Liquid cooling total current controller structure

Abstract

The invention relates to the technical field of battery controllers, and discloses a liquid-cooled total-current controller structure, which comprises a total-current controller, the total-current controller is arranged at the front end of a battery module, and the total-current controller comprises a shell, and a power board, a control board, a bypass contactor and an input / output copper bar terminal which are arranged in the shell; the control board is provided with a plurality of control terminals, and the plurality of control terminals are respectively used for being electrically connected with the battery module, the power board and the upper-level control cabinet; the power board is electrically connected with the input and output copper bar terminal, and the bypass contactor is connected with the power board in parallel; the power board is provided with a plurality of power electronic elements and a liquid cooling radiator, and the liquid cooling radiator is located below the power electronic elements when the total current controller is in a use state. The internal structure of the full-current controller is optimally designed, the structure is compact, installation, operation and maintenance are convenient, meanwhile, the liquid cooling radiator is designed, the heat dissipation efficiency is improved, the working temperature of the full-current controller is effectively regulated and controlled, and the working stability is ensured.

Description

Technical Field

[0001] The present invention relates to the technical field of battery controllers, and particularly to a liquid-cooled full-current controller structure. Background Art

[0002] Traditional energy storage systems adopt the scheme of connecting battery clusters in parallel to the PCS. During long-term operation, due to the inconsistency of the power output of each battery pack, a circulating current will be generated between the clusters, forming the so-called "barrel effect", that is, the performance of the entire system is limited by the worst battery cluster, seriously affecting long-term operation and greatly increasing the operation and maintenance costs. When an individual battery pack fails, the entire cluster or the entire machine system needs to be shut down, and it is necessary for personnel to go to the site to repair or replace the faulty battery pack in time, reducing the reliability of the energy storage system operation.

[0003] A full-current controller is a control device that uses power electronics technology to control the charging and discharging of battery modules and can achieve full-current balance control within and between clusters. A battery PACK with a full-current controller can avoid the battery working in an overcharged or overdischarged state at the source, actively isolate faults at the PACK level, prevent faulty or sub-healthy batteries from operating with problems, and greatly improve the service life of the battery. Therefore, optimizing the design of the full-current controller is the key to ensuring the stable operation of each battery pack and is also an important research topic for those skilled in the art. In addition, a large amount of heat is generated during the operation of the full-current controller, especially during high-load or long-term operation. How to improve the heat dissipation efficiency is also one of the issues that need to be considered in the design of the full-current controller. Summary of the Invention

[0004] The purpose of the present invention is to provide a liquid-cooled full-current controller structure, optimize the internal structure of the full-current controller, which is compact, convenient for installation and operation and maintenance. At the same time, a liquid-cooled radiator is designed to improve the heat dissipation efficiency, effectively control the temperature of power electronic devices during the operation of the full-current controller, and ensure the working stability.

[0005] To achieve the above purpose, the present invention provides the following solution:

[0006] A liquid-cooled full-current controller structure includes a full-current controller, the full-current controller is arranged at the front end of the battery module, the full-current controller includes a housing and a power board, a control board, a bypass contactor and input / output copper row terminals arranged in the housing; the control board is provided with a plurality of control terminals, the control board is electrically connected to the battery module and the power board respectively through the plurality of control terminals, and the control terminals are also used for being electrically connected to the upper-level control cabinet; the power board is electrically connected to the input / output copper row terminals, and the bypass contactor is connected in parallel with the power board;

[0007] A number of power electronic components and a liquid-cooled radiator are provided on the power board. When the full-current controller is in use, the liquid-cooled radiator is located below the power electronic components.

[0008] Further, the housing includes a housing base and a housing cover. The housing cover is fastened to the housing base to form a cavity for the full-current controller.

[0009] Further, an input / output busbar terminal insulating plate is embedded at a position on the housing cover corresponding to the input / output busbar terminals. Electrical isolation between the input / output busbar terminals and the housing is achieved through the input / output busbar terminal insulating plate.

[0010] Further, the power board is disposed on the housing base. The control board is fixedly arranged on the power board through a number of insulating columns. A control terminal insulating plate is provided on the housing base. Electrical isolation between the control terminals of the control board and the housing is achieved through the control terminal insulating plate.

[0011] Further, a plurality of ventilation and heat dissipation holes are provided on the housing cover.

[0012] Further, fixing brackets are provided on both sides of the housing base. The fixing brackets are fixed to the front end of the battery module by screws.

[0013] Further, the liquid-cooled radiator is provided with a liquid-cooled water inlet and a liquid-cooled water outlet. Both the liquid-cooled water inlet and the liquid-cooled water outlet penetrate through the housing and are connected to an external liquid-cooled unit.

[0014] Further, the power board is provided with power board main power terminals. The power board main power terminals are connected to the input / output busbar terminals, and a bypass contactor is connected in parallel at the connection point.

[0015] According to the specific embodiments provided by the present invention, the structure of the liquid-cooled full-current controller provided by the present invention discloses the following technical effects:

[0016] The full - current controller is set at the front end of the battery module, which is convenient for installation. The full - current controller includes a housing, and a power board, a control board, a bypass contactor, and input - output copper - bar terminals arranged inside the housing. It has a compact structure, which is convenient for installation, operation, and maintenance. The bypass contactor is set. When a fault occurs in the battery pack, it is bypassed to ensure the stable and reliable operation of the energy - storage system. There is a liquid - cooled radiator on the power board, and when the full - current controller is in use, the liquid - cooled radiator is located below the power - electronic components. On the one hand, efficient heat dissipation is achieved through the liquid - cooled radiator. On the other hand, when the full - current controller is in use, the liquid - cooled radiator is located below the power - electronic components, avoiding liquid flowing onto the power - electronic devices in case of liquid leakage from the liquid - cooled radiator and causing faults. The present invention further improves the convenience of use and the practical application value of the full - current controller by optimizing the structure of the full - current controller. Brief Description of the Drawings

[0017] In order to more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the following will briefly introduce the drawings required for use in the embodiments. Obviously, the drawings in the following description are only some embodiments of the present invention. For those of ordinary skill in the art, without creative efforts, other drawings can be obtained based on these drawings.

[0018] Figure 1 It is an installation schematic diagram of the structure of the liquid - cooled full - current controller in an embodiment of the present invention;

[0019] Figure 2 It is an internal layout diagram of the structure of the liquid - cooled full - current controller in an embodiment of the present invention;

[0020] Figure 3 It is an electrical schematic diagram of the liquid - cooled full - current controller in an embodiment of the present invention;

[0021] Explanation of the reference numerals: 1. Full - current controller; 2. Battery module; 3. Housing base; 4. Power board; 5. Control board; 6. Housing cover; 7. Heat - dissipation ventilation hole; 8. Insulating board for input - output copper - bar terminals; 9. Liquid - cooled radiator; 10. Input - output copper - bar terminals; 11. Bypass contactor; 12. Liquid - cooled water inlet; 13. Liquid - cooled water outlet; 14. Insulating board for control terminals; 15. Control terminals; 16. Fixed bracket; 17. Insulating column; 18. Main power terminals of the power board. Detailed Embodiments

[0022] The following will clearly and completely describe the technical solutions in the embodiments of the present invention with reference to the drawings in the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, rather than all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts belong to the scope of protection of the present invention.

[0023] In the description of this patent, if there are terms such as "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc. indicating the orientation or positional relationship, it is based on the actual shown orientation or positional relationship. It is only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation. Therefore, the terms used to describe the orientation or positional relationship in the present invention are only for exemplary illustration and cannot be understood as a limitation of this patent. For those of ordinary skill in the art, the specific meanings of the above terms can be understood in combination with the embodiments and according to the specific circumstances.

[0024] Unless otherwise clearly specified and defined, in this patent, if there are terms such as "set", "connected" and "connected", they should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a direct connection, or an indirect connection through an intermediate medium, and it can be the communication inside two elements. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood according to the specific circumstances.

[0025] The purpose of the present invention is to provide a liquid-cooled full-current controller structure, optimize the internal structure of the full-current controller, with a compact structure, facilitating installation, operation and maintenance. At the same time, a liquid-cooled radiator is designed to improve the heat dissipation efficiency, effectively reduce the temperature of the power electronic devices during the operation of the full-current controller, and ensure the working stability.

[0026] To make the above objects, features and advantages of the present invention more obvious and understandable, the present invention will be further described in detail below with reference to the drawings and specific embodiments.

[0027] As Figures 1 - 3 shown, the liquid-cooled full-current controller structure provided by the present invention includes a full-current controller 1, the full-current controller 1 is arranged at the front end of the battery module 2, and the full-current controller 1 and the battery module 2 form a battery PACK. The full-current controller 1 includes a housing and a power board 4, a control board 5, a bypass contactor 11 and input / output copper bar terminals 10 arranged in the housing; the control board 5 is provided with a plurality of control terminals 15, and the control board 5 is electrically connected to the battery module 2 and the power board 4 respectively through the plurality of control terminals 15, and the control terminals 15 are also used for electrically connecting to the upper-level control cabinet; the power board 4 is electrically connected to the input / output copper bar terminals 10, and the bypass contactor 11 is connected in parallel with the power board 4;

[0028] A plurality of power electronic components and a liquid-cooled radiator 9 are arranged on the power board 4. In the working state of the full-current controller, the liquid-cooled radiator 9 is located below the power electronic components.

[0029] Specifically, the housing includes a housing base 3 and a housing cover plate 6. The housing cover plate 6 is fastened on the housing base 3 to form a cavity of the full-current controller 1. For example, as Figure 2 shown, the housing base 3 includes a bottom plate and left and right side plates, forming a first U-shaped structure. The housing cover plate 6 includes a top plate and front and rear side plates, forming a second U-shaped structure. The second U-shaped structure is matched with the first U-shaped structure and spliced to form the housing.

[0030] A plurality of ventilation and heat dissipation holes are provided on the housing cover plate 6. Among them, the top plate and the front and rear side plates are respectively provided with ventilation and heat dissipation holes, which can realize natural heat dissipation of internal power electronic components without forced heat dissipation by a fan, reduce costs and reduce failure rates.

[0031] Fixed brackets 16 are provided on both sides of the housing base 3. The fixed brackets 16 are fixed to the front end of the battery module 2 by screws, which is convenient for installation and disassembly.

[0032] An input / output busbar terminal insulating plate 8 is embedded at a position on the housing cover plate 6 corresponding to the input / output busbar terminal 10 (the right part of the top plate). The input / output busbar terminal 10 passes through the housing from the hole on the busbar terminal insulating plate 8 and is connected to an external wiring. Electrical isolation between the input / output busbar terminal 10 and the housing is achieved through the input / output busbar terminal insulating plate 8. The input / output busbar terminal 10 has input and output functions and can be used as an input terminal during charging and an output terminal during discharging.

[0033] The power board 4 is arranged on the housing base 3. The control board 5 is fixedly arranged on the power board 4 through a plurality of insulating columns 17. A control terminal insulating plate 14 is arranged on the housing base 3. The control terminal 15 passes through the housing from the hole on the control terminal insulating plate 14 and is connected to an external wiring. Electrical isolation between the control terminal 15 of the control board 5 and the housing is achieved through the control terminal insulating plate 14.

[0034] The power board 4 is a power conversion unit used to control the charging and discharging of the battery module, and mainly includes a board and power electronic components on the board, and a liquid cooling radiator 9. Multiple power electronic components include capacitors, power semiconductor devices, etc. (refer to the internal power electronic component structure of the full current controller in "CN116581350A-A full current controlled liquid cooling battery pack and its design method"). When installed and in use, capacitors and the like are arranged on the upper part of the board, and a liquid cooling radiator 9 is arranged on the lower part. The purpose is that during use, when the liquid flows, the liquid cooling radiator leaks, and under the action of gravity, it falls downward to prevent the liquid from flowing to other power electronic components and causing failures. The liquid cooling radiator 9 can specifically adopt a liquid cooling heat pipe or a metal radiator with a higher thermal conductivity. The left side of the liquid cooling radiator 9 is a liquid cooling water inlet 12, and the right side is a liquid cooling water outlet 13. Its flow channel is simple, the flow resistance is small, and the heat dissipation efficiency is high. The main function of the liquid cooling radiator 9 is to take away the heat generated by the power electronic components during operation through the internal liquid, so as to ensure that the power electronic components operate within a reasonable temperature range.

[0035] The power board 4 is provided with a power board main power terminal 18 , and the power board main power terminal 18 is connected to the input and output copper bus terminal 10 , and the bypass contactor 11 is connected in parallel at the connection point.

[0036] The control board 5 is mainly used to control the charge and discharge of the entire battery PACK, and monitor the working status of the entire battery PACK in real time and transmit it to the upper-level control cabinet. The control board 5 is fixed on the power board 4 through the insulating column 17, and the left side of the control board 5 is the control terminal 15. It is connected to the battery module 2 to realize the detection and control of the battery module 2, and is connected to the power board 4 to realize the power conversion of the power board 4. It is connected to the upper-level control cabinet to control the charge and discharge of the battery PACK.

[0037] For example, the control board 5 may adopt a conventional control chip in the art, which will not be described in detail here.

[0038] The bypass contactor 11 is installed on the right side of the power board 4, connected in parallel between the main power terminal 18 of the power board and the input and output copper bus terminal 10, and is connected to the power board 4 and the input and output copper bus terminal 10 respectively. Its main function is to bypass the battery PACK when it fails to ensure that the normal operation of the entire system is not affected.

[0039] The input and output copper bus terminal 10 is connected to the bypass contactor 11, and its main function is to connect the battery PACK and the entire energy storage system to achieve power transmission. The input and output copper bus terminal 10 and the external copper bus are reliably connected by screws to avoid poor contact that is prone to occur in traditional plug-in terminals.

[0040] In the liquid-cooled full-current controller structure provided by the embodiments of the present invention, the full-current controller has a compact structure, which is convenient for installation, operation and maintenance; the inlet and outlet layout of the liquid-cooled radiator adopts a left-in and right-out layout, with a simple flow channel, reducing flow resistance and improving heat dissipation efficiency; the power board, control board and housing are electrically isolated by an insulating board, with a simple structure and low cost, solving the electrical safety regulations problems of the power board, control board and housing.

[0041] Specific examples are used in this article to elaborate on the principles and implementation manners of the present invention. The description of the above embodiments is only used to help understand the method and its core idea of the present invention; at the same time, for those of ordinary skill in the art, according to the idea of the present invention, there will be changes in the specific implementation manners and application scopes. In summary, the content of this specification should not be construed as a limitation of the present invention.

Claims

1. A liquid-cooled full current controller structure, comprising a full current controller (1), wherein the full current controller (1) is arranged at the front end of a battery module (2), characterized in that: The full current controller (1) comprises a housing and a power board (4), a control board (5), a bypass contactor (11) and an input / output copper bus terminal (10) arranged in the housing; the control board (5) is provided with a plurality of control terminals (15), the control board (5) is electrically connected to the battery module (2) and the power board (4) through the plurality of control terminals (15), and the control terminals (15) are also used to be electrically connected to an upper-level control cabinet; the power board (4) is electrically connected to the input / output copper bus terminal (10), and the bypass contactor (11) is connected in parallel to the power board (4); The power board (4) is provided with a plurality of power electronic components and a liquid cooling radiator (9), and the liquid cooling radiator (9) is located below the power electronic components.

2. The liquid-cooled full current controller structure according to claim 1, characterized in that: The housing comprises a housing base (3) and a housing cover (6), wherein the housing cover (6) is buckled onto the housing base (3) to form a cavity of the full current controller (1).

3. The liquid-cooled full current controller structure according to claim 2, characterized in that: An input / output copper bar terminal insulation plate (8) is embedded in a position on the housing cover plate (6) corresponding to the input / output copper bar terminal (10), and the input / output copper bar terminal (10) and the housing are electrically isolated via the input / output copper bar terminal insulation plate (8).

4. The liquid-cooled full current controller structure according to claim 2, characterized in that: The power board (4) is arranged on the housing base (3); the control board (5) is fixed to the power board (4) via a plurality of insulating columns (17); a control terminal insulating plate (14) is arranged on the housing base (3); and the control terminal (15) of the control board (5) and the housing are electrically isolated via the control terminal insulating plate (14).

5. The liquid-cooled full current controller structure according to claim 2, characterized in that: The housing cover plate (6) is provided with a plurality of ventilation and heat dissipation holes.

6. The liquid-cooled full current controller structure according to claim 2, characterized in that: Fixed brackets (16) are provided on both sides of the housing base (3), and the fixed brackets (16) are fixed to the front end of the battery module (2) by means of screws.

7. The liquid-cooled full current controller structure according to claim 1, characterized in that: The liquid-cooled radiator (9) is provided with a liquid-cooled water inlet (12) and a liquid-cooled water outlet (13), and the liquid-cooled water inlet (12) and the liquid-cooled water outlet (13) both pass through the shell and are connected to an external liquid cooling unit.

8. The liquid-cooled full current controller structure according to claim 1, characterized in that: The power board (4) is provided with a power board main power terminal (18), the power board main power terminal (18) is connected to the input and output copper bus terminal (10), and the bypass contactor (11) is connected in parallel at the connection point.

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