Three-phase integrated power module and three-port energy router

Abstract

The invention relates to a three-phase integrated power module. The three-phase integrated power module comprises a mounting plate, a supporting capacitor assembly fixed on the mounting plate, a heat dissipation unit, an IGBT module fixed on the heat dissipation unit, a current sensor connected with the IGBT module, an independent driving plate, a centralized driving plate connected with the independent driving plate, a laminated busbar connected with the supporting capacitor assembly and the IGBT module, and a protective cover. The IGBT module comprises three IGBTs, the three IGBTs are respectively used for controlling the A phase, the B phase and the C phase of an alternating current power supply from left to right, and the installation distances among the three IGBTs are the same; the laminated busbar comprises a positive busbar, an insulating layer and a negative busbar. According to the three-phase integrated power module, three-phase current equalization can be realized, stray inductance is reduced by adopting the laminated busbar, interference during working is reduced, and the three-phase integrated power module has high integration density, adaptive wide-range power and relatively high protection performance. The invention also provides a three-port energy router.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of power system control, in particular to a three-phase integrated power module and a three-port energy router. BACKGROUND

[0002] With the rapid development of new energy power generation and diversified loads, the problem of uneven load distribution in distribution networks is increasingly prominent. High-load areas have problems such as high power supply pressure, safety hazards, and so on, while low-load areas have problems such as idle and waste of power resources. Traditional solutions usually rely on grid capacity expansion and reconstruction, but this method has high investment cost, long construction period, and is limited by site conditions, making it difficult to implement. Therefore, through the interconnection and supply between areas to achieve load balancing and energy optimization distribution has become an important way to improve the efficiency and reliability of the power grid. As the core equipment for realizing flexible interconnection of areas, the performance of the multi-port energy router directly affects the efficiency and reliability of the entire system.

[0003] The multi-port energy router in the prior art is usually composed of multiple discrete power units. The current sharing accuracy of the multi-port energy router is low. Due to inconsistent device parameters and control signal delays, the output current deviation of each phase often exceeds 10%, causing some power devices to operate in overload and shorten their service life. In addition, the power unit is large in size, low in integration, and poor in scene adaptability. The existing power unit is difficult to adjust flexibly according to the actual power demand, causing resource waste or performance bottleneck.

[0004] Therefore, it is necessary to provide a new three-phase integrated power module and a three-port energy router. SUMMARY

[0005] Therefore, the present application provides a three-phase integrated power module and a three-port energy router. The three-phase integrated power module can achieve three-phase current balancing, low-loss transmission using a laminated busbar, high integration density, wide-range power adaptation, and high protection performance.

[0006] The technical solution adopted by the present application to solve its technical problems is to provide a three-phase integrated power module, comprising: a mounting plate, a support capacitor assembly fixed on the mounting plate, a heat dissipation unit, an IGBT module fixed on the heat dissipation unit, a current sensor connected with the IGBT module, an independent drive board, a centralized drive board connected with the independent drive board, a laminated busbar connecting the support capacitor assembly and the IGBT module, and a protective cover covering the IGBT module; the IGBT module includes three IGBTs, the three IGBTs are used to control the A / B / C three-phase of the alternating current power source from left to right, and the installation spacing between the three IGBTs is the same; the laminated busbar includes a positive busbar, an insulating layer, and a negative busbar, and the laminated busbar is pre-provided with capacitor positive and negative electrode interfaces and IGBT positive and negative electrode interfaces.

[0007] Further, the support capacitor assembly comprises DC support capacitors and a capacitor fixing plate, the DC support capacitors are fixed on the capacitor fixing plate through bottom screws, a plurality of DC support capacitors are arranged, and the positive and negative poles of the DC support capacitors are located at the top position and connected to the positive and negative DC ends of the IGBT module through the laminated busbar.

[0008] Further, the heat dissipation unit comprises a heat sink, a frame guide rail arranged at the bottom inlet of the heat sink, a wind guide net slidingly arranged on the frame guide rail, and a turning wind guide arranged at the top outlet of the heat sink.

[0009] Further, the number of current sensors is the same as the number of IGBTs, the current sensors are arranged on the power output lines of the IGBTs, the current sensors are in communication connection with the signal input end of the centralized driving board, and the current sensors are directly powered by the centralized driving board.

[0010] Further, the input end of the independent driving board is in communication connection with the output end of the centralized driving board, the output end of the independent driving board is connected with the signal pin of the single IGBT, the independent driving board is provided with a driving power supply by the centralized driving board, the centralized driving board is arranged above the independent driving board, the centralized driving board is used for receiving the current feedback signal of the current sensor and generating a synchronous driving signal to send to the independent driving board, so as to ensure the phase accuracy of the three-phase alternating current.

[0011] Further, the capacitor positive pole interface of the positive busbar is connected with the positive pole terminal of the DC support capacitor, the capacitor negative pole interface of the negative busbar is connected with the negative pole terminal of the DC support capacitor, the IGBT positive pole interface of the positive busbar is connected with the IGBT positive pole power pin of the IGBT module, and the IGBT negative pole interface of the negative busbar is connected with the negative pole power pin of the IGBT.

[0012] To achieve the above-mentioned purpose, the technical scheme adopted by the present application is to provide a three-port energy router comprising the three-phase integrated power module provided in any of the above-mentioned schemes.

[0013] Further, the three-port energy router further comprises a cabinet machine as a whole, a control module arranged in the interior of the cabinet machine as a whole, a first grid-connected module, a second grid-connected module, a first filter module and a second filter module, and the three-phase integrated power module is also arranged in the interior of the cabinet machine as a whole.

[0014] Further, the control module is in communication connection with the three-phase integrated power module, the first grid-connected module and the second grid-connected module respectively, for collecting the states of each module and sending control instructions to each module. The input end of the three-phase integrated power module is electrically connected with the output end of the first filter module, for receiving the electric energy after being stabilized and harmonic filtered by the first filter module; The output end of the three-phase integrated power module is electrically connected with the input end of the second filter module, for delivering the standardized electric energy converted by the three-phase integrated power module to the second filter module for secondary optimization; The input end of the first grid-connected module is electrically connected with the output end of an external power grid or a low-load area, for receiving the electric energy to be processed; The output end of the first grid-connected module is electrically connected with the output end of the first filter module, for delivering the electric energy to the first filter module; The input end of the second grid-connected module is electrically connected with the output end of the second filter module, for receiving the electric energy after being stabilized and harmonic filtered by the second filter module; The output end of the second grid-connected module is electrically connected with a high-load area and energy storage equipment through each grid-connected interface, for realizing electric energy distribution.

[0015] Further, the first input end of the control module is in communication connection with the three-phase integrated power module, for obtaining the first feedback signal including IGBT current signal and temperature signal; the first output end of the control module is in communication connection with the three-phase integrated power module, for sending the first control signal including IGBT driving instruction and power adjustment instruction; The second input end of the control module is in communication connection with the first grid-connected module, for obtaining the second feedback signal including grid-connected voltage or frequency signal of the first grid-connected module; the second output end of the control module is in communication connection with the first grid-connected module, for sending the second control signal including grid-connected / off-grid switching instruction; The third input end of the control module is in communication connection with the second grid-connected module, for obtaining the third feedback signal including grid-connected voltage or frequency signal of the second grid-connected module; the third output end of the control module is in communication connection with the second grid-connected module, for sending the third control signal including grid-connected / off-grid switching instruction.

[0016] The beneficial effects of the present application are: the three IGBTs of the three-phase integrated power module are arranged at equal intervals, combined with current sensing and centralized driving control, three-phase current balance is achieved, overload is avoided, and service life is prolonged; the laminated busbar design is adopted, the stray inductance is reduced, and the interference during work is reduced; the key components are integrated on a single mounting plate, the structure is compact, the heat dissipation is uniform, and high integration density is achieved; high flexibility and adaptation, modular design supports flexible coverage of a larger power range by adjusting the number of IGBTs and capacitors, without the need to replace the entire machine, and has higher reliable protection, and improves environmental adaptability. BRIEF DESCRIPTION OF DRAWINGS

[0017] The present application will be further described below in conjunction with the drawings and examples.

[0018] In the drawings: Figure 1 A structural schematic diagram of a three-port energy router provided for an embodiment of the present application; Figure 2 A structural block diagram of a three-port energy router provided for an embodiment of the present application; Figure 3 A structural schematic diagram of a three-phase integrated power module provided for an embodiment of the present application; Figure 4 An exploded view of a three-phase integrated power module provided for an embodiment of the present application; Figure 5 A partial enlarged view of an independent driving board and a current sensor provided for an embodiment of the present application.

[0019] In the drawings, various reference signs: Three-port energy router 100; Cabinet machine as a whole 1; control module 2; three-phase integrated power module 3, mounting plate 31, support capacitor assembly 32, DC support capacitor 321, capacitor fixing plate 322, heat dissipation unit 33, heat sink 331, heat dissipation fixing plate 332, frame guide rail 333, air guide net 334, turning air guide piece 335, IGBT module 34, current sensor 35, independent driving board 36, centralized driving board 37, laminated busbar 38, positive busbar 381, insulating layer 382, negative busbar 383, protective cover 39; first grid-connected module 4; second grid-connected module 5; first filter module 6; second filter module 7. DETAILED DESCRIPTION

[0020] In order to make the technical problems to be solved by the present application, the technical solutions and beneficial effects more clear and explicit, the present application will be further described in detail below in conjunction with the drawings and examples. It should be understood that the specific examples described herein are only used to explain the present application, and are not used to limit the present application.

[0021] It should be noted that when a component is referred to as "connected to" or "set on" another component, it can be directly on or indirectly on that other component. When a component is referred to as "connected to" another component, it can be directly connected to or indirectly connected to that other component.

[0022] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0023] It should be understood that the terms "length", "width", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. 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, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the present invention.

[0024] Throughout this specification, reference to "an embodiment" or "an embodiment" means that a particular feature, structure, or characteristic described in connection with an embodiment is included in at least one embodiment of this application. Therefore, the phrases "in one embodiment," "in some embodiments," or "in some of these embodiments" appear in various places throughout the specification, and not all refer to the same embodiment. Furthermore, in one or more embodiments, a particular feature, structure, or characteristic may be combined in any suitable manner.

[0025] like Figure 1 , Figure 2As shown, the present invention provides a three-port energy router 100 including a cabinet unit 1, a control module 2, a three-phase integrated power module 3, a first grid-connected module 4, a second grid-connected module 5, a first filter module 6, and a second filter module 7 disposed inside the cabinet unit 1. The control module 2 is communicatively connected to the three-phase integrated power module 3, the first grid-connected module 4, and the second grid-connected module 5, respectively, to collect the status of each module and send control commands to each module; the input terminal of the three-phase integrated power module 3 is electrically connected to the output terminal of the first filter module 6, receiving the electrical energy after current stabilization and harmonic filtering by the first filter module 6; the output terminal of the three-phase integrated power module 3 is electrically connected to the input terminal of the second filter module 7, transmitting the standardized electrical energy converted by the three-phase integrated power module 3 to the second filter module 7 for secondary optimization; the input terminal of the first grid-connected module 4 is connected to the external... The output terminals of the first grid-connected module 4 and the first filter module 6 are electrically connected to the power grid or low-load distribution area to receive the electrical energy to be processed. The output terminal of the first grid-connected module 4 is electrically connected to the output terminal of the first filter module 6. The first grid-connected module 4 is electrically connected to the external power grid or low-load distribution area through various grid-connected interfaces to distribute electrical energy and deliver it to the first filter module 6. The input terminal of the second grid-connected module 5 is electrically connected to the output terminal of the second filter module 7 to receive the electrical energy after it has been stabilized and harmonics filtered by the second filter module 7. The output terminal of the second grid-connected module 5 is electrically connected to the high-load distribution area and energy storage equipment through various grid-connected interfaces to realize electrical energy distribution. The cabinet unit 1 serves as the structural carrier for the control module 2, the three-phase integrated power module 3, the first grid-connected module 4, the second grid-connected module 5, the first filter module 6, and the second filter module 7. It also provides separate installation spaces for the control module 2, the three-phase integrated power module 3, the first grid-connected module 4, the second grid-connected module 5, the first filter module 6, and the second filter module 7 to ensure that the positions of each component are fixed and to prevent vibration and displacement. Control module 2 is used to collect real-time operating data from each module, issue control commands to adjust power output, and support communication with the backend system. Three-phase integrated power module 3 is used to standardize the form and parameters of electrical energy. First grid-connected module 4 is used to receive electrical energy from the external power grid or low-load distribution areas, responsible for receiving and initially distributing the raw electrical energy. Second grid-connected module 5 is used to receive processed electrical energy and send it to high-load distribution areas or energy storage devices. First filtering module 6 is used to preprocess the electrical energy from the external power grid or low-load distribution areas to ensure the stability of the electrical energy input to three-phase integrated power module 3. Second filtering module 7 is used to perform secondary optimization on the converted electrical energy, improving the quality of the electrical energy output to high-load distribution areas and energy storage devices.

[0026] In some embodiments, the cabinet unit 1 adopts a sheet metal frame structure, forming a closed cabinet. Inside the cabinet unit 1, a control module 2, a three-phase integrated power module 3, a first grid-connected module 4, a second grid-connected module 5, a first filter module 6, and a second filter module 7 are integrated, simultaneously isolating external dust, moisture, and foreign objects, and providing heat dissipation channels for the internal modules. The control module 2, three-phase integrated power module 3, first grid-connected module 4, second grid-connected module 5, first filter module 6, and second filter module 7 are fixed in predetermined positions inside the cabinet unit 1, and the cables between the modules are connected through internal cable trays. The cabinet unit 1 can support all internal modules, ensuring the fixed positions of each component, preventing vibration and displacement, and protecting the internal components from external environmental corrosion, thus reducing the probability of failure.

[0027] In some embodiments, the control module 2 is fixed in the internal mounting cavity of the cabinet assembly 1. The control module 2 includes a main control unit, a signal acquisition unit, a drive control unit, and a communication unit. The main control unit is used for internal logic operations. The signal acquisition unit receives signals from the current sensor and temperature sensor, processes them, and transmits them to the main control unit. The drive control unit sends switching commands to the three-phase integrated power module 3. The communication unit is used for communication with the background monitoring system and other modules. The first input terminal of the control module 2 is communicatively connected to the three-phase integrated power module 3 to acquire a first feedback signal, which includes receiving the IGBT current signal and temperature signal from the three-phase integrated power module 3. The first output terminal of the control module 2 is communicatively connected to the three-phase integrated power module 3 to acquire a first control signal, which includes sending IGBT drive commands and power adjustment commands to the three-phase integrated power module 3. The second input terminal of the control module 2 is communicatively connected to the first grid-connected module 4 to acquire a second feedback signal, which includes receiving the grid-connected voltage or frequency signal from the first grid-connected module 4. The second output terminal of control module 2 is communicatively connected to the first grid-connected module 4 to acquire a second control signal, which includes sending a grid-connected / off-grid switching command to the first grid-connected module 4. The third input terminal of control module 2 is communicatively connected to the second grid-connected module 5 to acquire a third feedback signal, which includes receiving the grid-connected voltage or frequency signal from the second grid-connected module 5. The second output terminal of control module 2 is also communicatively connected to the second grid-connected module 5 to acquire a third control signal, which includes sending a grid-connected / off-grid switching command to the third grid-connected module 4. Control module 2 collects real-time operating data from each module, such as current, voltage, and temperature, issues control commands to adjust power output and grid connection status, triggers protection actions such as power outages and alarms in case of faults, and supports remote monitoring via communication with a backend system. Control module 2 can adjust the output of the three-phase integrated power module 3 according to load demand, i.e., the power consumption of the distribution area, to achieve flexible switching of power from 50 to 200KW. It can also monitor the current, voltage, and temperature of each module in real time to ensure that the equipment operates within a safe range. When an IGBT overcurrent is detected in the three-phase integrated power module 3, or when the first grid-connected module 4 and the second grid-connected module 5 are not connected to the grid, the circuit breaker is immediately triggered to disconnect and an alarm is triggered to prevent damage to the devices. Control module 2 significantly reduces the current deviation of each phase by acquiring current signals in real time and accurately driving the IGBTs of the three-phase integrated power module 3. Control module 2 is linked with the backend through the communication unit, supporting remote viewing of operating data, modification of parameters, and fault diagnosis, reducing on-site operation and maintenance costs.

[0028] In some embodiments, both the first filter module 6 and the second filter module 7 are fixed inside the mounting cavity of the cabinet assembly 1. Each filter module includes two reactors and a filter. The two reactors are arranged back-to-back horizontally to reduce their space requirements. Two load-bearing beams are provided at the bottom of the reactors to fix them and prevent displacement due to vibration. Furthermore, a temperature sensor (not shown in the figure) is also provided on the side of the reactor to monitor its temperature. The first filter module 6 and the second filter module 7 serve as current stabilization and harmonic suppression components of the three-port power router 100. The first filter module 6 receives power from the external power grid or low-load distribution area, suppresses current surges through the inductive characteristics of the reactor, filters out some low-frequency harmonics, and suppresses current surges in the power from the external power grid or low-load distribution area through the filter components to avoid impacting the three-phase integrated power module 3. It also filters out low-frequency / high-frequency harmonics, purifies the power waveform, and outputs a stable current to the three-phase integrated power module 3. At the same time, it prevents the IGBT of the three-phase integrated power module 3 from being damaged by current fluctuations. The input terminal of the first filter module 6 is electrically connected to the output terminal of the first grid-connected module 4 to receive the electrical energy to be processed. The output terminal of the first filter module 6 is electrically connected to the input terminal of the three-phase integrated power module 3 to transmit the stabilized current to the three-phase integrated power module 3. The first filter module 6 is used to suppress the current fluctuation of external power energy, provide a stable input current for the three-phase integrated power module 3, and avoid damage to the IGBT due to sudden current changes. It filters out low-frequency harmonics in the external power grid or low-load distribution area, reduces the interference of harmonics on the three-phase integrated power module 3 and the grid-connected module 4, and improves the overall power quality. Through current buffering, it reduces the switching stress of the IGBT of the three-phase integrated power module 3 and extends the service life of the IGBT. The temperature sensor monitors the temperature rise of the reactor in real time to prevent the reactor from burning out due to overload and overheating. Through current stabilization protection of the IGBT, it reduces faults, suppresses harmonics and current fluctuations, avoids interference to the external power grid and distribution area equipment, and the back-to-back installation reduces the internal space of the cabinet and improves the overall power density. The input terminal of the second filter module 7 is electrically connected to the output terminal of the three-phase integrated power module 3, receiving the standardized electrical energy converted by the three-phase integrated power module 3. The output terminal of the second filter module 7 is electrically connected to the output terminal of the second grid-connected module 5, performing secondary optimization on the converted electrical energy to further smooth current fluctuations and ensure the stability of the current amplitude output to the second grid-connected module 5; filtering out high-frequency harmonics generated during the conversion process of the three-phase integrated power module 3, making the electrical energy waveform closer to the ideal sine wave.

[0029] In some embodiments, both the first grid-connected module 4 and the second grid-connected module 5 are fixed in the internal mounting cavity of the cabinet assembly 1. Both the first grid-connected module 4 and the second grid-connected module 5 include multiple sets of grid-connected interfaces, with the number of interfaces not exceeding four. Each grid-connected interface is independently configured with a circuit breaker / contactor, supporting automatic switching between grid-connected and off-grid operation. The input terminal of the first grid-connected module 4 is electrically connected to the output terminal of the external power grid or a low-load distribution area to receive the energy to be processed. The output terminal of the first grid-connected module 4 is electrically connected to the output terminal of the first filter module 6. The first grid-connected module 4 is electrically connected to the external power grid or a low-load distribution area through various grid-connected interfaces to distribute and deliver energy to the first filter module 6. The input terminal of the second grid-connected module 5 is electrically connected to the output terminal of the second filter module 7 to receive the energy optimized by the second filter module 7. The output terminal of the second grid-connected module 5 is electrically connected to a high-load distribution area and an energy storage device through multiple sets of grid-connected interfaces to achieve energy distribution. The first grid-connected module 4 and the second grid-connected module 5 are connected to the control module 2 via signal lines to receive grid-connected / off-grid switching commands. For example, if the control module 2 determines that a certain distribution area is short of power, it commands the grid-connected contactor corresponding to that grid-connected interface to close, and simultaneously feeds back data such as grid-connected voltage / frequency signals to the control module 2. The first grid-connected module 4 and the second grid-connected module 5 serve as a connection bridge between the three-port energy router 100 and the external power grid, low-load distribution areas, high-load distribution areas, and energy storage devices. They enable the reception of power from the external power grid or low-load distribution areas, and the transmission of the power converted by the three-phase integrated power module 3 to high-load distribution areas or energy storage devices. Up to four ports can be connected to different distribution areas or energy storage devices, adapting to cellular distribution network structures, thereby achieving efficient interconnection of multi-regional power grids, solving power waste in low-load distribution areas and power hazards in high-load distribution areas, and improving energy utilization efficiency.

[0030] In some embodiments, at least two sets of three-phase integrated power modules 3 are provided, and the three-phase integrated power modules 3 are fixed in the internal mounting cavity of the cabinet assembly 1. The input terminal of the three-phase integrated power module 3 is electrically connected to the output terminal of the first filter module 6 to receive electrical energy after it has been stabilized by the reactor. The output terminal of the three-phase integrated power module 3 is electrically connected to the input terminal of the grid-connected module 4 to transmit the standardized electrical energy after conversion to the grid-connected module 4. The three-phase integrated power module 3 is connected to the control module 2 through a signal line to receive IGBT drive commands and power adjustment commands from the control module 2, and at the same time, it feeds back current and temperature signals to the control module 3.

[0031] In some of these embodiments, such as Figure 3 , Figure 4As shown, the three-phase integrated power module 3 includes a mounting plate 31, a supporting capacitor assembly 32 fixed on the mounting plate 31, a heat dissipation unit 33, an IGBT module 34 fixed on the heat dissipation unit 33, a current sensor 35 connected to the IGBT module 34, an independent drive board 36, a centralized drive board 37 connected to the independent drive board 36, a stacked busbar 38 connecting the supporting capacitor assembly 32 and the IGBT module 34, and a protective cover 39 covering the IGBT module 34. The mounting plate 31 is a rectangular flat plate made of sheet metal to ensure its structural strength. Vertical folded edges are provided around the mounting plate 31 to improve structural rigidity and prevent deformation. The supporting capacitor assembly 32 includes DC supporting capacitors 321 and capacitor fixing plates 322. Multiple DC supporting capacitors 321 are provided, and the positive and negative terminals of the DC supporting capacitors 321 are located at the top away from the capacitor fixing plates 322. The top positive and negative terminals of the DC supporting capacitors 321 are connected to the positive and negative DC terminals of the IGBT module 34 through the stacked busbar 38, respectively. The DC support capacitor 321 is fixed to the capacitor mounting plate 322 by bottom screws. Different numbers of DC support capacitors can be used for three-phase integrated power modules 3 with different power levels. In this embodiment, a maximum of eight DC support capacitors 321 can be installed on the capacitor mounting plate 322. As an example, four DC support components 321 are provided. The capacitor mounting plate 322 is fixed to the upper part of one side of the mounting plate 31 by bolts or the like. The DC support capacitor 321 is used to store electrical energy to buffer power fluctuations, smooth the DC bus voltage, and provide a stable DC input for the IGBT module 34, preventing damage to the IGBT module 34 due to voltage fluctuations. When a high-power device is suddenly added to the distribution area, the stored electrical energy is quickly released to make up for the instantaneous gap in the grid input, preventing the module from shutting down due to a sudden drop in current. Furthermore, by increasing or decreasing the number of DC support capacitors 321, different power levels of IGBT modules 34 can be matched to achieve a power coverage of 50~200KW. In other words, the DC support capacitor 321 is adjusted synchronously with the level of the IGBT module 34, without the need to replace the entire three-phase integrated power module 3, adapting to different loads.

[0032] In some embodiments, the heat dissipation unit 33 is fixed to the mounting plate 31 and is located below the supporting capacitor assembly 32. The heat dissipation unit 33 includes a heat sink 331, a heat dissipation fixing plate 332 mounted on the mounting plate 31, a frame guide rail 333 located at the bottom inlet of the heat sink 331, an air guide net 334 slidably mounted on the frame guide rail 334, and a turning air guide component 335 located at the top outlet of the heat sink 331. The heat sink 331 is made of aluminum and has densely toothed surfaces. The IGBT module 34 is fixed on the mounting surface of the heat sink 331. Air cooling is input into the heat sink 331, and the aluminum teeth increase the heat dissipation area, thereby achieving cooling of the IGBT module 34. The radiator mounting plate 332 is fixedly connected to the mounting plate 31. The radiator mounting plate 332 has an L-shaped cross-section. The bottom plate of the radiator mounting plate 332 fixes the bottom of the radiator 331 and is fixedly connected to the mounting plate 31. The side plates of the radiator mounting plate 332 are fixed to the sides of the radiator 331 to prevent deformation of the radiator 331. The frame guide rail 333 is located at the bottom inlet of the radiator 331 and is fixedly connected to the side plate of the radiator mounting plate 332. The air guide net 334 is set on the frame guide rail 333 to guide air to flow evenly into the radiator 331. The turning air guide 335 is located at the top outlet of the radiator 331. The turning air guide 335 is roughly rectangular in shape with an L-shaped cavity inside, used to guide the air to turn at a right angle. The turning air guide 335 is fixed on the mounting plate 31. A connection port is opened at the bottom of the turning air guide 335, and an air outlet is opened on the side of the turning air guide 335. The connection port is matched with the top outlet of the radiator 331. The air output from the top outlet of the radiator 331 enters through the bottom of the turning air guide 335, and then is output from the air outlet on the side of the turning air guide 335 to the outside of the three-phase integrated power module 3, thereby realizing the turning of the air. In other words, the cold air from the outside first passes through the air guide net 334. After being diverted by the air guide net 334, the cold air passes vertically upward through the dense gaps between the teeth on the surface of the radiator 331. The cold air comes into full contact with the surface of the teeth, absorbs the heat transferred by the teeth, and becomes hot air itself. The top outlet of the radiator 331 is connected to the bottom connection port of the turning air guide 335. After the hot air is discharged from the top of the radiator 331, it directly enters the L-shaped cavity inside the turning air guide 335. The hot air changes from a vertical upward flow to a horizontal outward flow. After the hot air undergoes a right-angle turn, it is directly discharged from the side outlet of the turning air guide 335 to the outside of the three-phase integrated power module 3.

[0033] In some embodiments, the IGBT module 34 is fixed to the heat sink 331. The IGBT module 34 generates a large amount of heat during operation, which is conducted to the entire heat sink 331 for heat dissipation. The IGBT module 34 includes three IGBTs. From left to right, the three IGBTs control the A / B / C phases of the AC power supply, respectively. The three IGBTs are installed at equal intervals to ensure uniform heat distribution, facilitating heat dissipation and ensuring current sharing. The power pins of the three IGBTs are connected to the DC support capacitor 321 via a stacked busbar 38, and the signal pins of the three IGBTs are connected to an independent driver board 36 to receive drive signals. As the core of the three-phase integrated power module 3, the IGBT module 34 uses the IGBTs to perform DC-to-AC inversion or AC-to-DC rectification conversion by turning on / off, controlling the direction and magnitude of power flow, i.e., inverting the DC power from the support capacitor 32 into the AC power required by the transformer substation. IGBT module 34 can realize the inversion of DC bus voltage to three-phase AC voltage (or the reverse rectification of AC to DC) to match the voltage level of the distribution area / grid. The IGBT switching duty cycle is controlled by the independent driver board 36 to adjust the output power and achieve continuous adjustment. The other three IGBTs are arranged at equal intervals and switched synchronously to ensure the balance of the three-phase current of A / B / C and avoid overload of some IGBTs.

[0034] In some other embodiments, there are more than three IGBT modules 34, and the number of IGBTs in the IGBT module 34 is an integer multiple of 3. The IGBTs of the corresponding phases are connected in parallel to adapt to high-power operating environments.

[0035] In some of these embodiments, such as Figure 5 As shown, the number of current sensors 35 is the same as the number of IGBTs. The current sensors 35 are installed on the power output lines of the IGBTs, with one current sensor 35 corresponding to each IGBT branch. The current sensors 35 are communicatively connected to the signal input terminal of the centralized driver board 37, and are DC powered by the centralized driver board 37. The current sensors 35 monitor the current magnitude of each IGBT branch in real time, converting the current signal into an electrical signal and transmitting it to the centralized driver board 37. The centralized driver board 37 adjusts the switching signals of each independent driver board 36 according to the differences.

[0036] In some of these embodiments, such as Figure 5As shown, the independent driver board 36 serves as the driving component for a single IGBT. The input terminal of the independent driver board 36 is communicatively connected to the output terminal of the centralized driver board 37. The output terminal of the independent driver board 36 is connected to the signal pin of the single IGBT, and the independent driver board 36 is powered by the centralized driver board 37. The independent driver board 36 receives the unified control signal from the centralized driver board 37, and after isolation and amplification, outputs a switching drive signal recognizable by the single IGBT, simultaneously achieving isolation between the high-voltage power supply at the IGBT's power terminal and the low-voltage power supply at the control terminal.

[0037] In some embodiments, a centralized drive board 37 is located on independent drive boards 36. The input of the centralized drive board 37 is communicatively connected to the control module 2, and the output of the centralized drive board 37 is communicatively connected to multiple independent drive boards 36. The centralized drive board 37 is also communicatively connected to multiple current sensors 35 to receive current signals from each IGBT branch. The centralized drive board 37 receives power commands from the control module 2 and, combined with current feedback signals from the current sensors 35, generates synchronous drive signals to send to each independent drive board 36. The centralized drive board 37 generates synchronous switching signals for the A / B / C three phases, ensuring accurate phase of the three-phase AC power and avoiding three-phase imbalance. It can also compare the current feedback from each IGBT branch and fine-tune the switching duty cycle of the corresponding independent drive board 36 to achieve current sharing. The synchronous drive of the centralized drive board 37 ensures a precise 120° phase difference between the three-phase voltage and current, preventing damage to electrical equipment in the distribution area due to three-phase imbalance. It transforms the distributed control of multiple IGBTs into centralized and unified control, eliminating the need for the control module 2 to directly interface with each IGBT, thus reducing system complexity.

[0038] In some embodiments, the multilayer busbar 38 includes a positive busbar 381, an insulating layer 382, ​​and a negative busbar 383. The multilayer busbar 38 has pre-set positive and negative capacitor interfaces and IGBT positive and negative interfaces. The positive capacitor interface of the positive busbar 381 is connected to the positive terminal of the DC support capacitor 321, and the negative capacitor interface of the negative busbar 383 is connected to the negative terminal of the DC support capacitor 321. The positive IGBT interface of the positive busbar 381 is connected to the positive power pin of the IGBT module 34, and the negative IGBT interface of the negative busbar 383 is connected to the negative power pin of the IGBT. The multilayer busbar 38 can reduce stray inductance and reduce interference during operation.

[0039] In some embodiments, a protective cover 39 is disposed over the IGBT module 34, the independent driver board 36, and the centralized driver board 37, and is fixed to the mounting plate 31. The protective cover 39 provides physical protection for the IGBT module 34, the independent driver board 36, and the centralized driver board 37, isolating them from external dust, moisture, and foreign objects, and preventing dust accumulation from causing short circuits in the independent driver board 36 and the centralized driver board 37, as well as oxidation of the IGBT pins.

[0040] The three-port energy router 100 of the present invention includes a cabinet unit 1, a control module 2, a three-phase integrated power module 3, a first grid-connected module 4, a second grid-connected module 5, a first filter module 6, and a second filter module 7 disposed inside the cabinet unit 1. The control module 2 is communicatively connected to the three-phase integrated power module 3, the first grid-connected module 4, and the second grid-connected module 5, respectively, to collect the status of each module and send control commands to each module. The input terminal of the three-phase integrated power module 3 is electrically connected to the output terminal of the first filter module 6, receiving the electrical energy after it has been stabilized and harmonics filtered by the first filter module 6. The output terminal of the three-phase integrated power module 3 is electrically connected to the input terminal of the second filter module 7, transmitting the standardized electrical energy converted by the three-phase integrated power module 3 to the second filter module 7 for secondary processing. The optimization involves the following steps: The input terminal of the first grid-connected module 4 is electrically connected to the output terminal of the external power grid or low-load distribution area to receive the electrical energy to be processed; the output terminal of the first grid-connected module 4 is electrically connected to the output terminal of the first filter module 6 to transmit electrical energy to the first filter module 6; the input terminal of the second grid-connected module 5 is electrically connected to the output terminal of the second filter module 7 to receive the electrical energy after it has been stabilized and harmonics filtered by the second filter module 7; and the output terminal of the second grid-connected module 5 is electrically connected to the high-load distribution area and energy storage equipment through various grid-connected interfaces to realize power distribution. This invention achieves interconnection and mutual supply through the power flow path of the first grid-connected module 4, the first filter module 6, the three-phase integrated power module 3, the second filter module 7, and the second grid-connected module 5: The first grid-connected module 4 receives redundant power from the external power grid or low-load distribution area, which is then stabilized by the first filter module 6 and transmitted to the three-phase integrated power module 3 to be converted into standardized power. After secondary optimization by the second filter module 7, it is distributed to high-load distribution areas or energy storage devices through the second grid-connected module 5. This avoids the waste of power at low loads while alleviating the pressure at high loads, improving energy utilization, and balancing the load without additional power capacity expansion; the cabinet as a whole 1 is the control module 2. The three-phase integrated power module 3, the first grid-connected module 4, the second grid-connected module 5, the first filter module 6, and the second filter module 7 are provided with separate installation spaces. Each module is fixed in a preset position, which can effectively avoid vibration displacement during transportation or operation. Furthermore, the grid-connected module 4 can connect to different high-load distribution areas or energy storage devices through multiple grid-connected interfaces. Combined with the grid-connected module's ability to access power from multiple sources, it realizes an interconnection architecture of one router, multiple regional power grids, and energy storage devices. This breaks the limitation of existing technologies that can only interconnect two areas, adapts to the cellular layout requirements of urban power distribution networks, and provides core equipment support for distributed new energy grid connection and flexible interconnection of distribution areas.

[0041] The three-phase integrated power module 3 of the present invention includes a mounting plate 31, a capacitor assembly 32 fixed on the mounting plate 31, a heat dissipation unit 33, an IGBT module 34 fixed on the heat dissipation unit 33, a current sensor 35 connected to the IGBT module 34, an independent drive board 36, a centralized drive board 37 connected to the independent drive board 36, a stacked busbar 38 connecting the capacitor assembly 32 and the IGBT module 34, and a protective cover 39 covering the IGBT module 34. The IGBT module 34 includes three IGBTs; the three IGBTs, from left to right, are used to control the A / B / C phases of the AC power supply, and the installation spacing between the three IGBTs is the same. The stacked busbar 38 includes a positive busbar 381, an insulating layer 382, ​​and a negative busbar 383. The stacked busbar 38 has pre-set capacitor positive and negative interfaces and positive and negative IGBT interfaces. In this invention, the IGBT module 34 uses three IGBTs to control phases A, B, and C from left to right with equal spacing, ensuring uniform heat distribution across the three phases. Current sensors 35 connected to the IGBT module 34 monitor the current in each phase in real time. The centralized drive board 37 fine-tunes the switching signals of the independent drive boards 36 based on current feedback, achieving precise current sharing across the three phases, preventing IGBT overload, and extending the lifespan of core components. The laminated busbar 38 reduces stray inductance and minimizes interference during operation. A protective cover 39 covers the IGBT module 34, providing complete physical protection. The coverage enhances the reliability of module operation; the supporting capacitor assembly 32, heat dissipation unit 33, IGBT module 34, stacked busbar 38 and protective cover 39 are integrated on the mounting plate 31, increasing power density and saving installation space; in this invention, all components are assembled through standardized interfaces, and individual components can be replaced without disassembling the entire module during installation and maintenance. By increasing or decreasing the number of IGBTs in parallel and adjusting the number of supporting capacitors, it can adapt to a power range of 50~200KW without replacing the entire three-phase integrated power module 3, greatly improving equipment reusability and scenario adaptability.

[0042] Based on the above-described preferred embodiments of the present invention, and through the foregoing description, those skilled in the art can make various changes and modifications without departing from the scope of the present invention. The technical scope of this invention is not limited to the contents of the specification, but must be determined according to the scope of the claims.

Claims

1. A three-phase integrated power module, characterized in that, include: The system comprises a mounting plate, a supporting capacitor assembly fixed on the mounting plate, a heat dissipation unit, an IGBT module fixed on the heat dissipation unit, current sensors connected to the IGBT module, an independent drive board, a centralized drive board connected to the independent drive board, a stacked busbar connecting the supporting capacitor assembly and the IGBT module, and a protective cover covering the IGBT module. The IGBT module includes three IGBTs, which are used to control the A / B / C phases of the AC power supply from left to right, and the three IGBTs are installed at the same distance. The stacked busbar includes a positive busbar, an insulating layer, and a negative busbar, and the stacked busbar has pre-set positive and negative interfaces for capacitors and positive and negative interfaces for IGBTs.

2. The three-phase integrated power module according to claim 1, characterized in that, The supporting capacitor assembly includes a DC supporting capacitor and a capacitor fixing plate. The DC supporting capacitor is fixed to the capacitor fixing plate by a bottom screw. Multiple DC supporting capacitors are provided. The positive and negative terminals of the DC supporting capacitors are located at the top position and are respectively connected to the positive and negative DC terminals of the IGBT module through the stacked busbar.

3. The three-phase integrated power module according to claim 1, characterized in that, The heat dissipation unit includes a radiator, a frame guide rail disposed at the bottom inlet of the radiator, an air guide net slidably disposed on the frame guide rail, and a turning air guide component disposed at the top outlet of the radiator.

4. The three-phase integrated power module according to claim 1, characterized in that, The number of current sensors is the same as the number of IGBTs. The current sensors are installed on the power output lines of the IGBTs. The current sensors are communicatively connected to the signal input terminal of the centralized driver board, and the current sensors are DC powered by the centralized driver board.

5. The three-phase integrated power module according to claim 1, characterized in that, The input terminal of the independent drive board is communicatively connected to the output terminal of the centralized drive board. The output terminal of the independent drive board is connected to the signal pin of a single IGBT. The independent drive board is powered by the centralized drive board. The centralized drive board is positioned above the independent drive board. The centralized drive board is used to receive the current feedback signal from the current sensor and generate a synchronous drive signal to send to the independent drive board to ensure the phase accuracy of the three-phase AC power.

6. The three-phase integrated power module according to claim 2, characterized in that, The positive terminal of the capacitor on the positive busbar is connected to the positive terminal of the DC support capacitor, the negative terminal of the capacitor on the negative busbar is connected to the negative terminal of the DC support capacitor, the positive terminal of the IGBT on the positive busbar is connected to the positive power pin of the IGBT module, and the negative terminal of the IGBT on the negative busbar is connected to the negative power pin of the IGBT.

7. A three-port energy router, characterized in that, The three-port energy router includes the three-phase integrated power module as described in any one of claims 1 to 6.

8. The three-port energy router according to claim 7, characterized in that, The three-port energy router also includes a cabinet unit, a control module, a first grid-connected module, a second grid-connected module, a first filter module, and a second filter module, all located inside the cabinet unit. The three-phase integrated power module is also located inside the cabinet unit.

9. The three-port energy router according to claim 8, characterized in that, The control module is communicatively connected to the three-phase integrated power module, the first grid-connected module, and the second grid-connected module, respectively, and is used to collect the status of each module and send control commands to each module. The input terminal of the three-phase integrated power module is electrically connected to the output terminal of the first filter module, and receives electrical energy after being stabilized and filtered by the first filter module; The output terminal of the three-phase integrated power module is electrically connected to the input terminal of the second filter module, and the standardized electrical energy converted by the three-phase integrated power module is delivered to the second filter module for secondary optimization. The input terminal of the first grid-connected module is electrically connected to the output terminal of the external power grid or a low-load distribution area to receive the electrical energy to be processed. The output terminal of the first grid-connected module is electrically connected to the output terminal of the first filter module, so as to transmit electrical energy to the first filter module. The input terminal of the second grid-connected module is electrically connected to the output terminal of the second filter module, and receives electrical energy after it has been stabilized and harmonics filtered by the second filter module; The output of the second grid-connected module is electrically connected to high-load transformer areas and energy storage devices through various grid-connected interfaces to realize power distribution.

10. The three-port energy router according to claim 8, characterized in that, The first input terminal of the control module is communicatively connected to the three-phase integrated power module and is used to acquire a first feedback signal including IGBT current signal and temperature signal; the first output terminal of the control module is communicatively connected to the three-phase integrated power module and is used to send a first control signal including IGBT drive command and power adjustment command. The second input terminal of the control module is communicatively connected to the first grid-connected module and is used to acquire a second feedback signal including the grid-connected voltage or frequency signal of the first grid-connected module. The second output terminal of the control module is communicatively connected to the first grid-connected module and is used to send a second control signal including a grid-connected / off-grid switching command. The third input terminal of the control module is communicatively connected to the second grid-connected module and is used to obtain a third feedback signal including the grid-connected voltage or frequency signal of the second grid-connected module. The third output terminal of the control module is communicatively connected to the second grid-connected module and is used to send a third control signal including a grid-connected / off-grid switching command.

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