Integrated rectifier device, control system and method

Abstract

The present invention provides an integrated rectifier device, control system, and method. The integrated rectifier device includes a main body, a processing module, a power module, a first output element, a second output element, a host, and at least one slave. The processing module, power module, host, and slave are integrated on the main body. The host and slave are respectively communicatively connected to the processing module and electrically connected to the power module. The rated load current of the host is not less than the rated load current of the slave. The first output end of the host and the first output end of each slave are electrically connected to the first output element. The second output end of the host and the second output end of each slave are electrically connected to the second output element. One end of the first output element and the second output element protrudes from the outside of the main body. The present invention can simultaneously control the host and slave, ensure current sharing, avoid the tediousness of separate control, reduce occupied space, and greatly facilitate use.

Description

Technical Field

[0001] The present invention relates to the technical field of electroplating rectification, and in particular to an integrated rectification device, a control system and a method. Background Art

[0002] In existing industrial electroplating rectification, when the current to be carried reaches several thousand amperes or even tens of thousands of amperes, multiple rectifiers are usually connected to the rectification object separately, and then each rectifier is controlled separately. This is not only cumbersome to control, but also difficult to control the current balance, making it difficult to achieve the current balance effect and unable to guarantee the quality of the coating. In addition, the rectifiers are scattered and the temporary space is large. Summary of the Invention

[0003] In view of this, the purpose of the present invention is to provide an integrated rectifier device, control system and method to solve the problems in the prior art of connecting multiple rectifier devices to the rectifier object separately and then controlling each rectifier device separately, such as cumbersome control operations, difficult current balancing control, difficulty in achieving current balancing effect and large temporary space.

[0004] In order to solve the above technical problems, the technical solution used in the present invention is:

[0005] The integrated rectifier device of the present invention includes a main body, a processing module, a power module, a first output element, a second output element, a host device, and at least one slave device. The processing module, power module, host device, and slave device are integrated on the main body. The host device and the slave device are respectively communicatively connected to the processing module and are respectively electrically connected to the power module.

[0006] The rated load current of the host is not less than the rated load current of the slave, the first output end of the host and the first output end of each of the slaves are electrically connected to the first output element, the second output end of the host and the second output end of each of the slaves are electrically connected to the second output element, and one end of the first output element and the second output element both protrude from the outside of the main body.

[0007] Preferably, a first cavity and a second cavity are provided in the main body, the host and the slave are stacked in the first cavity, and the processing module and the power supply module are provided in the second cavity.

[0008] Preferably, the host and the slave are both liquid-cooled, and the main body is provided with a first main pipe and a second main pipe, the inlet end of the first main pipe and the outlet end of the second main pipe both extend out of the main body, the outlet end of the first main pipe is respectively connected to the liquid inlets of the host and the slave, and the inlet end of the second main pipe is respectively connected to the liquid outlets of the host and the slave.

[0009] Preferably, the processing module includes a management unit and a PLC unit, the management unit is communicatively connected to the PLC unit, the host and the slave are communicatively connected to the management unit respectively, and the PLC unit is used to communicate with a host computer.

[0010] Further preferably, the power module includes a master control power unit, a management power unit and a stand-alone power unit, and the number of the stand-alone power units is the same as the total number of the host and the slaves, and corresponds to the host and the slaves.

[0011] Preferably, the host or the slave includes a first heat sink and a second heat sink arranged in parallel and at intervals, and one or more transformer assemblies, the transformer assembly is located between the first heat sink and the second heat sink, and is arranged at intervals along the parallel extension direction of the first heat sink and the second heat sink, and a synchronous rectifier module corresponding to the transformer assembly is respectively provided on the upper and lower sides of one of the heat sinks, and the heat sink, the synchronous rectifier module and the corresponding transformer assembly form a current circuit, and the transformer assembly and the other heat sink form another current circuit.

[0012] Further preferably, the upper side and the lower side of the first heat dissipation block are provided with extension portions extending toward the second heat dissipation block, and the extension portions and the corresponding upper side or lower side of the first heat dissipation block together constitute a support portion;

[0013] The synchronous rectification module is fixed to the support portion, and a driving module corresponding to the synchronous rectification module is provided on the side of the first heat dissipation block facing away from the second heat dissipation block.

[0014] Further preferably, the synchronous rectification module includes a circuit board, a first output element, and two second output elements arranged in parallel, the first output element having two symmetrical and parallel rows of MOSFET chips, the two rows of MOSFET chips being separated by a preset distance, the second output elements within the preset distance being electrically connected to the transformer assembly, and the MOSFET chips in each row being evenly spaced and electrically connected to the first output element;

[0015] The second output elements are symmetrically arranged on both sides of the first output element, and each of the second output elements and one of the rows of MOSFET chips are located on the same side of the first output element. The MOSFET chips in each row are electrically connected to the second output elements on the same side. The second output elements are electrically connected to the heat sink of the rectifier device after being attached to each other.

[0016] The circuit board is provided with a first through hole, the two rows of MOSFET chips pass through the first through hole, the circuit board is stacked on the second output element, and each of the MOSFET chips is electrically connected to the circuit board.

[0017] Another object of the present invention is to provide a rectifier control system, comprising a host computer and the above-mentioned integrated rectifier device, wherein the host computer is communicatively connected to a processing module in the integrated rectifier device, the host computer is preset with a control program, the control program includes a voltage stabilization start mode and a current stabilization start mode, and the control program is preset with a first current value;

[0018] In the voltage stabilization startup mode, a preset target voltage value is input to the host computer, the host computer sends a first instruction to the processing module, and after receiving the first instruction, the processing module controls the host to start in the voltage stabilization mode. The host feeds back its output current value to the processing module in real time, and the processing module receives the output current value and determines whether the output current value is less than the first current value. If so, the processing module sends a first feedback signal to the host computer, and the host computer does not issue an instruction after receiving the first feedback signal. If not, the processing module sends a second feedback signal to the host computer, and after receiving the second feedback signal, the host computer sends a second instruction to the processing module. After receiving the second instruction, the processing module controls the slave to start in the current stabilization mode until the host voltage value reaches the preset target voltage value;

[0019] In the steady current startup mode, a preset target current value is input to the host computer, and the host computer sends a third instruction to the processing module. After receiving the third instruction, the processing module controls the host and each of the slaves to start in the steady current mode, and controls the host and each of the slaves to operate with equal current values according to the preset target current value.

[0020] The present invention also provides a rectification control method, based on the above-mentioned rectification control system, comprising the following steps:

[0021] The first output element and the second output element of the integrated rectifier device are electrically connected to the rectifier object, the power module thereof is connected to the external power supply, and the master and slave power supplies are connected;

[0022] Connect the host computer to the processing module;

[0023] Turn on the host computer and input a preset target voltage value to the host computer, start the voltage-stabilized startup mode of the control program, start the host and run it in the voltage-stabilized mode, and when the host computer receives the second feedback signal, send a second instruction to the processing module, and the slave starts in the current-stabilized mode until the host voltage value reaches the preset target voltage value; or turn on the host computer and input a preset target current value to the host computer, start the current-stabilized startup mode of the control program, and input a third instruction to the host computer to control the host and each of the slaves to run with equal current values.

[0024] Compared with the prior art, the beneficial effects of the integrated rectifier device of the present invention are mainly reflected in:

[0025] The rectifier device of the present invention is provided with a host and at least one slave, and the host and the slave are respectively communicatively connected to the processing module and respectively electrically connected to the power supply module, so that the host and the slave can be controlled simultaneously by the processing module, which can ensure the current sharing effect and avoid the tediousness of separate control; by setting the main body, the processing module, the power supply module, a host and at least one slave are integrated on the main body, so that the host and the slave form a whole, avoiding scattered distribution, reducing the occupied space by integrating the scattered, and greatly facilitating use, greatly reducing the workload of manual handling and regulation, so it can solve the problems of cumbersome control operations, difficult current sharing control, difficulty in achieving current sharing effect and large temporary space faced in the prior art of connecting multiple rectifiers to the rectification object separately and then controlling each rectifier separately.

[0026] Compared with the prior art, the rectifier control system described in the present invention uses the above-mentioned integrated rectifier device and has the beneficial effects of the integrated rectifier device.

[0027] Compared with the prior art, the rectification control method described in the present invention can meet the needs of larger output rectification current, can achieve better current sharing effect in both steady current and steady voltage start modes, and is easy to operate and has low workload. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] The above and other objects, features and advantages of the present invention will become more apparent through a more detailed description of the preferred embodiments of the present invention shown in the accompanying drawings. The same reference numerals indicate the same parts throughout the accompanying drawings, and the drawings are not drawn to scale with actual size. The emphasis is on illustrating the subject matter of the present invention.

[0029] Figure 1 A three-dimensional structural diagram of an integrated rectifier device provided in an embodiment of the present invention;

[0030] Figure 2An internal structural diagram of an integrated rectifier provided in an embodiment of the present invention (the side wall of the main body is not shown);

[0031] Figure 3 for Figure 2 A three-dimensional structural diagram of the master or slave (the top cover of the chassis is not shown);

[0032] Figure 4 for Figure 2 A three-dimensional structural diagram of the master or slave (the bottom cover of the chassis is not shown);

[0033] Figure 5 A three-dimensional structural diagram of the first heat dissipation block and the second heat dissipation block provided in an embodiment of the present invention;

[0034] Figure 6 The three-dimensional structure of the synchronous rectification module provided in the embodiment of the present invention Figure 1 ;

[0035] Figure 7 The three-dimensional structure of the synchronous rectification module provided in the embodiment of the present invention Figure 2 ;

[0036] Figure 8 for Figure 6 Front view of

[0037] Figure 9 A three-dimensional structural diagram of the transformer assembly provided in an embodiment of the present invention;

[0038] Figure 10 for Figure 9 Front view of

[0039] Figure 11 for Figure 9 Exploded structure diagram;

[0040] Description of the drawings: first heat sink 1, second heat sink 2, transformer assembly 3, magnetic core 301, coil 302, conductive core 303, conductive plate 304, synchronous rectifier module 4, drive module 5, extension portion 6, support portion 7, circuit board 8, first output element 9, flat base 901, ridge 902, notch 903, second output element 10, Mosfet chip 11, first through hole 12, insulating plate 13, chassis 14, first output conductor 15, second output conductor 16, conductive block 17, First inductor 18, second inductor 19, current Hall sensor 20, control system 21, input power supply unit 22, switching power supply unit 23, temperature sensor 24, main body 25, first output member 26, second output member 27, first connecting member 28, second connecting member 29, first cavity 30, second cavity 31, first main pipe 32, second main pipe 33, management unit 34, PLC unit 35, main control power supply unit 36, management power supply unit 37, stand-alone power supply unit 38, host or stand-alone 39. DETAILED DESCRIPTION

[0041] The technical solution of the present invention is further described in detail below in conjunction with the accompanying drawings and specific embodiments, so that those skilled in the art can better understand the present invention and implement it. However, the embodiments given do not limit the present invention. In this embodiment, it should be understood that the directions or positional relationships indicated by terms such as "longitudinal", "transverse", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", and "outside" are based on the directions or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention, rather than indicating or implying that the device or element referred to must have a specific direction, be constructed and operated in a specific direction, and therefore cannot be understood as a limitation of the present invention.

[0042] It should be noted that when an element is considered to be "connected" to another element, it may be directly connected to the other element and integrated therewith, or there may be an intermediate element. The terms "mounted," "one end," "the other end," and similar expressions used in this invention are for illustrative purposes only.

[0043] This embodiment provides an integrated rectifier device, such as Figures 1 to 2 As shown, it includes a main body 25, a processing module, a power module, a first output element 26, a second output element 27, a host and at least one slave. The processing module, the power module, the host and the slave are integrated on the main body 25. The host and the slave are respectively communicated with the processing module and are respectively electrically connected to the power module.

[0044] The rated load current of the host is not less than the rated load current of the slave. The first output end of the host and the first output end of each slave are electrically connected to the first output element 26, and the second output end of the host and the second output end of each slave are electrically connected to the second output element 27. One end of the first output element 26 and the second output element 27 protrude from the outside of the main body 25.

[0045] The rectifier device of the present invention is provided with a host and at least one slave, and the host and the slave are respectively communicatively connected to the processing module and respectively electrically connected to the power supply module, so that the host and the slave can be controlled simultaneously by the processing module, thereby ensuring the current sharing effect and avoiding the tediousness of separate control; by setting the main body 25, the processing module, the power supply module, a host and at least one slave are integrated on the main body 25, so that the host and the slave form a whole, avoiding scattered distribution, reducing the occupied space by integrating the scattered, and greatly facilitating use, greatly reducing the workload of manual handling and regulation, so it can solve the problems of the prior art of connecting multiple rectifiers to the rectifier object separately, and then controlling each rectifier separately, such as cumbersome control operation, difficult current sharing control, difficulty in achieving current sharing effect and large temporary space.

[0046] In a preferred embodiment, a first cavity 30 and a second cavity 31 are provided in the main body 25, and the host and the slave are stacked in the first cavity 30. Such concentrated placement can maximize the reduction of the spatial size of the first cavity 30. The processing module and the power supply module are arranged in the second cavity 31. Placing them outside the first cavity 30 can make the internal layout of the rectifier device clear and uncluttered. Furthermore, the second cavity 31 is located above the first cavity 30, which can improve the structural integrity of the rectifier device and further reduce the floor area and space occupied by the rectifier device.

[0047] In another preferred embodiment, both the host and the slave are liquid-cooled, and the main body 25 is provided with a first main pipe 32 and a second main pipe 33. The inlet end of the first main pipe 32 and the outlet end of the second main pipe 33 both extend out of the main body 25. The outlet end of the first main pipe 32 is respectively connected to the liquid inlets of the host and the slave, and the inlet end of the second main pipe 33 is respectively connected to the liquid outlets of the host and the slave. By providing the first main pipe 32 and the second main pipe 33, when connecting the external cooling water inlet and outlet pipes, the water inlet pipe can be directly connected to the inlet end of the first main pipe 32, and the water outlet pipe can be connected to the outlet end of the second main pipe 33, which is convenient and quick.

[0048] In another preferred embodiment, the processing module includes a management unit 34 and a PLC unit 35. The management unit 34 is communicatively connected to the PLC unit 35. The host and the slave are respectively communicatively connected to the management unit 34. The PLC unit 35 is used to communicate with the host computer. The host computer and the PLC unit 35 realize data transmission and action control through an internal protocol. The management unit 34 is preset with a control program to control the start, stop and operation of the host and the slave. It is convenient for users to use different management units 34 to adopt different control programs without replacing the PLC unit 35, thereby saving usage costs.

[0049] Further, such as Figure 2 As shown, the power supply module includes a master control power supply unit 36, a management power supply unit 37 and a stand-alone power supply unit 38. The master control power supply unit 36 is used to connect to the external power supply, the management power supply unit 37 is used to control the power switch of the management unit 34, and the stand-alone power supply unit 38 is used to control the power on and off of the host or slave. The number of stand-alone power supply units 38 is the same as the total number of hosts and slaves, and corresponds to the hosts and slaves. The switches of various valves, the above-mentioned power supply units and other hardware can be controlled by the PLC unit 35.

[0050] In a preferred embodiment, Figures 3 to 11 As shown, the host or slave includes a first heat sink 1 and a second heat sink 2 arranged in parallel and at intervals, and one or more transformer assemblies 3. The transformer assemblies 3 are located between the first heat sink 1 and the second heat sink 2, and are arranged at intervals along the parallel extension direction of the first heat sink 1 and the second heat sink 2. A synchronous rectifier module 4 corresponding to the transformer assembly 3 is provided on the upper and lower sides of one of the heat sinks. The heat sink and the synchronous rectifier module 4 and the corresponding transformer assembly 3 form a current circuit, that is, the synchronous rectifier module 4 is electrically connected to the heat sink and the corresponding transformer assembly 3 respectively, and the transformer assembly 3 and another heat sink form another current circuit, that is, the transformer assembly 3 is electrically connected to another heat sink.

[0051] It should be noted that the number of transformer assemblies 3 in this embodiment is three, and a single unit can carry a current of 3000A. Figure 2 The integrated rectifier device formed by combining the three stand-alone units in this embodiment can carry a rectified current exceeding 10,000A. In other embodiments, the number of the integrated rectifier device may be two or four, depending on the rectified current and the output induced current of the single transformer assembly 3.

[0052] In this embodiment, by disposing one or more transformer assemblies 3 at intervals along the parallel extension direction of the first heat dissipation block 1 and the second heat dissipation block 2, the total current required can be shared by the one or more transformer assemblies 3, thereby achieving current sharing and reducing the heat generated by a single transformer assembly 3, thereby reducing heat loss of the device.

[0053] On the other hand, the transformer assembly 3 can be located in different relative positions of the first heat dissipation block 1 and the second heat dissipation block 2, so that the first heat dissipation block 1 and the second heat dissipation block 2 can be fully utilized to dissipate heat in a timely manner, thereby avoiding the problem of current being concentrated on only one transformer assembly 3, which causes the transformer assembly 3 to generate a large amount of heat and the heat dissipation area to be limited and unable to dissipate heat in a timely manner;

[0054] By arranging the synchronous rectifier module 4 on the upper and lower sides of the heat sink, rather than only on one side of the heat sink, it is possible to avoid extending the heat sink due to the addition of the transformer assembly 3, which would increase the internal resistance of the heat sink and the size of the rectifier unit. This ensures the power utilization rate and the compactness of the device. It can avoid the problem of excessive heat concentration and difficulty in heat dissipation in existing rectifier units, which are usually only provided with one transformer in order to reduce materials and reduce equipment size. It is also beneficial to reducing the size of the integrated rectifier unit, especially when carrying a large rectifier current. The advantages are obvious.

[0055] like Figure 5 As shown, the upper and lower sides of the first heat dissipation block 1 are provided with extension portions 6 extending toward the second heat dissipation block 2 , and the extension portions 6 and the corresponding upper or lower side of the first heat dissipation block 1 together form a support portion 7;

[0056] The synchronous rectifier module 4 is fixed to the support part 7, and a driving module 5 corresponding to the synchronous rectifier module 4 is provided on the side of the first heat dissipation block 1 facing away from the second heat dissipation block 2. The driving module 5 is used to synchronously drive the synchronous rectifier module 4 electrically connected to the same transformer assembly 3.

[0057] In this embodiment, an extension portion 6 is provided on the upper and lower sides of the first heat dissipation block 1. The extension portion 6 and the upper or lower side of the corresponding first heat dissipation block 1 together constitute a support portion 7, so that the synchronous rectifier module 4 of the rectifier unit can be fixed on the support portion 7. In this way, the space on the upper and lower sides of the first heat dissipation block 1 is simultaneously utilized, avoiding the situation where the synchronous rectifier module 4 is only sequentially provided on one side of the first heat dissipation block 1, thereby greatly shortening the span size at both ends of the first heat dissipation block 1, and the second heat dissipation block 2 can also be shortened accordingly, thereby greatly reducing the internal resistance of the heat dissipation block and the external size and weight of the rectifier unit.

[0058] Furthermore, the overlapping area between the support portion 7 and each synchronous rectifier module 4 is not less than the cross-sectional area of the synchronous rectifier module 4. This ensures that the synchronous rectifier module 4 is securely fixed, while maximizing the contact area between the synchronous rectifier module 4 and the support portion 7, thereby increasing the heat transfer area of the synchronous rectifier module 4 and improving the heat dissipation efficiency of the synchronous rectifier module 4. In this embodiment, the extension portion 6 is a continuous plate-shaped structure. The extension portion 6 and the first heat dissipation block 1 are integrally formed. The first heat dissipation block 1 and the second heat dissipation block 2 are typically made of aluminum.

[0059] like Figures 6 to 8As shown, the synchronous rectification module 4 includes a circuit board 8, a first output element 9 and two parallel second output elements 10. The first output element 9 is symmetrically and parallelly provided with two rows of MOSFET chips 11. The two rows of MOSFET chips 11 are separated by a preset distance. The second output elements 10 within the preset distance are electrically connected to the transformer assembly 3. The MOSFET chips 11 in each row are evenly spaced and electrically connected to the first output element 9.

[0060] The second output elements 10 are symmetrically arranged on both sides of the first output element 9, and each second output element 10 and one row of MOSFET chips 11 are located on the same side of the first output element 9. The MOSFET chips 11 in each row are electrically connected to the second output elements 10 on the same side. The second output elements 10 are electrically connected to the heat sink of the rectifier after being attached.

[0061] The circuit board 8 is provided with a first through hole 12 , and two rows of MOSFET chips 11 pass through the first through hole 12 . The circuit board 8 is stacked on the second output element 10 , and each MOSFET chip 11 is electrically connected to the circuit board 8 .

[0062] In this embodiment, a circuit board 8, a first output element 9, and two parallel second output elements 10 are provided. The first output element 9 is symmetrically and parallelly provided with two rows of MOSFET chips 11. The MOSFET chips 11 in each row are arranged at equal intervals and are all electrically connected to the first output element 9. The two rows of MOSFET chips 11 are separated by a preset distance. The second output elements 10 within the preset distance are electrically connected to the transformer assembly 3 for conducting current. The second output elements 10 are symmetrically arranged on both sides of the first output element 9, and each of the second output elements 10 and one of the rows of MOSFET chips 11 is located on the same side of the first output element 9. The MOSFET chips 11 in each row are all electrically connected to the second output elements 10 on the same side. The circuit board 8 is stacked on the second output element 10, and each MOSFET chip 11 is electrically connected to the circuit board 8. In this way, the synchronous rectification module 4 of this embodiment can form a symmetrical structure, thereby ensuring a current sharing effect.

[0063] The two second output elements 10 are fitted with the heat sink of the rectifier to guide and dissipate heat. On the one hand, sufficient heat dissipation area is provided. On the other hand, the second output elements 10 are in direct contact with the heat sink, which can effectively improve the heat dissipation efficiency and have good heat dissipation performance. It can be suitable for large current loads, specifically for current loads of not less than 1000A.

[0064] It should be noted that in the synchronous rectifier module 4, electrical connection is achieved by welding different pins of the Mosfet chip 11 to the circuit board 8 and the second output element 10 respectively, and electrical connection is achieved by welding the substrate of the Mosfet chip 11 to the first output element 9. In this way, the relative fixation of the circuit board 8, the first output element 9 and the second output element 10 is also achieved through the two columns of Mosfet chips 11.

[0065] The synchronous rectifier module 4 also includes an insulating plate 13, which is located below the first output element 9 and is bonded to the first output element 9 to prevent the current from flowing directly through the first output element 9 and conducting with the heat sink, thereby ensuring the insulation performance of the first output element 9. The other side of the insulating plate 13 is bonded to the heat sink of the rectifier. On the one hand, this embodiment ensures that the current can flow to the two rows of MOSFET chips 11 after passing through the first output element 9, thereby ensuring the current sharing effect. On the other hand, the upper and lower surfaces of the insulating plate 13 are bonded to the first output element 9 and the heat sink, respectively. This stacked bonding structure can improve the heat transfer efficiency and increase the heat dissipation area in direct contact with the heat sink, thereby improving the heat dissipation efficiency. Specifically, the insulating plate 13 is a ceramic plate that is detachably connected to the first output element 9.

[0066] The second output element 10 is flat, and the MOSFET chip 11 is electrically connected to the second output element 10 on its top surface. The bottom surface of the second output element 10 is coplanar with the bottom surface of the first insulating plate 13. This ensures that the bottom surface of the second output element 10 also adheres to the surface of the heat sink during installation, facilitating installation.

[0067] The first output element 9 and the second output element 10 are both made of copper, and the surface is nickel-plated, which has an anti-corrosion effect and can also improve the conductivity of the elements. At the same time, the appearance and color are more beautiful.

[0068] Specifically, the first output element 9 includes a strip-shaped flat base 901. The flat base 901 has protrusions 902 arranged at predetermined intervals along its long sides. The transformer assembly 3 is electrically connected to the protrusions 902. The induced current generated by the transformer assembly 3 is introduced into the synchronous rectifier module 4 via the protrusions 902. The induced current is first conducted from the protrusions 902 to the flat base 901, then from the flat base 901 to the two rows of MOSFET chips 11, and then through the MOSFET chips 11 to the second output element 10. Preferably, the flat base 901 and the protrusions 902 are integrally formed in a T-shape, which can reduce processing costs and prevent differences in processing technology from affecting the conductive uniformity of the first output element 9. The protrusions 902 are detachably connected to the transformer assembly 3 to achieve electrical connection.

[0069] Further preferably, the synchronous rectifier module 4 is bolted to the first heat sink 1, the long side length of the protrusion 902 is shorter than the long side length of the flat base 901, and the protrusion 902 is centered on the flat base 901, and the middle of the protrusion 902 is broken to form a notch 903, so that fixing positions can be reserved at both ends and the middle of the flat base 901 for fixing the first output element 9, and its uniform and stable fixation can be ensured.

[0070] like Figures 9 to 11 As shown, the transformer assembly 3 includes a ring-shaped magnetic core 301 and a coil 302 wound on the magnetic core 301. A conductive core 303 is provided along the axial direction of the central hole of the magnetic core 301. Conductive plates 304 are provided at both ends of the conductive core 303. The conductive plates 304 are fixed and electrically connected to the first heat sink 1 and the second heat sink 2 of the rectifier unit respectively. After the conductive plates 304 are fixedly connected to the first heat sink 1 and the second heat sink 2, the central axis of the magnetic core 301 is perpendicular to the plane where the first heat sink 1 and the second heat sink 2 are located. During the installation process, after the transformer assembly 3 is installed between the first heat sink 1 and the second heat sink 2, thermal conductive glue is usually poured on the outer periphery of the coil 302, and the thermal conductive glue is connected to the first heat sink 1 and the second heat sink 2. In this way, the heat generated by the transformer assembly 3 can also be quickly transferred through the thermal conductive glue, thereby achieving the effect of timely heat dissipation.

[0071] In the existing rectifier unit, the axis of the magnetic core 301 of the transformer assembly 3 is parallel to the length of the heat sink, so that the magnetic lines of force can easily penetrate the chassis 14 or the housing of the rectifier unit, causing the housing to heat up significantly due to electromagnetic induction, resulting in a large amount of loss. In this embodiment, the transformer assembly 3 is fixed and electrically connected to the first heat sink 1 and the second heat sink 2 via a conductive plate 304. After the conductive plate 304 is fixedly connected to the first heat sink 1 and the second heat sink 2, the central axis of the magnetic core 301 is perpendicular to the plane where the first heat sink 1 and the second heat sink 2 are located. In this way, the direction of the magnetic field generated by the coil 302 relative to the chassis 14 of the rectifier unit can be changed, preventing the chassis 14 from being located in an area with large magnetic flux, and preventing the magnetic lines of force from penetrating the chassis 14 in large quantities and generating eddy currents, thereby significantly reducing the heat generation and energy loss of the chassis 14.

[0072] like Figure 3As shown, the first heat sink 1 is provided with a first output conductor 15 electrically connected thereto, and the first output conductor 15 is the first output end of the rectifier unit. The second heat sink 2 is correspondingly provided with a second output conductor 16 electrically connected thereto, and the second output conductor 16 is the second output end of the rectifier unit. The first output conductor 15 and the second output conductor 16 are the positive and negative output poles of the rectifier unit, and are made of copper. Since the existing rectifier units usually use one end of the first heat sink 1 and the second heat sink 2 as the output pole, and the first heat sink 1 and the second heat sink 2 are usually made of aluminum, aluminum is easily oxidized when exposed to the air for a long time, and the conductive performance will decrease to varying degrees, affecting the rectification effect. However, this embodiment outputs through the first output conductor 15 and the second output conductor 16 made of copper. Since copper is more resistant to corrosion and oxidation, the conductive performance can remain stable for a long time. Specifically, as Figure 2 As shown, the first output conductors 15 of the master and each slave are electrically connected to the first output member 26 via the first connector 28 , and the second output conductors 16 of the master and each slave are electrically connected to the second output member 27 via the second connector 29 .

[0073] Preferably, the copper surfaces of the first output conductor 15, the second output conductor 16, the first output member 26, the second output member 27, the first connecting member 28, and the second connecting member 29 are all galvanized to further improve the corrosion resistance. A conductive block 17 is sandwiched between the first heat dissipation block 1 and the first output conductor 15, and between the second output conductor 16 and the second heat dissipation block 2. The spacing between the output conductors and the heat dissipation blocks is designed in this way to avoid interference or collision between the first output conductor 15 and the liquid cooling pipe entering the first heat dissipation block 1, and between the second output conductor 16 and the liquid cooling pipe entering the second heat dissipation block 2. Of course, preferably, the conductive block 17 is also made of copper.

[0074] It should be noted that if Figure 3 and Figure 4As shown, the rectifier unit of the present invention also includes a first inductor 18 and a current Hall sensor 20 mounted on the first heat sink 1, a second inductor 19 mounted on the second heat sink 2, a control module 21, an input power unit 22 and a switching power unit 23 electrically connected to the input power unit 22. The control module 21 and the input power unit 22 are arranged on the side of the second heat sink 2 facing away from the first heat sink 1, and the switching power unit 23 is arranged on the side of the first heat sink 1 facing away from the second heat sink 2. The input power unit 22 is used to access external current, and the switching power unit 23 is used to power the drive modules 5 corresponding to each synchronous rectifier module 4. Each drive module 5 is communicatively connected to the control module 21. The functions of the above-mentioned components are all conventional basic functions of the rectifier unit, which are well known to those skilled in the art, so they will not be repeated here. The internal arrangement of the rectifier stand in this embodiment enables the first output conductor 15 and the second output conductor 16 to maintain equal distances from the casing 14 on the same side. This allows it to be used in the parallel rectification of the integrated rectifier device of the present invention. When the positive and negative poles need to be reversed, the first output conductor 15 and the second output conductor 16 will not mismatch and interfere with the main body of the integrated rectifier device, and thus there is no need to replace the main body of the integrated rectifier device.

[0075] Each synchronous rectifier module 4 is correspondingly provided with a temperature sensor 24, and the temperature sensor 24 is in communication with the control module 21. The temperature sensor 24 sends the monitored temperature information to the control module 21. When the temperature sensor 24 detects abnormal temperature information, the control module 21 will issue a shutdown or other action instruction accordingly to avoid burning of the rectifier unit.

[0076] Based on the above-mentioned integrated rectifier device, a rectifier control system is also provided, comprising a host computer and the above-mentioned integrated rectifier device, the host computer being communicatively connected to a processing module in the integrated rectifier device, the host computer being preset with a control program, the control program including a voltage-stabilized start-up mode and a current-stabilized start-up mode, the control program being preset with a first current value;

[0077] In the voltage-stabilized startup mode, a preset target voltage value is input to the host computer, and the host computer sends a first instruction to the processing module. After receiving the first instruction, the processing module controls the host to start in the voltage-stabilized mode. The host feeds back its output current value to the processing module in real time. The processing module receives the output current value and determines whether the output current value is less than the above-mentioned first current value. If so, the processing module sends a first feedback signal to the host computer. The host computer does not issue an instruction after receiving the first feedback signal. If not, the processing module sends a second feedback signal to the host computer. After receiving the second feedback signal, the host computer sends a second instruction to the processing module. After receiving the second instruction, the processing module controls the slave to start in the current-stabilized mode until the host voltage value reaches the preset target voltage value, that is, the first current value is the starting current value of the slave;

[0078] In the steady current startup mode, the preset target current value is input to the upper computer, and the upper computer sends a third instruction to the processing module. After receiving the third instruction, the processing module controls the host and each slave to start in the steady current mode, and controls the host and each slave to run at equal current values according to the preset target current value.

[0079] Furthermore, based on the above-mentioned rectification control system, a rectification control method is also provided, comprising the following steps:

[0080] The first output element and the second output element of the integrated rectifier device are electrically connected to the rectifier object, the power module thereof is connected to the external power supply, and the master and slave power supplies are connected;

[0081] Connect the host computer to the processing module;

[0082] Turn on the host computer and input a preset target voltage value to the host computer, start the voltage stabilization start mode of the control program, start the host and run it in the voltage stabilization mode. When the host computer receives the second feedback signal, it sends a second instruction to the processing module, and the slave starts in the current stabilization mode until the host voltage value reaches the preset target voltage value; or, turn on the host computer and input a preset target current value to the host computer, start the current stabilization start mode of the control program, and input a third instruction to the host computer to control the host and each slave to run with equal current values.

[0083] A rectification control method of this embodiment can meet the needs of a larger output rectification current, can achieve a good current sharing effect in both the steady current and steady voltage start modes, and is easy to operate with a small workload.

[0084] It should be noted that the above-mentioned voltage stabilization mode operation means that after the target voltage value is set, the host voltage is kept constant; the current stabilization mode means that after the target current value is preset, the current values of the host and each slave machine reach the preset target current value; the above-mentioned host and slave are only different descriptions of the startup sequence, and the host computer encodes the address for each rectifier unit. The rectifier unit with the address number as the starting value is the host, and the other rectifier units are all slaves; in the voltage stabilization startup mode, when the host fails and cannot output normally, the processing module will send the fault data to the host computer. The host computer will identify the fault code and communication status through the fault data and judge whether the fault has occurred. When it is judged that a fault has occurred, the host computer will immediately use the rectifier unit with the next address as the rectifier unit with the address as the starting value, that is, as the host. Therefore, when the rectifier unit serving as the host fails, the integrated rectifier device will not be paralyzed; and based on the connection status of the slaves in the aforementioned integrated rectifier device, the failure of any slave will not affect the operation of other rectifier units.

[0085] In this specification, unless otherwise expressly specified or limited, when a first feature is "above" or "below" a second feature, it can mean that the first and second features are in direct contact, or that the first and second features are in indirect contact through an intermediary. Furthermore, when a first feature is "above," "above," or "above" a second feature, it can mean that the first feature is directly above or diagonally above the second feature, or simply means that the first feature is at a higher level than the second feature. When a first feature is "below," "below," or "below" a second feature, it can mean that the first feature is directly below or diagonally below the second feature, or simply means that the first feature is at a lower level than the second feature.

[0086] In the description of this specification, the description with reference to the terms "preferred embodiment", "further embodiment", "other embodiments" or "specific example" means that the specific features, structures, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present application. In this specification, the schematic expressions of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described can be combined in any one or more embodiments or examples in a suitable manner. In addition, those skilled in the art can combine and combine different embodiments or examples described in this specification and the features of different embodiments or examples, unless they are contradictory.

[0087] Although the embodiments of the present application have been shown and described above, it can be understood that the above embodiments are exemplary and cannot be understood as limitations on the present application. Ordinary technicians in this field can change, modify, replace and modify the above embodiments within the scope of the present application.

Claims

1. An integrated rectifier device, characterized in that: The device comprises a main body, a processing module, a power module, a first output element, a second output element, a host and at least one slave, wherein the processing module, the power module, the host and the slave are integrated on the main body, and the host and the slave are respectively communicatively connected to the processing module and respectively electrically connected to the power module; The rated load current of the host is not less than the rated load current of the slave, the first output end of the host and the first output end of each of the slaves are electrically connected to the first output element, the second output end of the host and the second output end of each of the slaves are electrically connected to the second output element, and one end of the first output element and the second output element both protrude from the outside of the main body.

2. The integrated rectifier device according to claim 1, characterized in that: A first cavity and a second cavity are provided in the main body. The host and the slave are stacked and arranged in the first cavity. The processing module and the power supply module are arranged in the second cavity.

3. The integrated rectifier device according to claim 1, characterized in that: The host and the slave are both liquid-cooled, and the main body is provided with a first main pipe and a second main pipe. The inlet end of the first main pipe and the outlet end of the second main pipe both extend out of the main body, the outlet end of the first main pipe is respectively connected to the liquid inlets of the host and the slave, and the inlet end of the second main pipe is respectively connected to the liquid outlets of the host and the slave.

4. The integrated rectifier device according to claim 1, characterized in that: The processing module includes a management unit and a PLC unit. The management unit is communicatively connected to the PLC unit. The host and the slave are respectively communicatively connected to the management unit. The PLC unit is used to communicate with a host computer.

5. The integrated rectifier device according to claim 4, characterized in that: The power supply module includes a master control power supply unit, a management power supply unit and a stand-alone power supply unit. The number of the stand-alone power supply units is the same as the total number of the host and the slaves, and corresponds to the host and the slaves.

6. The integrated rectifier device according to claim 1, characterized in that: The host or the slave includes a first heat sink and a second heat sink arranged in parallel and at intervals, and one or more transformer assemblies. The transformer assemblies are located between the first heat sink and the second heat sink, and are arranged at intervals along the parallel extension direction of the first heat sink and the second heat sink. A synchronous rectifier module corresponding to the transformer assembly is respectively provided on the upper and lower sides of one heat sink, and the heat sink, the synchronous rectifier module and the corresponding transformer assembly form a current circuit, and the transformer assembly and the other heat sink form another current circuit.

7. The integrated rectifier device according to claim 6, characterized in that: The upper side and the lower side of the first heat dissipation block are provided with extension parts extending toward the second heat dissipation block, and the extension parts and the corresponding upper side or lower side of the first heat dissipation block together constitute a support part; The synchronous rectification module is fixed to the support portion, and a driving module corresponding to the synchronous rectification module is provided on the side of the first heat dissipation block facing away from the second heat dissipation block.

8. The integrated rectifier device according to claim 6, characterized in that: The synchronous rectification module includes a circuit board, a first output element, and two second output elements arranged in parallel. The first output element is symmetrically and parallelly arranged with two rows of MOSFET chips. The two rows of MOSFET chips are separated by a preset distance. The second output elements within the preset distance are electrically connected to the transformer assembly. The MOSFET chips in each row are evenly spaced and electrically connected to the first output element. The second output elements are symmetrically arranged on both sides of the first output element, and each of the second output elements and one of the rows of MOSFET chips are located on the same side of the first output element. The MOSFET chips in each row are electrically connected to the second output elements on the same side. The second output elements are electrically connected to the heat sink of the rectifier device after being attached to each other. The circuit board is provided with a first through hole, the two rows of MOSFET chips pass through the first through hole, the circuit board is stacked on the second output element, and each of the MOSFET chips is electrically connected to the circuit board.

9. A rectifier control system, characterized in that: The integrated rectifier device comprises a host computer and one of claims 1 to 8, wherein the host computer is communicatively connected to a processing module in the integrated rectifier device, the host computer is preset with a control program, the control program is preset with a first current value, and the control program includes a voltage-stabilized startup mode and a current-stabilized startup mode; In the voltage-stabilized startup mode, a preset target voltage value is input to the host computer, the host computer sends a first instruction to the processing module, and after receiving the first instruction, the processing module controls the host to start in the voltage-stabilized mode. The host feeds back its output current value to the processing module in real time, and the processing module receives the output current value and determines whether the output current value is less than the first current value. If so, the processing module sends a first feedback signal to the host computer, and the host computer does not issue an instruction after receiving the first feedback signal. If not, the processing module sends a second feedback signal to the host computer, and after receiving the second feedback signal, the host computer sends a second instruction to the processing module. After receiving the second instruction, the processing module controls the slave to start in the current-stabilized mode until the host voltage value reaches the preset target voltage value; In the steady current startup mode, a preset target current value is input to the host computer, and the host computer sends a third instruction to the processing module. After receiving the third instruction, the processing module controls the host and each of the slaves to start in the steady current mode, and controls the host and each of the slaves to operate at equal current values according to the preset target current value.

10. A rectification control method, characterized in that: A rectifier control system according to claim 9, comprising the following steps: The first output element and the second output element of the integrated rectifier device are electrically connected to the rectifier object, the power module thereof is connected to the external power supply, and the master and slave power supplies are connected; Connect the host computer to the processing module; Turn on the host computer and input a preset target voltage value to the host computer, start the voltage-stabilized startup mode of the control program, start the host and run it in the voltage-stabilized mode, and when the host computer receives the second feedback signal, send a second instruction to the processing module, and the slave starts in the current-stabilized mode until the host voltage value reaches the preset target voltage value; or turn on the host computer and input a preset target current value to the host computer, start the current-stabilized startup mode of the control program, and input a third instruction to the host computer to control the host and each of the slaves to run with equal current values.

Images