An integrated water-cooled simulated load cabinet and its control method

Abstract

This invention provides an integrated water-cooled simulated load cabinet and its control method, including an electrical control system, a water-cooling system, and a cabinet. The cabinet houses multiple water-cooled load units and DC contactors, allowing for the connection / disconnection of simulated loads of varying numbers and sizes to the test circuit as needed. The system monitors the load circuit's operating status and load connection status in real time and feeds this information back to the control system. The loads are cooled by the water-cooling system, and the temperature of the coolant in the cold water circulation pipes can be monitored in real time. Dynamic temperature control is achieved by adjusting the speed of the external cooling pump and cooling fan. The system's operating status is determined by information such as coolant pressure and inlet / outlet flow rate. The cabinet panel provides test connection ports, an operation panel, and a display panel. Multiple units can be connected in series or parallel via connecting cables to expand power output.

Description

Technical Field

[0001] This invention belongs to the field of experimental device technology, and particularly relates to an integrated water-cooled simulated load cabinet and its control method. Background Technology

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

[0003] Currently, 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 few channels and are expensive. From a cost perspective, analog loads usually have fixed resistance values, are mostly dedicated equipment, have low equipment utilization, and are mostly cooled by air. The resistance value will change due to the heat effect. In addition, for high-power loads, in order to ensure heat dissipation, they usually occupy a large space and have low power density. Summary of the Invention

[0004] Purpose of the invention: To address the problems of low heat dissipation efficiency, large size, and low expansion flexibility of current simulated loads, a high-power integrated water-cooled simulated load cabinet is designed. The main problems solved are as follows: It solves the problem of low heat dissipation efficiency of existing loads and can stably control the operating temperature of the load; it can realize the power expansion of the simulated load and eliminate the problems of low power and large size of conventional simulated loads.

[0005] In one aspect, this application provides an integrated water-cooled simulated load cabinet, which includes a cabinet, an electrical control system, and a water-cooling system. The cabinet serves as the main mounting carrier, and is connected to the inlet and outlet of a cooling unit via pipes through the water inlet and outlet ports at the bottom of the rear door, forming a self-circulating cold water loop. The cabinet includes a front door, a front side door, a rear door, an isolation mounting plate, shelves, a vertical mounting plate, a water inlet port, and a water outlet port. The front side door is equipped with test connection port 1, test connection port 2, test connection port 3, and a spare port for connecting the device under test or for multi-machine connection. The cable of test connection port 1 is led out to one end of an 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 contact of a DC contactor. The other contact is connected to the neutral contact of a switch. The contact 1 of the switch is connected to the positive terminal of an integrated water-cooled resistor, and its negative terminal is connected to the test connection terminal. Port 2 is connected, and the contact 3 of the switch is connected to the test connection port 3; the front door is equipped with a touch screen, status indicator lights, and an emergency stop switch. The touch screen is connected to the programmable logic controller via an RS485 cable and is used to issue operation commands and display the overall working status information of the load and load cabinet; the status indicator lights are connected in parallel 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 sides of the cabinet; the shelves are arranged parallel to each other in the cabinet, and the vertical mounting plate is set above the front side of the cabinet.

[0006] The electrical control system includes a programmable logic controller (PLC), a digital input module, a data acquisition module, overload protection terminals, a current sensor, a voltage sensor, a DC contactor, and a changeover switch. The digital input module and the data acquisition module are expansion modules of the PLC and are mounted on a vertical mounting plate. The PLC and the digital input module are connected to the DC contactor and the changeover switch to control the connection / disconnection of the load circuit. The data acquisition module is connected to the output terminals of the current sensor and the voltage sensor to acquire current / voltage data.

[0007] The water-cooling system includes an integrated water-cooled resistor, a multi-hole horizontal flow cooling water circulation pipeline, a flow sensor, a temperature sensor, a pressure sensor, a heat dissipation unit, and piping. The integrated water-cooled resistor is installed on the shelf of the control panel on the rear side of the cabinet via studs arranged in layers. Its positive and negative terminals are connected to a switch via an isolation mounting plate, and its inlet and outlet ports are connected to the multi-hole horizontal flow cooling water circulation pipeline. The multi-hole horizontal flow cooling water circulation pipeline includes an inlet pipe and an outlet pipe, which are respectively installed on the left and right sides of the cabinet. Its bottom inlet and outlet are placed parallel to each other and connected to the inlet and outlet ports of the cabinet via flanges. The flow sensor and pressure sensor are installed on the inlet pipe to monitor the inlet flow rate and coolant inlet pressure, and their output ports are connected to the acquisition module. The flow sensor and temperature sensor are installed on the outlet pipe to monitor the outlet flow rate and coolant temperature, and their output ports are connected to the acquisition module.

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

[0009] Preferably, the inlet and outlet pipes have similar overall structures. After opening one side of the main pipe, multi-hole parallel branch pipes are arranged in a toothed pattern. An air vent valve is installed at the top of the main pipe. Quick connectors are evenly distributed on one side of the multi-hole parallel branch pipes, and an air vent valve is installed at the other end. The inlet and outlet pipes are respectively set on the left and right sides inside the cabinet. The bottom inlet and outlet are placed in parallel. The main pipes of the two pipes are perpendicular to the ground and parallel to each other. Their multi-hole parallel branch pipes are interlaced in a toothed pattern.

[0010] Preferably, the inlet and outlet of the integrated water-cooled resistor are connected to quick-read connectors distributed on the multi-hole parallel diverter pipes of the inlet and outlet pipes respectively via flexible hoses.

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

[0012] Preferably, the integrated water-cooled resistor is composed of multiple resistors connected in series / parallel to form a load module. The load module consists of four resistors with different resistance values: R1, R2, R3, and R4. By switching different switches, the load module can switch between nine different power states.

[0013] Preferably, the normally closed contact of the emergency stop switch is directly connected to the DC contactor and the changeover switch and their power supply terminals, which can disconnect the load circuit;

[0014] Preferably, the switching switch is a 3-position switch, with contact 2 in the neutral position. By switching the switching switch to contact 1 to connect, the normal connection of the load circuit is realized. By switching the switching switch to contact 3 to connect, the real-time monitoring function is provided when the actual load is connected.

[0015] Preferably, the cabinet can be connected in series with test connection port 1 and test connection port 2 via cables; the load cabinets can be connected in parallel by connecting test connection port 2 to test connection port 3 of another load cabinet, and test connection port 3 to test connection port 2 of another load cabinet; thus enabling expansion to meet different power levels and load requirements.

[0016] Secondly, the present invention also proposes a control method based on the load cabinet as described above, wherein the control flow is as follows:

[0017] After the equipment starts up, it performs a self-test, checks internal alarm information and communication status. After the self-test passes, the equipment parameters are initialized. The user configures the connection status of the load circuit and the configuration information of the load unit, the protection value and protection time of the current / voltage, as well as the operating parameters and protection parameters of the water cooling system through the human-machine interface. Then, the programmable logic controller drives the contactor of the load unit to connect, completes the status configuration of the load unit, drives the contactor on the load circuit to connect, completes the loading of the load channel, and starts the water cooling unit according to the set parameters.

[0018] The programmable logic controller reads the feedback signals from the auxiliary contacts of the contactor and the return information from the chiller unit, and updates and reports the information in real time. After startup, it monitors the inlet and outlet pressures and flow rates of the chiller system in real time to determine whether the inlet / outlet pressure, inlet / outlet pressure difference, inlet / outlet flow rate, and inlet / outlet flow rate difference exceed the protection range. It also monitors the voltage status of the load circuit and the current of each load channel 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. Furthermore, when the current is continuously detected to exceed the protection value, protection is provided according to the set conditions.

[0019] The system monitors information such as the temperature of the coolant inside the water cooling system in real time. When the temperature exceeds the set value, it drives the water cooling unit to increase the speed of the heat exchange fan and water pump to improve the heat dissipation effect. It also records the temperature data in real time and judges the heat dissipation status of the water cooling system 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, thereby realizing high power density integration and automatic control of the simulated load, effectively enhancing heat dissipation and load stability, and improving test efficiency.

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

[0022] This invention proposes a water-cooled simulated load cabinet, which can connect / disconnect simulated loads of different numbers and sizes to the test circuit as needed. The loads are cooled by a water-cooling system, and the operating status of the water-cooling system is determined by monitoring information such as coolant pressure and inlet / outlet flow rate. Multiple units can be connected in series / parallel to expand power output. Any channel of this invention can be used as a monitoring path by switching the load source via a switch. It also provides a remote communication port, supporting local operation and remote control, reducing safety risks for operators. It features high power capacity, high power density, high measurement accuracy, and flexible usage, meeting various test conditions and functional requirements. Its strong power scalability and versatility improve equipment utilization and effectively reduce equipment resource waste. Attached Figure Description

[0023] Figure 1 This is a schematic diagram of the overall device of the present invention;

[0024] Figure 2 This is a schematic block diagram of the structure of the present invention;

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

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

[0027] Figure 5 These are schematic diagrams illustrating different connection methods used in this invention;

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

[0029] Figure 7 This is a schematic diagram of the integrated water-cooled resistor and its internal structure according to the present invention.

[0030] Figure 8 This is a schematic flowchart of the control method of the present invention;

[0031] In the diagram: 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 - Shelf, 16 - Vertical mounting plate, 17 - Water inlet port, 18 - Water outlet port, 21 - Programmable Logic Controller, 22 - Switching module, 23 - Data acquisition module, 24 - Overload protection terminal, 25 - Current sensor, 26 - Voltage sensor, 27 - DC contactor, 28 - Switching switch 31 - Integrated water-cooled resistor; 32 - Multi-hole horizontal flow cold water circulation pipe; 33 - Flow sensor; 34 - Temperature sensor; 35 - Pressure sensor; 36 - Cooling unit; 37 - Piping; 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 Implementation

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

[0033] This invention proposes a high-power integrated water-cooled analog load cabinet, which includes a cabinet, an electrical control system, and a water-cooling system. The cabinet serves as the main mounting carrier. Some components of the electrical control system and water-cooling system are installed on the front and rear sides of the cabinet's interior space via isolation mounting plates. The water inlet and outlet ports at the bottom of the cabinet's rear door are connected to the inlet and outlet ports of the cooling unit via pipes, forming a self-circulating cold water loop (see...). Figure 1 The front door of the rack is equipped with a touchscreen, which allows users to control and view the load status and the operating status of the water cooling system. Remote access and control are also possible via a network port. The internal load type uses integrated water-cooled resistors and features a modular design (see...). Figure 2 This enables power scalability of the simulated load, improving power density and load operational stability. Specifically:

[0034] The cabinet includes a front door, a front side door, a rear door, an isolation mounting plate, shelves, a vertical mounting plate, a water inlet port, and a water outlet port. The front side door is equipped with test connection port 1, test connection port 2, test connection port 3, and a spare port. The test connection ports use aviation sockets for connecting the device under test (DUT) or for multi-device connection. The cable from test connection port 1 is led out to one end of the overload protection terminal. The other end is connected in series with a current sensor and a voltage sensor, and then mounted to one contact of a DC contactor. The other contact is connected to the neutral contact of a switch. Contact 1 of the switch is connected to the positive terminal of the load module, and its negative terminal is connected to test connection port 2. Contact 3 of the switch is connected to test connection port 3. The number of load modules can be expanded according to the required number of channels. Each load unit is equipped with an overload protection terminal, a current sensor, and a contactor, enabling individual control and protection of each circuit.

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

[0036] The cabinet can achieve different functions via cables and test connection ports. The load cabinet is equivalent to one load and two sets of switches (see equivalent diagram). Figure 4 When set to monitoring mode, by switching on both switches (K1 and K2), the test circuit is connected to test connection port 1, and test connection port 3 is connected to the actual load, enabling real-time monitoring of the load circuit. Switching by switching on switch K1 and off switch K2, test connection ports 1 and 2 can be connected in series via cables. Test connection ports 2 and 3 of another load cabinet can be connected in parallel via cables. This allows for expansion to different power levels and load requirements (see [link to load cabinet expansion methods]). Figure 5 (as shown);

[0037] The front door is equipped with a touch screen, status indicator lights, and an emergency stop switch. The touch screen is connected to a programmable logic controller via an RS485 cable for issuing operation commands and displaying the overall working status information of the load and load cabinet. The status indicator lights are connected in parallel 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, isolating the electrical control system and the water cooling system in the front and rear spaces of the cabinet. The shelves are arranged parallel to each other in the cabinet, and the vertical mounting plate is set above the front space of the cabinet.

[0038] The electrical control system includes a programmable logic controller (PLC), a digital input module, a data acquisition module, overload protection terminals, a current sensor, a voltage sensor, a DC contactor, and a changeover switch. The PLC also connects to the cooling unit via an RS485 expansion interface to remotely control the cooling system to operate in the expected state based on user commands or set parameters, automatically controlling the coolant temperature to not exceed a preset value. It also provides a TCP network access port via an RJ45 interface to query the current load cabinet's operating status and control the load to switch between different states. Remote / local control can be achieved through provided dedicated software. The digital input module and data acquisition module are expansion modules of the PLC, mounted on a vertical mounting plate. The PLC and digital input module are connected to the DC contactor and changeover switch to control the connection / disconnection of the load circuit. The data acquisition module is connected to the output terminals of the current and voltage sensors to acquire current / voltage data.

[0039] The water-cooling system includes an integrated water-cooled resistor, a multi-hole horizontal flow cooling water circulation pipeline, a flow sensor, a temperature sensor, a pressure sensor, a heat dissipation unit, and piping. The integrated water-cooled resistor is installed on the shelf of the control panel on the rear side of the cabinet via studs arranged in layers. Its positive and negative terminals are connected to a switch via an isolation mounting plate, and its inlet and outlet ports are connected to the multi-hole horizontal flow cooling water circulation pipeline. The multi-hole horizontal flow cooling water circulation pipeline includes an inlet pipe and an outlet pipe, which are respectively installed on the left and right sides of the cabinet. Its bottom inlet and outlet are placed parallel to each other and connected to the inlet and outlet ports of the cabinet via flanges. The flow sensor and pressure sensor are installed on the inlet pipe to monitor the inlet flow rate and coolant inlet pressure, and their output ports are connected to the acquisition module. The flow sensor and temperature sensor are installed on the outlet pipe to monitor the outlet flow rate and coolant temperature, and their output ports are connected to the acquisition module.

[0040] The aforementioned inlet and outlet pipes (see...) Figure 6 The overall structure is similar. After the main pipe is opened on one side, the multi-hole parallel diverter pipes are placed in a tooth-like distribution. An exhaust valve is installed at the top of the main pipe. Quick connectors are evenly distributed on one side of the multi-hole parallel diverter pipes, and an exhaust valve is installed at the other end, which can effectively remove air bubbles in the water cooling pipeline.

[0041] The inlet and outlet pipes are respectively installed on the left and right sides inside the cabinet. The bottom inlet and outlet are placed in parallel. The main pipes of the two pipes are perpendicular to the ground and parallel to each other. Their multi-hole parallel branch pipes are intersected in a toothed manner.

[0042] The integrated water-cooled resistor (see) Figure 7The outer shell is made of all-plastic material, consisting of a top cover and a bottom. The interior is sealed with a sealing ring. The inlet and outlet are connected to quick connectors distributed on the multi-hole parallel distribution pipe of the inlet and outlet pipes, respectively, via hoses. The coolant enters the spiral water channel from the upper inlet port of the water-cooled resistor. The resistor element adopts an alloy sheet reciprocating structure and is distributed in the water channel. After the coolant comes into direct contact, it enters the outlet pipe through the lower outlet port, effectively distributing the coolant evenly to the interior of each water-cooled resistor, improving heat dissipation efficiency and making the power performance more stable.

[0043] The water cooling system uses high-purity water / 50% ethylene glycol and other liquids with extremely low conductivity, which can directly contact the resistive element.

[0044] The control method described is as follows (flowchart shown) Figure 8 As shown, after the equipment starts, it performs a self-test, checks internal alarm information and communication status. After the self-test passes, it initializes the equipment parameters. Based on the touchscreen or remote port, it sets the load circuit access selection (selecting the number of connection paths), load unit configuration information (setting the load unit configuration status based on power or current), rated input voltage, current upper limit protection value, overload delay protection time, water cooling system preset temperature, water pump speed, heat exchange fan speed, etc. The programmable logic controller (PLC) drives the contactors of the load units to connect according to the user settings. It completes the load unit status configuration through series / parallel connection of four resistors (R1, R2, R3, R4), drives the contactors on the load circuit to connect, completes the load channel loading, and simultaneously sends down the preset parameters of the water cooling system to start the water cooling system. The PLC reads the feedback signals from the contactor auxiliary contacts and the return information from the chiller unit, updating and reporting the information in real time. After startup, it monitors the inlet and outlet pressures and flow rates of the chiller system in real time. The system determines whether inlet / outlet pressure, inlet / outlet pressure difference, inlet / outlet flow rate, and inlet / outlet flow rate difference exceed the protection range. It also monitors the voltage status of the load circuit and the current of each load channel in real time, determining if these values ​​are within the protection range. Furthermore, if the current continuously exceeds the protection value, it initiates protection based on set conditions. The system also monitors the internal coolant temperature of the water-cooling system in real time. When the temperature exceeds the set value, it drives the water-cooling unit to increase the speed of the heat exchange fan and water pump to improve heat dissipation, and records temperature data in real time to determine the cooling system's operating status. In case of abnormalities, it selects different active protection measures based on different fault parameters, disconnects the main circuit of the load, and reports the error information. All monitoring and detection information can be obtained in real time through a touchscreen and remote port during the test, enabling high power density integration and automatic control of the simulated load, effectively enhancing heat dissipation and load stability, and improving test efficiency.

[0045] This invention provides an integrated water-cooled simulated load cabinet and its control method, including an electrical control system, a water-cooling system, and a cabinet. The cabinet houses multiple water-cooled load units and DC contactors, allowing for the connection / disconnection of simulated loads of varying numbers and sizes to the test circuit as needed. The system monitors the load circuit's operating status and load connection status in real time and feeds this information back to the control system. The loads are cooled by the water-cooling system, and the temperature of the coolant in the cold water circulation pipes can be monitored in real time. Dynamic temperature control is achieved by adjusting the speed of the external cooling pump and cooling fan. The system's operating status is determined by information such as coolant pressure and inlet / outlet flow rate. The cabinet panel provides test connection ports, an operation panel, and a display panel. Multiple units can be connected in series or parallel via connecting cables to expand power output. A switch can be used to switch the load source, allowing any channel of this invention to be used as a monitoring path. A remote communication port is also provided, supporting both local operation and remote control. This invention enables local / remote control, reduces safety risks for operators, has high power capacity, high power density, high measurement accuracy, and flexible usage, and can meet various test conditions and functional requirements. It also has strong power scalability and versatility, which can improve equipment utilization and effectively reduce equipment resource waste.

Claims

1. An integrated water-cooled simulated load cabinet, characterized in that, It includes a cabinet (1), an electrical control system (2) and a water cooling system (3). The cabinet (1) is connected to the inlet and outlet of the heat dissipation unit (36) through the water inlet port (17) and the water outlet port (18) at the bottom of the rear door, respectively, by means of pipes (37) to form a cold water self-circulation loop. The cabinet (1) includes a front door (11), a front side door (12), a rear door (13), an isolation mounting plate (14), a shelf (15), a vertical mounting plate (16), a water inlet port (17), and a water outlet port (18). The front side door (12) is equipped with test connection port 1 (121), test connection port 2 (122), test connection port 3 (123), and a spare port (124). The test connection port uses an aviation socket for connecting the device under test or for multi-machine connection. The cable of test connection port 1 (121) is led out to one end of the overload protection terminal (24), and the other end is connected in series with a current sensor (25) and a voltage sensor (26) and then installed to one end of the contact of a DC contactor (27). The other end of the contact is connected to the neutral contact of a switch (28). The contact 1 of the switch (28) is connected to an integrated water... The positive terminal of the cold resistor (31) is connected to the test connection port 2 (122), and the contact 3 of the 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 (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 commands and display the overall working status information of the load and the load cabinet. The status indicator (112) is connected in parallel to both ends of the water-cooled load circuit and is used to indicate the working status of the load circuit. The isolation mounting plate (14) is installed in the middle of the cabinet (1) to isolate the electrical control system (2) and the water-cooling system (3) in the front and rear spaces of the cabinet. The shelf (15) is arranged parallel to the cabinet, and the vertical mounting plate (16) is arranged above the front space of the cabinet. The electrical control system (2) includes a programmable controller (21), a digital input module (22), a data acquisition module (23), an overload protection terminal (24), a current sensor (25), a voltage sensor (26), a DC contactor (27), and a changeover switch (28). The digital input module (22) and the data acquisition module (23) are extension modules of the programmable controller (21) and are mounted on a vertical mounting plate (16). The programmable controller (21) and the digital input module (22) are connected to the DC contactor (27) and the changeover switch (28) to control the connection / disconnection of the load circuit. The data acquisition module (23) is connected to the output terminals of the current sensor (25) and the voltage sensor (26) to acquire current / voltage data. The water cooling system (3) includes an integrated water-cooled resistor (31), a multi-hole horizontal flow cold water circulation pipe (32), a flow sensor (33), a temperature sensor (34), a pressure sensor (35), a heat dissipation unit (36), and pipes (37). The integrated water-cooled resistor (31) is installed on the shelf (15) of the control panel on the back of the cabinet by means of bottom studs arranged in layers. Its positive and negative terminals are connected to the switch (28) through the isolation mounting plate (14), and its tail end inlet and outlet are connected to the multi-hole horizontal flow cold water circulation pipe (32). The multi-hole horizontal flow cold water circulation pipe (32) includes an inlet pipe (33). 21) and outlet pipe (322) are respectively set on the left and right sides inside the cabinet, with the bottom inlet and outlet of the pipe placed parallel to each other and connected to the inlet port (17) and outlet port (18) of the cabinet (1) through flanges; the flow sensor (33) and pressure sensor (35) are installed on the inlet pipe (321) to monitor the inlet flow and coolant inlet pressure, and their output ports are connected to the acquisition module (23); the flow sensor (33) and temperature sensor (34) are installed on the outlet pipe (322) to monitor the outlet flow and coolant temperature, and their output ports are 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 heat dissipation unit (36) via an RS485 expansion interface, which is used to remotely control the heat dissipation system to be in the expected working state according to user instructions or set parameters, and automatically control the coolant temperature to not exceed the preset value. The programmable controller (21) also provides a TCP network access port through the RJ45 interface, which can query the current working status of the load cabinet, control the load to switch between different states, and realize remote / local control.

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

4. The integrated water-cooled simulated load cabinet according to claim 3, characterized in that, The normally closed contact of the emergency stop switch (113) is connected directly to the DC contactor (27) and the switching switch (28) and its power supply terminal, which can disconnect the load circuit. The water cooling system (3) consists of multiple integrated water cooling resistors (31) connected in series / parallel to form a load module. The load module consists of four resistors with different resistance values: R1, R2, R3, and R4. By switching different switches, the load module can switch 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 3-position switch with its contact 2 in the neutral position. By switching the switching switch (28) to contact 1 to connect, the normal connection of the load circuit is realized. By switching the switching switch (28) to contact 3 to connect, the actual load is connected and the monitoring function is provided.

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

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

8. A control method for an integrated water-cooled simulated load cabinet, characterized in that, The control method employs the load cell as described in any one of claims 1-7, and the control method is as follows: After the equipment starts up, it performs a self-test, checks internal alarm information and communication status. After the self-test passes, the equipment parameters are initialized. The user configures the connection status of the load circuit and the configuration information of the load unit, the protection value and protection time of the current / voltage, as well as the operating parameters and protection parameters of the water cooling system through the human-machine interface. Then, the programmable logic controller drives the contactor of the load unit to connect, completes the status configuration of the load unit, drives the contactor on the load circuit to connect, completes the loading of the load channel, and starts the water cooling unit according to the set parameters. The programmable logic controller reads the feedback signals from the auxiliary contacts of the contactor and the return information from the chiller unit, and updates and reports the information in real time. After startup, the system monitors the inlet and outlet pressures and flow rates of the chilled water system in real time to determine whether the inlet / outlet pressure, inlet / outlet pressure difference, inlet / outlet flow rate, and inlet / outlet flow rate difference exceed the protection range. It also monitors the voltage status of the load circuit and the current of each load channel 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. Furthermore, when the current is continuously detected to exceed the protection value, protection is provided according to the set conditions. The system monitors information such as the temperature of the coolant inside the water cooling system in real time. When the temperature exceeds the set value, it drives the water cooling unit to increase the speed of the heat exchange fan and water pump to improve the heat dissipation effect. It also records the temperature data in real time and judges the heat dissipation status of the water cooling system 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 heat dissipation and load stability, and improving test efficiency.

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