Combined high-voltage cascade energy storage power unit

Abstract

The invention relates to the technical field of energy storage equipment, and discloses a combined high-voltage cascade energy storage power unit, which comprises a PCS power module used for realizing bidirectional conversion and control of electric energy; according to the invention, the PCS power module, the high-voltage box module and the reactor module are combined into an integral energy storage power unit through the connecting cross beams, the energy storage power unit is decomposed into a plurality of small modules, and a compact layout design is adopted, so that the problem that the size of a traditional single energy storage power unit is too large is avoided; the positions of the PCS power module and the high-voltage box module are mutually exchanged, battery pack layouts of different manufacturers can be flexibly adapted, the width size of the energy storage power unit is consistent with the sizes of most battery packs in the market, and the energy storage power unit can be matched with the battery packs of different manufacturers. By optimizing the modular design, the structural layout and the electrical connection mode, the problems that an existing energy storage power unit is too large in size, low in installation efficiency, poor in universality and the like are solved.

Description

Technical Field

[0001] The present invention relates to the technical field of energy storage devices, and particularly to a combined high-voltage cascaded energy storage power unit. Background Art

[0002] Currently, energy storage products on the market are mainly divided into two categories: one is the low-voltage energy storage system that uses a transformer for step-up and step-down, and the other is the high-voltage cascaded energy storage system that uses series-connected power modules. Although the low-voltage energy storage system has mature technology, due to its need to perform voltage conversion through a transformer, there are problems such as low efficiency, large volume, and high cost. In contrast, the high-voltage cascaded energy storage system has gradually been recognized by the market and its market share has been continuously increasing due to its advantages such as high efficiency, no circulating current, and modularity.

[0003] However, there are still some problems in the design and application of the power unit modules of the existing high-voltage cascaded energy storage system. With the development of battery technology, battery manufacturers are gradually moving towards large battery cells and large PACKs, and the energy density is continuously increasing. This poses new challenges to traditional energy storage power unit modules: on the one hand, the volume of a single power unit module is gradually increasing, resulting in low efficiency during installation and maintenance, and it is difficult to adapt to the modern assembly line production method; on the other hand, due to the differences in the sizes and layouts of battery PACKs from different manufacturers, the existing power unit modules with fixed structures are difficult to match them flexibly, which limits the versatility and applicability of the energy storage system. In addition, there are also deficiencies in the electrical connection and structural layout of the existing energy storage power unit modules. For example, the electrical terminals of some power unit modules are concentratedly arranged at the front end, resulting in complex wiring and easy confusion, increasing the difficulty of installation and maintenance. At the same time, the heat dissipation design and space utilization efficiency inside the module also need to be improved to meet the growing high-performance requirements. Summary of the Invention

[0004] In view of the deficiencies of the prior art, the present invention provides a combined high-voltage cascaded energy storage power unit, which solves the problems of the existing power unit modules such as too large volume, low installation efficiency, and poor versatility.

[0005] To achieve the above objectives, the present invention is realized through the following technical solutions: A combined high-voltage cascaded energy storage power unit, comprising:

[0006] A PCS power module for realizing bidirectional conversion and control of electric energy;

[0007] A high-voltage box module for providing electrical connection, protection, and control functions;

[0008] A reactor module for suppressing current fluctuations and improving power quality;

[0009] A connecting crossbeam;

[0010] Among them, the PCS power module and the high-voltage box module are connected by a connecting crossbeam, and the PCS power module and the high-voltage box module can be swapped with each other; the reactor module is located at the rear side of the PCS power module and the high-voltage box module, and the reactor module and the high-voltage box module are connected into an integrated energy storage power unit.

[0011] Preferably, the PCS power module includes:

[0012] IGBT components, which are installed on the L-shaped bracket inside the PCS housing;

[0013] A contactor, which is installed at the bottom of the L-shaped bracket;

[0014] A capacitor, which is installed at the rear side of the IGBT components and is connected through a busbar and a long copper bar;

[0015] A bypass copper bar, which is connected to a bypass contactor and is connected to the output copper bar to realize the unit bypass function;

[0016] A switching power supply one, which is installed outside the L-shaped bracket and is insulated and installed by means of an insulating strip.

[0017] Preferably, the high-voltage box module includes:

[0018] A circuit breaker, which is installed on the middle bottom plate of the high-voltage box housing;

[0019] A positive copper bar and a negative copper bar, which are respectively installed on the rear side and the middle side of the high-voltage box housing and are connected to the circuit breaker;

[0020] A BCMU module, which is installed at the bottom of the high-voltage box housing;

[0021] A switching power supply two, which is installed on the high-voltage box housing and is fixed by a switching power supply bracket;

[0022] An air switch, a Hall sensor, a DC contactor, a buffer contactor, a buffer resistor and a relay are all installed inside the high-voltage box housing.

[0023] Preferably, the reactor module includes:

[0024] A reactor, which is installed on the upper surface of the reactor base;

[0025] An L-shaped mounting frame, which serves as a fixed bracket for the reactor and at the same time serves as the rear side plate of the PCS power module and the high-voltage box module, and the bottom serves as the bottom plate of the entire energy storage power unit.

[0026] Preferably, the connecting cross beam is arranged at the front end of the PCS power module and the high-voltage box module, used to connect the PCS power module and the high-voltage box module, and fix the entire unit module during the installation of the whole machine.

[0027] Preferably, in the PCS power module, the output copper busbar of the IGBT component is connected to the bypass copper busbar of the bypass contactor on the outside of the unit, realizing the bypass function, which is convenient for maintenance and fault isolation.

[0028] Preferably, in the high-voltage box module, the positive copper busbar and the negative copper busbar are respectively located on different sides of the high-voltage box housing.

[0029] Preferably, the L-shaped mounting bracket of the reactor module is reinforced with ribs to ensure the fixing strength of the reactor and the stability of the overall structure.

[0030] Beneficial Effects

[0031] The present invention provides a combined high-voltage cascaded energy storage power unit, which has the following beneficial effects compared with the prior art:

[0032] 1. In the present invention, by combining the PCS power module, the high-voltage box module and the reactor module into an integrated energy storage power unit through a connecting cross beam, the energy storage power unit is decomposed into multiple small modules and a compact layout design is adopted. The present invention avoids the problem of the too large volume of the traditional single energy storage power unit. The positions of the PCS power module and the high-voltage box module are swapped with each other, which can flexibly adapt to the battery pack layouts of different manufacturers. And the width dimension of the energy storage power unit is consistent with the sizes of most battery packs on the market, which can match the battery packs of different manufacturers. In summary, the present invention solves the problems of the existing energy storage power unit such as too large volume, low installation efficiency and poor versatility by optimizing the modular design, structural layout and electrical connection method, significantly improving the flexibility, versatility and reliability of the system, and providing a new solution for the design and application of the high-voltage cascaded energy storage system;

[0033] 2. In the present invention, in the PCS power module, the IGBT component is located above and the contactor is located below. The IGBT output copper busbar is connected to the bypass contactor copper busbar on the outside of the unit, realizing the unit bypass function, which is convenient for maintenance and fault handling. In the PCS power module, the IGBT component is located above and the contactor is located below. The IGBT output copper busbar is connected to the bypass contactor copper busbar on the outside of the unit, realizing the unit bypass function, which is convenient for maintenance and fault handling. Brief Description of the Drawings

[0034] Figure 1 It is a schematic diagram of the overall layout of a combined high-voltage cascaded energy storage power unit proposed by the present invention;

[0035] Figure 2Schematic diagram of the left - hand layout of the PCS power module in a combined high - voltage cascaded energy storage power unit proposed by the present invention;

[0036] Figure 3 Top - view layout schematic diagram of the PCS power module in a combined high - voltage cascaded energy storage power unit proposed by the present invention;

[0037] Figure 4 Schematic diagram of the layout of one - side view of the high - voltage box module in a combined high - voltage cascaded energy storage power unit proposed by the present invention;

[0038] Figure 5 Schematic diagram of the layout of the other - side view of the high - voltage box module in a combined high - voltage cascaded energy storage power unit proposed by the present invention;

[0039] Figure 6 Schematic diagram of the reactor module layout in a combined high - voltage cascaded energy storage power unit proposed by the present invention.

[0040] Legend description:

[0041] 1. PCS power module; 1 - 1. PCS housing; 1 - 2. Capacitor; 1 - 3. Busbar; 1 - 4. IGBT component; 1 - 5. L - shaped bracket; 1 - 6. Output copper bar; 1 - 7. Bypass copper bar; 1 - 8. Bypass contactor; 1 - 9. Switching power supply one; 1 - 10. Long copper bar; 2. High - voltage box module; 2 - 1. Positive copper bar; 2 - 2. High - voltage box housing; 2 - 3. Switching power supply two; 2 - 4. Negative copper bar; 2 - 5. Circuit breaker; 2 - 6. Indicator light; 2 - 7. BCMU module; 2 - 8. Switching power supply bracket; 2 - 9. Terminal block; 2 - 10. Air switch; 2 - 11. Network - to - wide module; 2 - 12. Hall sensor; 2 - 13. DC contactor; 2 - 14. Buffer contactor; 2 - 15. Buffer resistor; 2 - 16. Relay; 3. Reactor module; 3 - 1. Reactor base; 3 - 2. Reactor; 4. Connecting crossbeam. Specific implementation manners

[0042] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without making creative efforts belong to the scope of protection of the present invention.

[0043] Please refer to Figures 1 - 6 , the present invention provides two technical solutions, specifically including the following embodiments:

[0044] Embodiment 1:

[0045] A combined high-voltage cascaded energy storage power unit, comprising:

[0046] A PCS power module 1 for realizing bidirectional conversion and control of electric energy. The PCS power module 1 includes:

[0047] IGBT components 1-4, and the IGBT components 1-4 are installed on the L-shaped bracket 1-5 inside the PCS housing 1-1;

[0048] A contactor, and the contactor is installed at the bottom of the L-shaped bracket 1-5;

[0049] A capacitor 1-2, and the capacitor 1-2 is installed at the rear side of the IGBT components 1-4 and is connected through a busbar 1-3 and a long strip copper bar 1-10;

[0050] A bypass copper bar 1-7, the bypass copper bar 1-7 is connected to a bypass contactor 1-8 and is connected to an output copper bar 1-6 to realize the unit bypass function; A switching power supply 1-9, and the switching power supply 1-9 is installed outside the L-shaped bracket 1-5 and is installed in an insulated manner through an insulating strip;

[0051] A high-voltage box module 2 for providing electrical connection, protection and control functions. The high-voltage box module 2 includes:

[0052] A circuit breaker 2-5, and the circuit breaker 2-5 is installed on the middle bottom plate of the high-voltage box housing 2-2;

[0053] A positive copper bar 2-1 and a negative copper bar 2-4, and the positive copper bar 2-1 and the negative copper bar 2-4 are respectively installed on the rear side and the middle side of the high-voltage box housing 2-2 and are connected to the circuit breaker 2-5;

[0054] A BCMU module 2-7, and the BCMU module 2-7 is installed at the bottom of the high-voltage box housing 2-2. The high-voltage box module 2 includes:

[0055] A circuit breaker 2-5, and the circuit breaker 2-5 is installed on the middle bottom plate of the high-voltage box housing 2-2;

[0056] A positive copper bar 2-1 and a negative copper bar 2-4, and the positive copper bar 2-1 and the negative copper bar 2-4 are respectively installed on the rear side and the middle side of the high-voltage box housing 2-2 and are connected to the circuit breaker 2-5;

[0057] A BCMU module 2-7, and the BCMU module 2-7 is installed at the bottom of the high-voltage box housing 2-2;

[0058] A reactor 3-2 module 3 for suppressing current fluctuations and improving power quality. The reactor 3-2 module 3 includes:

[0059] A reactor 3-2, and the reactor 3-2 is installed on the upper surface of the reactor 3-2 base 3-1;

[0060] The L-shaped mounting bracket serves as the fixed bracket for the reactor 3-2, and at the same time serves as the rear side plate of the PCS power module 1 and the high-voltage box module 2. The bottom serves as the bottom plate of the entire energy storage power unit. The reactor 3-2 in the reactor 3-2 module 3 is directly mounted on the L-shaped mounting bracket and uses natural heat dissipation. The L-shaped mounting bracket can not only play the role of fixing the reactor 3-2, but also play the role of connecting the PCS power module 1 and the BMS module into a whole;

[0061] Connecting crossbeam 4;

[0062] Among them, the PCS power module 1 and the high-voltage box module 2 are connected by the connecting crossbeam 4, and the positions of the PCS power module 1 and the high-voltage box module 2 can be interchanged; the reactor 3-2 module 3 is located at the rear side of the PCS power module 1 and the high-voltage box module 2. The reactor 3-2 module 3 and the high-voltage box module 2 are connected into a whole energy storage power unit. The positions of the PCS power module 1 and the high-voltage box module 2 can be interchanged, and the width dimension is consistent with the dimensions of most battery packs on the market, which can better match the battery packs of different manufacturers.

[0063] During operation, in the PCS power module 1, the IGBT component 1-4 is in the upper front, the contactor is at the bottom of the IGBT component 1-4, the capacitors 1-2 are behind the IGBT component 1-4, and the bypass busbar 1-7 is directly connected to the output busbar 1-6. In the high-voltage box module 2, devices such as the handle of the circuit breaker 2-5, the air switch, the B positive and negative terminals, etc. are all installed on the front panel. The P positive terminal is at the rear side, and the P negative terminal is at the middle side. They are connected to the reactor 3-2 and the PCS power module 1 by busbars. In the reactor 3-2 module 3, the reactor 3-2 is directly installed on the L-shaped mounting bracket and uses natural heat dissipation. The L-shaped mounting bracket can not only play the role of fixing and installing the reactor 3-2, but also play the role of connecting the PCS power module 1 and the BMS module into a whole. The PCS power module 1 and the high-voltage box module 2 are in the front, and their positions can be interchanged. They are connected together by the connecting cross beam 4 at the front end. The connecting cross beam 4 can not only play the connecting role, but also play the role of fixing and rectifying the unit module during the installation of the whole machine. The reactor 3-2 module 3 is at the rear end and connects the PCS power module 1 and the high-voltage box module 2 together. The three major modules of the PCS power module 1, the high-voltage box module 2, and the reactor 3-2 module 3 are connected to each other to form a high-voltage cascaded energy storage power unit. The left and right positions of the PCS power module 1 and the high-voltage box module 2 can be interchanged, which can better adapt to battery packs from different manufacturers. By combining the PCS power module 1, the high-voltage box module 2, and the reactor 3-2 module 3 into a whole energy storage power unit through the connecting cross beam 4, the energy storage power unit is decomposed into multiple small modules and adopts a compact layout design. The present invention avoids the problem of the excessively large volume of the traditional single energy storage power unit. The positions of the PCS power module 1 and the high-voltage box module 2 are interchanged, which can flexibly adapt to the battery pack layouts of different manufacturers, and the width dimension of the energy storage power unit is consistent with the dimensions of most battery packs on the market, which can match the battery packs of different manufacturers. In summary, the present invention solves the problems of the excessively large volume, low installation efficiency, and poor versatility of the existing energy storage power unit by optimizing the modular design, structural layout, and electrical connection method, significantly improves the flexibility, versatility, and reliability of the system, and provides a new solution for the design and application of the high-voltage cascaded energy storage system.

[0064] Embodiment 2:

[0065] On the basis of Embodiment 1, the connecting crossbeam 4 is arranged at the front end of the PCS power module 1 and the high-voltage box module 2, used to connect the PCS power module 1 and the high-voltage box module 2, and fix the entire unit module during the installation of the whole machine. In the PCS power module 1, the output copper busbar 1-6 of the IGBT component 1-4 is connected to the bypass copper busbar 1-7 of the bypass contactor 1-8 outside the unit to achieve the bypass function, which is convenient for maintenance and fault isolation. In the high-voltage box module 2, the positive copper busbar 2-1 and the negative copper busbar 2-4 are located on different sides of the high-voltage box housing 2-2 respectively. The L-shaped mounting bracket of the reactor 3-2 module 3 is reinforced with ribs to ensure the fixing strength of the reactor 3-2 and the stability of the overall structure. In the PCS power module 1, the IGBT component 1-4 is on the upper side and the contactor is on the lower side. The IGBT output copper busbar 1-6 is connected to the copper busbar of the bypass contactor 1-8 outside the unit to achieve the unit bypass function. In the high-voltage box module 2, the P positive and P negative terminals are respectively at the rear side and the right side, and are connected to the PCS power module 1 with copper busbars, avoiding the wiring chaos caused by all the terminals being at the front end. In the PCS power module, the IGBT component is located above and the contactor is located below. The IGBT output copper busbar 1-6 is connected to the copper busbar of the bypass contactor 1-8 outside the unit to achieve the unit bypass function, which is convenient for maintenance and fault handling. In the PCS power module, the IGBT component is located above and the contactor is located below. The IGBT output copper busbar 1-6 is connected to the copper busbar of the bypass contactor 1-8 outside the unit to achieve the unit bypass function, which is convenient for maintenance and fault handling.

[0066] The above are only the preferred embodiments of the present application and are not intended to limit the present application. Any modifications, equivalent replacements, and improvements made within the spirit and principle of the application shall be included in the protection scope of the present application.

Claims

1. A combined high-voltage cascaded energy storage power unit, characterized in that: Including: A PCS power module (1) for realizing bidirectional conversion and control of electric energy; A high-voltage box module (2) for providing electrical connection, protection and control functions; A reactor module (3) for suppressing current fluctuations and improving power quality; A connecting crossbeam (4); Wherein, the PCS power module (1) and the high-voltage box module (2) are connected by the connecting crossbeam (4), and the positions of the PCS power module (1) and the high-voltage box module (2) can be interchanged; the reactor module (3) is located at the rear side of the PCS power module (1) and the high-voltage box module (2), and the reactor module (3) and the high-voltage box module (2) are connected into an integral energy storage power unit.

2. The combined high-voltage cascaded energy storage power unit according to claim 1, wherein: The PCS power module (1) includes: An IGBT component (1-4), and the IGBT component (1-4) is installed on an L-shaped bracket (1-5) inside a PCS housing (1-1); A contactor (1-8), and the contactor (1-8) is installed at the bottom of the L-shaped bracket (1-5); A capacitor (1-2), and the capacitor (1-2) is installed at the rear side of the IGBT component (1-4) and is connected through a busbar (1-3) and a long copper bar (1-10); A bypass copper bar (1-7), and the bypass copper bar (1-7) is connected to a bypass contactor (1-8) and is connected to an output copper bar (1-6) to realize the unit bypass function; A first switching power supply (1-9), and the first switching power supply (1-9) is installed outside the L-shaped bracket (1-5) and is installed in an insulated manner through an insulating strip support.

3. The combined high-voltage cascaded energy storage power unit according to claim 1, characterized in that: The high-voltage box module (2) includes: A circuit breaker (2-5), and the circuit breaker (2-5) is installed on the middle bottom plate of a high-voltage box housing (2-2); A positive copper bar (2-1) and a negative copper bar (2-4), and the positive copper bar (2-1) and the negative copper bar (2-4) are respectively installed at the rear side and the middle side of the high-voltage box housing (2-2) and are connected to the circuit breaker (2-5); A BCMU module (2-7), and the BCMU module (2-7) is installed at the bottom of the high-voltage box housing (2-2); A second switching power supply (2-3), and the second switching power supply (2-3) is installed on the high-voltage box housing (2-2) and is fixed through a switching power supply bracket (2-8); An air switch (2-10), a Hall sensor (2-12), a DC contactor (2-13), a buffer contactor (2-14), a buffer resistor (2-15) and a relay (2-16), all of which are installed inside the high-voltage box housing (2-2).

4. A combined high-voltage cascaded energy storage power unit according to claim 1, characterized in that: The reactor module (3) includes: A reactor (3-2), and the reactor (3-2) is installed on the upper surface of a reactor base (3-1); An L-shaped mounting frame, which serves as a fixing bracket for the reactor (3-2), and at the same time serves as the rear side plate of the PCS power module (1) and the high-voltage box module (2), and the bottom serves as the bottom plate of the entire energy storage power unit.

5. A combined high-voltage cascaded energy storage power unit according to claim 1, characterized in that: The connecting crossbeam (4) is arranged at the front end of the PCS power module (1) and the high-voltage box module (2) for connecting the PCS power module (1) and the high-voltage box module (2) and fixing the entire unit module during the installation of the whole machine.

6. The combined high-voltage cascaded energy storage power unit according to claim 1, wherein: In the PCS power module (1), the output copper bar (1-6) of the IGBT component (1-4) is connected to the bypass copper bar (1-7) of the bypass contactor (1-8) outside the unit to achieve the bypass function, which is convenient for maintenance and fault isolation.

7. A combined high-voltage cascaded energy storage power unit according to claim 1, characterized in that: In the high-voltage box module (2), the positive copper bar (2-1) and the negative copper bar (2-4) are located on different sides of the high-voltage box housing (2-2) respectively.

8. A combined high-voltage cascaded energy storage power unit according to claim 1, characterized in that: The L-shaped mounting bracket of the reactor module (3) is reinforced with ribs to ensure the fixing strength of the reactor (3-2) and the stability of the overall structure.

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