Electric heater system utilizing high-voltage bus magnetic field and using method thereof

Abstract

The invention belongs to the technical field of electric heaters, and relates to an electric heater system utilizing a high-voltage bus magnetic field and a using method of the electric heater system. Comprising a magnetic field coupling unit which sleeves the periphery of a high-voltage bus in a non-contact manner; the input end of the electromagnetic induction heating unit is connected with the output end of the magnetic field coupling unit; the electromagnetic induction heating unit is used for converting the alternating magnetic field energy gathered by the magnetic field coupling unit into direct-current electric energy and further converting the direct-current electric energy into heat energy; the heat exchange unit is thermally coupled with the heat output end of the electromagnetic induction heating unit; the heat exchange unit is used for diffusing heat energy generated by the electromagnetic induction heating unit into the environment; the mounting and fixing unit is used for fixedly sleeving the periphery of the high-voltage bus with the magnetic field coupling unit in a non-contact manner; and the control unit is respectively connected with the magnetic field coupling unit, the electromagnetic induction heating unit and the heat exchange unit. According to the invention, the inherent magnetic field energy of the high-voltage bus can be efficiently recycled, and non-contact and self-adaptive intelligent heating is realized.

Description

Technical Field

[0001] This invention belongs to the field of electric heater technology, and relates to an electric heater system that utilizes the magnetic field of a high-voltage bus and its usage method. Background Technology

[0002] Traditional electric heaters, such as resistive and film heaters, rely on an external power source to directly generate heat. This method not only generally consumes more energy, increasing heating costs, but also typically requires complex wiring. In specific industrial or professional settings such as high-voltage substations and power distribution rooms, the flexibility and convenience of their installation and deployment are significantly limited.

[0003] Existing technologies include so-called "magnetic field utilization" electric heaters, which aim to generate heat by utilizing the electromagnetic field energy around electrical equipment. However, these devices still have significant technical defects, resulting in poor overall performance and hindering practical application. Firstly, in terms of energy conversion mechanisms, existing technologies mostly employ active energization to generate a magnetic field, essentially failing to effectively utilize the naturally existing power frequency magnetic field around current-carrying conductors such as high-voltage busbars. Furthermore, existing devices generally lack the ability to dynamically adjust power based on real-time load current (i.e., magnetic field strength) or ambient temperature changes in the high-voltage busbar. This passive, fixed operating mode easily leads to "overheating waste" when the busbar current is low or the ambient temperature is high, while "insufficient heating" occurs when the current is high or the ambient temperature is low, resulting in low overall energy conversion efficiency. Secondly, existing devices suffer from severe lack of intelligence, lacking remote monitoring, data acquisition, and fault self-diagnosis functions. Their operating status and health condition heavily rely on regular manual inspections and maintenance, which not only results in delayed maintenance response but also significantly increases the overall cost of long-term use. Furthermore, the spatial magnetic field strength and distribution characteristics generated by busbars at different voltage levels (such as 110kV and 220kV) in power systems vary greatly. Existing technical solutions are usually designed with fixed parameters, making it difficult to adaptively match these differences. This leads to a sharp drop in energy capture and conversion efficiency when the application scenario changes, typically below 30%, making them impractical. In addition, there are serious shortcomings in safety design. Electromagnetic interference in high-voltage, strong electric field environments is not adequately considered. There is a lack of effective protection and early warning mechanisms for risks such as mechanical loosening due to long-term vibration of the equipment itself, or local overheating due to power mismatch. These risks pose potential hazards of electric shock that could cause equipment failure or even endanger the safety of inspection personnel. Summary of the Invention

[0004] To address the problems in existing technologies, this invention provides an electric heater system utilizing the magnetic field of a high-voltage busbar and its usage method. This system can efficiently recover and utilize the inherent magnetic field energy of the high-voltage busbar, achieving non-contact, adaptive intelligent heating. At the same time, through multiple safety designs and remote monitoring, it significantly improves operational safety and ease of maintenance in high-voltage environments.

[0005] To achieve the above objectives, the present invention employs the following technical solution: In a first aspect, the present invention provides an electric heater system utilizing the magnetic field of a high-voltage busbar, comprising: A magnetic field coupling unit is non-contactly sleeved on the outer periphery of the high-voltage busbar; the magnetic field coupling unit is used to concentrate the alternating magnetic field of the high-voltage busbar. An electromagnetic induction heating unit has its input end connected to the output end of the magnetic field coupling unit; the electromagnetic induction heating unit is used to convert the alternating magnetic field energy gathered by the magnetic field coupling unit into direct current electrical energy and further into heat energy; A heat exchange unit is thermally coupled to the heat output terminal of the electromagnetic induction heating unit; the heat exchange unit is used to diffuse the heat energy generated by the electromagnetic induction heating unit into the environment. The mounting and fixing unit is used to fix the magnetic field coupling unit to the outer periphery of the high voltage busbar in a non-contact manner. The control unit is connected to the magnetic field coupling unit, the electromagnetic induction heating unit, and the heat exchange unit, respectively.

[0006] Preferably, the magnetic field coupling unit includes a magnetic core, an adjustable magnetic gap assembly, and an electromagnetic shielding layer; The magnetic core is made of stacked silicon steel sheets and includes two C-shaped magnetic cores arranged opposite each other. The openings of the two C-shaped magnetic cores are arranged opposite each other to jointly enclose and form an inner cavity for accommodating the high-voltage busbar and to form a closed magnetic circuit. The adjustable magnetic gap assembly is disposed between the ends of the two C-shaped magnetic cores and is used to adjust their relative distance to change the magnetic gap width. The electromagnetic shielding layer covers the outside of the magnetic core.

[0007] Preferably, the electromagnetic induction heating unit includes an induction coil, a rectifier filter module, a heating element, and a power regulation module; The induction coil is wound on the magnetic core; The input terminal of the rectifier and filter module is connected to the output terminal of the induction coil; The heating element is electrically connected to the output terminal of the rectifier and filter module through the power regulation module.

[0008] Preferably, the heat exchange unit includes a heat dissipation substrate and a fan system; The back side of the heat dissipation substrate is attached to and fixedly connected to the heat-generating element, and a thermally conductive medium is filled between the two; the front side of the heat dissipation substrate is provided with a fin structure. The fan system includes at least one fan, the fan's airflow direction being toward the fin structure of the heat dissipation substrate.

[0009] Preferably, the mounting and fixing unit includes: An insulating bracket, the first end of which is fixedly connected to the magnetic field coupling unit, is used to support the magnetic field coupling unit; A clamp, connected to the second end of the insulating bracket, is used to surround and lock the high-voltage busbar so that the magnetic field coupling unit is fixedly sleeved on the outer periphery of the high-voltage busbar.

[0010] Preferably, the mounting and fixing unit further includes a safety interlock device and a grounding terminal; The safety interlock device includes a limit switch disposed between the magnetic core and the clamp in the magnetic field coupling unit. When the distance between the magnetic core and the high-voltage busbar is less than a preset safety distance, the limit switch is triggered and an alarm signal is output to the control unit. The grounding terminal is disposed on the insulating bracket and connected to the grounding grid.

[0011] Preferably, the control unit includes a sensor module and a controller; The sensor module is used to collect system operating parameters, including: A magnetic field sensor is installed at the opening of the magnetic core of the magnetic field coupling unit to measure the magnetic field strength around the high-voltage busbar. A temperature sensor is disposed inside the heating element of the electromagnetic induction heating unit and on the surface of the heat dissipation substrate of the heat exchange unit. A current sensor is non-contactly fitted onto the high-voltage busbar to monitor the current of the high-voltage busbar. The controller is electrically connected to the sensor module, the electromagnetic induction heating unit, and the heat exchange unit, respectively, and is used to control the output power of the electromagnetic induction heating unit and the heat dissipation intensity of the heat exchange unit according to the parameters collected by the sensor module.

[0012] Preferably, the control unit further includes a communication module, which is electrically connected to the controller; the communication module is used to upload the system operating parameters collected by the sensor module and the operating status and fault information generated by the controller to the cloud server, and to receive control commands and parameter settings from the user terminal via the cloud server.

[0013] Secondly, the present invention provides a method for using an electric heater system utilizing the magnetic field of a high-voltage busbar, comprising the following steps: The magnetic field coupling unit is fixedly sleeved onto the outer periphery of the high-voltage busbar in a non-contact manner by the installation and fixing unit, while maintaining a preset safe distance. The alternating magnetic field generated by the alternating current of the high-voltage bus is concentrated by the magnetic field coupling unit. The electromagnetic induction heating unit converts the concentrated alternating magnetic field energy into DC power and further converts the DC power into heat energy. The control unit controls the output power of the electromagnetic induction heating unit and the heat dissipation intensity of the heat exchange unit based on the collected system operating parameters. The heat exchange unit diffuses the heat generated by the electromagnetic induction heating unit to the surrounding environment.

[0014] Preferably, the control unit controls the output power of the electromagnetic induction heating unit and the heat dissipation intensity of the heat exchange unit based on the collected system operating parameters, including: The current of the high-voltage bus or the magnetic field strength generated by the current, as well as the temperature of the electromagnetic induction heating unit, are collected in real time. Based on the collected bus current or magnetic field strength, by querying the preset mapping relationship, a first power control command is determined and sent to the electromagnetic induction heating unit to adjust its basic output power. Based on the difference between the preset target temperature and the collected temperature, a second power control command is generated through a closed-loop control algorithm and sent to the electromagnetic induction heating unit to fine-tune the basic output power so that the actual temperature approaches the target temperature. The fan speed of the heat exchange unit is controlled based on the collected temperature to adjust the heat dissipation intensity.

[0015] Compared with the prior art, the present invention has the following beneficial effects: The non-contact magnetic field coupling unit directly captures alternating magnetic field energy from the high-voltage bus, avoiding safety risks associated with electrical connections at the source. The electromagnetic induction heating unit efficiently converts magnetic field energy into directly usable heat energy, achieving directional energy recovery and utilization. The heat exchange unit ensures rapid and uniform heat diffusion, improving heating efficiency. The installation and fixing unit provides mechanical protection for the stable and safe installation of the entire system in a high-voltage environment. The control unit connects and coordinates the work of each unit, giving the system real-time sensing, intelligent adjustment, and remote control capabilities. Attached Figure Description

[0016] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of the present invention and should not be regarded as a limitation on the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0017] Figure 1 This is a schematic diagram of an electric heater system utilizing the magnetic field of a high-voltage busbar according to the present invention.

[0018] The components include: 1. High-voltage busbar; 2. Magnetic field coupling unit; 3. Electromagnetic induction heating unit; and 4. Heat exchange unit. Detailed Implementation

[0019] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The components of the embodiments of the present invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0020] Therefore, the following detailed description of the embodiments of the invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the invention without inventive effort are within the scope of protection of the invention.

[0021] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0022] In the description of the embodiments of the present invention, it should be noted that if terms such as "upper," "lower," "horizontal," or "inner" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship commonly used when the product of the invention is 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, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the present invention. Furthermore, terms such as "first" and "second" are only used to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0023] Furthermore, the use of the term "horizontal" does not imply that the component must be absolutely horizontal, but rather that it can be slightly tilted. For example, "horizontal" simply means that its direction is more horizontal than "vertical," and does not mean that the structure must be completely horizontal, but can be slightly tilted.

[0024] In the description of the embodiments of the present invention, it should also be noted that, unless otherwise explicitly specified and limited, the terms "set," "install," "connect," and "link" 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; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in the present invention according to the specific circumstances.

[0025] The present invention will now be described in further detail with reference to the accompanying drawings: The first objective of this invention is to provide an electric heater system that utilizes the magnetic field of a high-voltage bus, such as... Figure 1 As shown, it includes: The magnetic field coupling unit 2 is non-contactly sleeved on the outer periphery of the high-voltage bus 1; the magnetic field coupling unit 2 is used to concentrate the alternating magnetic field of the high-voltage bus 1; The electromagnetic induction heating unit 3 has its input end connected to the output end of the magnetic field coupling unit 2; the electromagnetic induction heating unit 3 is used to convert the alternating magnetic field energy gathered by the magnetic field coupling unit 2 into DC electrical energy and further into heat energy. The heat exchange unit 4 is thermally coupled to the heat output terminal of the electromagnetic induction heating unit 3; the heat exchange unit 4 is used to diffuse the heat energy generated by the electromagnetic induction heating unit 3 into the environment. The mounting and fixing unit is used to fix the magnetic field coupling unit 2 to the outer periphery of the high voltage busbar 1 in a non-contact manner. The control unit is connected to the magnetic field coupling unit 2, the electromagnetic induction heating unit 3, and the heat exchange unit 4, respectively.

[0026] The magnetic field coupling unit 2 is the energy harvesting front end of the system. It employs a non-contact structure surrounding the high-voltage busbar 1, and its main function is to directionally concentrate the alternating magnetic field generated by the busbar current, providing a stable and enhanced magnetic flux for subsequent energy conversion. The electromagnetic induction heating unit 3, as the core of energy conversion, is responsible for first converting the magnetic field energy transmitted by the magnetic field coupling unit 2 into alternating current, then rectifying it into direct current, and finally driving the internal heating element to efficiently convert it into directly usable heat energy. The heat exchange unit 4 is responsible for heat management and dissipation. Through a tight thermal connection with the heating unit, it rapidly and evenly diffuses the generated heat energy to the target environment, ensuring stable and comfortable heating. The installation and fixing unit is the physical guarantee for the safe and reliable operation of the system under high-voltage conditions. It must ensure that the magnetic field coupling unit 2 and the high-voltage busbar 1 always maintain a preset, safe insulation distance, and provide stable mechanical support for the entire device. The control unit monitors various parameters such as magnetic field strength, temperature, and current in real time, and adjusts the working status of each unit accordingly, such as controlling the output power and heat dissipation intensity, so as to achieve adaptive operation, optimal energy efficiency management, and fault warning and protection under changing operating conditions.

[0027] For example, the magnetic field coupling unit 2 includes a magnetic core, an adjustable magnetic gap assembly, and an electromagnetic shielding layer. The magnetic core is made of laminated silicon steel sheets, using 35WW230 grade silicon steel sheets with a thickness of 0.2~0.5mm and a stack thickness of 100~150mm, forming a double C-shaped closed magnetic circuit structure. The magnetic core includes two C-shaped magnetic core bodies arranged opposite each other, with the openings of the two C-shaped magnetic core bodies facing each other, together enclosing an inner cavity for accommodating the high-voltage busbar 1, thus forming a closed magnetic circuit. The inner diameter of the magnetic core is 5~30mm larger than the outer diameter of the high-voltage busbar 1, which can directionally concentrate the 50Hz alternating magnetic field of the busbar. The adjustable magnetic gap assembly is located between the ends of the two C-shaped magnetic core bodies, including a non-magnetic stainless steel sliding adjustment block with an insulating varnish coating. The magnetic gap width is adjusted within the range of 0.5~2mm by a stepper motor-controlled screw to adapt to the strong magnetic field distribution of 110kV and above busbars under high currents of 1000-3000A. The electromagnetic shielding layer covers the outside of the magnetic core and adopts a composite structure of copper foil and ferrite absorbing material. The copper foil is 0.1mm thick and the ferrite absorbing material is 2mm thick. It can isolate high voltage electric field interference and absorb external stray magnetic field noise, and withstand voltage of over 110kV.

[0028] For example, the electromagnetic induction heating unit 3 includes an induction coil, a rectifier and filter module, a heating element, and a power adjustment module. The induction coil is wound on a magnetic core, using multi-strand enameled copper wire with a cross-sectional area of ​​4-6 mm², a temperature resistance of 180℃, and 200-1000 turns. The number of turns is adjustable to four levels: 200 turns, 400 turns, 600 turns, and 1000 turns, through a tap switching module. The input terminal of the rectifier and filter module is connected to the output terminal of the induction coil. It uses a KBPC5010 bridge rectifier in conjunction with a π-type filter circuit. The filter circuit includes a 1000μF / 100V capacitor and a 10mH inductor, outputting a DC voltage of 24-48V. The heating element is electrically connected to the output of the rectifier and filter module via the power regulation module. It employs a modular PTC ceramic heating element, with a single module power of 750W, a Curie temperature of 80-120℃, and a withstand voltage of AC5000V. 1-4 modules can be connected in parallel to achieve a flexible configuration with a total power of 750-3000W. It incorporates a built-in PT100 platinum resistance temperature sensor with a temperature measurement accuracy of ±0.5℃. The power regulation module, based on the IRGP4068DPBF type IGBT and PWM technology, allows for stepless adjustment of the heating element's input voltage within the 0-100% range by adjusting the duty cycle, with an adjustment accuracy of ±0.5V.

[0029] For example, the heat exchange unit 4 includes a heat dissipation substrate and a fan system; The back side of the heat dissipation substrate is attached to and fixedly connected to the heat-generating element, and a thermally conductive medium is filled between the two; the front side of the heat dissipation substrate is provided with a fin structure. The fan system includes at least one fan, the fan's airflow direction being toward the fin structure of the heat dissipation substrate.

[0030] The heat dissipation substrate is made of 6063-T5 aluminum alloy, with a thickness of 5-8mm and an area of ​​400×400mm to 600×600mm. The back of the heat dissipation substrate is attached and fixedly connected to the heat-generating element, with graphene thermal grease filling the space between them as a thermal conductive medium. The thermal conductivity is greater than 12W / (m²). The heat sink has a thickness of 0.1 mm and a thermal resistance of less than 0.03℃ / W. The front side of the heat sink features a finned structure, machined into a wave-shaped fin shape, with a height of 25~35 mm and a spacing of 12~18 mm, increasing the heat dissipation area by 50% compared to a flat substrate. The fan system includes at least one fan, using a DC brushless axial fan with a power of 10~20W and an airflow of 30~60 m³ / h. 3 / h, the fan's airflow direction is towards the fin structure of the heat sink substrate. The fan system also includes a PWM speed control module, which allows the fan speed to be adjusted within the range of 500~3000rpm. The fan speed is linked to the substrate temperature, operating at full speed when the temperature exceeds 80℃ and at low speed when the temperature is below 50℃.

[0031] For example, the mounting and fixing unit includes: An insulating bracket, the first end of which is fixedly connected to the magnetic field coupling unit 2, is used to support the magnetic field coupling unit 2. A clamp, connected to the second end of the insulating bracket, is used to surround and lock the high-voltage busbar 1 so that the magnetic field coupling unit 2 is fixedly sleeved on the outer periphery of the high-voltage busbar 1.

[0032] The insulating bracket is made of glass fiber reinforced plastic with a tensile strength greater than 350MPa. Its length can be adjusted within the range of 500~2000mm with an adjustment accuracy of 10mm. The inner side of the clamp is padded with a fluororubber insulation layer with a thickness of 8~12mm and a withstand voltage of AC220kV.

[0033] For example, the mounting and fixing unit further includes a safety interlock device and a grounding terminal; The safety interlock device includes a limit switch located between the magnetic core and the clamp in the magnetic field coupling unit 2, with a travel of 5 mm. When the distance between the magnetic core and the high-voltage busbar 1 is less than 15 mm or a preset safety distance, the limit switch is triggered and outputs an alarm signal to the control unit, while simultaneously cutting off the power supply. The clamp has a built-in MPX5700AP pressure sensor with a range of 0~700 kPa and a monitoring clamping force set threshold of 80~120 N. m, automatically locking or releasing the lead screw driven by a micro motor. The grounding terminal is set on an insulating bracket, using yellow-green bicolor wire with a cross-sectional area of ​​10mm², and is connected to the substation grounding grid with a grounding resistance of less than 4Ω.

[0034] For example, the control unit includes a sensor module and a controller; The sensor module is used to collect system operating parameters, including a magnetic field sensor, a temperature sensor, and a current sensor. Specifically, the magnetic field sensor is an ACS712ELCTR-50A Hall effect sensor with a range of 0-50mT and an accuracy of ±1%. It is installed at the core opening of the magnetic field coupling unit 2 to measure the magnetic field strength around the high-voltage busbar 1. The temperature sensor is a PT100 platinum resistance thermometer with a temperature range of -50~200℃. Three sensors are arranged, located inside the heating element of the electromagnetic induction heating unit 3, on the surface of the heat dissipation substrate of the heat exchange unit 4, and at the ambient temperature monitoring point. The current sensor is a CSM020A closed-loop Hall current transformer with a range of 0~3000A and an accuracy of ±0.5%. It is non-contactly mounted on the high-voltage busbar 1 to monitor the current of the high-voltage busbar 1. The sensor module also includes an ADXL345 vibration sensor to monitor device loosening, an MQ-2 smoke sensor to monitor electrical faults, and an SHT31 tilt sensor to monitor bracket tilting. The controller is electrically connected to the sensor module, electromagnetic induction heating unit 3, and heat exchange unit 4, respectively. It uses an STM32F407ZGT6 ARM Cortex-M4 core MCU with a main frequency of 168MHz, integrating a 12-bit ADC and PWM generator. Based on the parameters collected by the sensor module, it controls the output power of the electromagnetic induction heating unit 3 and the heat dissipation intensity of the heat exchange unit 4. The controller incorporates a magnetic field-power mapping algorithm, establishing a current-magnetic field-power correspondence based on 110kV bus experimental data. It employs a temperature closed-loop PID control algorithm with a sampling period of 1s and uses a fault diagnosis algorithm to determine fault states such as over-temperature, short circuit, and looseness.

[0035] For example, the control unit further includes a communication module electrically connected to the controller. The communication module includes a CC2541 Bluetooth 5.0 module connected to a 3.5-inch LCD touchscreen, and an EC200S-CN 4G Cat.1 module. These modules are used to upload system operating parameters collected by the sensor module and operating status and fault information generated by the controller to a cloud server, and to receive control commands and parameter settings from the user terminal via the cloud server. The communication module transmits data with the Alibaba Cloud IoT platform using the MQTT protocol and AES-128 encryption, supporting functions such as remote monitoring via mobile APP and Web, fault push notifications, and historical data queries.

[0036] The second objective of this invention is to provide a method for using an electric heater system that utilizes the magnetic field of a high-voltage busbar, comprising the following steps: The magnetic field coupling unit 2 is fixedly sleeved onto the outer periphery of the high-voltage busbar 1 in a non-contact manner by the installation and fixing unit, while maintaining a preset safe distance; The alternating magnetic field generated by the alternating current of the high-voltage bus 1 is concentrated by the magnetic field coupling unit 2, and the electromagnetic induction heating unit 3 converts the concentrated alternating magnetic field energy into DC power, and further converts the DC power into heat energy. The control unit controls the output power of the electromagnetic induction heating unit 3 and the heat dissipation intensity of the heat exchange unit 4 based on the collected system operating parameters. The heat exchange unit 4 diffuses the heat generated by the electromagnetic induction heating unit 3 to the surrounding environment.

[0037] This method fully utilizes the inherent electromagnetic field energy of high-voltage busbar 1 to achieve clean heating. Firstly, it achieves efficient energy recovery and utilization, converting the magnetic field energy dissipated in the environment into directly usable heat energy, directly extracting energy from the source without consuming additional grid power, resulting in significant energy savings. Secondly, through closed-loop control of the control unit, the system can automatically and accurately match output power and heat dissipation intensity according to real-time fluctuations in busbar load and target heating needs, ensuring stable and comfortable heating and achieving intelligent on-demand heating. Simultaneously, the non-contact energy acquisition process and rigorous safety design fundamentally eliminate the risk of high-voltage electric shock. Combined with multi-state monitoring and interlocking protection, it greatly improves the reliability and safety of long-term operation in complex high-voltage environments.

[0038] The control unit controls the output power of the electromagnetic induction heating unit 3 and the heat dissipation intensity of the heat exchange unit 4 based on the collected system operating parameters, including: The current of the high-voltage bus 1 or the magnetic field strength generated by the current, as well as the temperature of the electromagnetic induction heating unit 3, are collected in real time. Based on the collected bus current or magnetic field strength, by querying the preset mapping relationship, a first power control command is determined and sent to the electromagnetic induction heating unit 3 to adjust its basic output power. Based on the difference between the preset target temperature and the collected temperature, a second power control command is generated through a closed-loop control algorithm and sent to the electromagnetic induction heating unit 3 to fine-tune the basic output power so that the actual temperature approaches the target temperature. The fan speed of the heat exchange unit 4 is controlled according to the collected temperature to adjust the heat dissipation intensity.

[0039] This method enables the system to respond quickly to load changes by real-time monitoring of bus current or magnetic field strength and performing first-stage power regulation based on a preset mapping relationship. Secondly, a second-stage closed-loop fine-tuning based on the difference between the target temperature and the actual temperature is introduced, achieving refined and adaptive control of the output heat energy. This effectively overcomes temperature deviations caused by fluctuations in external environment or internal parameters, ensuring accurate and constant heating temperature. Finally, the temperature signal is synchronously linked to the fan speed control of heat exchange unit 4, achieving dynamic matching and optimization of heat generation and dissipation intensity. This avoids the risk of equipment overheating due to heat accumulation and improves overall heat exchange efficiency and energy utilization quality.

[0040] Example This embodiment provides a method for using an electric heater system that utilizes the magnetic field of a high-voltage busbar, including: S1. The magnetic field coupling unit 2 is fixedly mounted on the outer periphery of the high-voltage busbar 1 in a non-contact manner using the installation fixing unit, maintaining a preset safe distance. Specifically, the first end of the insulating bracket is fixedly connected to the magnetic field coupling unit 2. Then, the high-voltage busbar 1 is surrounded and locked with clamps, ensuring a safe distance of at least 15mm between the magnetic field coupling unit 2 and the high-voltage busbar 1. During installation, the limit switch in the safety interlock device continuously monitors the distance between the magnetic core and the busbar. When the distance is less than the preset safe distance, an alarm is automatically triggered and the power is cut off to ensure installation safety.

[0041] The alternating magnetic field generated by the alternating current of high-voltage bus 1 (S2) is concentrated by magnetic field coupling unit 2. Electromagnetic induction heating unit 3 converts the concentrated alternating magnetic field energy into DC electrical energy, and further converts the DC electrical energy into heat energy. During this process, the double-C-type closed magnetic circuit structure in magnetic field coupling unit 2 effectively concentrates the 50Hz alternating magnetic field. The induction coil generates an induced electromotive force under the action of the magnetic field, which is converted into a 24-48V DC voltage by a rectifier and filter module, and finally converted into heat energy by a PTC ceramic heating element. The adjustable magnetic gap component automatically adjusts the magnetic gap width according to the bus current magnitude to optimize the magnetic field concentration effect.

[0042] S3. The control unit controls the output power of the electromagnetic induction heating unit 3 and the heat dissipation intensity of the heat exchange unit 4 based on the collected system operating parameters, including: S31. The sensor module collects the current of the high-voltage bus 1 or the magnetic field strength generated by the current, as well as the temperature of the electromagnetic induction heating unit 3 in real time. The magnetic field sensor measures the magnetic field strength around the bus, the current sensor monitors the bus current, and the temperature sensor collects the internal temperature of the heating element, the surface temperature of the heat dissipation substrate, and the ambient temperature.

[0043] S32. Based on the collected bus current or magnetic field strength, the controller determines and sends a first power control command to the electromagnetic induction heating unit 3 by querying a preset mapping relationship, in order to adjust its basic output power. This mapping relationship is established based on 110kV bus experimental data. When the bus current is 1500A, the corresponding magnetic field strength is 1.2mT, and the system's basic output power is set to 2000W; when the bus current is 2500A, the corresponding magnetic field strength is 2.0mT, and the basic output power is adjusted to 2800W.

[0044] S33. Based on the difference between the preset target temperature and the collected temperature, the controller generates a second power control command through a closed-loop control algorithm and sends it to the electromagnetic induction heating unit 3 to fine-tune the basic output power, so that the actual temperature approaches the target temperature. This closed-loop control uses a PID algorithm with a sampling period of 1 second, a proportional coefficient Kp=3.0, an integral coefficient Ki=0.4, and a derivative coefficient Kd=0.2. Precise power control is achieved by adjusting the PWM duty cycle.

[0045] S34. The controller controls the fan speed of heat exchange unit 4 based on the collected temperature to adjust the heat dissipation intensity. When the temperature of the heat sink exceeds 80°C, the fan system runs at full speed up to 3000 rpm; when the temperature is below 50°C, the fan runs at a low speed of 500 rpm to achieve energy-saving operation.

[0046] S4 and heat exchange unit 4 diffuse the heat generated by electromagnetic induction heating unit 3 to the surrounding environment. The heat dissipation substrate is tightly bonded to the heating element with graphene thermal grease, with a thermal resistance of less than 0.03℃ / W, ensuring efficient heat conduction. The corrugated heat dissipation fins increase the heat dissipation area by 50%, and together with the forced convection of the intelligent fan system, the heat is quickly diffused into the environment, achieving uniform heating.

[0047] Furthermore, throughout the entire usage process, the control unit continuously monitors the system's operating status and identifies abnormalities such as overheating, short circuits, and loosening through fault diagnosis algorithms. When a sudden temperature rise exceeding 10°C / minute, a sudden current change exceeding 20%, or a vibration acceleration exceeding 5g is detected, the system automatically triggers an audible and visual alarm and uploads fault information to the cloud server. Users can remotely monitor, set parameters, and query faults via a mobile app or web interface, and it supports customized heating strategies such as peak-valley electricity pricing.

[0048] This embodiment achieves efficient utilization of the magnetic field energy of high-voltage busbar 1, with an energy conversion efficiency exceeding 55%, saving more than 75% energy compared to traditional electric heaters. Through multiple safety protections and intelligent control, it ensures the safe and reliable operation of the system in high-voltage busbar 1 environments ranging from 110kV to 750kV, providing a clean and energy-saving heating solution for high-voltage facilities such as substations.

[0049] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. An electric heater system utilizing the magnetic field of a high-voltage busbar, characterized in that, include: A magnetic field coupling unit (2) is non-contactly sleeved on the outer periphery of the high-voltage busbar (1); the magnetic field coupling unit (2) is used to concentrate the alternating magnetic field of the high-voltage busbar (1); The electromagnetic induction heating unit (3) has its input end connected to the output end of the magnetic field coupling unit (2); the electromagnetic induction heating unit (3) is used to convert the alternating magnetic field energy gathered by the magnetic field coupling unit (2) into DC electrical energy and further into heat energy; The heat exchange unit (4) is thermally coupled to the heat output terminal of the electromagnetic induction heating unit (3); the heat exchange unit (4) is used to diffuse the heat energy generated by the electromagnetic induction heating unit (3) into the environment; The mounting and fixing unit is used to fix the magnetic field coupling unit (2) to the outer periphery of the high voltage bus (1) in a non-contact manner; The control unit is connected to the magnetic field coupling unit (2), the electromagnetic induction heating unit (3) and the heat exchange unit (4), respectively.

2. The electric heater system utilizing the magnetic field of a high-voltage busbar according to claim 1, characterized in that, The magnetic field coupling unit (2) includes a magnetic core, an adjustable magnetic gap assembly, and an electromagnetic shielding layer; The magnetic core is made of stacked silicon steel sheets and includes two C-shaped magnetic cores arranged opposite each other. The openings of the two C-shaped magnetic cores are arranged opposite each other to jointly enclose and form an inner cavity for accommodating the high voltage bus (1) and constitute a closed magnetic circuit. The adjustable magnetic gap assembly is disposed between the ends of the two C-shaped magnetic cores and is used to adjust their relative distance to change the magnetic gap width. The electromagnetic shielding layer covers the outside of the magnetic core.

3. The electric heater system utilizing the magnetic field of a high-voltage busbar according to claim 2, characterized in that, The electromagnetic induction heating unit (3) includes an induction coil, a rectifier filter module, a heating element, and a power adjustment module; The induction coil is wound on the magnetic core; The input terminal of the rectifier and filter module is connected to the output terminal of the induction coil; The heating element is electrically connected to the output terminal of the rectifier and filter module through the power regulation module.

4. The electric heater system utilizing the magnetic field of a high-voltage busbar according to claim 3, characterized in that, The heat exchange unit (4) includes a heat dissipation substrate and a fan system; The back side of the heat dissipation substrate is attached to and fixedly connected to the heat-generating element, and a thermally conductive medium is filled between the two; the front side of the heat dissipation substrate is provided with a fin structure. The fan system includes at least one fan, the fan's airflow direction being toward the fin structure of the heat dissipation substrate.

5. An electric heater system utilizing the magnetic field of a high-voltage busbar according to claim 2, characterized in that, The mounting and fixing unit includes: An insulating bracket, the first end of which is fixedly connected to the magnetic field coupling unit (2), is used to support the magnetic field coupling unit (2). The clamp is connected to the second end of the insulating bracket and is used to surround and lock the high voltage busbar (1) so that the magnetic field coupling unit (2) is fixedly sleeved on the outer periphery of the high voltage busbar (1).

6. An electric heater system utilizing the magnetic field of a high-voltage busbar according to claim 5, characterized in that, The mounting and fixing unit also includes a safety interlock device and a grounding terminal; The safety interlock device includes a limit switch between the magnetic core and the clamp in the magnetic field coupling unit (2). When the distance between the magnetic core and the high voltage bus (1) is less than the preset safety distance, the limit switch is triggered and an alarm signal is output to the control unit. The grounding terminal is disposed on the insulating bracket and connected to the grounding grid.

7. An electric heater system utilizing the magnetic field of a high-voltage busbar according to claim 2, characterized in that, The control unit includes a sensor module and a controller; The sensor module is used to collect system operating parameters, including: A magnetic field sensor is installed at the opening of the magnetic core of the magnetic field coupling unit (2) to measure the magnetic field strength around the high voltage bus (1); Temperature sensors are arranged inside the heating element of the electromagnetic induction heating unit (3) and on the surface of the heat dissipation substrate of the heat exchange unit (4). A current sensor is non-contactly fitted onto the high-voltage busbar (1) to monitor the current of the high-voltage busbar (1); The controller is electrically connected to the sensor module, the electromagnetic induction heating unit (3) and the heat exchange unit (4) respectively, and is used to control the output power of the electromagnetic induction heating unit (3) and the heat dissipation intensity of the heat exchange unit (4) according to the parameters collected by the sensor module.

8. An electric heater system utilizing the magnetic field of a high-voltage busbar according to claim 7, characterized in that, The control unit further includes a communication module, which is electrically connected to the controller. The communication module is used to upload the system operating parameters collected by the sensor module and the operating status and fault information generated by the controller to the cloud server, and to receive control commands and parameter settings from the user terminal via the cloud server.

9. A method of using an electric heater system utilizing a high-voltage bus magnetic field according to any one of claims 1 to 8, characterized in that, Includes the following steps: The magnetic field coupling unit (2) is fixedly sleeved on the outer periphery of the high voltage busbar (1) in a non-contact manner through the installation and fixing unit, while maintaining a preset safe distance; The alternating magnetic field generated by the alternating current of the high-voltage bus (1) is gathered by the magnetic field coupling unit (2), and the electromagnetic induction heating unit (3) converts the gathered alternating magnetic field energy into DC power, and further converts the DC power into heat energy. The control unit controls the output power of the electromagnetic induction heating unit (3) and the heat dissipation intensity of the heat exchange unit (4) based on the collected system operating parameters. The heat exchange unit (4) diffuses the heat generated by the electromagnetic induction heating unit (3) to the surrounding environment.

10. A method of using an electric heater system utilizing a high-voltage bus magnetic field according to claim 9, characterized in that, The control unit controls the output power of the electromagnetic induction heating unit (3) and the heat dissipation intensity of the heat exchange unit (4) based on the collected system operating parameters, including: Real-time acquisition of the current of the high-voltage bus (1) or the magnetic field strength generated by the current, as well as the temperature of the electromagnetic induction heating unit (3); Based on the collected bus current or magnetic field strength, by querying the preset mapping relationship, a first power control command is determined and sent to the electromagnetic induction heating unit (3) to adjust its basic output power; Based on the difference between the preset target temperature and the collected temperature, a second power control command is generated by a closed-loop control algorithm and sent to the electromagnetic induction heating unit (3) to fine-tune the basic output power so that the actual temperature approaches the target temperature. The fan speed of the heat exchange unit (4) is controlled according to the collected temperature to adjust the heat dissipation intensity.

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