Cooling system for junction box of electric heater in high-temperature environment and control method
The compressed purified air is conveyed to the electric heater junction box through an external air compression purifier and a multi-pipe structure, and forced convection heat exchange is achieved, solving the problem that traditional junction boxes are difficult to dissipate heat in high temperature environments, significantly improving the cooling efficiency and equipment reliability and safety.
Patent Information
- Application Number
- CN202510141088.7
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-02-08
- Publication Date
- 2025-05-16
AI Technical Summary
Traditional electric heater junction boxes are difficult to effectively dissipate heat in high temperature environments, resulting in an increase in the internal temperature of the junction boxes, posing safety hazards and risk of equipment aging.
An external air compression purifier is used to transport compressed purified air to the electric heater junction box through a multi-pipe structure, achieving forced convection heat exchange and rapidly reducing the temperature in the junction box.
It effectively improves the cooling and heat dissipation efficiency of the electric heater junction box, eliminates the disadvantages of the difficulty of heat dissipation of traditional junction boxes themselves, and can keep the temperature in the junction box within a safe range under high temperature and harsh environments, extends the service life of the equipment and improves safety.
Smart Images
Figure CN120010589A_ABST
Abstract
Description
Technical Field
[0001] The invention belongs to the technical field of cooling a junction box of an electric heater, and in particular relates to a cooling and temperature reduction system and a control method for a junction box of an electric heater in a high-temperature environment. Background Art
[0002] The ambient temperature that a traditional electric heater junction box can withstand is -40 to 40°C. In order to ensure the safety and reliability of the copper busbars and cables in the junction box, the industry standard requires that the temperature inside the junction box be ≤60°C. However, because the junction box structure is a closed space, the heat generated by the copper busbars and cables themselves cannot be effectively dissipated through natural convection, posing a safety hazard.
[0003] The traditional electric heater junction box consists of a junction box cylinder, a cover, a seal, and internal connectors. Since the wiring inside the junction box is all charged, it is necessary to have certain protection level requirements, so the junction box can only be made into a closed space. Under this closed space condition, the heat generated by the connecting copper busbar and the cable itself cannot be effectively dissipated through natural convection. At the same time, when the ambient temperature is poor, the heat will be further transferred to the junction box through the junction box cylinder, causing the overall temperature of the junction box to continue to rise, accelerating the aging of the copper busbar and cable inside the junction box. If the temperature inside the junction box rises to above 110°C, the temperature tolerance limit of the internal connection material is reached, and the internal connector is also at risk of damage, causing the equipment to be short-circuited. If it is an electric heater with lower power, the temperature inside the junction box is not greatly affected by its own heat generation, but if the power is greater than 1MW, the number of internal connecting copper busbars increases, and the cable specifications increase, then the heat generation itself will also increase, and the inside of the junction box cannot be effectively dissipated and cooled, resulting in an increase in the temperature inside the junction box, which poses certain safety hazards. For this reason, we propose a high-temperature environment electric heater junction box cooling system and control method. Summary of the invention
[0004] The object of the present invention is to provide a cooling system and control method for a junction box of an electric heater in a high temperature environment, so as to solve the problems raised in the above background technology.
[0005] To achieve the above-mentioned purpose, the present invention provides the following technical solutions: a high-temperature environment electric heater junction box cooling and temperature reduction system, comprising an air compression purifier, wherein the output end of the air compression purifier is connected to a plurality of electric heater junction boxes through an air intake main line and a plurality of air intake branch lines, an air intake main line stop valve and a flow transmitter are sequentially arranged between the air compression purifier and the air intake main line, and an air intake branch line stop valve is arranged on a plurality of the air intake branch lines; The electric heater junction box and the input end of the air compressor purifier are connected through an outlet main line and an outlet branch line, an outlet main line stop valve is provided between the input end of the air compressor purifier and the outlet main line, and an outlet branch line stop valve is provided on the outlet branch line; A first temperature sensor is arranged on each of the plurality of electric heater junction boxes, and a second temperature sensor is arranged between the input end of the air compression purifier and the main air outlet line.
[0006] Preferably, the main air intake pipeline, the branch air intake pipeline, the main air outlet pipeline and the branch air outlet pipeline are all pipelines made of stainless steel.
[0007] Preferably, the outer sides of the main air inlet pipeline, the branch air inlet pipeline, the main air outlet pipeline and the branch air outlet pipeline are all provided with a pipeline insulation layer with a thickness of 25-35 mm.
[0008] Preferably, the electric heater junction box comprises a junction box body and a junction box cover, and the junction box body and the junction box cover are sealedly connected.
[0009] Preferably, an air inlet port and an air outlet port are provided on one side of the junction box body, and the air inlet port and the air outlet port are connected to the air inlet branch pipeline and the air outlet branch pipeline respectively.
[0010] Preferably, an inner insulation layer and an outer insulation layer are respectively provided on the inner and outer sides of the junction box body and the junction box cover, the thickness of the inner insulation layer is 15-35 mm, and the thickness of the outer insulation layer is 45-55 mm.
[0011] Preferably, the inner insulation layer and the outer insulation layer are both silica insulation felt.
[0012] A control method for a cooling system of a high temperature environment electric heater junction box comprises the following steps: A: According to the on-site installation requirements of the electric heater junction box, connect the air intake main line, air intake branch line, air outlet main line and air outlet branch line between the air compressor purifier and the electric heater junction box, and install the air intake main line stop valve, flow transmitter, air intake branch line stop valve, air outlet main line stop valve, air outlet branch line stop valve, first temperature sensor and second temperature sensor in sequence; B: Start the air compressor purifier, open the shut-off valve of the main air inlet line and the shut-off valve of the main air outlet line in sequence, and then open the shut-off valve of the air inlet branch line and the shut-off valve of the air outlet branch line corresponding to the running electric heater junction box; C: The air compressor purifier compresses and purifies the air, and transports the compressed and purified air into the electric heater junction box through the air intake main line and the air intake branch line, performs forced convection heat exchange, realizes cooling of the inside of the electric heater junction box, and discharges the replaced air through the air outlet main line and the air outlet branch line; D: During the compressed purified air delivery process, the flow transmitter detects the compressed purified air flow in the air intake main line, adjusts the working frequency of the air compressor and purifier according to the detection signal, and then adjusts the compressed purified air flow in the air intake main line to ensure stable delivery of compressed purified air; E: Finally, the first temperature sensor and the second temperature sensor are used to detect the temperature in the electric heater junction box and the air outlet main line respectively. According to the temperature signals detected by the first temperature sensor and the second temperature sensor, the operating frequency of the air compressor and purifier is further adjusted, and the compressed purified air flow in the air intake main line is adjusted to meet the cooling requirements, so that the operating temperatures of the electric heater junction box and the air outlet main line meet the standard requirements.
[0013] Compared with the prior art, the present invention has the following beneficial effects: The present invention uses an external air compressor and purifier to transport compressed and purified air to several electric heater junction boxes through a multi-pipe structure, and performs forced convection heat exchange in the electric heater junction box, which can quickly cool the inside of the electric heater junction box, improve the cooling and heat dissipation efficiency, and eliminate the disadvantage that the traditional electric heater junction box itself has difficulty in heat dissipation. The cooling and cooling system of the present invention can have an absolute cooling and cooling advantage in a high-temperature and harsh environment, and can cool down multiple electric heater junction boxes at the same time, and the maximum tolerable ambient temperature can reach 300°C. The electric heater junction box is effectively cooled in a reciprocating cycle to ensure the reliability and stability of the electric heater during use. BRIEF DESCRIPTION OF THE DRAWINGS
[0014] Figure 1 It is a schematic diagram of the structure of the cooling system of the present invention; Figure 2 It is a three-dimensional structural schematic diagram of the electric heater junction box of the present invention; Figure 3 It is a simulation diagram of the overall temperature distribution of the electric heater junction box of the present invention; Figure 4 This is a simulation diagram of the temperature distribution inside the junction box of the electric heater of the present invention; Figure 5 This is a simulation diagram of the temperature distribution on the interface of the electric heater junction box of the present invention.
[0015] In the figure: 1. air compression purifier; 2. main air intake line; 3. branch air intake line; 4. junction box of electric heater; 401. junction box body; 402. junction box cover; 403. air intake port; 404. air outlet port; 5. shut-off valve of main air intake line; 6. flow transmitter; 7. shut-off valve of branch air intake line; 8. main air outlet line; 9. branch air outlet line; 10. shut-off valve of main air outlet line; 11. shut-off valve of branch air outlet line; 12. first temperature sensor; 13. second temperature sensor. DETAILED DESCRIPTION
[0016] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.
[0017] See also Figure 1-Figure 2 The high temperature environment electric heater junction box cooling and temperature reduction system provided by the present invention comprises an air compression purifier 1, the output end of the air compression purifier 1 is connected to a plurality of electric heater junction boxes 4 through an air intake main line 2 and a plurality of air intake branch lines 3, an air intake main line stop valve 5 and a flow transmitter 6 are sequentially arranged between the air compression purifier 1 and the air intake main line 2, and an air intake branch line stop valve 7 is arranged on each of the plurality of air intake branch lines 3; The electric heater junction box 4 and the input end of the air compressor purifier 1 are connected through the main outlet pipe 8 and the branch outlet pipe 9. A main outlet pipe stop valve 10 is provided between the input end of the air compressor purifier 1 and the main outlet pipe 8, and a branch outlet pipe stop valve 11 is provided on the branch outlet pipe 9. A first temperature sensor 12 is disposed on each of the plurality of electric heater junction boxes 4 , and a second temperature sensor 13 is also disposed between the input end of the air compression purifier 1 and the main air outlet passage 8 .
[0018] The present invention uses an external air compressor purifier 1 and a multi-pipe structure to transport compressed and purified air to several electric heater junction boxes 4, and performs forced convection heat exchange in the electric heater junction box 4, which can quickly cool the inside of the electric heater junction box 4, improve the cooling and heat dissipation efficiency, and eliminate the disadvantage of the traditional electric heater junction box's own heat dissipation difficulty. The cooling and cooling system of the present invention can have an absolute cooling and cooling advantage in a high-temperature and harsh environment, and can cool down multiple electric heater junction boxes 4 at the same time, and the maximum tolerable ambient temperature can reach 300°C. The electric heater junction box 4 is effectively cooled in a reciprocating cycle to ensure the reliability and stability of the electric heater during use.
[0019] In this embodiment, the air inlet main line 2, the air inlet branch line 3, the air outlet main line 8 and the air outlet branch line 9 are all made of stainless steel, and the outer sides of the air inlet main line 2, the air inlet branch line 3, the air outlet main line 8 and the air outlet branch line 9 are all provided with a pipeline insulation layer with a thickness of 25-35 mm to ensure that the air inlet main line 2, the air inlet branch line 3, the air outlet main line 8 and the air outlet branch line 9 are dry and clean, and improve the thermal insulation performance.
[0020] In this embodiment, if Figure 2 As shown, the electric heater junction box 4 includes a junction box body 401 and a junction box cover 402, the junction box body 401 and the junction box cover 402 are sealed and connected, an air inlet port 403 and an air outlet port 404 are arranged on one side of the junction box body 401, the air inlet port 403 and the air outlet port 404 are respectively connected to the air inlet branch pipe 3 and the air outlet branch pipe 9, the inner and outer sides of the junction box body 401 and the junction box cover 402 are respectively provided with an inner thermal insulation layer and an outer thermal insulation layer, the thickness of the inner thermal insulation layer is 15-35mm, the thickness of the outer thermal insulation layer is 45-55mm, the inner thermal insulation layer and the outer thermal insulation layer are both silica thermal insulation felt, which ensures the multi-layer thermal insulation performance of the electric heater junction box 4 and plays an effective protection to the electric heater junction box 4.
[0021] The present invention provides a control method for a cooling system of a high temperature environment electric heater junction box, comprising the following steps: A: According to the on-site installation requirements of the electric heater junction box 4, connect the air intake main line 2, the air intake branch line 3, the air outlet main line 8 and the air outlet branch line 9 between the air compressor purifier 1 and the electric heater junction box 4, and install the air intake main line stop valve 5, the flow transmitter 6, the air intake branch line stop valve 7, the air outlet main line stop valve 10, the air outlet branch line stop valve 11, the first temperature sensor 12 and the second temperature sensor 13 in sequence; B: Start the air compressor purifier 1, open the main air intake line stop valve 5 and the main air outlet line stop valve 10 in sequence, and then open the main air intake line stop valve 7 and the main air outlet line stop valve 11 corresponding to the running electric heater junction box 4; C: The air compressor 1 compresses and purifies the air, and delivers the compressed and purified air into the electric heater junction box 4 through the air intake main line 2 and the air intake branch line 3, performs forced convection heat exchange, and realizes cooling of the inside of the electric heater junction box 4, and discharges the replaced air through the air outlet main line 8 and the air outlet branch line 9; D: During the compressed purified air delivery process, the flow transmitter 6 detects the compressed purified air flow in the air intake main line 2, and adjusts the working frequency of the air compressor 1 according to the detection signal, thereby adjusting the compressed purified air flow in the air intake main line 2, so that the compressed purified air can be delivered stably; E: Finally, the temperatures in the electric heater junction box 4 and the air outlet main line 8 are detected respectively by the first temperature sensor 12 and the second temperature sensor 13. According to the temperature signals detected by the first temperature sensor 12 and the second temperature sensor 13, the operating frequency of the air compressor purifier 1 is further adjusted, and the compressed purified air flow in the air intake main line 2 is adjusted to meet the cooling requirements, so that the operating temperatures of the electric heater junction box 4 and the air outlet main line 8 meet the standard requirements.
[0022] This embodiment provides a performance experiment of the cooling system of the present invention in an electric heater junction box (the inner and outer sides of the junction box body 401 and the junction box cover 402 are respectively provided with an inner insulation layer and an outer insulation layer, the thickness of the inner insulation layer is 20 mm, and the thickness of the outer insulation layer is 50 mm) at an ambient temperature of 300°C: like Figure 3-Figure 5 As shown, Figure 3 This is the simulation diagram of the overall temperature distribution of the electric heater junction box; Figure 4 This is a simulation diagram of the temperature distribution inside the junction box of the electric heater; Figure 5 This is a simulation diagram of the temperature distribution on the interface of the electric heater junction box; Depend on Figure 3 and Figure 5 It can be seen that the ambient temperature of the electric heater junction box is 300℃ (573.15K). When the air inlet port temperature is 30℃ and the flow rate is 18m / s, the average temperature inside the electric heater junction box is 33.07℃ (306.22K), and the maximum temperature inside the electric heater junction box is 59.3℃ (332.45K); the maximum temperature inside the electric heater junction box does not exceed 60℃.
[0023] The present invention has the following effects: 1. Efficient cooling: Through forced convection heat exchange, the present invention can quickly reduce the temperature inside the electric heater junction box, prevent equipment failure and safety risks caused by overheating, and ensure stable operation of the equipment in a high temperature environment; 2. Improve the temperature tolerance: The present invention enables the maximum temperature tolerance of the electric heater junction box to reach 300°C, which is much higher than the 40°C of the traditional junction box, thus broadening the application scenarios of the electric heater; 3. Extend service life: effectively reduce the temperature inside the junction box of the electric heater, slow down the aging speed of the connecting copper busbar and cable, and extend the service life of the equipment; 4. Improve safety: eliminate the risk of equipment circuit breaker caused by high temperature and improve the safety and reliability of electric heaters; 5. Easy operation: The invention has a simple structure, easy operation, and easy maintenance and upkeep; 6. Use an external compressed air purifier to ensure the cleanliness of the input air and reduce pollution and damage to the inside of the electric heater junction box.
[0024] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.
Claims
1. A high temperature environment electric heater junction box cooling system, characterized in that: It comprises an air compression purifier (1), wherein the output end of the air compression purifier (1) is connected to a plurality of electric heater junction boxes (4) via an air intake main line (2) and a plurality of air intake branch lines (3), an air intake main line stop valve (5) and a flow transmitter (6) are arranged in sequence between the air compression purifier (1) and the air intake main line (2), and an air intake branch line stop valve (7) is arranged on each of the plurality of air intake branch lines (3); The electric heater junction box (4) and the input end of the air compressor purifier (1) are connected via a main air outlet line (8) and a branch air outlet line (9); a main air outlet line stop valve (10) is provided between the input end of the air compressor purifier (1) and the main air outlet line (8); and a branch air outlet line stop valve (11) is provided on the branch air outlet line (9); A first temperature sensor (12) is provided on each of the plurality of electric heater junction boxes (4), and a second temperature sensor (13) is also provided between the input end of the air compression purifier (1) and the main air outlet passage (8).
2. A high temperature environment electric heater junction box cooling system according to claim 1, characterized in that: The main air intake line (2), the branch air intake line (3), the main air outlet line (8) and the branch air outlet line (9) are all made of stainless steel.
3. A high temperature environment electric heater junction box cooling system according to claim 1, characterized in that: The outer sides of the main air intake pipeline (2), the branch air intake pipeline (3), the main air outlet pipeline (8) and the branch air outlet pipeline (9) are all provided with a pipeline insulation layer with a thickness of 25-35 mm.
4. A high temperature environment electric heater junction box cooling system according to claim 1, characterized in that: The electric heater junction box (4) comprises a junction box body (401) and a junction box cover (402), and the junction box body (401) and the junction box cover (402) are sealedly connected.
5. A high temperature environment electric heater junction box cooling system according to claim 4, characterized in that: An air inlet port (403) and an air outlet port (404) are provided on one side of the junction box body (401); the air inlet port (403) and the air outlet port (404) are connected to the air inlet branch pipeline (3) and the air outlet branch pipeline (9) respectively.
6. A high temperature environment electric heater junction box cooling system according to claim 4, characterized in that: An inner heat insulation layer and an outer heat insulation layer are respectively provided on the inner and outer sides of the junction box body (401) and the junction box cover (402); the thickness of the inner heat insulation layer is 15-35 mm, and the thickness of the outer heat insulation layer is 45-55 mm.
7. A high temperature environment electric heater junction box cooling system according to claim 6, characterized in that: The inner insulation layer and the outer insulation layer are both silicon dioxide insulation felt.
8. A control method for a high temperature environment electric heater junction box cooling system according to any one of claims 1 to 7, characterized in that: The steps include: A: According to the on-site installation requirements of the electric heater junction box (4), connect the main air inlet line (2), the branch air inlet line (3), the main air outlet line (8) and the branch air outlet line (9) between the air compressor purifier (1) and the electric heater junction box (4), and install the main air inlet line stop valve (5), the flow transmitter (6), the branch air inlet line stop valve (7), the main air outlet line stop valve (10), the branch air outlet line stop valve (11), the first temperature sensor (12) and the second temperature sensor (13) in sequence; B: Start the air compressor purifier (1), open the main air intake line stop valve (5) and the main air outlet line stop valve (10) in sequence, and then open the main air intake line stop valve (7) and the main air outlet line stop valve (11) corresponding to the running electric heater junction box (4); C: The air compressor purifier (1) compresses and purifies the air, and transmits the compressed and purified air into the electric heater junction box (4) through the air intake main line (2) and the air intake branch line (3), performs forced convection heat exchange, and realizes cooling of the interior of the electric heater junction box (4), and discharges the replaced air through the air outlet main line (8) and the air outlet branch line (9); D: During the compressed purified air delivery process, the flow transmitter (6) detects the flow rate of the compressed purified air in the air intake main line (2), and adjusts the operating frequency of the air compression purifier (1) according to the detection signal, thereby adjusting the flow rate of the compressed purified air in the air intake main line (2) to ensure stable delivery of the compressed purified air; E: Finally, the temperatures in the electric heater junction box (4) and the air outlet main line (8) are detected respectively by the first temperature sensor (12) and the second temperature sensor (13). Based on the temperature signals detected by the first temperature sensor (12) and the second temperature sensor (13), the operating frequency of the air compressor (1) is further adjusted, and the flow rate of compressed purified air in the air intake main line (2) is adjusted to meet the cooling requirements, so that the operating temperatures of the electric heater junction box (4) and the air outlet main line (8) meet the standard requirements.