New energy locomotive high-voltage box

Abstract

The invention discloses a high-voltage box of a new energy locomotive, which relates to the technical field of new energy locomotives and comprises a box body, a high-voltage control device and a low-voltage control device, the high-voltage control device comprises a contactor, a fuse and an insulation detector, and the contactor is a contactor with an arc extinguishing function; the low-voltage control device comprises a power conversion module, a current sensor and a voltage sensor; the contactor is a contactor with an arc extinguishing function; the high-voltage box body is insulated in a multi-layer insulation isolation mode; the wiring mode between the devices in the high-voltage box body is flexible busbar connection, and the connection mode between the wiring terminals in the high-voltage box body is flexible busbar connection; a positive electrode in the high-voltage box body is provided with a plurality of branches connected in parallel, and mixed control is achieved through the multiple branches. By adopting the arc extinguishing function contactor, multi-layer insulation protection, flexible busbar connection between devices, multi-branch hybrid control and other measures, the difficulty of the high-voltage devices in the aspects of electrical clearance, electromagnetic compatibility and wiring protection is reduced, and the safety and reliability of the high-voltage box are guaranteed.

Description

Technical Field

[0001] The present invention relates to the technical field of new energy locomotives, and more specifically to the technical field of a new energy locomotive high-voltage box. Background Art

[0002] The high voltage box (HVB) of a new energy locomotive is one of the core components of the locomotive's traction power battery, primarily responsible for the distribution, management, and safety control of the power battery's electrical energy. Existing patents disclose the following technologies: Patent publication number CN221428637U, titled "High-Voltage Control Box and Energy Storage System," discloses the following: A high-voltage control box, configured to control a first battery cluster and a second battery cluster, comprises: a box body including a front panel having a first battery input interface, a first battery output interface, a second battery input interface, and a second battery output interface; a first control circuit, connected to the first battery input interface and the first battery output interface, for controlling the operating state of the first battery cluster; and a second control circuit, connected to the second battery input interface and the second battery output interface, for controlling the operating state of the second battery cluster. The high-voltage control box provided by the present invention can improve the safety and reliability of power distribution.

[0003] Currently, the high-voltage boxes of the aforementioned patents and existing railway new energy locomotive power battery systems generally integrate high and low voltage components within a single cabinet. Due to the compact layout of the power battery system, the selection of high and low voltage components, electrical clearances, electromagnetic compatibility, and wiring protection are all significantly restricted, hindering the design and reliable operation of the high-voltage box. Summary of the Invention

[0004] The purpose of the present invention is to solve the above technical problems and provide a new energy locomotive high-voltage box.

[0005] In order to achieve the above-mentioned purpose, the present invention specifically adopts the following technical solutions: The present invention provides a new energy locomotive high-voltage box, comprising a box body and a high-voltage control device and a low-voltage control device both arranged in the box body; The high-voltage control device includes a contactor, a fuse and an insulation tester. The contactor is a contactor with an arc extinguishing function; the low-voltage control device includes a power conversion module, a current sensor and a voltage sensor; The high-voltage box is insulated with multi-layer insulation isolation; the connection method between the devices in the high-voltage box is flexible busbar connection, and the connection method between the terminal blocks in the high-voltage box is flexible busbar connection; the positive pole in the high-voltage box is equipped with multiple parallel branches, which are controlled by multi-branch mixing.

[0006] Specifically, this solution reduces the difficulty of high-voltage devices in terms of electrical clearance, electromagnetic compatibility, and wiring protection by adopting measures such as arc-extinguishing contactors, multi-layer insulation protection, flexible busbar connections between devices, and multi-branch hybrid control, thereby ensuring the safety and reliability of high-voltage boxes.

[0007] The safety and reliability of the high-voltage box are improved, the availability of the vehicle's power battery system is increased, and the occurrence of machine damage in the event of a fault is avoided.

[0008] In one embodiment, an arc extinguishing hood with an arc extinguishing function is provided on the outside of the contactor.

[0009] Railway locomotive operating conditions and control strategies are more complex than those in the automotive industry, placing higher demands on reliability. When a contactor disconnects under load, the contacts must open promptly without sticking, and the resulting arc energy must be rapidly released without focusing and burning the contactor. Therefore, electromagnetic contactors with arc extinguishing hoods and multiple arc extinguishing capabilities should be selected for railway locomotives, rather than high-voltage relays used in the automotive industry that use inert gas for a one-time short-circuit arc extinguishing function. This ensures the proper operation and function of the contactor.

[0010] In one embodiment, the high-voltage box is insulated using a three-layer insulation isolation method, which includes a basic insulation method, a double insulation method, and a supplementary insulation method.

[0011] Specifically, in order to enhance the insulation function of the high-voltage box, three methods of basic insulation, double insulation and additional insulation are adopted in the high-voltage box to achieve higher insulation protection effect.

[0012] In one embodiment, the basic insulation means is the protection between electrical components and the setting of electrical clearance and creepage distance.

[0013] In one embodiment, double insulation is adopted: the copper busbars, terminals, and wiring harnesses in the high-voltage box are insulated to prevent insulation failure due to wear and tear; The total positive circuit and the total negative circuit in the high-voltage box are isolated by insulating plates, and the arc-spraying surface of the arc extinguishing hood is isolated by insulating plates.

[0014] In one embodiment, the additional insulation method is to apply a high-voltage insulating paint coating on the inner wall of the high-voltage box.

[0015] In one embodiment, the connection between devices is made by a flexible busbar connection, and the connection between the connection terminals is made by a flexible busbar connection.

[0016] Specifically, the wiring methods between components and the connection methods between terminal blocks can easily cause deviations in the connection holes due to installation errors, which can lead to stress concentration at the electrical connections, loss of contact surface, and circuit failure. To address this, flexible busbars are used to connect some surfaces that cross spatial dimensions. The flexible busbar's characteristics reduce stress and installation hole errors.

[0017] In one embodiment, the positive electrode in the high-voltage box is provided with two parallel branches, which serve as redundant backups for each other. When a branch fails, the faulty branch can be cut off.

[0018] Specifically, there are two branches on the positive pole in the high-voltage box, which serve as redundant backups for each other. When a branch fails, the faulty branch can be cut off, thereby ensuring that the locomotive can continue to operate at reduced power and avoid damage.

[0019] The beneficial effects of the present invention are as follows: 1. This patent reduces the difficulty of high-voltage devices in terms of electrical clearance, electromagnetic compatibility, and wiring protection by adopting arc-extinguishing contactors, multi-layer insulation protection, flexible busbar connection between devices, multi-branch hybrid control and other measures, thereby ensuring the safety and reliability of high-voltage boxes.

[0020] 2. Improve the safety and reliability of the high-voltage box, improve the availability of the vehicle's power battery system, and avoid machine damage in the event of a fault.

[0021] 3. The wiring method between components and the connection method between terminal blocks can easily cause deviations in the connection holes due to installation errors, which can lead to stress concentration at the electrical connection, loss of contact surface, and circuit failure. To this end, flexible busbars are used between some surfaces that cross spatial dimensions. The flexible busbar's characteristics can reduce stress and installation hole errors. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the following is a brief introduction to the drawings required for use in the embodiments. It should be understood that the following drawings only illustrate certain embodiments of the present invention and therefore should not be regarded as limiting the scope. For ordinary technicians in this field, other relevant drawings can be obtained based on these drawings without paying any creative work.

[0023] Figure 1 It is a schematic structural diagram of the multi-layer insulation protection of the present invention.

[0024] Figure 2 It is a structural schematic diagram of the flexible busbar connection of the present invention.

[0025] Figure 3 It is a structural diagram of the multi-branch hybrid control of the present invention. DETAILED DESCRIPTION

[0026] To make the technical problems, technical solutions, and technical effects of the present invention more clear, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Generally, the components of the embodiments of the present invention described and shown in the drawings herein can be arranged and designed in various different configurations.

[0027] Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the invention as claimed, but rather merely represents selected embodiments of the present invention. All other embodiments derived by persons of ordinary skill in the art based on the embodiments of the present invention without creative effort are intended to fall within the scope of protection of the present invention.

[0028] It should be noted that similar reference numerals and letters represent similar items in the following drawings. Therefore, once an item is defined in one drawing, it does not need to be further defined or explained in subsequent drawings. In addition, the terms "first," "second," etc. are used only to distinguish the descriptions and are not to be understood as indicating or implying relative importance.

[0029] In the description of the embodiments of the present invention, it should be noted that the terms "inside", "outside", "upper", etc. indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, or are the orientations or positional relationships in which the inventive product is usually placed when in use. They are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation. Therefore, they cannot be understood as limitations on the present invention.

[0030] Example 1 like Figures 1 to 3 As shown, this embodiment provides a high-voltage box for a new energy locomotive, comprising a box body and a high-voltage control device and a low-voltage control device both arranged in the box body.

[0031] The high-voltage control device includes a contactor, a fuse and an insulation tester. The contactor is a contactor with an arc extinguishing function; the low-voltage control device includes a power conversion module, a current sensor and a voltage sensor; The high-voltage box is insulated with multi-layer insulation isolation; the connection method between the devices in the high-voltage box is flexible busbar connection, and the connection method between the terminal blocks in the high-voltage box is flexible busbar connection; the positive pole in the high-voltage box is equipped with multiple parallel branches, which are controlled by multi-branch mixing.

[0032] Specifically, this solution reduces the difficulty of high-voltage devices in terms of electrical clearance, electromagnetic compatibility, and wiring protection by adopting measures such as arc-extinguishing contactors, multi-layer insulation protection, flexible busbar connections between devices, and multi-branch hybrid control, thereby ensuring the safety and reliability of high-voltage boxes.

[0033] The safety and reliability of the high-voltage box are improved, the availability of the vehicle's power battery system is increased, and the occurrence of machine damage in the event of a fault is avoided.

[0034] Example 2 This embodiment is a further optimization based on the embodiment 1, specifically: An arc extinguishing cover with arc extinguishing function is provided on the outside of the contactor.

[0035] Railway locomotive operating conditions and control strategies are more complex than those in the automotive industry, placing higher demands on reliability. When a contactor disconnects under load, it is crucial that the contacts open promptly without sticking, and that the resulting arc energy is quickly released without focusing and burning the contactor. Therefore, electromagnetic contactors with arc extinguishing hoods and multiple arc extinguishing capabilities should be selected for railway locomotives, rather than high-voltage relays used in the automotive industry that use inert gas for a one-time arc extinguishing function. This ensures the proper operation and function of the contactor.

[0036] Example 3 This embodiment is a further optimization based on the second embodiment, specifically: The high voltage box is insulated with three layers of insulation isolation, which are basic insulation, double insulation and additional insulation.

[0037] Specifically, in order to enhance the insulation function of the high-voltage box, three methods of basic insulation, double insulation and additional insulation are adopted in the high-voltage box to achieve higher insulation protection effect.

[0038] The basic insulation method is the protection between electrical components and the setting of electrical clearance and creepage distance.

[0039] Double insulation method: The copper busbars, terminals and wiring harnesses in the high-voltage box are insulated to prevent insulation failure due to wear and tear; The total positive circuit and the total negative circuit in the high-voltage box are isolated by insulating plates, and the arc-spraying surface of the arc extinguishing hood is isolated by insulating plates.

[0040] The additional insulation method is to apply high-voltage insulating paint coating on the inner wall of the high-voltage box.

[0041] Example 4 This embodiment is a further optimization based on the embodiment 3, specifically: The connection between devices adopts flexible busbar connection, and the connection between terminals adopts flexible busbar connection.

[0042] Specifically, the wiring methods between components and the connection methods between terminal blocks can easily cause deviations in the connection holes due to installation errors, which can lead to stress concentration at the electrical connections, loss of contact surface, and circuit failure. To address this, flexible busbars are used to connect some surfaces that cross spatial dimensions. The flexible busbar's characteristics reduce stress and installation hole errors.

[0043] Example 5 This embodiment is a further optimization based on the embodiment 3, specifically: There are two parallel branches on the positive pole of the high-voltage box. The two branches serve as redundant backup for each other. When a branch fails, the faulty branch can be cut off.

[0044] Specifically, there are two branches on the positive pole in the high-voltage box, which serve as redundant backups for each other. When a branch fails, the faulty branch can be cut off, thereby ensuring that the locomotive can continue to operate at reduced power and avoid damage.

Claims

1. A new energy locomotive high-voltage box, characterized in that: It includes a box body and a high-voltage control device and a low-voltage control device both of which are arranged in the box body; The high-voltage control device includes a contactor, a fuse, and an insulation tester. The contactor is a contactor with an arc extinguishing function; the low-voltage control device includes a power conversion module, a current sensor, and a voltage sensor; The high-voltage box is insulated with multi-layer insulation isolation; the connection method between the devices in the high-voltage box is flexible busbar connection, and the connection method between the terminal blocks in the high-voltage box is flexible busbar connection; the positive pole in the high-voltage box is equipped with multiple parallel branches, which are controlled by multi-branch mixing.

2. A new energy locomotive high-voltage box according to claim 1, characterized in that: An arc extinguishing hood with arc extinguishing function is provided on the outside of the contactor.

3. A new energy locomotive high-voltage box according to claim 2, characterized in that: The high voltage box is insulated with three layers of insulation isolation, which are basic insulation, double insulation and additional insulation.

4. A new energy locomotive high-voltage box according to claim 3, characterized in that: The basic insulation method is the protection between electrical components and the setting of electrical clearance and creepage distance.

5. A new energy locomotive high-voltage box according to claim 3, characterized in that: Double insulation method: The copper busbars, terminals and wiring harnesses in the high-voltage box are insulated to prevent insulation failure due to wear and tear; The total positive circuit and the total negative circuit in the high-voltage box are isolated by insulating plates, and the arc-spraying surface of the arc extinguishing hood is isolated by insulating plates.

6. A new energy locomotive high-voltage box according to claim 3, characterized in that: The additional insulation method is to apply high-voltage insulating paint coating on the inner wall of the high-voltage box.

7. A new energy locomotive high-voltage box according to claim 1, characterized in that: The connection between devices adopts flexible busbar connection, and the connection between terminals adopts flexible busbar connection.

8. A new energy locomotive high-voltage box according to claim 1, characterized in that: There are two parallel branches on the positive pole of the high-voltage box. The two branches serve as redundant backup for each other. When a branch fails, the faulty branch can be cut off.

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