Circulating cooling structure of generator

Abstract

The invention belongs to the technical field of generator cooling, and particularly relates to a circulating cooling structure of a generator, which comprises a cooling liquid circulating system, a heat exchange system, a cooling airflow channel and a temperature control system. The problems of low cooling efficiency and unstable system in the prior art are effectively solved; through the synergistic effect of cooling liquid and air, it is ensured that the cooling effect can be kept in the optimal state under different loads and environment conditions; the intelligent adjusting system can automatically adjust the flow speed of cooling liquid and the rotating speed of a fan, and energy consumption is reduced while efficient operation of the system is ensured; the self-cleaning function and the intelligent monitoring system reduce the maintenance cost, improve the reliability of the system and prolong the service life of the system.

Description

Technical Field

[0001] The invention relates to the technical field of generator cooling, and in particular to a circulating cooling structure of a generator. Background Art

[0002] In existing generator cooling technologies, common cooling methods include air cooling, liquid cooling, and oil cooling.

[0003] In the relevant technology, air cooling is the most common method of traditional generator cooling technology. Although this method has a simple structure and low cost, its efficiency is limited by factors such as ambient temperature and air circulation. Under high temperature and high load operating conditions, the effect of air cooling is significantly reduced, which may cause the generator temperature to be too high, affecting the normal operation and life of the equipment. The liquid cooling method absorbs the heat generated inside the generator through circulating coolant and then discharges the heat. Although liquid cooling can provide higher heat exchange efficiency than air cooling, its system is complex and has high maintenance costs, and the leakage of coolant may also affect the stability of the system. In addition, the working effect of the liquid cooling system is also easily affected by the quality of the coolant and temperature fluctuations, making it difficult to achieve long-term stable operation. For this reason, we propose a circulating cooling structure for the generator.

[0004] The above information disclosed in this Background section is only for understanding the background of the present inventive concept and therefore it may contain information that does not constitute prior art. Summary of the invention

[0005] In order to overcome the shortcomings of the prior art, the present invention provides a circulating cooling structure for a generator to solve the problems proposed in the above background technology that the efficiency of air cooling is limited by factors such as ambient temperature and air circulation, the liquid cooling system is complex and the maintenance cost is high, and the leakage of the coolant may also affect the stability of the system.

[0006] The technical solution adopted by the present invention to solve the technical problem is: a circulating cooling structure of a generator, comprising the following structures:

[0007] Coolant circulation system: This system includes a circulation pump, coolant pipes, radiator, and coolant storage tank. The coolant flows continuously in the pipes through the circulation pump, absorbs the heat generated inside the generator, and discharges the heat through the radiator;

[0008] Heat exchange system: The heat exchanger is used to achieve heat exchange between the coolant and the air. During this process, the coolant comes into contact with the outside air and releases the heat it carries. The heat exchanger uses efficient heat exchange materials, such as copper or aluminum alloy, to ensure high heat exchange efficiency.

[0009] Cooling air flow channel: In order to improve the heat dissipation efficiency, the cooling device is equipped with multiple air channels and high-efficiency fans. The fans force air into the generator through mechanical power or electric drive, remove heat through convection, and then discharge the hot air through the cooling air flow channel;

[0010] Temperature control system: The system is equipped with multiple temperature sensors to monitor the temperature of various parts of the generator in real time. When the temperature exceeds the preset threshold, the temperature control system starts the corresponding cooling program and automatically adjusts the coolant flow rate or fan speed to ensure that the generator runs within the optimal temperature range;

[0011] The circulating cooling structure adopts a dual cooling mechanism of coolant and air. Under high load or high temperature environment, the coolant absorbs the heat inside the generator and exchanges heat with the external air through the heat exchanger to ensure that the coolant temperature does not exceed the safe range. At the same time, the air in the cooling air flow channel is enhanced by the fan to enhance the heat dissipation capacity of the heat exchanger, further improving the cooling effect. This dual cooling mechanism maintains a high cooling efficiency under different working environments to ensure that the generator is always in a stable operating state.

[0012] As an optimized technical solution, the coolant circulation system is composed of the following components:

[0013] Circulation pump: provides power to circulate the coolant in the system, located at the starting point of the coolant pipeline or near the coolant storage tank;

[0014] Coolant pipeline: a channel connecting various components to ensure that the coolant can flow within the system. It is made of high temperature and corrosion resistant materials, stainless steel or special plastic;

[0015] Radiator: used to transfer the heat absorbed by the coolant to the air to cool the coolant. There are multiple layers of fine pipes inside the radiator to increase the heat transfer area.

[0016] Coolant storage tank: used to store coolant, provide the liquid source required for circulation, and replenish the coolant in the system when necessary;

[0017] Temperature control sensor and automatic regulating valve: used to monitor coolant temperature and adjust flow rate to ensure that the system operates in the best condition;

[0018] Fan: located behind or beside the radiator, used to accelerate air flow and improve the cooling efficiency of the radiator;

[0019] Structural connection method:

[0020] The coolant enters the circulating pump from the storage tank through the pipe. The circulating pump pushes the coolant to the cooling pipe inside the generator or the casing around the heat source. After absorbing heat, the coolant flows to the radiator and releases heat by contacting with the outside air. After cooling, the coolant flows back to the storage tank to form a closed loop.

[0021] As an optimized technical solution, the heat exchange system:

[0022] Heat exchanger: Made of high-efficiency heat exchange materials, with a large surface area to enhance heat dissipation, the structure includes internal coils and external fins, the coolant flows through the coils, and the air flows through the fins;

[0023] Connection method: The heat exchanger is installed in the coolant circulation pipeline, the coolant inlet end is connected to the circulation pump outlet, and the outlet end is connected to the return pipeline to form a closed loop. The external air channel directly contacts the heat sink and is connected to the cooling air flow channel;

[0024] The cooling air flow channel:

[0025] Air channel: including multiple parallel air ducts, arranged inside the generator to ensure that the air flow evenly covers different parts of the generator. The inlet of the air channel is set at the cooling fan, and the outlet is connected to the external exhaust port;

[0026] Fan system: High-efficiency fans are installed at the entrance of the air channel, and air is forced in through mechanical power or electric drive. The fans ensure uniform air distribution through adjustable guide blades;

[0027] Connection method: The air channel runs through the core area of ​​the generator and is arranged side by side or in series with the heat exchanger. The fan draws air from the environment, enters the generator through the duct and flows through the heat exchanger.

[0028] As an optimized technical solution, the temperature control system:

[0029] Temperature sensors: Multiple temperature sensors are placed at key locations of the generator, including the stator, rotor, coolant inlet and outlet. The sensors are connected to the central control unit (CCU) via cables.

[0030] Central Control Unit (CCU): connected to temperature sensors and fan and coolant pump adjustment equipment, receives temperature data in real time through wireless or wired transmission and issues control signals based on analysis results;

[0031] Actuator: includes electric fan regulator and coolant pump speed controller, which receives instructions from the central control unit to adjust the coolant flow rate and fan speed.

[0032] As an optimized technical solution, the circulating cooling structure has an intelligent adjustment function, which can automatically adjust the coolant flow rate and fan speed according to the working load, ambient temperature and other operating conditions of the generator. When the load is high or the temperature is high, the system automatically speeds up the coolant circulation rate and fan speed; when the load is low or the ambient temperature is low, the system slows down the coolant flow rate and fan speed to reduce energy consumption. The intelligent adjustment system uses temperature control sensors and control units to adjust system parameters through real-time monitoring data to ensure a balance between cooling effect and energy efficiency.

[0033] Implementation process of intelligent adjustment function:

[0034] Sensor data acquisition: Temperature control sensors and load sensors detect the internal temperature, ambient temperature and current load level of the generator in real time, and transmit the data to the control unit;

[0035] Control unit analysis: The control unit runs algorithms based on the received sensor data to analyze the current operating conditions and determine if the coolant flow rate and fan speed need to be adjusted;

[0036] Regulation execution: The control unit drives the frequency converter or motor controller of the circulation pump and fan through signals to achieve real-time regulation of flow rate and speed.

[0037] As an optimized technical solution, the circulating cooling device is designed with a self-cleaning function to ensure that dust and dirt in the radiator and coolant pipes will not affect the cooling effect. The coolant circulation system is equipped with a filter device to automatically clean or replace the coolant regularly to reduce the impact of coolant pollution and sediment on the system. The system is equipped with an intelligent monitoring function that can provide real-time feedback on coolant quality, temperature and pressure parameters to remind operators to perform necessary maintenance work;

[0038] The self-cleaning structure composition and component connection method are as follows:

[0039] Filter device:

[0040] Automatic cleaning filter: It is installed in the coolant pipeline and removes the sediment in the filter by mechanical means or backwashing principle;

[0041] Pipe connection: The filter is connected to the inlet of the coolant circulation pump to ensure that the coolant is cleaned before entering the circulation system;

[0042] Drain valve: installed at the bottom of the filter, draining sediment regularly through an automatic control system;

[0043] Self-cleaning radiator:

[0044] Compressed air nozzle: arranged on the surface of the radiator, used to periodically spray compressed air to clean the dust on the surface;

[0045] Pipeline and control valve: connected to the compressed air storage tank, the control valve is triggered to open and close by an electrical signal;

[0046] Coolant quality monitoring module:

[0047] Sensors: including temperature sensors, pressure sensors, turbidity sensors and conductivity sensors, installed at key locations of the pipeline to monitor the status of the coolant in real time;

[0048] Data transmission line: collects the data of each sensor to the central control unit;

[0049] Intelligent monitoring components:

[0050] Temperature sensor: installed at multiple nodes of the coolant pipeline to monitor temperature changes;

[0051] Pressure sensor: installed at different locations of the pipeline to monitor system pressure to determine whether the pipeline is blocked or leaking;

[0052] Turbidity sensor: located before and after the filter device, used to detect the content of particulate matter in the coolant and determine the contamination level of the coolant;

[0053] Conductivity sensor: used to detect the conductivity of the coolant and evaluate its quality and impurity content.

[0054] As an optimized technical solution, the circulating cooling device adopts an efficient thermal management structure, which can effectively solve the problem of heat accumulation when the generator is running at high power. The collaborative work of coolant and air ensures uniform temperature distribution in different parts, avoiding thermal stress and equipment damage caused by excessive regional temperature. When the generator load fluctuates greatly, the system can respond quickly and adjust the cooling method to ensure the stability of the cooling effect.

[0055] The realization mechanism of uniform temperature distribution:

[0056] Dynamic flow distribution: The central control unit calculates the flow rate of each cooling channel through an algorithm based on the data from multiple temperature sensors, and uses proportional valves to control the coolant flow rate in different areas. It can increase the flow rate in areas with higher temperatures to ensure temperature balance.

[0057] Segmented circulation cooling: The piping system is designed in a segmented circulation mode, allowing the coolant circulation rate in each area to be adjusted individually as needed.

[0058] As an optimized technical solution, the operation process of the temperature control system is as follows:

[0059] Monitoring: The temperature sensor collects the internal temperature data of the generator in real time and transmits it to the central control unit;

[0060] Analysis and response: The central control unit analyzes the temperature data and determines the cooling demand based on the preset temperature threshold. If the temperature exceeds the set value, the central control unit sends a command to the execution component;

[0061] Adjust cooling measures:

[0062] Adjust the coolant flow rate: By adjusting the output power of the coolant pump, the coolant flow rate can be increased or decreased to enhance or reduce heat exchange;

[0063] Adjust fan speed: Automatically adjust fan speed based on temperature data to increase or decrease air flow to enhance or weaken convection cooling;

[0064] Stability control: After the temperature returns to the normal range, the central control unit gradually reduces the fan speed and coolant flow rate to maintain stable operation of the generator.

[0065] The beneficial effects of the present invention are:

[0066] It provides an efficient and stable circulating cooling system, which effectively solves the problems of low cooling efficiency and unstable system in the prior art; through the synergistic effect of coolant and air, it ensures that the cooling effect can be maintained in the best state under different loads and environmental conditions; the intelligent adjustment system can automatically adjust the coolant flow rate and fan speed to ensure that the system operates efficiently while reducing energy consumption; the self-cleaning function and intelligent monitoring system reduce maintenance costs and improve the reliability and service life of the system. BRIEF DESCRIPTION OF THE DRAWINGS

[0067] Figure 1 It is a system connection block diagram of a circulating cooling structure of a generator provided by the present invention;

[0068] Figure 2 It is a flow chart of the self-cleaning monitoring steps of a circulating cooling structure of a generator provided by the present invention. DETAILED DESCRIPTION

[0069] The present invention is further described below in conjunction with the accompanying drawings and specific implementation methods. It should be noted that, under the premise of no conflict, the various embodiments or technical features described below can be arbitrarily combined to form a new embodiment.

[0070] It should be noted that the terms "center", "up", "down", "left", "right", "vertical", "horizontal", "inside", "outside", etc. indicate directions or positional relationships based on the directions or positional relationships shown in the accompanying drawings, or are the directions or positional relationships in which the inventive product is usually placed when in use. They are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific direction, be constructed and operated in a specific direction, and therefore should not be understood as a limitation on the present invention.

[0071] In the description of the present invention, it is also necessary to explain that, unless otherwise clearly specified and limited, the terms "set", "install", "connect", and "connect" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection, or it can be indirectly connected through an intermediate medium, or it can be the internal communication of two elements. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0072] Embodiment 1:

[0073] A circulating cooling structure of a generator in this embodiment includes the following structures:

[0074] Coolant circulation system: This system includes a circulation pump, coolant pipes, radiator, and coolant storage tank. The coolant flows continuously in the pipes through the circulation pump, absorbs the heat generated inside the generator, and discharges the heat through the radiator;

[0075] Heat exchange system: The heat exchanger is used to achieve heat exchange between the coolant and the air. During this process, the coolant comes into contact with the outside air and releases the heat it carries. The heat exchanger uses efficient heat exchange materials, such as copper or aluminum alloy, to ensure high heat exchange efficiency.

[0076] Cooling air flow channel: In order to improve the heat dissipation efficiency, the cooling device is equipped with multiple air channels and high-efficiency fans. The fans force air into the generator through mechanical power or electric drive, remove heat through convection, and then discharge the hot air through the cooling air flow channel;

[0077] Temperature control system: The system is equipped with multiple temperature sensors to monitor the temperature of various parts of the generator in real time. When the temperature exceeds the preset threshold, the temperature control system starts the corresponding cooling program and automatically adjusts the coolant flow rate or fan speed to ensure that the generator runs within the optimal temperature range;

[0078] The circulating cooling structure adopts a dual cooling mechanism of coolant and air. Under high load or high temperature environment, the coolant absorbs the heat inside the generator and exchanges heat with the external air through the heat exchanger to ensure that the coolant temperature does not exceed the safe range. At the same time, the air in the cooling air flow channel is enhanced by the fan to enhance the heat dissipation capacity of the heat exchanger, further improving the cooling effect. This dual cooling mechanism maintains a high cooling efficiency in different working environments to ensure that the generator is always in a stable operating state;

[0079] Coolant and air work together to ensure the generator maintains optimal operating conditions while dissipating heat efficiently. The specific principles are as follows:

[0080] Double heat dissipation: The coolant absorbs internal heat through the generator and exchanges heat with the outside air in the radiator. At this time, the fan drives the air to flow through the surface of the radiator to take away the heat released from the coolant;

[0081] Temperature feedback mechanism: The temperature control system monitors the temperature of the coolant and the generator in real time. When the temperature exceeds the preset threshold, the system will increase the flow rate of the circulation pump or speed up the fan to enhance the heat dissipation effect;

[0082] Load response: When the generator load changes, the system quickly responds to the load change by adjusting the coolant flow rate and fan speed to maintain a stable cooling effect.

[0083] As an optimized technical solution, the coolant circulation system consists of the following components:

[0084] Circulation pump: provides power to circulate the coolant in the system, located at the starting point of the coolant pipeline or near the coolant storage tank;

[0085] Coolant pipeline: a channel connecting various components to ensure that the coolant can flow within the system. It is made of high temperature and corrosion resistant materials, stainless steel or special plastic;

[0086] Radiator: used to transfer the heat absorbed by the coolant to the air to cool the coolant. There are multiple layers of fine pipes inside the radiator to increase the heat transfer area.

[0087] Coolant storage tank: used to store coolant, provide the liquid source required for circulation, and replenish the coolant in the system when necessary;

[0088] Temperature control sensor and automatic regulating valve: used to monitor coolant temperature and adjust flow rate to ensure that the system operates in the best condition;

[0089] Fan: located behind or beside the radiator, used to accelerate air flow and improve the cooling efficiency of the radiator;

[0090] Structural connection method:

[0091] The coolant enters the circulation pump from the storage tank through the pipeline. The circulation pump pushes the coolant to the cooling pipe inside the generator or the casing around the heat source. After absorbing heat, the coolant flows to the radiator and releases heat by contacting with the outside air. After cooling, the coolant flows back to the storage tank to form a closed loop.

[0092] The specific working process is as follows:

[0093] Coolant circulation start: When the generator starts running, the temperature control sensor detects that the temperature of the generator has risen, and the system starts the circulation pump to make the coolant start to flow in the pipeline;

[0094] Heat absorption: The coolant flows through the heat source inside the generator, such as around the generator coil or casing, absorbing heat;

[0095] Heat transfer to radiator: The coolant with heat flows into the radiator, and the fine pipes in the radiator exchange heat between the coolant and the air flowing outside it. The heat is transferred to the outside air through the pipe wall;

[0096] Air synergistic cooling: The fan behind the radiator accelerates the air flow electrically or mechanically to quickly take away the heat. This process enhances the convection heat transfer between the radiator and the air, improving the cooling efficiency;

[0097] Coolant reflux: The cooled coolant flows out of the radiator and returns to the coolant storage tank, completing a cycle;

[0098] Circulation regulation: The intelligent control unit automatically adjusts the operating frequency of the circulation pump and the speed of the fan according to the sensor data to ensure a balance between cooling effect and energy consumption;.

[0099] As an optimized technical solution, the heat exchange system:

[0100] Heat exchanger: Made of high-efficiency heat exchange materials, with a large surface area to enhance heat dissipation, the structure includes internal coils and external fins, the coolant flows through the coils, and the air flows through the fins;

[0101] Connection method: The heat exchanger is installed in the coolant circulation pipeline, the coolant inlet end is connected to the circulation pump outlet, and the outlet end is connected to the return pipeline to form a closed loop. The external air channel directly contacts the heat sink and is connected to the cooling air flow channel;

[0102] Cooling air flow channels:

[0103] Air channel: including multiple parallel air ducts, arranged inside the generator to ensure that the air flow evenly covers different parts of the generator. The inlet of the air channel is set at the cooling fan, and the outlet is connected to the external exhaust port;

[0104] Fan system: High-efficiency fans are installed at the entrance of the air channel, and air is forced in through mechanical power or electric drive. The fans ensure uniform air distribution through adjustable guide blades;

[0105] Connection method: The air channel runs through the core area of ​​the generator and is arranged side by side or in series with the heat exchanger. The fan draws air from the environment, enters the generator through the duct and flows through the heat exchanger;

[0106] Heat exchange process:

[0107] The coolant flows through the coil inside the heat exchanger, taking away the heat inside the generator, and the air flows through the fins of the heat exchanger, receiving the heat released by the coolant and taking the heat away;

[0108] The high thermal conductivity of the heat exchange material ensures that heat is quickly transferred from the coolant to the heat sink and the outside air, maintaining a high heat exchange efficiency;

[0109] How the cooling airflow channel works:

[0110] After the fan is started, it forces external air into the cooling air flow channel through mechanical force or electric drive. The air flows through various cooling channels inside the generator, conducts convection heat exchange with the surface of the generator components, and takes away the heat generated when the equipment is running;

[0111] The heated air is discharged at the outlet of the air flow channel, completing the heat exchange cycle.

[0112] As an optimized technical solution, the temperature control system:

[0113] Temperature sensors: Multiple temperature sensors are placed at key locations of the generator, including the stator, rotor, coolant inlet and outlet. The sensors are connected to the central control unit (CCU) via cables.

[0114] Central Control Unit (CCU): connected to temperature sensors and fan and coolant pump adjustment equipment, receives temperature data in real time through wireless or wired transmission and issues control signals based on analysis results;

[0115] Actuator: including electric fan regulator and coolant pump speed controller, receiving instructions from the central control unit to adjust the coolant flow rate and fan speed;

[0116] Operation of temperature control system:

[0117] Monitoring: The temperature sensor collects the internal temperature data of the generator in real time and transmits it to the central control unit;

[0118] Analysis and response: The central control unit analyzes the temperature data and determines the cooling demand based on the preset temperature threshold. If the temperature exceeds the set value, the central control unit sends a command to the execution component;

[0119] Adjust cooling measures:

[0120] Adjust the coolant flow rate: By adjusting the output power of the coolant pump, the coolant flow rate can be increased or decreased to enhance or reduce heat exchange;

[0121] Adjust fan speed: Automatically adjust fan speed based on temperature data to increase or decrease air flow to enhance or weaken convection cooling;

[0122] Stability control: After the temperature returns to the normal range, the central control unit gradually reduces the fan speed and coolant flow rate to maintain stable operation of the generator.

[0123] In this embodiment, the circulating cooling structure has an intelligent adjustment function, which can automatically adjust the flow rate of the coolant and the speed of the fan according to the working load, ambient temperature and other operating conditions of the generator. When the load is high or the temperature is high, the system automatically speeds up the coolant circulation rate and the fan speed; when the load is low or the ambient temperature is low, the system slows down the coolant flow rate and the fan speed to reduce energy consumption. The intelligent adjustment system uses a temperature control sensor and a control unit to adjust the system parameters through real-time monitoring data to ensure a balance between cooling effect and energy efficiency.

[0124] Implementation process of intelligent adjustment function:

[0125] Sensor data acquisition: Temperature control sensors and load sensors detect the internal temperature, ambient temperature and current load level of the generator in real time, and transmit the data to the control unit;

[0126] Control unit analysis: The control unit runs algorithms based on the received sensor data to analyze the current operating conditions and determine if the coolant flow rate and fan speed need to be adjusted;

[0127] Regulation execution: The control unit drives the inverter or motor controller of the circulation pump and fan through signals to achieve real-time regulation of flow rate and speed;

[0128] A hybrid control strategy combining fuzzy control and PID (proportional-integral-differential) control is used to ensure that the cooling system can make quick and accurate adjustments under different load and environmental conditions;

[0129] (a) PID control model: The PID controller adjusts the coolant flow rate and fan speed according to the following formula:

[0130]

[0131] Where: u(t) is the control signal (such as coolant pump and fan speed);

[0132] K p , K i , K d are proportional, integral and differential gain coefficients respectively;

[0133] e(t) is the system error, that is, the difference between the set temperature and the current temperature

[0134] (b) Fuzzy logic control model: Fuzzy control is used to deal with nonlinear changes in generator load and ambient temperature. The cooling system parameters are adjusted according to the input variables through the fuzzy inference system (FIS). The input variables are generator temperature, ambient temperature and load level, and the output is the coolant flow rate and fan speed adjustment;

[0135] Fuzzy rule example:

[0136] If the generator temperature is high and the ambient temperature is high, increase the coolant flow rate and fan speed;

[0137] If the generator temperature is low and the load is light, reduce the coolant flow rate and fan speed;

[0138] Heat balance equation: The system must satisfy the heat balance relationship while maintaining cooling efficiency:

[0139] Q abs =m·C p ΔT=Q dissipated ;

[0140] in:

[0141] Q abs The heat absorbed by the coolant;

[0142] m is the mass flow rate of coolant;

[0143] C p is the specific heat capacity of the coolant;

[0144] ΔT is the temperature difference between the coolant inlet and outlet;

[0145] Flow rate and speed control equation: Combining heat balance and PID output, the control expression of the system's coolant flow rate V and fan speed ω is:

[0146] V=f(u PID ),ω=g(u PID );

[0147] Where f and g are control signals u PID The nonlinear function mapped to flow rate and rotation speed, the specific form of which can be calibrated experimentally;

[0148] The process of realizing intelligent adjustment

[0149] Data input and preprocessing:

[0150] The control unit receives the sensor data, filters the noise and smoothes the data input.

[0151] Error calculation:

[0152] Calculate the error e(t) between the current temperature of the generator and the set temperature;

[0153] PID adjustment calculation:

[0154] The control signal u(t) is calculated using the PID formula for preliminary adjustment.

[0155] Fuzzy control correction:

[0156] According to the current ambient temperature and load level, the output value of u(t) is adjusted through fuzzy reasoning.

[0157] Adjustment execution:

[0158] The final calculated V and ω signals are sent to the circulation pump and fan driver to regulate their flow rate and speed.

[0159] Feedback Update:

[0160] The control unit continuously receives updated temperature and load data to form a closed-loop control.

[0161] Embodiment 2:

[0162] In this embodiment, the circulating cooling device is designed with a self-cleaning function to ensure that dust and dirt in the radiator and coolant pipes will not affect the cooling effect. A filtering device is provided in the coolant circulation system to automatically clean or replace the coolant regularly to reduce the impact of coolant pollution and sediment on the system. The system is equipped with an intelligent monitoring function, which can provide real-time feedback on the coolant quality, temperature and pressure parameters to remind the operator to perform necessary maintenance work;

[0163] The self-cleaning structure and component connection methods are as follows:

[0164] Filter device:

[0165] Automatic cleaning filter: It is installed in the coolant pipeline and removes the sediment in the filter by mechanical means or backwashing principle;

[0166] Pipe connection: The filter is connected to the inlet of the coolant circulation pump to ensure that the coolant is cleaned before entering the circulation system;

[0167] Drain valve: installed at the bottom of the filter, draining sediment regularly through an automatic control system;

[0168] Self-cleaning radiator:

[0169] Compressed air nozzle: arranged on the surface of the radiator, used to periodically spray compressed air to clean the dust on the surface;

[0170] Pipeline and control valve: connected to the compressed air storage tank, the control valve is triggered to open and close by an electrical signal;

[0171] Coolant quality monitoring module:

[0172] Sensors: including temperature sensors, pressure sensors, turbidity sensors and conductivity sensors, installed at key locations of the pipeline to monitor the status of the coolant in real time;

[0173] Data transmission line: collects the data of each sensor to the central control unit;

[0174] Intelligent monitoring components:

[0175] Temperature sensor: installed at multiple nodes of the coolant pipeline to monitor temperature changes;

[0176] Pressure sensor: installed at different locations of the pipeline to monitor system pressure to determine whether the pipeline is blocked or leaking;

[0177] Turbidity sensor: located before and after the filter device, used to detect the content of particulate matter in the coolant and determine the contamination level of the coolant;

[0178] Conductivity sensor: used to detect the conductivity of the coolant and evaluate its quality and impurity content;

[0179] The algorithm model for realizing intelligent monitoring adopts data fusion and analysis model:

[0180] The data analysis algorithm uses the weighted average method and threshold detection algorithm to comprehensively evaluate the coolant quality. The expression is as follows:

[0181]

[0182] in:

[0183] Q status It is a comprehensive score of the coolant quality status;

[0184] T norm is the normalized value of the temperature sensor data;

[0185] P norm is the normalized value of the pressure sensor data;

[0186] C real and E realare the measured values ​​of current turbidity and conductivity respectively;

[0187] C threshold and E threshold For preset turbidity and conductivity thresholds;

[0188] α, β, γ, and δ are weight coefficients, which are adjusted according to the importance of different parameters;

[0189] Maintenance reminder trigger condition: The system uses the following expression to determine whether maintenance is required:

[0190]

[0191] Where Q min The lowest score allowed for the coolant condition;

[0192] Specific monitoring steps and processes:

[0193] Data collection: Each sensor collects temperature, pressure, turbidity and conductivity data and transmits the data to the central control unit;

[0194] Data analysis: The central control unit runs the data fusion and analysis algorithm to calculate Q status ;

[0195] Result evaluation and feedback: The system compares the calculation result with the preset threshold Q min Make comparisons;

[0196] Maintenance reminder: If M trigger =1, the system sends a reminder to the operator or automatically starts the self-cleaning program;

[0197] Self-cleaning start: The system activates the compressed air nozzle to clean the radiator, or opens the drain valve to clean the filter;

[0198] Real-time Updates: The system continuously monitors and repeats analysis based on new data, ensuring coolant quality and system performance remain at optimal levels.

[0199] Specifically, the circulating cooling device adopts an efficient thermal management structure, which can effectively solve the problem of heat accumulation when the generator is running at high power. The collaborative work of coolant and air ensures uniform temperature distribution in different parts, avoiding thermal stress and equipment damage caused by excessive regional temperature. When the generator load fluctuates greatly, the system can respond quickly and adjust the cooling method to ensure the stability of the cooling effect.

[0200] The realization mechanism of uniform temperature distribution:

[0201] Dynamic flow distribution: The central control unit calculates the flow rate of each cooling channel through an algorithm based on the data from multiple temperature sensors, and uses proportional valves to control the coolant flow rate in different areas. It can increase the flow rate in areas with higher temperatures to ensure temperature balance.

[0202] Segmented circulation cooling: The piping system is designed in a segmented circulation mode, allowing the coolant circulation rate in each area to be adjusted individually as needed;

[0203] Efficient thermal management uses a combination of Thermal Field Balancing Algorithm (TFBA) and distributed PID control strategy to achieve uniform temperature distribution:

[0204] (a) Overview of Thermal Field Balancing Algorithm (TFBA): TFBA calculates the temperature of each sensor point based on its value T. i Calculate heat distribution and adjust coolant distribution. The control goal is to maintain the temperature of all detection points within the target range T set ;

[0205] Mathematical expression:

[0206] Q i =K adj ·(T i -T set );

[0207] Where: Q i is the adjusted coolant flow rate; K adj is the adjustment coefficient, used to control the response speed;

[0208] (b) PID control model is applied in each zone: The PID expression of each cooling zone is:

[0209]

[0210] where e i (t) = T set -T i (t) is the temperature error of the ith region;

[0211] Operation steps flow:

[0212] Data acquisition: The temperature sensor network transmits current temperature data to the central control unit.

[0213] Error calculation: Calculate the temperature error e for each area i (t);

[0214] PID control adjustment: Calculate the flow adjustment signal u according to PID control i (t);

[0215] Flow regulation: TFBA further balances the coolant flow in different areas.

[0216] Execution feedback: Regulate the circulation pump and proportional valve to adjust the coolant flow rate, and the speed of the fan system is adjusted according to the overall heat removal requirements;

[0217] Real-time monitoring and loop: continuously monitor the temperature and repeat the above process;

[0218] The operation process of the temperature control system is as follows:

[0219] Monitoring: The temperature sensor collects the internal temperature data of the generator in real time and transmits it to the central control unit;

[0220] Analysis and response: The central control unit analyzes the temperature data and determines the cooling demand based on the preset temperature threshold. If the temperature exceeds the set value, the central control unit sends a command to the execution component;

[0221] Adjust cooling measures:

[0222] Adjust the coolant flow rate: By adjusting the output power of the coolant pump, the coolant flow rate can be increased or decreased to enhance or reduce heat exchange;

[0223] Adjust fan speed: Automatically adjust fan speed based on temperature data to increase or decrease air flow to enhance or weaken convection cooling;

[0224] Stability control: After the temperature returns to the normal range, the central control unit gradually reduces the fan speed and coolant flow rate to maintain stable operation of the generator.

[0225] The above-mentioned embodiments are only preferred embodiments of the present invention and cannot limit the scope of protection of the present invention in turn. Various combinations, modifications or equivalent substitutions of the technical solutions of the present invention by technicians in this field do not depart from the spirit and scope of the technical solutions of the present invention, and should be included in the scope of the claims of the present invention.

Claims

1. A circulating cooling structure for a generator, characterized in that: Includes the following structures: Coolant circulation system: This system includes a circulation pump, coolant pipes, radiator, and coolant storage tank. The coolant flows continuously in the pipes through the circulation pump, absorbs the heat generated inside the generator, and discharges the heat through the radiator; Heat exchange system: The heat exchanger is used to achieve heat exchange between the coolant and the air. During this process, the coolant comes into contact with the outside air and releases the heat it carries. The heat exchanger uses efficient heat exchange materials, such as copper or aluminum alloy, to ensure high heat exchange efficiency. Cooling air flow channel: In order to improve the heat dissipation efficiency, the cooling device is equipped with multiple air channels and high-efficiency fans. The fans force air into the generator through mechanical power or electric drive, remove heat through convection, and then discharge the hot air through the cooling air flow channel; Temperature control system: The system is equipped with multiple temperature sensors to monitor the temperature of various parts of the generator in real time. When the temperature exceeds the preset threshold, the temperature control system starts the corresponding cooling program and automatically adjusts the coolant flow rate or fan speed to ensure that the generator runs within the optimal temperature range; The circulating cooling structure adopts a dual cooling mechanism of coolant and air. Under high load or high temperature environment, the coolant absorbs the heat inside the generator and exchanges heat with the external air through the heat exchanger to ensure that the coolant temperature does not exceed the safe range. At the same time, the air in the cooling air flow channel is enhanced by the fan to enhance the heat dissipation capacity of the heat exchanger, further improving the cooling effect. This dual cooling mechanism maintains a high cooling efficiency under different working environments to ensure that the generator is always in a stable operating state.

2. A circulating cooling structure for a generator according to claim 1, characterized in that: The coolant circulation system is composed of the following components: Circulation pump: provides power to circulate the coolant in the system, located at the starting point of the coolant pipeline or near the coolant storage tank; Coolant pipeline: a channel connecting various components to ensure that the coolant can flow within the system. It is made of high temperature and corrosion resistant materials, stainless steel or special plastic; Radiator: used to transfer the heat absorbed by the coolant to the air to cool the coolant. There are multiple layers of fine pipes inside the radiator to increase the heat transfer area. Coolant storage tank: used to store coolant, provide the liquid source required for circulation, and replenish the coolant in the system when necessary; Temperature control sensor and automatic regulating valve: used to monitor coolant temperature and adjust flow rate to ensure that the system operates in the best condition; Fan: located behind or beside the radiator, used to accelerate air flow and improve the cooling efficiency of the radiator; Structural connection method: The coolant enters the circulating pump from the storage tank through the pipe. The circulating pump pushes the coolant to the cooling pipe inside the generator or the casing around the heat source. After absorbing heat, the coolant flows to the radiator and releases heat by contacting with the outside air. After cooling, the coolant flows back to the storage tank to form a closed loop.

3. The circulating cooling structure of a generator according to claim 1, characterized in that: The heat exchange system: Heat exchanger: Made of high-efficiency heat exchange materials, with a large surface area to enhance heat dissipation, the structure includes internal coils and external fins, the coolant flows through the coils, and the air flows through the fins; Connection method: The heat exchanger is installed in the coolant circulation pipeline, the coolant inlet end is connected to the circulation pump outlet, and the outlet end is connected to the return pipeline to form a closed loop. The external air channel directly contacts the heat sink and is connected to the cooling air flow channel; The cooling air flow channel: Air channel: including multiple parallel air ducts, arranged inside the generator to ensure that the air flow evenly covers different parts of the generator. The inlet of the air channel is set at the cooling fan, and the outlet is connected to the external exhaust port; Fan system: High-efficiency fans are installed at the entrance of the air channel, and air is forced in through mechanical power or electric drive. The fans ensure uniform air distribution through adjustable guide blades; Connection method: The air channel runs through the core area of ​​the generator and is arranged side by side or in series with the heat exchanger. The fan draws air from the environment, enters the generator through the duct and flows through the heat exchanger.

4. The circulating cooling structure of a generator according to claim 1, characterized in that: The temperature control system: Temperature sensors: Multiple temperature sensors are placed at key locations of the generator, including the stator, rotor, coolant inlet and outlet. The sensors are connected to the central control unit (CCU) via cables. Central Control Unit (CCU): connected to temperature sensors and fan and coolant pump adjustment equipment, receives temperature data in real time through wireless or wired transmission and issues control signals based on analysis results; Actuator: includes electric fan regulator and coolant pump speed controller, which receives instructions from the central control unit to adjust the coolant flow rate and fan speed.

5. The circulating cooling structure of a generator according to claim 1, characterized in that: The circulating cooling structure has an intelligent adjustment function, which can automatically adjust the coolant flow rate and fan speed according to the working load, ambient temperature and other operating conditions of the generator. When the load is high or the temperature is high, the system automatically speeds up the coolant circulation rate and fan speed; when the load is low or the ambient temperature is low, the system slows down the coolant flow rate and fan speed to reduce energy consumption. The intelligent adjustment system uses temperature control sensors and control units to adjust system parameters through real-time monitoring data to ensure a balance between cooling effect and energy efficiency. Implementation process of intelligent adjustment function: Sensor data acquisition: Temperature control sensors and load sensors detect the internal temperature, ambient temperature and current load level of the generator in real time, and transmit the data to the control unit; Control unit analysis: The control unit runs algorithms based on the received sensor data to analyze the current operating conditions and determine if the coolant flow rate and fan speed need to be adjusted; Regulation execution: The control unit drives the frequency converter or motor controller of the circulation pump and fan through signals to achieve real-time regulation of flow rate and speed.

6. A circulating cooling structure for a generator according to claim 1, characterized in that: The circulating cooling device is designed with a self-cleaning function to ensure that dust and dirt in the radiator and coolant pipes will not affect the cooling effect. The coolant circulation system is equipped with a filter device to automatically clean or replace the coolant regularly to reduce the impact of coolant pollution and sediment on the system. The system is equipped with an intelligent monitoring function that can provide real-time feedback on coolant quality, temperature and pressure parameters to remind operators to perform necessary maintenance work; The self-cleaning structure composition and component connection method are as follows: Filter device: Automatic cleaning filter: It is installed in the coolant pipeline and removes the sediment in the filter by mechanical means or backwashing principle; Pipe connection: The filter is connected to the inlet of the coolant circulation pump to ensure that the coolant is cleaned before entering the circulation system; Drain valve: installed at the bottom of the filter, draining sediment regularly through an automatic control system; Self-cleaning radiator: Compressed air nozzle: arranged on the surface of the radiator, used to periodically spray compressed air to clean the dust on the surface; Pipeline and control valve: connected to the compressed air storage tank, the control valve is triggered to open and close by an electrical signal; Coolant quality monitoring module: Sensors: including temperature sensors, pressure sensors, turbidity sensors and conductivity sensors, installed at key locations of the pipeline to monitor the status of the coolant in real time; Data transmission line: collects the data of each sensor to the central control unit; Intelligent monitoring components: Temperature sensor: installed at multiple nodes of the coolant pipeline to monitor temperature changes; Pressure sensor: installed at different locations of the pipeline to monitor system pressure to determine whether the pipeline is blocked or leaking; Turbidity sensor: located before and after the filter device, used to detect the content of particulate matter in the coolant and determine the contamination level of the coolant; Conductivity sensor: used to detect the conductivity of the coolant and evaluate its quality and impurity content.

7. A circulating cooling structure for a generator according to claim 1, characterized in that: The circulating cooling device adopts an efficient thermal management structure, which can effectively solve the problem of heat accumulation when the generator is running at high power. The collaborative work of coolant and air ensures uniform temperature distribution in different parts, avoiding thermal stress and equipment damage caused by excessive regional temperature. When the generator load fluctuates greatly, the system can respond quickly and adjust the cooling method to ensure the stability of the cooling effect. The realization mechanism of uniform temperature distribution: Dynamic flow distribution: The central control unit calculates the flow rate of each cooling channel through an algorithm based on the data from multiple temperature sensors, and uses proportional valves to control the coolant flow rate in different areas. It can increase the flow rate in areas with higher temperatures to ensure temperature balance. Segmented circulation cooling: The piping system is designed in a segmented circulation mode, allowing the coolant circulation rate in each area to be adjusted individually as needed.

8. A circulating cooling structure for a generator according to claim 4, characterized in that: The operation process of the temperature control system is as follows: Monitoring: The temperature sensor collects the internal temperature data of the generator in real time and transmits it to the central control unit; Analysis and response: The central control unit analyzes the temperature data and determines the cooling demand based on the preset temperature threshold. If the temperature exceeds the set value, the central control unit sends a command to the execution component; Adjust cooling measures: Adjust the coolant flow rate: By adjusting the output power of the coolant pump, the coolant flow rate can be increased or decreased to enhance or reduce heat exchange; Adjust fan speed: Automatically adjust fan speed based on temperature data to increase or decrease air flow to enhance or weaken convection cooling; Stability control: After the temperature returns to the normal range, the central control unit gradually reduces the fan speed and coolant flow rate to maintain stable operation of the generator.

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