heavy and does not meet the principle of lightweighting, resulting in a decrease in system power density and an increase in processing and operating costs. In addition, the existing magnetic component mounting beam 17a is only connected to the main welded frame 11a at both ends in the length direction. Its span is large and its own lateral stiffness is poor. The system's natural frequency is low, which may lead to resonance. Summary of the Invention

[0013] To address the shortcomings of related technologies, this invention provides a converter device that aims to optimize the structural design of the converter and meet the development trend of lightweight and compact converters.

[0014] This invention provides a converter device, including a cabinet and a charger module installed inside the cabinet; wherein, the charger module is equipped with a vacuum DC contactor, the vacuum DC contactor including a housing, a contactor body disposed within the housing, and an arc-extinguishing shroud; the opening and closing end of the contactor body is located inside the arc-extinguishing shroud, and the housing is filled with inert gas; the cabinet includes a main frame, the main frame including:

[0015] roof;

[0016] The base plate is positioned opposite the top plate.

[0017] Sidewalls, the sidewalls include:

[0018] Two oppositely arranged side panels are respectively located at both ends of the longitudinal direction of the base plate. The top of each side panel is connected to the top plate and the bottom is connected to the base plate through a frame installation beam.

[0019] Two door frame panels are arranged opposite each other, and the two door frame panels are respectively located at both ends of the horizontal direction of the bottom plate. Each door frame panel is connected to the top plate, the bottom plate, the two side plates and the two frame mounting beams.

[0020] Two inner partitions are parallel to the door frame panels and are spaced apart between the two door frame panels. The two inner partitions divide the inner cavity of the main frame into a central chamber and two side chambers located on both sides of the central chamber.

[0021] Several lifting lugs are fixed to the frame mounting beam.

[0022] This technical solution solves the problems of heavy weight, large size, and large space occupation of existing traditional contactors, and solves the problems of large number of parts, heavy weight, high production cost, and complex assembly of existing converter cabinets. It simplifies the structure of the converter cabinet and thus achieves the optimized design of lightweight and compact converter.

[0023] In some embodiments, the vacuum DC contactor further includes an isolation cover, two conductive plates, and two wiring screws disposed outside the housing; the ends of the two conductive plates that are close to each other are respectively connected to the contactor body, and the ends that are far apart from each other are respectively connected to a wiring screw, and the isolation cover is disposed outside the ends of the two conductive plates that are close to each other.

[0024] In some of these embodiments,

[0025] The frame mounting beam has a first mounting part and a second mounting part that are perpendicular to each other. The first mounting part is butt-welded to the top plate, and the second mounting part is butt-welded to a side plate.

[0026] The bottom of the side plate is provided with a bent section, which is butt-welded to the bottom plate;

[0027] The two door frame panels are connected to the top plate, bottom plate, two side plates and two frame mounting beams by fillet welds, and the discontinuous positions of the fillet welds are sealed with sealant.

[0028] The two inner partitions are connected to the top plate, bottom plate, two side plates and two frame installation beams by fillet welds, and the discontinuous positions of the fillet welds are sealed with sealant.

[0029] This technical solution solves the problems of severe stress concentration in the welds of existing converter cabinets, low fatigue strength, large amount of rivets, large amount of drilling and caulking work, and high cost, thus ensuring the strength and sealing of the main frame of the converter cabinet.

[0030] In some embodiments, several support ribs are provided on the bottom plate located in both side chambers. The support ribs are arranged laterally along the bottom plate and are corner welded to the bottom plate. This technical solution further enhances the strength of the main frame of the converter cabinet.

[0031] In some embodiments, the converter cabinet further includes two magnetic element mounting beams disposed within the central cavity. Each magnetic element mounting beam is vertically connected between the two frame mounting beams, and each magnetic element mounting beam is connected to the top plate and an inner partition. This technical solution achieves the connection between the magnetic element mounting beams and the main frame of the converter cabinet.

[0032] In some embodiments, each magnetic element mounting beam is fitted with at least two reinforcing plates along its length to connect it to the top plate and an inner partition. This technical solution solves the problems of existing magnetic element mounting beams having large spans, poor lateral stiffness, and low system natural frequencies.

[0033] In some embodiments, each magnetic element mounting beam has an adapter at both ends for connection to the frame mounting beam; a lifting lug is provided at the connection point between the frame mounting beam and the magnetic element mounting beam, and the lifting lug is fixedly connected to the corresponding adapter. This technical solution realizes the connection between the magnetic element mounting beam, the frame mounting beam, and the lifting lug.

[0034] In some embodiments, the magnetic component mounting beam is a fish-belly-shaped variable cross-section beam with weight-reduction holes. This technical solution achieves lightweighting of the magnetic component mounting beam and improves the system's natural frequency.

[0035] In some embodiments, a plurality of bent plates are connected between the two magnetic element mounting beams; each bent plate has at least one upper plate portion, two lower plate portions, and an inclined plate portion connecting the upper and lower plate portions, so that the bent plate is in a continuous bending state with up-and-down undulations. This technical solution further improves the lateral stiffness of the magnetic element mounting beam 2.

[0036] In some embodiments, the cabinet further includes an internal component mechanism disposed within the central cavity, the internal component mechanism including:

[0037] Air duct components, the air duct components include:

[0038] The main air duct plate is placed on the base plate and connected to the base plate by fillet welding.

[0039] Two opposing air duct plates are respectively located on both sides of the main air duct plate and connected to the main air duct plate. Each air duct plate is corner-welded to the top plate, an inner partition plate and the bottom plate, and each air duct plate and an inner partition plate form an air duct. The top plate is provided with two air inlets, which correspond one-to-one with the air duct and are connected to the air duct.

[0040] Two wind deflectors are arranged opposite each other. The two wind deflectors are located between two air distribution duct plates and are connected to the air distribution duct plates and the main air distribution duct plate. Each wind deflector is corner welded to the bottom plate.

[0041] The first reinforcing rib is located on the main air duct plate and is connected between the two wind deflectors.

[0042] Several second reinforcing ribs are provided on the main air duct plate and connected between the two branch air duct plates;

[0043] The mounting box is located opposite the main air duct plate and is corner welded to one side plate.

[0044] This technical solution enables the connection between the duct assembly and mounting box and the main frame of the converter cabinet, and also solves the problem of increased system air resistance caused by the obstruction of the air inlet of the existing converter cabinet by the angle aluminum profile.

[0045] In some embodiments, the top plate, bottom plate, side plates, frame mounting beams, door frame plates, inner partitions, lifting lugs, support ribs, magnetic component mounting beams, reinforcing plates, adapters, main air duct plates, branch air duct plates, wind deflectors, first reinforcing ribs, second reinforcing ribs, and mounting boxes are all sheet metal formed parts. This technical solution improves the processing technology of variable fluid cabinet components, shortens processing time, saves raw materials, and reduces production costs.

[0046] Based on the above technical solutions, the converter device in the embodiments of the present invention solves the various drawbacks of existing converters, realizes the optimized design of converter structure, and enables the converter to meet the development trend of lightweight and compact design. Attached Figure Description

[0047] The accompanying drawings, which are included to provide a further understanding of the invention and form part of this application, illustrate exemplary embodiments of the invention and, together with their description, serve to explain the invention and do not constitute an undue limitation thereof. In the drawings:

[0048] Figure 1 A perspective view of a converter cabinet in the prior art;

[0049] Figure 2 Exploded view of components in a converter cabinet of existing technology;

[0050] Figure 3Exploded views of the main unit components and secondary unit components in the prior art;

[0051] Figure 4 Exploded views of the main welded frame and secondary welded frame in the prior art;

[0052] Figure 5 This is a perspective view of the overall structure of the converter device of the present invention;

[0053] Figure 6 This is a schematic diagram of the charger module of the present invention;

[0054] Figure 7 This is a schematic diagram of the structure of the vacuum DC contactor of the present invention;

[0055] Figure 8 This is a perspective view of the converter cabinet of the present invention (bending plates are not shown);

[0056] Figure 9 The three-dimensional structure of the main frame of the present invention Figure 1 ;

[0057] Figure 10 The three-dimensional structure of the main frame of the present invention Figure 2 ;

[0058] Figure 11 for Figure 9 A magnified view of a section at point A in the middle;

[0059] Figure 12 This is an exploded view of the main frame structure of the present invention;

[0060] Figure 13 This is a perspective view of some components of the present invention that are connected to the main frame;

[0061] Figure 14 This is a perspective view of the reinforcing plate of the present invention.

[0062] Figure 15 This is a perspective view of the adapter of the present invention;

[0063] Figure 16 This is a perspective view of the lifting lug of the present invention;

[0064] Figure 17 A perspective view of the magnetic element mounting beam of the present invention;

[0065] Figure 18 Density distribution diagram of the topology optimization of the magnetic element mounting beam of the present invention;

[0066] Figure 19 Structural stress diagram for topology optimization of the magnetic element mounting beam of the present invention;

[0067] Figure 20This is a connection diagram of the magnetic element mounting beam and the bending plate of the present invention;

[0068] Figure 21 This is a cross-sectional view of the bent plate of the present invention.

[0069] Figures 1-4 middle:

[0070] 1a. Main unit assembly; 11a. Main welded frame; 111a / 112a / 113a / 114a. Angle aluminum profiles; 12a. Main top plate; 121a. Air inlet; 13a. First side plate; 14a. Second side plate; 15a. Main air duct plate; 16a. Branch air duct plate; 161a. Air duct; 17a. Magnetic component mounting beam;

[0071] 2a. Secondary unit assembly; 21a. Secondary welded frame; 211a / 212a / 213a / 214a. Angle aluminum profiles; 22a. Secondary top plate; 23a. Secondary bottom plate; 24a. Third side plate; 25a. Fourth side plate; 26a. Fifth side plate; 27a. Door frame panel;

[0072] 3a. Lifting lug assembly; 31a. Angle aluminum profile; 32a. Lifting lug;

[0073] Figures 5-21 middle:

[0074] 1. Main frame; 11. Top plate; 111. Air inlet; 12. Bottom plate; 121. Support rib; 13. Side wall; 131. Side plate; 1311. Bending section; 132. Door frame panel; 133. Frame mounting beam; 1331. First mounting section; 1332. Second mounting section; 14. Inner partition; 15. Lifting lug; 151. First mounting section of lifting lug; 151. Second mounting section of lifting lug;

[0075] 2. Magnetic component mounting beam; 21. Reinforcing plate; 211. First mounting part of reinforcing plate; 212. Second mounting part of reinforcing plate; 213. Third mounting part of reinforcing plate; 22. Adapter; 221. First mounting part of adapter; 222. Second mounting part of adapter; 223. Third mounting part of adapter; 23. Weight reduction hole; 24. Bending plate; 241. Upper plate; 242. Lower plate; 243. Inclined plate; 244. Opening.

[0076] 3. Internal component structure; 31. Air duct assembly; 311. Main air duct plate; 312. Branch air duct plate; 3121. Air duct; 313. Wind baffle; 314. First reinforcing rib; 315. Second reinforcing rib; 32. Mounting box;

[0077] 4. Charger module; 5. Vacuum DC contactor; 51. Housing; 52. Contactor body; 521. Stationary contact; 522. Moving contact; 53. Arc extinguishing chamber; 54. Isolation chamber; 55. Conductive plate; 56. Wiring screw; 57. Conductive screw; 6. Capacitor assembly; 7. Filter assembly; 8. Heat dissipation assembly;

[0078] C1, central chamber; C2, side chamber; F1, transition surface; WL1, first butt weld; WL2, second butt weld; WL3, third butt weld. Detailed Implementation

[0079] The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of them. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0080] In the description of this invention, it should be understood that the terms "lateral," "longitudinal," "vertical," "top," "bottom," "inner," and "outer," etc., indicate the orientation or positional relationship based on the appendix. Figure 8 The orientations or positional relationships shown are for the convenience of describing the invention and for simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as limiting the invention. It should be noted that the appendix... Figure 8 The terms "lateral", "longitudinal", and "vertical" are defined based on the overall orientation of the locomotive and rolling stock. "Largeitudinal" is consistent with the width direction of the locomotive and rolling stock, "longitudinal" is consistent with the length direction of the locomotive and rolling stock, i.e., the direction of operation of the locomotive and rolling stock, and "vertical" is consistent with the height direction of the locomotive and rolling stock.

[0081] The terms "first," "second," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined with "first," "second," etc., may explicitly or implicitly include one or more of that feature.

[0082] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "joining" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal communication between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0083] like Figures 5-10 As shown, a converter device of the present invention includes a cabinet, a charger module 4, a capacitor assembly 6, a filter assembly 7, and a heat dissipation assembly 8, etc.; wherein, the heat dissipation assembly 8 is installed on the upper part of the cabinet, and the charger module 4, the capacitor assembly 6, and the filter assembly 7 are installed inside the cabinet. A vacuum DC contactor 5 is configured inside the charger module 4; the vacuum DC contactor 5 includes a housing 51, a contactor body 52 disposed within the housing 51, and an arc-extinguishing shroud 53; the opening and closing end of the contactor body 52 is located inside the arc-extinguishing shroud 53. The contactor body 52 includes two stationary contacts 521 and a moving contact 522 disposed opposite to the two stationary contacts 521; the opening and closing end of the contactor body 52 is the relative engaging end of the stationary contacts 521 and the moving contact 522; the opening and closing of the vacuum DC contactor 5 is realized by the moving contact 522 moving up and down driven by a coil or a return spring. The housing 51 is filled with an inert gas. To further explain, the inert gas encapsulation within the housing 51 effectively prevents oxidation of the stationary contact 521 and the moving contact 522, enabling faster disconnection and virtually eliminating arcing. Furthermore, the arc-extinguishing shroud 53 further ensures the operational safety of the vacuum DC contactor 5. Therefore, compared to traditional contactors, the vacuum DC contactor 5 offers better safety and a longer lifespan. Consequently, applying the vacuum DC contactor 5 to the charger module 4 of the converter essentially eliminates the need for pre-reserved arc-extinguishing space, significantly reducing the contactor's weight and volume, thereby minimizing its footprint, increasing the converter cabinet's volumetric efficiency, and promoting the lightweight and compact development of converters.

[0084] The cabinet includes a main frame 1, which further includes a top plate 11, a bottom plate 12, side walls 13, two inner partitions 14, and several hanging lugs 15.

[0085] The base plate 12 and the top plate 11 are arranged opposite each other in the vertical direction; it can be understood that, for ease of explanation, the top plate 11 and the base plate 12 are used as a reference. Figure 8 The orientation is defined in the vertical direction shown.

[0086] The side wall 13 includes two oppositely arranged side panels 131 and two oppositely arranged door frame panels 132. The two side panels 131 are respectively located at both ends of the longitudinal direction of the base plate 12. The top of each side panel 131 is connected to the top plate 11 via a frame mounting beam 133, and the bottom is connected to the base plate 12. The two door frame panels 132 are respectively located at both ends of the transverse direction of the base plate 12. Each door frame panel 132 is connected to the top plate 11, the base plate 12, the two side panels 131, and the two frame mounting beams 133.

[0087] Both inner partitions 14 are parallel to the door frame panels 132 and are spaced apart between the two door frame panels 132. The two inner partitions 14 divide the inner cavity of the main frame 1 into a central chamber C1 and two side chambers C2 located on both sides of the central chamber C1. It should be noted that in this embodiment, the entire inner cavity of the main frame 1 is divided into three relatively regular sub-chambers by two parallel inner partitions 14, but the present invention is not limited thereto; those skilled in the art can adjust the arrangement and number of inner partitions 14 according to actual needs to obtain the desired shape and number of sub-chambers.

[0088] The lifting lugs 15 are fixed to the frame mounting beams 133. In this embodiment, four lifting lugs 15 are arranged on each frame mounting beam 133, but it is understood that the present invention is not limited thereto.

[0089] In the above illustrative embodiment, the application of the vacuum DC contactor 5 significantly reduces the weight and volume of the contactor, thereby reducing the space occupied by the contactor, increasing the volumetric efficiency of the converter cabinet, and contributing to the development of lightweight and compact converters. Furthermore, the main frame 1 of the converter cabinet has fewer and more precise components, and the connection relationships between the components are simple and clear, resulting in fewer dimensional chain links and easier assurance of machining accuracy. Combined with... Figure 2 , Figure 3 As shown, existing converter cabinets have a large number of complex components, are heavy, and costly. The connections between components are also cumbersome and complicated, resulting in a large number of dimensional chain links and making it difficult to ensure machining accuracy. Therefore, the converter cabinet of the present invention solves the above-mentioned problems of existing converter cabinets, simplifies the structure of the converter cabinet, reduces production costs, and reduces the weight of the converter, thereby achieving an optimized design of lightweight and compact converter.

[0090] like Figure 6 , Figure 7 As shown, in some embodiments, the vacuum DC contactor 5 further includes an isolation cover 54, two conductive plates 55, and two wiring screws 56 disposed outside the housing 51. The ends of the two conductive plates 55 that are close to each other are respectively connected to the contactor body 52; specifically, two conductive screws 57 are provided on the upper part of the housing 51 to connect one conductive plate 55 and one stationary contact 521 respectively; it is understood that the two conductive plates 55 do not directly contact each other, and an isolation plate is provided between them. The ends of the two conductive plates 55 that are far apart from each other are respectively connected to a wiring screw 56. When using the vacuum DC contactor 5, the wires are connected to the wiring screws 56. Because the two wiring screws 56 are far apart from each other, the distance between the two terminals is relatively larger, resulting in better isolation. The isolation cover 54 is disposed outside the ends of the two conductive plates 55 that are close to each other, and the isolation cover 54 is used for insulation.

[0091] like Figures 9-12As shown, in some embodiments, each frame mounting beam 133 has a first mounting portion 1331 and a second mounting portion 1332 that are perpendicular to each other. The first mounting portion 1331 is butt-welded to the top plate 11, forming a first butt weld WL1 between them; the second mounting portion 1332 is butt-welded to a side plate 131, forming a second butt weld WL2 between them. Each side plate 131 has a bent portion 1311 at its bottom, which is butt-welded to the bottom plate 12, forming a third butt weld WL3 between them. Figure 4 As shown, the main welded frame 11a and secondary welded frame 21a of the existing converter cabinet are each welded from 12 angle aluminum profiles, and the welds are all located in positions of geometric discontinuity, resulting in severe stress concentration and low fatigue strength at the welds. In contrast, the first butt weld WL1, the second butt weld WL2, and the third butt weld WL3 of the present invention are all located in positions of geometric continuity, resulting in smooth welds, low stress concentration, high fatigue strength, good welding strength, high production efficiency, and good weld sealing, eliminating the need for additional sealant application.

[0092] Furthermore, the thicknesses of the two plates connected by butt welding can be the same or different. For example... Figure 11 As shown, taking the butt welding of the top plate 11 and the first mounting part 1331 as an example, when the thickness of the first mounting part 1331 is greater than the thickness of the top plate 11, a chamfer is applied to the first mounting part 1331 to form a transition surface F1 that smoothly connects with the top plate 11, thereby improving the fatigue strength of the weld. The smoother the transition surface, the higher the fatigue strength of the weld. It is understood that those skilled in the art can flexibly choose to set the transition surface F1 on one or both sides of the thicker plate according to the requirements of butt welding two plates of different thicknesses.

[0093] The two door frame panels 132 are corner-welded to the top plate 11, bottom plate 12, two side plates 131, and two frame mounting beams 133, respectively, with intermittent fillet weld seams sealed with sealant. Similarly, the two inner partitions 14 are corner-welded to the top plate 11, bottom plate 12, two side plates 131, and two frame mounting beams 133, with intermittent fillet weld seams sealed with sealant. Compared to the existing method of applying sealant to all skins of the converter cabinet before connecting them to the frame, the present invention significantly reduces the amount of sealant applied to the converter cabinet, lowering production costs and saving production time.

[0094] The above illustrative embodiments solve the problems of severe stress concentration in the welds of existing converter cabinets, low fatigue strength, large amount of rivets, large amount of drilling and rivet hole work and high cost, and ensure the strength and sealing of the main frame 1 of the converter cabinet.

[0095] like Figure 9As shown, in some embodiments, the base plate 12 located in both side chambers C2 is provided with a plurality of support ribs 121. The support ribs 121 are arranged transversely along the base plate 12 and are corner welded to the base plate 12. This illustrative embodiment further enhances the strength of the main frame 1 of the converter cabinet.

[0096] like Figure 8 , Figure 9 As shown, in some embodiments, the cabinet also includes two magnetic element mounting beams 2 disposed in the central chamber C1. Each magnetic element mounting beam 2 is vertically connected between two frame mounting beams 133, and each magnetic element mounting beam 2 is connected to the top plate 11 and an inner partition 14. This illustrative embodiment realizes the connection between the magnetic element mounting beams 2 and the main frame 1 of the converter cabinet.

[0097] like Figure 8 , Figure 13 As shown, in some embodiments, each magnetic element mounting beam 2 is equipped with at least two reinforcing plates 21 along its length to connect to the top plate 11 and an inner partition 14 via the reinforcing plates 21.

[0098] Furthermore, such as Figure 8 , Figure 13 , Figure 14 As shown, the reinforcing plate 21 has a first mounting part 211, a second mounting part 212, and a third mounting part 213. The first mounting part 211 is connected to the magnetic element mounting beam 2, the second mounting part 212 is connected to the top plate 11, and the third mounting part 213 is connected to an inner partition 14. Based on its connection to the frame mounting beam 133 at both ends, the magnetic element mounting beam 2 benefits from the addition of the reinforcing plate 21, which provides auxiliary support, reduces the span, and thus increases the lateral stiffness of the magnetic element mounting beam 2, ensuring the required stiffness under load and increasing the system's natural frequency to avoid resonance. It is understood that those skilled in the art can also use other structural components to achieve the same auxiliary support for the magnetic element mounting beam 2.

[0099] Compared to the existing magnetic element mounting beam 17a, which is only connected to the main welded frame 11a at both ends of its length, the above illustrative embodiment solves the problems of large span, poor lateral stiffness, and low system natural frequency of the existing magnetic element mounting beam 17a by setting the reinforcing plate 21, and significantly improves the lateral stiffness of the magnetic element mounting beam 2.

[0100] like Figure 8 , Figure 13As shown, in some embodiments, each magnetic element mounting beam 2 has a connector 22 installed at both ends to connect to the frame mounting beam 133 via the connector 22; a lifting lug 15 is provided at the connection position between the frame mounting beam 133 and the magnetic element mounting beam 2, and the lifting lug 15 is fixedly connected to the corresponding connector 22.

[0101] Furthermore, such as Figure 8 , Figure 13 , Figure 15 , Figure 16 As shown, the adapter 22 has a first mounting portion 221, a second mounting portion 222, and a third mounting portion 223 that are perpendicular to each other; the lifting lug 15 has a first mounting portion 151 and a second mounting portion 152 that are perpendicular to each other. The first mounting portion 151 is connected to the first mounting portion 221 of the adapter; the second mounting portion 152 is connected to the second mounting portion 222 of the adapter; and the third mounting portion 223 is connected to the magnetic element mounting beam 2.

[0102] In the above illustrative embodiment, the connection between the magnetic element mounting beam 2, the frame mounting beam 133, and the lifting lug 15 is realized through the setting of the adapter 22, thereby improving the overall lifting strength of the converter cabinet.

[0103] like Figure 8 , Figure 17 As shown, in some embodiments, the magnetic element mounting beam 2 is a fish-belly-shaped variable cross-section beam with weight-reducing holes 23. The fish-belly-shaped variable cross-section beam structure has a larger cross-sectional dimension in the middle position, thus ensuring the vertical stiffness of the magnetic element mounting beam 2. Specifically, looking along the length of the magnetic element mounting beam 2, the vertical dimension of the cross-section in the middle is larger than that at both ends, thus giving the entire magnetic element mounting beam 2 a fish-belly-shaped variable cross-section. Furthermore, the cross-sectional shape of the magnetic element mounting beam 2 is U-shaped, and the opening directions of the U-shaped cross-sections of the two magnetic element mounting beams 2 are opposite to each other.

[0104] To further explain, in order to achieve the goal of lightweighting, the shape of the weight-reducing hole 23 is obtained through topology optimization in this embodiment. Figure 18 For the density distribution diagram of topology optimization, density analysis is performed on magnetic component mounting beam 2 without weight reduction design; Figure 18 The color bar on the left side represents the density value. The darker the color, the higher the density value, indicating that the material is more necessary to leave. Therefore, based on the analysis results of this density distribution map, the area where the material is removed, namely the area of ​​the weight reduction hole 23, is determined, and the three-dimensional structural optimization design of the magnetic component mounting beam 2 is carried out. Figure 19 To obtain the structural stress diagram for topology optimization, a strength analysis is performed on the magnetic component mounting beam 2 after structural optimization. Figure 19The color bars on the left represent stress values; the darker the color, the greater the stress value. The maximum stress value obtained from the analysis is less than the material's yield stress, indicating that the structural optimization of the magnetic component mounting beam 2 is satisfactory, meaning the weight-reduction holes 23 are reasonably placed. Through the above topology optimization, the volume of the magnetic component mounting beam 2 can be minimized, reducing its weight and also increasing the system's natural frequency.

[0105] Furthermore, the magnetic element mounting beam 2 is manufactured using sheet metal bending. Compared to the existing carbon steel square tube structure of the magnetic element mounting beam 17a, the magnetic element mounting beam 2 of the present invention is lighter in weight, has better manufacturability, can improve system power density, and reduce processing and operating costs.

[0106] The above illustrative embodiment ensures the vertical stiffness of the magnetic element mounting beam 2 and achieves the lightweighting of the magnetic element mounting beam 2.

[0107] like Figure 20 , Figure 21 As shown, in some embodiments, a plurality of bent plates 24 are connected between the two magnetic element mounting beams 2. Each bent plate 24 has at least one upper plate portion 241, two lower plate portions 242, and an inclined plate portion 243 connecting the upper plate portion 241 and the lower plate portions 242, so that the bent plate 24 is in a continuous bending state with up and down undulation; this continuous bending state allows the bent plate 24 to form a truss structure when combined with the two magnetic element mounting beams 2, which improves the lateral stiffness of the magnetic element mounting beams 2, ensures the stiffness required when bearing load, and increases the natural frequency of the system to avoid resonance. The lower plate portion 242 of the bent plate 24 is connected to two magnetic element mounting beams 2; the upper plate portion 241 of the bent plate 24 can be provided with openings 244 as needed to connect the upper plate portion 241 to other cover plates outside the converter cabinet, further improving the lateral stiffness of the magnetic element mounting beams 2 and the system's natural frequency; the inclined plate portion 243 is connected and supported between the upper plate portion 241 and the lower plate portion 242, enhancing the stiffness of the bent plate 24. It should be noted that the present invention does not limit the number of bent plates 24 or the number of consecutive bends on each bent plate 24; those skilled in the art can flexibly adjust and arrange them according to actual needs.

[0108] Compared to the existing magnetic element mounting beam 17a, which is only connected to the main welded frame 11a at both ends along its length, the above illustrative embodiment solves the problems of large span, poor lateral stiffness, and low system natural frequency of the existing magnetic element mounting beam 17a by setting the bending plate 24, and significantly improves the lateral stiffness of the magnetic element mounting beam 2.

[0109] like Figure 8 , Figure 10 , Figure 13As shown, in some embodiments, the converter cabinet also includes an internal component mechanism 3 disposed in the central chamber C1, the internal component mechanism 3 including an air duct assembly 31 and a mounting box 32.

[0110] The air duct assembly 31 further includes a main air duct plate 311, two branch air duct plates 312, two baffle plates 313, a first reinforcing rib 314, and several second reinforcing ribs 315. The main air duct plate 311 is disposed on the base plate 12 and is corner-welded to the base plate 12. The two branch air duct plates 312 are arranged opposite to each other, respectively disposed on both sides of the main air duct plate 311 and connected to the main air duct plate 311. Each branch air duct plate 312 is corner-welded to the top plate 11, an inner partition plate 14, and the base plate 12, and each branch air duct plate 312 and the inner partition plate 14 form an air duct 3121. The top plate 11 is provided with two air inlets 111, each corresponding to an air duct 3121, and the air inlets 111 are connected to the air duct 3121. The air inlet 111 is unobstructed and has a large size, resulting in lower system air resistance. This solves the problem of increased system air resistance caused by the obstruction of the existing converter cabinet air inlet 121a by the angle aluminum profile 111a.

[0111] Two baffle plates 313 are arranged opposite each other, located between two branch air duct plates 312 and connected to the branch air duct plates 312 and the main air duct plate 311. Each baffle plate 313 is corner-welded to the base plate 12. A first reinforcing rib 314 is provided on the main air duct plate 311 and is connected between the two baffle plates 313. Several second reinforcing ribs 315 are provided on the main air duct plate 311 and are connected between the two branch air duct plates 312.

[0112] The mounting box 32 is located opposite the main air duct plate 311 and is corner welded to the side plate 131 opposite the main air duct plate 311.

[0113] The above illustrative embodiment realizes the connection between the air duct assembly 31 and the mounting box 32 and the main frame 1 of the converter cabinet, and solves the problem of increased system wind resistance caused by the obstruction of the existing converter cabinet air inlet 121a by the angle aluminum profile 111a.

[0114] In some embodiments, the top plate 11, bottom plate 12, side plate 131, frame mounting beam 133, door frame plate 132, inner partition 14, lifting lug 15, support rib 121, magnetic element mounting beam 2, reinforcing plate 21, adapter 22, main air duct plate 311, branch air duct plate 312, wind baffle 313, first reinforcing rib 314, second reinforcing rib 315, and mounting box 32 are all sheet metal formed parts. This illustrative embodiment improves the processing technology of the variable fluid cabinet components, shortens processing time, saves raw materials, and reduces production costs.

[0115] As can be seen from the above description of the embodiments, the converter device of the present invention has at least the following advantages:

[0116] 1) By applying the vacuum DC contactor 5 on the charger module 4, the weight and volume of the contactor are significantly reduced, thereby reducing the space occupied by the contactor, increasing the volume ratio of the converter cabinet, and contributing to the development of lightweight and compact converters.

[0117] 2) The main frame 1 of the cabinet is mainly formed by welding, which significantly reduces the number of parts of the converter cabinet, improves the processing and assembly process, increases welding strength and production efficiency, reduces production costs, simplifies the structure of the converter cabinet, and thus realizes the lightweight and compact design of the converter.

[0118] 3) The magnetic component mounting beam 2 of the cabinet adopts a fish-belly-shaped variable cross-section beam design to ensure its vertical stiffness; the magnetic component mounting beam 2 is set with a reinforcing plate 21 or a bent plate 24 or a combination of both to reduce the span and improve its lateral stiffness, thereby significantly improving the natural frequency of the system; the magnetic component mounting beam 2 is provided with weight reduction holes 23, which realizes the weight reduction of the magnetic component mounting beam 2 and also improves the natural frequency of the system; in addition, the magnetic component mounting beam 2 is connected to the frame mounting beam 133 and the lifting lug 15 through the setting of the adapter 22, which improves the overall lifting strength of the converter cabinet;

[0119] 4) The air duct plate 312 and the inner partition plate 14 form an air duct 3121. The air inlet 111 on the top plate 11 corresponds to and is connected to the air duct 3121. The air inlet 111 is unobstructed and has a large size, which reduces the system's air resistance.

[0120] 5) Through the optimized design of the converter cabinet, the cabinet structure is simple, easy to manufacture, strong and lightweight, which significantly improves production efficiency and reduces production costs.

[0121] Finally, it should be noted that the various embodiments in this specification are described in a progressive manner, with each embodiment focusing on the differences from other embodiments. The same or similar parts between the various embodiments can be referred to each other.

[0122] The above embodiments are only used to illustrate the technical solutions of the present invention and not to limit them; although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications can still be made to the specific implementation of the present invention or equivalent substitutions can be made to some technical features without departing from the spirit of the technical solutions of the present invention, and all such modifications and substitutions should be covered within the scope of the technical solutions claimed in the present invention.

Claims

1. A converter device, characterized in that, The system includes a cabinet and a charger module installed within the cabinet. The charger module contains a vacuum DC contactor, which includes a housing, a contactor body disposed within the housing, and an arc-extinguishing shroud. The opening and closing ends of the contactor body are located within the arc-extinguishing shroud, and the housing is filled with inert gas. The cabinet includes a main frame and two magnetic component mounting beams. The main frame includes: roof; A base plate, which is disposed opposite to the top plate; Sidewall, the sidewall comprising: Two opposing side plates are respectively arranged at both ends of the longitudinal direction of the base plate. The top of each side plate is connected to the top plate and the bottom is connected to the base plate through a frame mounting beam. Two door frame panels are arranged opposite each other, and the two door frame panels are respectively arranged at both ends of the horizontal direction of the bottom plate. Each door frame panel is connected to the top plate, the bottom plate, the two side plates and the two frame mounting beams. Two inner partitions, both parallel to the door frame panels and spaced apart, divide the inner cavity of the main frame into a central chamber and two side chambers located on either side of the central chamber. Two magnetic element mounting beams are disposed within the central chamber, each vertically connected between the two frame mounting beams. Each magnetic element mounting beam has at least two reinforcing plates mounted along its length to connect to the top plate and one of the inner partitions. The magnetic element mounting beams are fish-belly type variable cross-section beams and have weight-reducing holes. Several lifting lugs are fixed to the frame mounting beam.

2. The converter device as described in claim 1, characterized in that, The vacuum DC contactor also includes an isolation cover, two conductive plates, and two wiring screws disposed outside the housing; the ends of the two conductive plates that are close to each other are respectively connected to the contactor body, and the ends that are far apart from each other are respectively connected to one of the wiring screws, and the isolation cover is disposed outside the ends of the two conductive plates that are close to each other.

3. The converter device as described in claim 1, characterized in that, The frame mounting beam is provided with a first mounting part and a second mounting part that are perpendicular to each other. The first mounting part is butt-welded to the top plate, and the second mounting part is butt-welded to a side plate. The bottom of the side plate is provided with a bent part, which is butt-welded to the bottom plate; The two door frame panels are respectively corner-welded to the top plate, the bottom plate, the two side plates and the two frame mounting beams, and the discontinuous positions of the corner welds are sealed with sealant; The two inner partitions are respectively corner-welded to the top plate, bottom plate, two side plates and two frame mounting beams, and the discontinuous positions of the corner welds are sealed with sealant.

4. The converter device as described in claim 1 or 3, characterized in that, Several support ribs are provided on the bottom plate located in the two side chambers. The support ribs are arranged in the transverse direction of the bottom plate and are corner welded to the bottom plate.

5. The converter device as claimed in claim 1, characterized in that, Each of the magnetic element mounting beams has an adapter at both ends for connection to the frame mounting beam; a lifting lug is provided at the connection position between the frame mounting beam and the magnetic element mounting beam, and the lifting lug is fixedly connected to the corresponding adapter.

6. The converter device as claimed in claim 1, characterized in that, A plurality of bending plates are connected between the two magnetic element mounting beams; each bending plate has at least one upper plate portion, two lower plate portions, and an inclined plate portion connecting the upper plate portion and the lower plate portion, so that the bending plate is in a continuous bending state of up and down undulation.

7. The converter device as claimed in claim 1, characterized in that, The cabinet also includes an internal component mechanism disposed within the central cavity, the internal component mechanism comprising: Air duct assembly, the air duct assembly comprising: The main air duct plate is disposed on the base plate and is corner welded to the base plate; Two opposing air duct plates are respectively located on both sides of the main air duct plate and connected to the main air duct plate. Each air duct plate is corner-welded to the top plate, an inner partition plate, and the bottom plate, and each air duct plate and the inner partition plate form an air duct. The top plate is provided with two air inlets, each corresponding to an air duct, and the air inlets are connected to the air duct. Two wind baffles are arranged opposite each other. The two wind baffles are located between the two air distribution duct plates and are connected to the air distribution duct plates and the main air duct plate. Each wind baffle is corner welded to the bottom plate. The first reinforcing rib is disposed on the main air duct plate and is connected between the two wind deflectors. Several second reinforcing ribs are provided on the main air duct plate and connected between the two branch air duct plates; The mounting box is located opposite the main air duct plate and is corner welded to one of the side plates.

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