Integrated water-cooling simulation load cabinet and control method thereof

Abstract

The invention provides an integrated water-cooling simulation load cabinet and a control method thereof, the integrated water-cooling simulation load cabinet comprises an electrical control system, a water-cooling system and a cabinet, a plurality of water-cooling load units and direct current contactors are installed in the cabinet, and simulation loads with different paths and sizes can be connected / disconnected to a test loop according to requirements. The working state of the load loop and the load connection state are monitored in real time and fed back to the control system, the load dissipates heat through the water cooling system, the temperature of cooling liquid in a cold water circulation pipeline can be monitored in real time, and the rotating speed of a cooling pump and a cooling fan of an external cooling fan is adjusted to achieve dynamic control over the temperature. Whether the working state of the water cooling system is normal or not is judged according to the pressure of the cooling liquid, the inlet and outlet flow and other information, a test connection port, an operation panel and a display panel are arranged on a cabinet panel, multi-machine series / parallel connection can be achieved through a connection cable, and power expansion is achieved.

Description

Technical Field

[0001] The invention belongs to the technical field of test devices, and in particular relates to an integrated water-cooled simulated load cabinet and a control method thereof. Background Art

[0002] With the development of electric power technology, many electrical equipment need to be connected to loads for power-on testing during the research and production stages to verify their functions and performance.

[0003] At present, loads are mainly divided into two categories: electronic loads and analog loads. Electronic loads are flexible in configuration and can achieve stepless load adjustment, but they have fewer channels and are expensive. From the cost perspective of analog loads, since their resistance values ​​are usually fixed, they are mostly special equipment with low equipment utilization rates, and the cooling method is mostly air cooling. The resistance value will change due to thermal effects, and for high-power loads, in order to ensure the heat dissipation effect, they usually occupy a larger space and have a lower power density. Summary of the invention

[0004] Purpose of the invention: In view of the problems of low heat dissipation efficiency, large size and low expansion flexibility of simulated loads at this stage, a high-power integrated water-cooled simulated load cabinet is designed. The main problems to be solved are as follows: It solves the problem of low heat dissipation efficiency of existing loads and can stably control the load operating temperature; It can realize the power scalability of simulated loads and solve the problems of low power and large size of conventional simulated loads.

[0005] In the first aspect, the present application provides an integrated water-cooled simulated load cabinet, which includes a cabinet, an electrical control system and a water cooling system. The cabinet is the main installation carrier, and the water inlet port and the water outlet port at the bottom of the rear door are connected to the water inlet and outlet of the heat dissipation unit through pipes to form a cold water self-circulation loop. The cabinet includes a front door, a front side door, a rear door, an isolation mounting plate, a shelf, a vertical mounting plate, a water inlet port and a water outlet port; the front side door is equipped with a test connection port 1, a test connection port 2 and a test connection port 3 and a spare port for connecting the test device or multiple machines; the cable lead of the test connection port 1 is connected to one end of the overload protection terminal, and the other end is connected in series with a current sensor and a voltage sensor respectively, and then installed to one end of the contact of the DC contactor, and the other end of the contact is connected to the neutral contact of the switching switch, and the contact 1 of the switching switch is connected to the positive pole of the integrated water-cooled resistor, and its negative pole is connected to the test connection terminal The front door is connected to the test connection port 2, and the contact 3 of the switch is connected to the test connection port 3; the front door is equipped with a touch screen, a status indicator light and an emergency stop switch, and the touch screen is connected to the programmable logic controller through an RS485 cable, which is used to issue operation instructions and display the overall working status information of the load and the load cabinet; the status indicator light is connected to both ends of the water-cooled load circuit in parallel, which is used to indicate the working status of the load circuit; the isolation mounting plate is installed in the middle of the cabinet, isolating the electrical control system and the water cooling system in the space on the front and rear sides of the cabinet; the layer plate is arranged in parallel in the cabinet, and the vertical mounting plate is arranged above the front space of the cabinet;

[0006] The electrical control system includes a programmable controller, a switch quantity module, an acquisition module, an overload protection terminal, a current sensor, a voltage sensor, a DC contactor and a switching switch. The switch quantity module and the acquisition module are extension modules of the programmable controller and are installed on a vertical mounting plate; the programmable controller and the switch quantity module are connected to the DC contactor and the switching switch to control the connection / disconnection of the load circuit; the acquisition module is connected to the output ends of the current sensor and the voltage sensor to collect current / voltage data.

[0007] The water cooling system includes an integrated water-cooling resistor, a multi-porous horizontal cold water circulation pipeline, a flow sensor, a temperature sensor, a pressure sensor, a heat dissipation unit and a pipeline. The integrated water-cooling resistor is evenly arranged in layers on the shelf of the control panel at the rear side of the cabinet through the bottom end studs. The positive and negative electrodes on the front side are connected to the switching switch through the isolation mounting plate, and the water inlet and outlet at the tail end are connected to the multi-porous horizontal cold water circulation pipeline; the multi-porous horizontal cold water circulation pipeline includes an inlet pipe and an outlet pipe, which are respectively arranged on the left and right sides in the cabinet, and the bottom inlet and outlet are placed in parallel, and are connected to the water inlet port and the water outlet port of the cabinet through flanges; the flow sensor and the pressure sensor are installed on the inlet pipe for monitoring the inlet flow and the coolant inlet pressure, and the output port thereof is connected to the acquisition module; the flow sensor and the temperature sensor are installed on the outlet pipe for monitoring the outlet flow and the coolant temperature, and the output port thereof is connected to the acquisition module;

[0008] Preferably, the programmable controller is connected to the cooling unit via an RS485 expansion interface, and is used to remotely control the cooling system to be in the expected working state according to user instructions or set parameters, and automatically control the coolant temperature not to exceed the preset value. The programmable controller also provides a TCP network access port through an RJ45 interface, which can query the current working state of the load cabinet, control the load to switch to different states, and realize remote / local control.

[0009] Preferably, the water inlet pipe and the water outlet pipe have similar overall structures. After a hole is opened on one side of the mother pipe, a multi-hole parallel shunt pipe is placed in a toothed distribution. An exhaust valve is installed on the top of the mother pipe. A quick connector is evenly distributed on one side of the multi-hole parallel shunt pipe, and an exhaust valve is installed on the other end. The water inlet pipe and the water outlet pipe are respectively arranged on the left and right sides of the cabinet, and the water inlet and the water outlet at the bottom are placed in parallel. The mother pipes of the two pipelines are perpendicular to the ground and parallel to each other, and the multi-hole parallel shunt pipes are mutually toothed and staggered.

[0010] Preferably, the water inlet and the water outlet of the integrated water-cooled resistor are respectively connected to the quick-reading joints distributed on the porous parallel shunt pipes of the water inlet pipe and the water outlet pipe through hoses;

[0011] Preferably, the internal water channel of the integrated water-cooled resistor adopts a spiral water channel, in which the coolant (high-purity water / 50% ethylene glycol) directly contacts the resistor body, which has a stronger heat dissipation effect, higher efficiency, higher load power and more stable performance;

[0012] Preferably, the integrated water-cooled resistor is composed of a plurality of resistors connected in series / parallel to form a load module, and the load module is composed of four resistors with different resistance values, namely R1, R2, R3 and R4. By switching different switches, the load module can be switched to nine different power states;

[0013] Preferably, the normally closed point of the emergency stop switch is connected directly to the DC contactor and the switching switch and its power supply end, which can disconnect the load circuit;

[0014] Preferably, the switch is a 3-gear switch, with contact 2 being in the neutral position. By switching the switch to contact 1 to connect, the load circuit is normally connected. By switching the switch to contact 3 to connect, the monitoring function is provided when the actual load is connected.

[0015] Preferably, the cabinet can connect the load cabinets in series by connecting the test connection port 1 and the test connection port 2 through a cable; the load cabinets can be connected in parallel by connecting the test connection port 2 and the test connection port 3 of another set of load cabinets, and the test connection port 3 and the test connection port 2 of another set of load cabinets through a cable; the expansion of different power levels and load requirements can be achieved;

[0016] In a second aspect, the present invention further proposes a control method based on the load cabinet as described above, wherein the control process is as follows:

[0017] After the equipment is started, it will conduct self-test, internal alarm information check and communication status check. After the self-test passes, the equipment parameters will be initialized. After the user configures the access status of the load circuit and the configuration information of the load unit, the protection value and protection time of the current / voltage, and the operating parameters and protection parameters of the water cooling system through the human-machine interface, the programmable logic controller drives the contactor of the load unit to turn on, completes the state configuration of the load unit, drives the contactor on the load circuit to turn on, completes the loading of the load channel, and starts the water cooling unit according to the set parameters;

[0018] The feedback signal of the contactor auxiliary contact and the return information of the chiller are read through the programmable logic controller, and the information is updated and reported in real time; after startup, the inlet and outlet pressures and flows of the chilled water system are detected in real time, and it is determined whether the inlet / outlet pressure, inlet / outlet pressure difference, inlet / outlet flow, inlet / outlet flow difference, etc. exceed the protection range; the voltage state of the load circuit and the current of each load channel are detected in real time, and it is determined whether the voltage value of the load circuit and the current value of each load channel are within the protection range; further, when it is continuously detected that the current exceeds the protection value, protection is performed according to the set conditions;

[0019] Real-time detection of the coolant temperature and other information inside the water cooling system. When the temperature exceeds the set value, the water cooling unit is driven to increase the speed of the heat exchange fan and water pump to improve the heat dissipation effect. The temperature data is recorded in real time, and the heat dissipation working status of the water cooling system is determined based on the temperature data.

[0020] During the test, all monitoring and detection information can be obtained in real time through the touch screen and remote port, thus realizing high power density integration and automatic control of simulated loads, effectively enhancing the heat dissipation effect and load stability, and improving test efficiency;

[0021] The present invention has at least the following advantages and beneficial effects:

[0022] The present invention proposes a water-cooled simulated load cabinet, which can connect / disconnect simulated loads of different numbers and sizes to the test circuit according to needs. The load dissipates heat through the water cooling system, and monitors the pressure of the coolant, the inlet and outlet flow rate and other information to determine whether the working state of the water cooling system is normal. It can realize multiple machines in series / parallel connection to achieve power expansion, and can also use any channel of the present invention as a monitoring path by switching the load source through a switch. At the same time, it provides a remote communication port, supports local operation and remote control, and can reduce the safety risk of operators. It has high power capacity, high power density, high measurement accuracy, and flexible use. It can meet a variety of test conditions and functional requirements, has strong power expandability and versatility, can improve equipment utilization, and effectively reduce equipment resource waste. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 It is an overall schematic diagram of the device of the present invention;

[0024] Figure 2 It is a structural schematic diagram of the present invention;

[0025] Figure 3 It is a schematic diagram of the load module principle of the present invention;

[0026] Figure 4 It is a load equivalent schematic diagram of the present invention;

[0027] Figure 5 Schematic diagram of different connection modes of use of the present invention;

[0028] Figure 6 It is a schematic diagram of the porous advection cold water circulation pipeline structure and installation method of the present invention;

[0029] Figure 7 It is a schematic diagram of the integrated water-cooled resistor and its internal structure of the present invention;

[0030] Figure 8 It is a schematic flow chart of the control method of the present invention;

[0031] In the figure: 1-cabinet, 2-electrical control system, 3-water cooling system, 11-front door, 12-front side door, 13-rear door, 14-isolation mounting plate, 15-layer plate, 16-vertical mounting plate, 17-water inlet port, 18-water outlet port, 21-programmable logic controller, 22-switch module, 23-collection module, 24-overload protection terminal, 25-current sensor, 26-voltage sensor, 27-DC contactor, 28-switch switch OFF, 31 - integrated water-cooled resistor, 32 - multi-hole horizontal cold water circulation pipeline, 33 - flow sensor, 34 - temperature sensor, 35 - pressure sensor, 36 - cooling unit, 37 - pipeline, 111 - touch screen, 112 - status indicator light, 113 - emergency stop switch, 121 - test connection port 1, 122 - test connection port 2, 123 - test connection port 3, 124 - spare port, 321 - water inlet pipe, 322 - water outlet pipe. DETAILED DESCRIPTION

[0032] The following is combined with Figure 1 , Attachment Figure 2 , Attachment Figure 3 , Attachment Figure 4 , Attachment Figure 5 , Attachment Figure 6 , Attachment Figure 7 , Attachment Figure 8 The high-power integrated water-cooled simulated load cabinet of the present invention is further described in detail.

[0033] The present invention proposes a high-power integrated water-cooled simulated load cabinet, which includes a cabinet, an electrical control system and a water cooling system. The cabinet is the main installation carrier, and some components of the electrical control system and the water cooling system are installed on the front and back sides of the cabinet internal space through isolation mounting plates. The water inlet port and the water outlet port at the bottom of the cabinet rear door are connected to the water inlet and outlet of the heat dissipation unit through pipelines to form a cold water self-circulation loop (see Figure 1 The cabinet front door is equipped with a touch screen, through which the load working status and the running status of the water cooling system can be controlled and viewed, and remote access control can also be achieved through the network port; the internal load type adopts an integrated water-cooled resistor and adopts a modular design (see Figure 2 ), realizing the power scalability of the simulated load and improving the power density and load working stability. Among them:

[0034] The cabinet includes a front door, a front side door, a rear door, an isolation mounting plate, a shelf, a vertical mounting plate, a water inlet port and a water outlet port; the front side door is installed with a test connection port 1, a test connection port 2, a test connection port 3 and a spare port, and the test connection port adopts an aviation socket for connecting the tested device or connecting multiple machines; the cable lead of the test connection port 1 is connected to one end of the overload protection terminal, and the other end is connected in series with a current sensor and a voltage sensor respectively, and then installed to one end of the contact of the DC contactor, and the other end of the contact is connected to the neutral contact of the switching switch, the contact 1 of the switching switch is connected to the positive pole of the load module, and its negative pole is connected to the test connection port 2, and the contact 3 of the switching switch is connected to the test connection port 3; the number of load modules can be expanded according to the number of channels required, and each load unit is equipped with an overload protection terminal, a current sensor and a contactor, which can realize the separate control and circuit protection of each circuit.

[0035] The load module (see Figure 3 ) is composed of multiple integrated water-cooled resistors and DC contactors, among which resistors R1, R2, R3, and R4 are designed with resistance values ​​according to different usage conditions. By connecting contactors K1, K2, K3, and K4 in groups, the module equivalent resistance can be adjusted by series / parallel resistors, thereby realizing 9 different resistance outputs and power carrying functions.

[0036] The cabinet can realize different functions through cables and test connection ports, and the load cabinet is equivalent to 1 load and 2 sets of switches (see the equivalent diagram Figure 4 ), when set to the monitoring working state, by switching the switch (turning on switch K1 and switch K2), the test circuit is connected to the test connection port 1, and the test connection port 3 is connected to the actual load, so that the load circuit can be monitored in real time; by switching the switch (turning on switch K1, turning off switch K2), the load cabinets can be connected in series by connecting the test connection port 1 and the test connection port 2 through a cable; the load cabinets can be connected in parallel by connecting the test connection port 2 and the test connection port 3 of another set of load cabinets, and the test connection port 3 and the test connection port 2 of another set of load cabinets through a cable; the expansion of different power levels and load requirements can be achieved (see the expansion method of the load cabinet Figure 5 shown);

[0037] The front door is equipped with a touch screen, a status indicator light and an emergency stop switch. The touch screen is connected to the programmable logic controller through an RS485 cable to issue operation instructions and display the overall working status information of the load and the load cabinet; the status indicator light is connected to both ends of the water-cooled load circuit to indicate the working status of the load circuit; the isolation mounting plate is installed in the middle of the cabinet to isolate the electrical control system and the water cooling system in the front and rear spaces of the cabinet; the layer plate is arranged in parallel in the cabinet, and the vertical mounting plate is arranged above the front space of the cabinet;

[0038] The electrical control system includes a programmable controller, a switch quantity module, an acquisition module, an overload protection terminal, a current sensor, a voltage sensor, a DC contactor and a switching switch. The programmable controller is also connected to the cooling unit through an RS485 expansion interface, and is used to remotely control the cooling system to be in an expected working state according to user instructions or set parameters, and automatically control the coolant temperature not to exceed a preset value. It also provides a TCP network access port through an RJ45 interface, which can query the current working state of the load cabinet and control the load to switch to different states. Remote / local control can be achieved through the provided special software; the switch quantity module and the acquisition module are expansion modules of the programmable controller, which are installed on the vertical mounting plate; the programmable controller and the switch quantity module are connected to the DC contactor and the switching switch, and are used to control the connection / disconnection of the load circuit; the acquisition module is connected to the output ends of the current sensor and the voltage sensor, and is used to collect current / voltage data.

[0039] The water cooling system includes an integrated water-cooling resistor, a multi-porous horizontal cold water circulation pipeline, a flow sensor, a temperature sensor, a pressure sensor, a heat dissipation unit and a pipeline. The integrated water-cooling resistor is evenly arranged in layers on the shelf of the control panel at the rear side of the cabinet through the bottom end studs. The positive and negative electrodes on the front side are connected to the switching switch through the isolation mounting plate, and the water inlet and outlet at the tail end are connected to the multi-porous horizontal cold water circulation pipeline; the multi-porous horizontal cold water circulation pipeline includes an inlet pipe and an outlet pipe, which are respectively arranged on the left and right sides in the cabinet, and the bottom inlet and outlet are placed in parallel, and are connected to the water inlet port and the water outlet port of the cabinet through flanges; the flow sensor and the pressure sensor are installed on the inlet pipe for monitoring the inlet flow and the coolant inlet pressure, and the output port thereof is connected to the acquisition module; the flow sensor and the temperature sensor are installed on the outlet pipe for monitoring the outlet flow and the coolant temperature, and the output port thereof is connected to the acquisition module;

[0040] The water inlet pipe and the water outlet pipe (see Figure 6 ) has a similar overall structure, with holes opened on one side of the mother pipe and multi-hole parallel shunt pipes arranged in a toothed shape, an exhaust valve installed on the top of the mother pipe, quick connectors evenly distributed on one side of the multi-hole parallel shunt pipes, and an exhaust valve installed on the other end, which can effectively discharge bubbles in the water cooling pipeline;

[0041] The water inlet and outlet pipes are arranged on the left and right sides of the cabinet respectively, the water inlet and outlet at the bottom are placed in parallel, the main pipes of the two pipes are perpendicular to the ground and parallel to each other, and the multi-hole parallel diversion pipes are interlaced in a toothed shape;

[0042] The integrated water-cooled resistor (see Figure 7) uses a full plastic shell, which consists of an upper cover and a bottom. The interior is sealed and installed by a sealing ring. The water inlet and outlet are respectively connected to the quick connectors distributed on the multi-hole parallel shunt pipes of the water inlet pipe and the water outlet pipe through a hose. The coolant enters the spiral water channel from the upper water inlet port of the water-cooled resistor. The resistor body adopts an alloy sheet reciprocating structure and is distributed in the water channel. After direct contact, the coolant enters the water outlet pipe through the lower water outlet port, effectively and evenly diverting the coolant to the inside of each water-cooled resistor, improving the heat dissipation efficiency and making the power performance more stable;

[0043] The cooling liquid selected for the water cooling system is a liquid with extremely low conductivity such as high-purity water / 50% ethylene glycol, which can directly contact the resistor body;

[0044] The control method is as follows (flow chart as shown in Figure 8 As shown), after the device is started, it will perform self-test, internal alarm information check and communication status check. After the self-test passes, the device parameters will be initialized; according to the touch screen or remote port, the access selection of the load circuit (select the number of access channels), the configuration information of the load unit (set the configuration status of the load unit according to power or current), the rated input voltage, the current upper limit protection value, the overload delay protection time, the preset temperature of the water cooling system, the water pump speed, the heat exchange fan speed and other information will be set; the programmable logic controller drives the contactor of the load unit to connect according to the user settings, completes the state configuration of the load unit through the series / parallel connection of four resistance values ​​such as R1, R2, R3, and R4, drives the contactor on the load circuit to connect, completes the loading of the load channel, and sends the preset parameters of the water cooling system to start the water cooling system; the feedback signal of the contactor auxiliary contact and the return information of the chiller are read through the programmable logic controller, and the information is updated and reported in real time; after startup, the inlet and outlet pressures and flow rates of the chilled water system are detected in real time, Determine whether the inlet / outlet pressure, inlet / outlet pressure difference, inlet / outlet flow, inlet / outlet flow difference, etc. exceed the protection range, detect the voltage state of the load circuit and the current of each load channel in real time, determine whether the voltage value of the load circuit and the current value of each load channel are within the protection range, and further, when the current is continuously detected to exceed the protection value, perform protection according to the set conditions; detect the coolant temperature and other information inside the water cooling system in real time, and when the temperature exceeds the set value, drive the water cooling unit to increase the speed of the heat exchange fan and water pump to improve the heat dissipation effect, and record the temperature data in real time, and determine the heat dissipation working status of the water cooling system according to the temperature data; when an abnormal situation occurs, select different active protection measures according to different fault parameters, disconnect the main circuit of the load, and report the error information; during the test process, all monitoring and detection information can be obtained in real time through the touch screen and remote port, thereby realizing high power density integration and automatic control of the simulated load, effectively enhancing the heat dissipation effect and load stability, and improving test efficiency.

[0045] The present invention provides an integrated water-cooled simulated load cabinet and a control method thereof, including an electrical control system, a water-cooling system and a cabinet. A plurality of water-cooled load units and a DC contactor are installed inside the cabinet. Simulated loads of different numbers and sizes can be connected / disconnected to a test circuit according to demand. The working state of the load circuit and the connection state of the load are monitored in real time and fed back to the control system. The load is cooled by the water-cooling system. The temperature of the coolant in the cold water circulation pipeline can be monitored in real time. The speed of the cooling pump and the cooling fan of the external cooling fan can be adjusted to realize dynamic temperature control. Whether the working state of the water cooling system is normal can be judged by information such as the pressure of the coolant and the inlet and outlet flow rates. A test connection port, an operation panel and a display panel are provided on the cabinet panel. Multiple machines can be connected in series / parallel by connecting cables to realize power expansion. The load source can also be switched by switching a switch to use any channel of the present invention as a monitoring path. At the same time, a remote communication port is provided to support local operation and remote control. The present invention can realize local / remote control, can reduce the safety risk of operators, has high power capacity, high power density, high measurement accuracy, and flexible usage, can meet a variety of test conditions and functional requirements, has strong power expandability and versatility, can improve equipment utilization rate, and effectively reduce equipment resource waste.

Claims

1. An integrated water-cooled simulated load cabinet, characterized in that: It comprises a cabinet (1), an electrical control system (2) and a water cooling system (3); the cabinet (1) is connected to the water inlet and outlet of a heat dissipation unit (36) through a water inlet port (17) and a water outlet port (18) at the bottom of a rear door using pipelines (37) to form a cold water self-circulation loop; The cabinet (1) comprises a front door (11), a front side door (12), a rear door (13), an isolation mounting plate (14), a layer plate (15), a vertical mounting plate (16), a water inlet port (17) and a water outlet port (18); the front side door (12) is provided with a test connection port 1 (121), a test connection port 2 (122), a test connection port 3 (123) and a spare port (124); the test connection port adopts an aviation socket for connecting a device under test or for connecting multiple machines; the cable of the test connection port 1 (121) is connected to one end of an overload protection terminal (24), the other end of which is respectively connected in series with a current sensor (25) and a voltage sensor (26) and then installed to one end contact of a DC contactor (27), the other end contact of which is connected to a neutral contact of a switching switch (28), and the contact 1 of the switching switch (28) is connected to an integrated water The positive electrode of the cold resistor (31) and the negative electrode thereof are connected to the test connection port 2 (122), and the contact 3 of the switching switch (28) is connected to the test connection port 3 (123); the front door (11) is equipped with a touch screen (111), a status indicator light (112) and an emergency stop switch (113); the touch screen (111) is connected to the programmable logic controller (21) via an RS485 cable, and is used to issue operation instructions and display the overall working status information of the load and the load cabinet; the status indicator light (112) is connected to both ends of the water-cooled load circuit in parallel, and is used to indicate the working status of the load circuit; the isolation mounting plate (14) is installed in the middle position of the cabinet (1), and isolates the electrical control system (2) and the water cooling system (3) in the front and rear side spaces of the cabinet; the layer plate (15) is arranged in parallel in the cabinet, and the vertical mounting plate (16) is arranged above the front side space of the cabinet; The electrical control system (2) comprises a programmable controller (21), a switch quantity module (22), a collection module (23), an overload protection terminal (24), a current sensor (25), a voltage sensor (26), a DC contactor (27) and a switch (28); the switch quantity module (22) and the collection module (23) are expansion modules of the programmable controller (21) and are installed on a vertical mounting plate (16); the programmable controller (21) and the switch quantity module (22) are connected to the DC contactor (27) and the switch (28) to control the connection / disconnection of a load circuit; the collection module (23) is connected to the output ends of the current sensor (25) and the voltage sensor (26) to collect current / voltage data; The water cooling system (3) comprises an integrated water cooling resistor (31), a porous advection cold water circulation pipeline (32), a flow sensor (33), a temperature sensor (34), a pressure sensor (35), a heat sink (36) and a pipeline (37); the integrated water cooling resistor (31) is evenly arranged in layers on a layer plate (15) of a control panel at the rear side of the cabinet through bottom studs; the positive and negative electrodes on the front side are connected to a switch (28) through an isolation mounting plate (14); and the water inlet and outlet at the rear end are connected to the porous advection cold water circulation pipeline (32); the porous advection cold water circulation pipeline (32) comprises a water inlet pipe (3 The cabinet (21) and the water outlet pipe (322) are respectively arranged on the left and right sides of the cabinet, and the water inlet and water outlet at the bottom are placed in parallel and connected to the water inlet port (17) and the water outlet port (18) of the cabinet (1) through flanges; the flow sensor (33) and the pressure sensor (35) are installed on the water inlet pipe (321) for monitoring the inlet flow and the inlet pressure of the coolant, and the output port thereof is connected to the acquisition module (23); the flow sensor (33) and the temperature sensor (34) are installed on the water outlet pipe (322) for monitoring the outlet flow and the temperature of the coolant, and the output port thereof is connected to the acquisition module (23).

2. The water-cooled simulated load cabinet according to claim 1, characterized in that: The programmable controller (21) is also connected to the cooling unit (36) via an RS485 expansion interface, and is used to remotely control the cooling system to be in an expected working state according to user instructions or set parameters, and automatically control the coolant temperature not to exceed a preset value; The programmable controller (21) also provides a TCP network access port through an RJ45 interface, which can query the current working status of the load cabinet, control the load to switch to different states, and realize remote / local control.

3. The water-cooled simulated load cabinet according to claim 2, characterized in that: The water inlet pipe (321) and the water outlet pipe (322) have similar overall structures. After a hole is opened on one side of the main pipe, a multi-porous parallel shunt pipe is arranged in a toothed shape. An exhaust valve is installed at the top of the main pipe. Quick connectors are evenly distributed on one side of the multi-porous parallel shunt pipe, and an exhaust valve is installed at the other end. The water inlet pipe (321) and the water outlet pipe (322) are respectively arranged on the left and right sides of the cabinet, and the water inlet and the water outlet at the bottom are arranged in parallel. The main pipes of the two pipelines are perpendicular to the ground and parallel to each other, and the multi-porous parallel shunt pipes are interlaced in a toothed shape. The water inlet and the water outlet of the integrated water-cooled resistor (31) are respectively connected to the quick connectors distributed on the multi-porous parallel shunt pipes of the water inlet pipe (321) and the water outlet pipe (322) through hoses.

4. The integrated water-cooled simulated load cabinet according to claim 3 is characterized in that: The normally closed point of the emergency stop switch (113) is directly connected to the DC contactor (27) and the switching switch (28) and its power supply end, and can disconnect the load circuit; in the water cooling system (3), a plurality of integrated water cooling resistors (31) are connected in series / parallel to form a load module, and the load module is composed of four resistors with different resistance values, namely R1, R2, R3, and R4. By switching different switches, the load module can be switched between eight different power states.

5. The water-cooled simulated load cabinet according to claim 4, characterized in that: The switching switch (28) is a three-gear switch, and its contact 2 is in the neutral position. By switching the switching switch (28) to contact 1 to connect, normal access to the load circuit is achieved. By switching the switching switch (28) to contact 3 to connect, a monitoring function is provided when the actual load is connected.

6. The water-cooled simulated load cabinet according to claim 5, characterized in that: The load cabinets can be connected in series by connecting the test connection port 1 (121) and the test connection port 2 (122) through a cable; the load cabinets can be connected in parallel by connecting the test connection port 2 (122) and the test connection port 3 (123) of another set of load cabinets, and the test connection port 3 (123) and the test connection port 2 (122) of another set of load cabinets through a cable; the expansion of different power levels and load requirements can be achieved; the resistor body of the integrated water-cooled resistor (31) is located inside the shell, and its pins extend out of the shell after being connected with the terminals, and a water channel is provided between the resistor body and the shell, and a water inlet and outlet port of the water channel is provided at the shell on the other side of the lead-out terminal of the resistor body.

7. The water-cooled simulated load cabinet according to claim 6, characterized in that: The integrated water-cooled resistor (31) has a fully plastic shell, which is composed of an upper cover plate and a bottom. A sealing ring is installed between the upper cover plate and the bottom. A water inlet, a water outlet, a mounting terminal and a resistor connection terminal are distributed on the side of the bottom shell. The water channel between the resistor body and the shell is a spiral water channel. The resistor body adopts an alloy sheet reciprocating structure and is installed in the water channel. A cooling method of high-purity water / 50% ethylene glycol directly contacting the resistor body is selected, which has a stronger heat dissipation effect, higher efficiency, higher load power and more stable performance.

8. A method for controlling an integrated water-cooled simulated load cabinet, characterized in that: The control method adopts the load cabinet as described in any one of claims 1 to 7, and the control method is: After the equipment is started, it will conduct self-test, internal alarm information check and communication status check. After the self-test passes, the equipment parameters will be initialized. After the user configures the access status of the load circuit and the configuration information of the load unit, the protection value and protection time of the current / voltage, and the operating parameters and protection parameters of the water cooling system through the human-machine interface, the programmable logic controller drives the contactor of the load unit to turn on, completes the state configuration of the load unit, drives the contactor on the load circuit to turn on, completes the loading of the load channel, and starts the water cooling unit according to the set parameters; The feedback signal of the contactor auxiliary contact and the return information of the chiller are read through the programmable logic controller, and the information is updated and reported in real time; After startup, the inlet and outlet pressures and flows of the cold water system are detected in real time to determine whether the inlet / outlet pressure, inlet / outlet pressure difference, inlet / outlet flow, inlet / outlet flow difference, etc. exceed the protection range; the voltage state of the load circuit and the current of each load channel are detected in real time to determine whether the voltage value of the load circuit and the current value of each load channel are within the protection range; further, when the current is continuously detected to exceed the protection value, protection is performed according to the set conditions; Real-time detection of the coolant temperature and other information inside the water cooling system. When the temperature exceeds the set value, the water cooling unit is driven to increase the speed of the heat exchange fan and water pump to improve the heat dissipation effect. The temperature data is recorded in real time, and the heat dissipation working status of the water cooling system is determined based on the temperature data. During the test, all monitoring and detection information can be obtained in real time through the touch screen and remote port, thereby realizing high power density integration and automatic control of the simulated load, effectively enhancing the heat dissipation effect and load stability, and improving test efficiency.

Images