Energy storage converter

Abstract

The invention discloses an energy storage converter which comprises a box body and two energy storage converter units, a protection cavity is formed in the box body, and a liquid cooling plate extending in the Y-axis direction is arranged in the protection cavity; the two energy storage converter units are arranged in the protection cavity in the Y-axis direction. Each energy storage conversion unit comprises a power module and an inversion inductance module which are attached to the liquid cooling plate, a bus capacitor module arranged above the power module and an alternating current filtering module arranged above the inversion inductance module; each power module is connected with the corresponding bus capacitor module and inversion inductor module; the wiring terminals of the AC filtering module and the inversion inductance module are close to each other along the Y-axis direction, are close to the second side of the box body along the X-axis direction, and are connected through a copper bar. According to the invention, when the energy storage converter has high power, the flat installation of the inversion inductor can be ensured, the maintenance cost is reduced, and the convenient wiring operation can be realized.

Description

TECHNICAL FIELD

[0001] The present application relates to the electrical technical field, in particular to a kind of energy storage converter. BACKGROUND

[0002] Energy storage converter unit includes bus capacitor module, power module, inverter inductance module, AC filter module etc., wherein, power module and inverter inductance module heat quantity is larger, in order to improve the heat dissipation efficiency of energy storage converter unit in prior art, power module and inverter inductance module are usually attached to liquid cooling plate and dissipate heat, when the power of energy storage converter unit needs to be increased, the volume of inverter inductance module is also increased accordingly, because in electronic circuit, the inductance of larger power usually cannot be replaced by multiple small inductances in series simply, and the problems such as efficiency decline, overheating risk, high frequency instability will be caused by replacing large power inductance with small inductances in series, so it is usually not feasible, therefore when the power of energy storage converter unit is increased, only large volume and large power inductance can be used, this design not only puts forward high positioning requirement to the installation process of heavy components such as inverter inductance module, increases the installation difficulty;At the same time, the processing technology of large size component is complex, it is difficult to guarantee the flatness of its key installation base surface (such as the contact surface of liquid cooling plate), thereby affecting the uniform coating of heat conducting medium (such as heat conducting silicone grease) and the final heat dissipation performance.In addition, once any part of such large integrated module fails, it often needs to be replaced as a whole, resulting in high maintenance cost. SUMMARY

[0003] The present application aims to overcome the above-mentioned defects or problems in the background art, and to provide an energy storage converter that can ensure the flat installation of inverter inductance when the energy storage converter has high power, and can also realize convenient wiring operation.

[0004] To achieve the above-mentioned purpose, the present application and its preferred embodiments adopt the following technical solutions, but the embodiments are not limited to the following solutions: The first technical scheme and its preferred embodiments relate to an energy storage converter, which comprises a box body forming a protection cavity, the protection cavity is provided with a liquid cooling plate extending along the Y-axis direction;Two energy storage converter units are arranged in the protection cavity along the Y-axis direction;Each energy storage converter unit comprises a power module and an inverter inductance module attached to the liquid cooling plate, a bus capacitor module arranged above the power module, and an AC filter module arranged above the inverter inductance module;Each power module is connected with the corresponding bus capacitor module and inverter inductance module;The wiring terminals of the AC filter module and the wiring terminals of the inverter inductance module are close to each other along the Y-axis direction and close to the second side of the X-axis direction of the box body, and they are connected by a copper bar.

[0005] Based on technical solution one, technical solution two is also provided, and in the preferred embodiment of technical solution two, an output terminal is further included, the first side wall is arranged on the front side of the box body along the Y-axis direction, and the output terminal is embedded in the first side wall; the AC filter module close to the first side wall along the Y-axis direction is defined as the first AC filter module, and the AC filter module away from the first side wall along the Y-axis direction is defined as the second AC filter module; the support member is arranged below the first AC filter module, the support member is provided with a through channel extending along the Y-axis direction and penetrating through; the second AC filter module is connected with the output terminal through the first copper bar, the first copper bar penetrates through the through channel and is supported on the support member, and the support member is also adapted to shield the electromagnetic interference of the first copper bar.

[0006] Based on technical solution two, technical solution three is also provided, and in the preferred embodiment of technical solution three, the support member includes a support body and a plurality of support columns arranged at intervals along the Y-axis direction and fixed to the support body, and the support body forms the through channel; the support columns are made of insulating material, and are fixed to the support body and the first copper bar to arrange the first copper bar at intervals from the channel wall of the through channel.

[0007] Based on technical solution three, technical solution four is also provided, and in the preferred embodiment of technical solution four, the part of the first copper bar located in the through channel is covered with an insulating layer.

[0008] Based on technical solution three, technical solution five is also provided, and in the preferred embodiment of technical solution five, the number of the first copper bars is three, each first copper bar is arranged at intervals along the X-axis direction, each support column forms a column of support columns, and each column of support columns includes a plurality of support columns arranged at intervals along the Y-axis direction; a plurality of insulating partitions are further arranged in the support member, the insulating partitions are located between adjacent support columns along the X-axis direction; and a heat dissipation hole is arranged on the channel wall of at least one side of the through channel along the X-axis direction.

[0009] Based on technical solution one, technical solution six is also provided, and in the preferred embodiment of technical solution six, an input terminal and an output terminal are further included, the first side wall is arranged on the front side of the box body along the Y-axis direction, and the input terminal and the output terminal are embedded in the first side wall; the bus capacitor module and the AC filter module of each energy storage converter unit are fixed to the same support plate; the second side wall and the third side wall are arranged on the first side and the second side of the box body along the X-axis direction, respectively, at least two connecting frames are protrudingly arranged on the second side wall and the third side wall, and the support plate is detachably fixed to each connecting frame.

[0010] Based on the sixth technical solution, the seventh technical solution is further provided, and in the seventh technical solution and the preferred embodiments thereof, the box body comprises a liquid cooling plate, a frame and a top plate, the frame is open at both ends along the Z-axis direction, and the liquid cooling plate and the top plate are respectively arranged on the openings at both ends of the frame along the Z-axis direction to form the protection cavity; the liquid cooling plate is provided with a plurality of positioning columns corresponding to the middle part of the support plate along the X-axis direction and avoiding the cooling liquid flow channel of the liquid cooling plate.

[0011] Based on the seventh technical solution, the eighth technical solution is further provided, and in the eighth technical solution and the preferred embodiments thereof, the liquid cooling plate comprises a flow channel processing plate and a cover plate, the cooling liquid channel is formed on the flow channel processing plate, and the cover plate is fixedly connected with the flow channel processing plate to cooperatively form the cooling liquid flow channel; the flow channel processing plate is provided with a mounting surface suitable for being attached to the power module and the inverter inductor module; and the positioning column is detachably fixedly connected with the flow channel processing plate.

[0012] Based on the second technical solution, the ninth technical solution is further provided, and in the ninth technical solution and the preferred embodiments thereof, the first heat dissipation fan, the second heat dissipation fan and the third heat dissipation fan are further included; the first heat dissipation fan and the second heat dissipation fan are respectively arranged at the front and rear ends along the Y-axis direction in the protection cavity and close to the second side of the box body along the X-axis direction, and the third heat dissipation fan is located between the two bus capacitor modules along the Y-axis direction; the first heat dissipation fan, the second heat dissipation fan and the third heat dissipation fan cooperatively form a circulating air flow passing through the bus capacitor module and the alternating current filter module of each energy storage converter unit; and the first alternating current filter module and the second alternating current filter module are at least partially mirror-symmetrical.

[0013] Based on the ninth technical solution, the tenth technical solution is further provided, and in the tenth technical solution and the preferred embodiments thereof, the first wind guide cover, the second wind guide cover and the third wind guide cover are further included; the axes of the first heat dissipation fan and the second heat dissipation fan are inclined relative to the X-axis direction; the first wind guide cover is at least partially arranged on the first alternating current filter module and is provided with a first air port opposite to the first heat dissipation fan, a second air port facing the rear side of the box body and a third air port facing the first side of the box body along the X-axis direction; the second wind guide cover is at least partially arranged on the second alternating current filter module and is provided with a fourth air port opposite to the second heat dissipation fan, a fifth air port facing the front side of the box body and a sixth air port facing the first side of the box body along the X-axis direction; the first wind guide cover and the second wind guide cover are spaced apart along the Y-axis direction; the axis of the third heat dissipation fan extends along the Y-axis direction; and the third wind guide cover is at least partially arranged on at least one bus capacitor module and opposite to the third heat dissipation fan.

[0014] From the above description of the present application and the preferred embodiments thereof, it can be seen that, compared with the prior art, the technical solutions of the present application and the preferred embodiments thereof have the following beneficial effects due to the following technical means: In the technical solution one and its preferred embodiments, the applicant first considers in practice to split the high-power module and the large inverter inductor module into two small power modules and two small inverter inductor modules, so that the volume and weight of the inverter inductor are reduced, but it is found in practice that if the AC filter module still adopts integrated design (i.e. one large AC filter module simultaneously serves two inverter inductor modules), the challenge of difficult effective alignment and connection between the centralized input terminals of the AC filter module and the output terminals of the two dispersed inverter inductor modules along the Y-axis direction will be faced. Especially when these terminal interfaces all need to be close to the side wall of the box (the second side along the X-axis direction) to facilitate external wiring, the use of copper bars for connection needs to design a complex bending path, the route is complex, not only needs to customize special-shaped copper bars, which increases the cost, but also needs to expand the size of the box in the X-axis direction, and needs to be strictly installed according to the installation order during installation, in addition, the length of the copper bar is relatively long, the long-distance copper bar needs to be stacked in multiple layers to avoid short circuit, which has the problem of safety regulation; and the use of large-current cable connection will cause the bending radius of the cable itself to be large, the flexibility is limited, also needs to expand the size of the box in the X-axis direction, and may introduce unnecessary stress. Therefore, the applicant further splits the originally planned one large AC filter module into two independent AC filter modules serving the respective small inverter inductor modules.

[0015] Therefore, the final solution adopted by the applicant is to provide two energy storage conversion units in the cabinet, and the power module, the inverter inductor module, the bus capacitor module and the AC filter module are all split into two, that is, a large-power energy storage conversion unit is split into two small-power energy storage conversion units, so that the volume and weight of the inverter inductor module corresponding to each energy storage conversion unit are reduced, and the miniaturization and light weight of the module significantly reduce the installation difficulty. When a module fails, only the corresponding faulty module needs to be replaced, which greatly reduces the maintenance cost and improves the overall redundancy and availability of the system. At the same time, the processing workability and transportation convenience are improved. The processing precision of small-size modules (especially the flatness index such as the contact surface of the inverter inductor bottom and the liquid cooling plate) is easier to control, which ensures the uniform and effective filling of the heat-conducting silicone grease and improves the heat dissipation efficiency. The reduction of the weight and volume of the components also brings convenience to material transportation, production line circulation and on-site installation operation. In addition, the structural strength and reliability are optimized. The reduction of the weight of the single module reduces the requirement for the internal support structure of the cabinet, and the potential structural risk caused by external factors such as vibration during transportation and operation is also reduced. In addition, the bus capacitor module is arranged above the power module, and the AC filter module is arranged above the inverter inductor module, which is more conducive to the connection of the power module with the corresponding bus capacitor module and inverter inductor module in each energy storage conversion unit, and the connection of the AC filter module with the corresponding inverter inductor module. The connection port of each small-power AC filter module can be optimally arranged according to the position of the wiring terminal of the corresponding inverter inductor module. The wiring terminals of the AC filter module and the wiring terminals of the inverter inductor module are close to each other along the Y-axis direction, so as to realize more direct and shorter connection, which not only greatly shortens the length of the copper bar, reduces the cost and assembly difficulty, but also meets the safety requirements. This scheme significantly simplifies the electrical connection topology and actual assembly operation between the upper AC filter module and the lower inverter inductor module, improves the reliability and maintainability of the connection. In addition, the provision of two energy storage conversion units is conducive to creating conditions for adjusting the output power of the energy storage converter, such as outputting the power of one energy storage conversion unit or outputting the power of two energy storage conversion units.

[0016] Therefore, the technical scheme can not only ensure the flat installation of the inverter inductor when the energy storage converter has large power and reduce the maintenance cost, but also realize convenient wiring operation.

[0017] In the second technical solution and its preferred embodiment, due to the need for high current transmission, if the traditional flying wire (high current cable) method is used to connect the second AC filter module and the output terminal over a long distance, it may not only face problems such as difficulty in selecting cable paths, occupying a large space, and complex assembly processes, but also may lead to increased voltage drop and limited current carrying capacity due to excessive cable length. Furthermore, long-distance parallel cable laying is more likely to generate or be subject to electromagnetic interference, affecting EMC performance. This technical solution uses a first copper busbar as the main current-carrying conductor. This first copper busbar is cleverly positioned below the first AC filter module. Utilizing the gap created by the height of the first AC filter module itself and the structural space between the first AC filter module and the corresponding inverter inductor module, it travels from back to front along the Y-axis. To meet safety regulations (such as creepage distance and clearance), a specially designed support shield is added between the first copper busbar and the inverter inductor module below. This support not only plays a crucial role in electromagnetic isolation but also provides additional structural support for the first copper busbar traveling above. This achieves a clean, compact, reliable, and low-impedance solution for long-distance, high-current connections from the second AC filter module to the front output terminals. By replacing flying wires with the first copper busbar, voltage drop and line loss are effectively reduced, and current-carrying capacity is improved. The support ensures electrical safety and excellent EMC performance of the connection, avoiding electromagnetic interference to other electrical components.

[0018] In Technical Solution 3 and its preferred embodiments, the connection reliability, electrical safety, and electromagnetic compatibility (EMC) of the first copper busbar are further enhanced by optimizing the structural design of the support component. Specifically, the support column, made of insulating material, is fixed to the support body and directly fixed to the first copper busbar, thereby ensuring a stable gap between the first copper busbar and the channel wall of the through-channel. This design not only achieves electrical isolation, effectively preventing the risk of short circuits, leakage, or arcing that may occur under high current conditions, and meeting the stringent requirements for creepage distance and clearance in safety regulations; at the same time, the insulating material and spacing characteristics of the support column reduce the coupling of electromagnetic interference between the first copper busbar and the support component, improving the overall EMC performance and avoiding signal crosstalk. In addition, the fixed connection structure between the support column and the first copper busbar enhances the mechanical stability of the first copper busbar, resisting vibration and displacement during transportation and operation, ensuring a low impedance state at the connection point, and reducing the risk of increased contact resistance and heat generation due to loosening, thereby further optimizing the current carrying capacity and heat dissipation efficiency of Technical Solution 2. Therefore, the improvements in technical solution three not only simplify the installation process of the support components, but also improve the long-term reliability and maintainability of the system and reduce potential failure points.

[0019] In Technical Solution 4 and its preferred embodiments, an insulating layer (such as epoxy resin or silicone) is coated on the surface of the first copper busbar, forming a dual physical and material isolation with the insulating support column of Technical Solution 3. Even if the support component undergoes slight displacement due to vibration, it can still ensure absolute insulation between the first copper busbar and the channel wall of the through channel, avoiding the risk of high-voltage breakdown. In addition, the insulating layer can resist the intrusion of condensate and dust, improving the operational safety in humid and polluted environments and expanding the application scenarios of the equipment.

[0020] In technical solution five and its preferred embodiments, the three-phase first copper busbar is physically isolated by insulating partitions arranged at intervals along the X-axis, avoiding magnetic field coupling caused by parallel large currents and reducing harmonic interference. At least one side of the channel wall along the X-axis of the through channel is provided with heat dissipation holes, which can guide cold air near the liquid cooling plate through the gap of the first copper busbar for direct convection heat dissipation and improve the heat dissipation efficiency of the first copper busbar.

[0021] In Technical Solution Six and its preferred embodiments, the bus capacitor module and the AC filter module are fixedly connected to the same support plate, forming a pre-assembled functional unit, which improves assembly efficiency. The support plate is detachably fixed by a connecting bracket, enabling the replacement of the entire faulty module (such as disassembling only a single energy storage converter unit), shortening maintenance time and significantly reducing downtime costs. The connecting bracket protrudes bidirectionally from the side walls (second and third side walls) of the enclosure, improving support stability.

[0022] In Technical Solution 7 and its preferred embodiments, the top plate and liquid-cooled plate enclose both ends of the frame, which means that the liquid-cooled plate has a high thickness and high strength. When the energy storage converter adopts a double-layer structure layout, the existing design is insufficient in ensuring that the support plate supporting the upper module has sufficient structural strength and rigidity. This makes the upper structure prone to deformation, loosening of connections, or damage to components when the equipment is subjected to internal vibrations during normal operation and external impacts and vibrations during transportation and installation. By setting reinforced connection points on the lower high-strength structural components (such as the liquid-cooled plate) and forming a multi-point, high-rigidity support and fixing system with the upper support plate, this setting significantly improves the support strength and stability of the upper structure, effectively preventing excessive deformation or instability of the upper structure under static load and dynamic excitation, enhancing the vibration and impact resistance of the whole machine, and enabling the entire energy storage converter to better withstand vibrations from internal working components and mechanical impacts from the external environment, ensuring long-term reliable operation of components. The stable mechanical support structure helps maintain the precise relative positional relationship between components and the reliability of electrical connections.

[0023] In Technical Solution 8 and its preferred embodiments, the conventional manufacturing process of a single-sided flow channel liquid cooling plate typically involves precisely welding a relatively thin metal plate, serving as the device mounting surface, to another flow channel plate (usually thicker) with complex coolant flow channels. This traditional process presents several potential technical challenges: First, the thin plate serving as the device mounting surface is more prone to thermal or stress deformation during welding, subsequent machining, and device mounting, affecting its final surface flatness and consequently impacting the quality of thermal contact with the power device. Second, if the screw holes for mounting the power device need to penetrate this thin mounting surface and enter the lower flow channel plate, extremely high requirements are placed on the reliability and sealing of the welding quality; any minute welding defect could become a potential coolant leakage risk point. This technical solution innovatively employs a novel layered processing method for liquid cooling plates, where the coolant channels and device mounting surface are machined on the same relatively thick plate. In this solution, the core structure of the liquid cooling plate is composed of a single, sufficiently thick plate. In practical applications, complex internal channels for coolant circulation can be machined on the inside or the other side using machining processes. Finally, a simple cover plate is welded to the open side of the machined thick plate to seal the channels, completing the manufacturing of the entire liquid cooling plate. By adopting a novel layered processing method for liquid cooling plates that integrates the coolant channels and device mounting surfaces onto the same thick plate, the machining accuracy, surface flatness, and structural rigidity of the device mounting surfaces are significantly improved. This provides a better mounting base for the power devices and positioning posts of the power module, helping to reduce contact thermal resistance and improve heat dissipation efficiency. At the same time, it fundamentally reduces the risk of coolant leakage that may be caused by mounting screw holes penetrating the welded layer, significantly improving the long-term operational reliability and overall service life of the liquid cooling plate.

[0024] In technical solution nine and its preferred embodiments, the first, second, and third cooling fans are arranged in separate areas (at both ends of the Y-axis and in the middle of the X-axis), forcing airflow through the bus capacitor module and the AC filter module, forming a dual-path heat dissipation of liquid cooling and air cooling in conjunction with the liquid cooling plate. When two AC filter modules with similar structures are arranged one after the other along the airflow direction, and the first and second cooling fans are located at both ends blowing in, the existing heat dissipation design is difficult to ensure that the two AC filter modules (especially the components in different positions inside) receive uniform and efficient heat dissipation. It is easy to cause local insufficient heat dissipation due to differences in fan position and airflow attenuation. The first AC filter module and the second AC filter module are at least partially mirror-symmetrical, which improves the heat dissipation efficiency and temperature distribution uniformity of the two AC filter modules as a whole and the key components inside, reduces the operating temperature of the devices, and improves the long-term operational reliability and lifespan of the modules.

[0025] In technical solution ten and its preferred embodiments, the first air guide shroud helps ensure that the airflow from the first cooling fan is concentrated and blown towards the first AC filter module through the first air outlet. After flowing over the surface of the first AC filter module, part of the airflow passes through the second air outlet and flows along the second side wall of the housing along the X-axis direction to the air inlet side of the first cooling fan. Part of the airflow passes through the third air outlet to the adjacent bus capacitor module and then returns to the air inlet side of the first cooling fan, forming a loop. The second air guide shroud helps ensure that the airflow from the second cooling fan is concentrated and blown towards the second AC filter module through the fourth air outlet. After flowing over the surface of the second AC filter module, the airflow passes through the fifth air outlet and flows along the second side wall of the housing along the X-axis direction to the air inlet side of the second cooling fan. Part of the airflow passes through the sixth air outlet to the adjacent bus capacitor module and then returns to the air inlet side of the second cooling fan, forming a loop. This shortens the circulation path of the circulating airflow and improves the heat dissipation efficiency of the upper module devices. The axis of the third cooling fan extends along the Y-axis. Combined with the third air guide shroud, which at least partially covers at least one bus capacitor module and is opposite to the third cooling fan, it is more conducive to the complete flow of air over the surfaces of the two bus capacitor modules arranged along the Y-axis, thereby improving the temperature uniformity of the upper module. Attached Figure Description

[0026] To more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the following description of the embodiments are briefly introduced. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0027] Figure 1 A schematic diagram of an energy storage converter according to an embodiment of the present invention is shown; Figure 2 A schematic diagram of a liquid cooling plate, a first heat exchange section, a second heat exchange section, a third heat exchange section, and two power modules according to an embodiment of the present invention is shown. Figure 3 An exploded perspective view of the liquid cooling plate according to an embodiment of the present invention is shown. Figure 4 The diagram illustrates the hidden top plate and upper-layer modules (bus capacitor module and AC filter module) according to an embodiment of the present invention. Figure 1 ; Figure 5 This diagram illustrates the hidden top plate and upper module according to an embodiment of the present invention. Figure 2 ; Figure 6 A side view of the concealed top plate and frame according to an embodiment of the present invention is shown; Figure 7 This diagram illustrates the upper-layer module of an embodiment of the present invention. Figure 1 ; Figure 8This diagram illustrates the upper-layer module of an embodiment of the present invention. Figure 2 ; Figure 9 for Figure 7 A bottom view; Figure 10 for Figure 9 Partial sectional view along the A_A direction; Figure 11 This is a schematic diagram of the support member and the first copper busbar according to an embodiment of the present invention.

[0028] Explanation of key figure labels: Housing 10; Protective cavity 01; Liquid cooling plate 11; Flow channel processing plate 111; Mounting surface 1111; Positioning post 1112; Cover plate 112; Liquid inlet port 113; Liquid outlet port 114; Frame 12; First side wall 121; Second side wall 122; Third side wall 123; Fourth side wall 124; Connecting frame 125; Top plate 13; Input terminal 21; Output terminal 22; Relay module 23; Relay unit 231; Output magnetic ring 24; Common mode inductor 25; Energy storage converter unit 30; Power module 31; Inverter inductor module 32; bus capacitor module 33; AC filter module 34; first AC filter module 341; second AC filter module 342; support component 343; support body 3431; support column 3432; through channel 3433; insulating partition 3434; heat dissipation hole 3435; first copper busbar 02; insulating layer 021; support plate 37; through hole 371; first cooling fan 41; second cooling fan 42; third cooling fan 43; fourth cooling fan 44; first air guide shroud 51; first air outlet 511; second air outlet 512; third air outlet 513; second air guide shroud 52; fourth air outlet 521; fifth air outlet 522; sixth air outlet 523; third air guide shroud 53; first heat exchange section 61; second heat exchange section 62; third heat exchange section 63. Detailed Implementation

[0029] 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 preferred embodiments of the present invention and should not be considered as excluding other embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0030] Unless otherwise expressly defined, the use of terms such as "first," "second," or "third" in the claims, description, and accompanying drawings of this invention is for distinguishing different objects and not for describing a specific order.

[0031] Unless otherwise expressly defined, in the claims, description, and accompanying drawings of this invention, the use of directional terms such as "center," "lateral," "longitudinal," "horizontal," "vertical," "top," "bottom," "inner," "outer," "upper," "lower," "front," "rear," "left," "right," "clockwise," and "counterclockwise" to indicate orientation or positional relationships is based on the orientation and positional relationships shown in the accompanying drawings and is only for the convenience of describing the invention and simplifying the description, and is not intended to 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 limiting the specific scope of protection of this invention.

[0032] Unless otherwise expressly defined, the terms "fixed connection" or "fixed connection" used in the claims, description and drawings of this invention should be interpreted broadly to refer to any connection in which there is no displacement or relative rotation relationship between the two parties, including non-removable fixed connection, detachable fixed connection, integral connection and fixed connection by other means or components.

[0033] In the claims, description and accompanying drawings of this invention, the terms "comprising," "having," and variations thereof are used to mean "including but not limited to."

[0034] In the claims and the description other than the embodiments, the terms "X-axis direction," "Y-axis direction," and "Z-axis direction" only refer to a feature having one of the aforementioned directions being perpendicular to a feature having another direction, and do not require that they be implemented according to the "X-axis direction," "Y-axis direction," and "Z-axis direction" described in the embodiments. In the embodiments, the X-axis direction is perpendicular to both the Y-axis direction and the Z-axis direction. The X-axis direction can be divided into left and right, the Y-axis direction into front and back, and the Z-axis direction into up and down.

[0035] See Figures 1-11 , Figures 1-11 An energy storage converter is shown, including a housing 10, an input terminal 21, an output terminal 22, a relay module 23, an output magnetic ring 24, a common mode inductor 25, two energy storage converter units 30, a support plate 37, a first cooling fan 41, a second cooling fan 42, a third cooling fan 43, a first air guide shroud 51, a second air guide shroud 52, and a third air guide shroud 53.

[0036] See Figures 1-4 The enclosure 10 forms a protective cavity 01, and the protective cavity 01 is provided with a liquid cooling plate 11 extending along the Y-axis direction. The enclosure 10 includes a liquid cooling plate 11, a frame 12 and a top plate 13. The frame 12 has openings at both ends along the Z-axis direction, and the liquid cooling plate 11 and the top plate 13 respectively cover the openings at both ends of the frame 12 along the Z-axis direction to form the protective cavity 01.

[0037] In this embodiment, the liquid cooling plate 11 serves directly as the base support and has a relatively thick thickness. (See attached image.) Figures 2-3 The liquid cooling plate 11 includes a flow channel processing plate 111 and a cover plate 112. Coolant channels are formed on the flow channel processing plate 111, and the cover plate 112 is fixedly connected to the flow channel processing plate 111 to cooperate in forming coolant flow channels. The flow channel processing plate 111 has a mounting surface 1111 suitable for contacting with the power module 31 and inverter inductor module 32 described below. The liquid cooling plate 11 has a number of positioning posts 1112 in the middle of the X-axis direction corresponding to the support plate 37 described below, which avoids the coolant flow channels of the liquid cooling plate 11. The positioning posts 1112 are detachably fixedly connected to the flow channel processing plate 111. For example, threaded holes can be opened on the flow channel processing plate 111, and the positioning posts 1112 can be screwed into the threaded holes. The conventional manufacturing process of the single-sided flow channel liquid cooling plate 11 usually involves precisely welding a relatively thin metal plate, which serves as the device mounting surface, to another flow channel plate (usually thicker) with complex coolant flow channels. This traditional process presents several potential technical challenges: First, the thin plate serving as the device mounting surface is more susceptible to thermal or stress deformation during welding, subsequent machining, and device fastening, affecting its final surface flatness and consequently impacting the quality of thermal contact with the power device. Second, if the screw holes for mounting the power device need to penetrate this thin mounting surface 1111 and enter the underlying flow channel plate, extremely high requirements are placed on the reliability and sealing of the welding quality; any minute welding defect could become a potential source of coolant leakage. This technical solution innovatively employs a novel layered processing method for the liquid cooling plate 11, where the coolant channels and the device mounting surface 1111 are machined on the same relatively thick plate. In this solution, the core structure of the liquid cooling plate 11 is composed of a single, sufficiently thick plate. In practical applications, complex internal channels for coolant circulation can be machined inside or on the other side using precision CNC milling and other machining processes. Finally, a simple cover plate 112 is welded to the open side of the thick plate with the flow channels to seal the flow channels, completing the manufacturing of the entire liquid cooling plate 11. By adopting a novel layered processing method for the liquid cooling plate 11, which integrates the coolant channels and the device mounting surface 1111 into the same thick plate, the processing accuracy, surface flatness, and structural rigidity of the device mounting surface 1111 are significantly improved. This provides a better mounting base for the power devices and positioning posts 1112 of the power module 31 described below, helping to reduce contact thermal resistance and improve heat dissipation efficiency. At the same time, it fundamentally reduces the risk of coolant leakage that may be caused by mounting screw holes penetrating the welded layer, greatly improving the long-term operational reliability and overall service life of the liquid cooling plate 11. The front side of the liquid cooling plate 11 along the Y-axis is provided with an inlet connector 113 and an outlet connector 114 arranged along the X-axis.

[0038] SeeFigures 4-5 The housing 10 has a first sidewall 121 on its front side along the Y-axis, and a second sidewall 122 and a third sidewall 123 on its first and second sides along the X-axis, respectively. At least two connecting brackets 125 protrude from both the second and third sidewalls 122 and 123. A fourth sidewall 124 is provided on the rear side of the housing 10 along the Y-axis. In this embodiment, the first sidewall 121, second sidewall 122, third sidewall 123, and fourth sidewall 124 are all formed on the frame 12. The inlet connector 113 and outlet connector 114 both penetrate the first sidewall 121 and extend out of the protective cavity 01. At least two connecting brackets 125 protrude from both the second and third sidewalls 122 and 123, respectively. In this embodiment, six connecting brackets 125 protrude from both the second and third sidewalls 122 and 123. The connecting brackets 125 are used for detachable connection to the support plate 37 described below.

[0039] See Figure 1 and Figure 4 The input terminal 21 and output terminal 22 adopt an embedded mounting structure, both embedded in the first sidewall 121, forming the electrical input and output terminals of the entire energy storage converter. The input terminal 21 is directly connected to the DC power bus, and the output terminal 22 is connected to the AC load circuit. Figure 1 and Figure 4 In this configuration, there are 4 input terminals 21 and 3 output terminals 22.

[0040] See Figure 5 The relay module 23 is arranged adjacent to the input terminal 21 along the X-axis and forms a low-impedance direct connection with the input terminal 21 through a copper busbar. The relay module 23 adopts a double-layer Z-axis stacked structure, which includes two relay units 231. Each relay unit 231 is connected to two input terminals. Each relay unit 231 also independently controls the on / off state of an energy storage converter unit 30 mentioned below through direct connection with the power module 31. Vertical stacking can save space of the relay module 23 in the XY plane, and the modular structure supports redundancy and fault tolerance. In this embodiment, the relay module 23 also integrates an input-side magnetic ring and a DC filter.

[0041] The output magnetic ring 24 and the relay module 23 are arranged along the X-axis and adjacent to the output terminal 22. The common mode inductor 25 is arranged adjacent to the output magnetic ring 24 and close to the first side wall 121 of the housing 10. The input and output ends of the common mode inductor 25 are both located at its upper end, that is, the end close to the top plate 13. Its input end is connected to the first AC filter module 341 and the second AC filter module 342 mentioned below, and its output end is connected to the output terminal 22. In this embodiment, the common mode inductor 25 and the output terminal 22 are electrically connected through a copper busbar and the copper busbar passes through the central hole of the output magnetic ring 24, thereby suppressing high-frequency conducted interference.

[0042] Input terminal 21 and relay module 23 form the power input area, while output magnetic ring 24 and common-mode inductor 25 form the filter output area. The power input area and filter output area are arranged along the X-axis. Both relay module 23 and common-mode inductor 25 have a height similar to the two-layer structure of energy storage converter unit 30 described below.

[0043] In existing technical solutions, when the power of the energy storage converter unit 30 increases, the installation of the inverter inductor module 32 becomes difficult and the maintenance cost is high. In electronic circuits, high-power inductors cannot usually be simply replaced by multiple small inductors connected in series. Replacing high-power inductors with small inductors in series will lead to problems such as reduced efficiency, overheating risk, and high-frequency instability, which is usually not feasible. Therefore, when the power of the energy storage converter unit 30 increases, only high-power inductors can be used, which inevitably leads to problems such as large installation difficulty, poor flatness of the fit with the liquid cooling plate 11, and high maintenance costs due to the large size of the high-power inductors.

[0044] In practice, the applicant initially considered splitting the high-power module 31 and the large inverter inductor module 32 into two low-power modules 31 and two small inverter inductor modules 32, thereby reducing the size and weight of the inverter inductors. However, in practice, it was found that if the AC filter module 34 still adopts an integrated design (i.e., one large AC filter module serves two inverter inductor modules 32 at the same time), it will face the challenge of effectively aligning and connecting the centralized input terminals of the AC filter module 34 with the output terminals of the two physically dispersed inverter inductor modules 32. Especially when these terminal interfaces need to be close to the side wall of the enclosure (third side wall 123) for convenient external wiring, using copper busbars for connection requires a complex bending path design and a complicated routing. This not only requires custom-shaped copper busbars, increasing costs, but also requires increasing the size of the enclosure 10 in the X-axis direction. Installation also requires strict adherence to the installation sequence. Furthermore, the copper busbars are relatively long, and long-distance copper busbars require multiple stacks to avoid short circuits, raising safety regulations. Using high-current cables for connection, due to the large bending radius and limited flexibility of the cables themselves, also requires increasing the size of the enclosure in the X-axis direction and may introduce unnecessary stress. Therefore, the applicant further divided the originally planned large AC filter module 34 into two independent AC filter modules 34, each serving its own small inverter inductor module 32.

[0045] Therefore, the applicant's final solution was to set up two energy storage converter units 30 in the enclosure 10, and to split the power module 31, inverter inductor module 32, bus capacitor module 33 and AC filter module 34 into two, that is, to split a large-power energy storage converter unit 30 into two small-power energy storage converter units 30.

[0046] Specifically, see Figures 4-8Two energy storage converter units 30 are arranged along the Y-axis in the protective cavity 01. Each energy storage converter unit 30 includes a power module 31 and an inverter inductor module 32 attached to the liquid cooling plate 11, a bus capacitor module 33 located above the power module 31, and an AC filter module 34 located above the inverter inductor module 32. Each power module 31 is connected to one of the relay units 231 of the relay module 23 via a flying wire. The flying wire connecting the power module 31 near the rear (near the fourth side wall 124) to the relay unit 231 is fixed to the second relay unit 231 by a cable tie. On the side wall 122, each power module 31 is connected to the corresponding bus capacitor module 33 and inverter inductor module 32 via copper busbars; the terminals of AC filter module 34 and inverter inductor module 32 are close to each other along the Y-axis and are both close to the second side of the X-axis direction of the housing 10, and are connected to each other via copper busbars. Each AC filter module 34 is connected to the common mode inductor 25 on the front side; in this embodiment, the terminals of AC filter module 34 and inverter inductor module 32 are arranged along the X-axis direction, and the copper busbars connecting the two are ordinary Z-shaped copper busbars, which are low in cost.

[0047] The above configuration reduces the size and weight of the inverter inductor module 32 corresponding to each energy storage converter unit 30. The miniaturization and weight reduction of the modules significantly lowers installation difficulty. When a module fails, only the faulty module needs to be replaced, greatly reducing maintenance costs and improving the overall redundancy and availability of the system. Simultaneously, it improves manufacturability and transportation convenience. The machining accuracy of small-sized modules (especially key flatness indicators, such as the contact surface between the bottom of the inverter inductor and the liquid cooling plate 11) is easier to control, ensuring uniform and effective filling of thermal grease and improving heat dissipation efficiency. The reduction in component weight and volume also facilitates material transportation, production line flow, and on-site installation. Furthermore, it optimizes structural strength and reliability. The reduced weight of individual modules lowers the requirements for the internal support structure of the enclosure 10, and correspondingly reduces potential structural risks caused by external factors such as vibration during transportation and operation. Furthermore, the bus capacitor module 33 is positioned above the power module 31, and the AC filter module 34 is positioned above the inverter inductor module 32. This arrangement facilitates the connection of the power module 31 to its corresponding bus capacitor module 33 and inverter inductor module 32 within each energy storage converter unit 30, and the connection of the AC filter module 34 to its corresponding inverter inductor module 32. The connection ports of each low-power AC filter module 34 can be optimized based on the terminal positions of its corresponding inverter inductor module 32, significantly shortening the copper busbar length, reducing cost and assembly difficulty, and meeting safety regulations, thus achieving a more direct and efficient connection. This scheme significantly simplifies the electrical connection topology and actual assembly operation between the upper AC filter module 34 and the lower inverter inductor module 32, improving connection reliability and maintainability. Moreover, the arrangement of two energy storage converter units 30 allows for adjustable output power of the energy storage converter, such as outputting the power of one energy storage converter unit 30 or the power of two energy storage converter units 30.

[0048] Power module 31 is generally also an IGBT module. In the prior art, IGBT integrates multiple high-loss converter devices (such as MOSFETs) and low-loss converter devices (such as diodes), and the similar devices are arranged in a concentrated manner, which not only leads to the large size of IGBT, but also causes uneven heat distribution inside the module. In this embodiment, the traditional IGBT module is further divided into multiple independent converter devices. Each power module 31 includes 3 converter units (corresponding to three phases). Each converter unit includes multiple converter devices formed by semiconductor switching devices. The types of converter devices include high-loss devices (such as MOSFETs) and low-loss devices (such as diodes). This arrangement is beneficial to reducing the size of IGBT, to fitting with the liquid cooling plate 11, and to making the flow channel design of the liquid cooling plate 11 easy to accurately match the heat-generating parts of the power module 31, so as to achieve balanced heat dissipation of each part. In practical applications, see Figures 7-9Each energy storage converter unit 30 has its bus capacitor module 33 and AC filter module 34 fixedly connected to the same support plate 37. The support plate 37 is detachably fixed to each connecting bracket 125. In this embodiment, the support plate 37 is screwed to each connecting bracket 125. The bus capacitor module 33 and AC filter module 34 are fixedly connected to the same support plate 37, forming a pre-assembled functional unit, which improves assembly efficiency. The support plate 37 is detachably fixed through the connecting bracket 125, which enables the replacement of the entire board of faulty modules (such as disassembling only a single energy storage converter unit 30), shortening maintenance time and significantly reducing downtime costs. The connecting bracket 125 protrudes bidirectionally from the side walls (second and third side walls) of the housing 10, improving support stability.

[0049] In this embodiment, the support plate 37 is provided with 6 through holes 371 arranged at intervals along the Y-axis near the third side wall 123, and each AC filter module 34 is provided with 3 through holes 371. The three connecting copper busbars of the AC filter module 34 and the inverter inductor module 32 pass through the 3 through holes 371 respectively.

[0050] See Figures 7-8 The AC filter module 34 closer to the first sidewall 121 along the Y-axis is defined as the first AC filter module 341, and the AC filter module 34 further away from the first sidewall 121 along the Y-axis is defined as the second AC filter module 342. Due to the requirement of high current transmission, if the traditional flying wire (high current cable) method is used to connect the second AC filter module 342 and the output terminal 22 (through the common mode inductor 25) over a long distance, it may not only face problems such as difficulty in selecting cable paths, occupying a large space, and complex assembly processes, but may also lead to increased voltage drop and limited current carrying capacity due to excessively long cables. Furthermore, long-distance parallel cables are more likely to generate or be subject to electromagnetic interference, affecting EMC performance.

[0051] In this embodiment, see Figures 9-11The first AC filter module 341 is provided with a support member 343 below it. The support member 343 has a through channel 3433 extending and penetrating along the Y-axis. The second AC filter module 342 is connected to the output terminal 22 through the first copper busbar 02. In this embodiment, the second AC filter module 342 is connected to the common mode inductor 25 through the first copper busbar 02, and then connected to the output terminal 22. The first copper busbar 02 passes through the through channel 3433 and is supported on the support member 343. The support member 343 is also suitable for shielding the electromagnetic interference of the first copper busbar 02. In this embodiment, the support member 343 includes a support body 3431 and a plurality of support columns 3432 fixedly connected to the support body 3431 and spaced apart along the Y-axis. The support body 3431 forms a through channel 3433. The support body 3431 is made of metal, and the support columns 3432 are made of insulating material. The support columns 3432 are fixedly connected to the support body 3431 and to the first copper busbar 02 so that the first copper busbar 02 is spaced apart from the channel wall of the through channel 3433. The portion of the first copper busbar 02 located within the through channel 3433 is covered with an insulating layer 021. There are three first copper busbars 02, each spaced apart along the X-axis. The support columns 3432 are combined to form three support column rows. Each support column row includes several support columns 3432 spaced apart along the Y-axis. Several insulating partitions 3434 are also provided inside the support member 343. The insulating partitions 3434 are located between adjacent support columns 3432 along the X-axis. At the locations corresponding to the support columns 3432, the first copper busbar 02 is not covered with the insulating layer 021. At least one side of the through channel 3433 along the X-axis has heat dissipation holes 3435. In this embodiment, heat dissipation holes 3435 are provided on both sides of the through channel 3433 along the X-axis.

[0052] In this embodiment, a first copper busbar 02 is used as the main current-carrying conductor. This first copper busbar 02 is cleverly positioned below the first AC filter module 341. Utilizing the gap created by the height of the first AC filter module 341 itself and the structural space between the first AC filter module 341 and the corresponding inverter inductor module 32, it travels from back to front along the Y-axis. To meet safety regulations (such as creepage distance and clearance), a specially designed support member 343 is added between the first copper busbar 02 and the inverter inductor module 32 below for shielding. This support member 343 not only plays a crucial role in electromagnetic isolation but also provides additional structural support for the first copper busbar 02 traveling above. This achieves a clean, compact, reliable, and low-impedance solution for long-distance, high-current connections from the second AC filter module 342 to the front output terminal 22. By replacing flying wires with the first copper busbar 02, voltage drop and line loss are effectively reduced, and current-carrying capacity is improved. The support member 343 ensures the electrical safety and excellent EMC performance of the connection, avoiding electromagnetic interference to other electrical components.

[0053] Furthermore, by optimizing the structural design of the support member 343, the connection reliability, electrical safety, and electromagnetic compatibility (EMC) of the first copper busbar 02 are further enhanced. Specifically, the support column 3432, made of insulating material, is fixed to the support body 3431 and directly fixed to the first copper busbar 02, thereby ensuring a stable gap between the first copper busbar 02 and the channel wall of the through channel 3433. This design not only achieves electrical isolation, effectively preventing the risk of short circuits, leakage, or arcing that may occur under high current conditions, and meeting the stringent requirements for creepage distance and clearance in safety regulations; at the same time, the insulating material and spacing characteristics of the support column 3432 reduce the coupling of electromagnetic interference between the first copper busbar 02 and the support member 343, improving the overall EMC performance and avoiding signal crosstalk. Furthermore, the fixed connection structure between the support column 3432 and the first copper busbar 02 enhances the mechanical stability of the first copper busbar 02, resisting vibration and displacement during transportation and operation, ensuring a low impedance state at the connection point, and reducing the risk of increased contact resistance and overheating due to loosening. This further optimizes the current carrying capacity and heat dissipation efficiency of the first copper busbar 02. Therefore, it not only simplifies the installation process of the support component 343, but also improves the long-term reliability and maintainability of the system, and reduces potential failure points.

[0054] An insulating layer 021 (such as epoxy resin or silicone) is applied to the surface of the first copper busbar 02, forming a dual physical and material isolation with the insulating support column 3432. Even if the support member 343 experiences slight displacement due to vibration, it can still ensure absolute insulation between the first copper busbar 02 and the channel wall of the through channel 3433, avoiding the risk of high-voltage breakdown. In addition, the insulating layer 021 can resist the intrusion of condensate and dust, improving the operational safety in humid and polluted environments and expanding the application scenarios of the equipment. The three-phase first copper busbar 02 is physically isolated by insulating partitions 3434 arranged at intervals along the X-axis, avoiding magnetic field coupling caused by parallel high currents and reducing harmonic interference. At least one side of the channel wall of the through channel 3433 along the X-axis direction has heat dissipation holes 3435, which can guide cold air near the liquid cooling plate 11 through the gaps of the first copper busbar 02 for direct convection heat dissipation, offsetting the additional heat generated by the first copper busbar 02 due to the skin effect and proximity effect, and avoiding the heat dissipation weakening problem that the insulating layer 021 may cause.

[0055] To improve the heat dissipation efficiency of the upper-layer module, see [link / reference]. Figure 4In this embodiment, a first cooling fan 41, a second cooling fan 42, and a third cooling fan 43 are provided. The first cooling fan 41 and the second cooling fan 42 are respectively located at the front and rear ends along the Y-axis direction inside the protective cavity 01 and close to the second side of the housing 10 along the X-axis direction. The axes of the first cooling fan 41 and the second cooling fan 42 are inclined relative to the X-axis direction. The third cooling fan 43 is located between the two bus capacitor modules 33 along the Y-axis direction. The first cooling fan 41, the second cooling fan 42, and the third cooling fan 43 cooperate to form a circulating airflow through the bus capacitor module 33 and the AC filter module 34 of each energy storage converter unit 30. The first AC filter module 341 and the second AC filter module 342 are at least partially mirror-symmetrical. In this embodiment, the high-heat-generating components of the first AC filter module 341 and the second AC filter module 342, such as power frequency inductors and relays, are symmetrical about a first plane. The first plane is perpendicular to the Y-axis direction and located between the two AC filter modules.

[0056] In this embodiment, to fully utilize the heat dissipation effect of the liquid cooling plate 11, see... Figure 2 and Figure 4 It also includes a heat exchange structure and two fourth cooling fans 44. The heat exchange structure includes a first heat exchange part 61, a second heat exchange part 62, and two third heat exchange parts 63 protruding from the liquid cooling plate 11 along the Z-axis. Each heat exchange part is formed as an air-liquid heat exchanger, and its liquid cooling pipes are connected in parallel or in series on the cooling liquid flow channel of the liquid cooling plate 11. In this embodiment, the first heat exchange part 61 is arranged adjacent to the air outlet side of the first cooling fan 41, and the second heat exchange part 62 is arranged adjacent to the air outlet side of the second cooling fan 42. The airflow direction of the air passage of the first heat exchange part 61 is parallel to that of the first cooling fan 41. The axes are parallel to reduce wind resistance. The airflow direction of the air passage of the second heat exchange section 62 is parallel to the axis direction of the second cooling fan 42 to reduce wind resistance. The cold air from the first cooling fan 41 passing through the first heat exchange section 61 is suitable for passing through the upper AC filter module 34 and bus capacitor module 33, and also suitable for passing through the lower power module 31 and inverter inductor module 32. The cold air from the second cooling fan 42 passing through the second heat exchange section 62 is suitable for passing through the upper AC filter module 34 and bus capacitor module 33, and also suitable for passing through the lower power module 31 and inverter inductor module 32.

[0057] Two third heat exchange sections 63 are spaced apart along the Y-axis and are both close to the second side wall 122 of the housing 10. The air ducts of the two third heat exchange sections 63 extend along the X-axis and are located on the outlet side of the two fourth cooling fans 44. One third heat exchange section 63 is close to the middle of the liquid cooling plate 11 along the Y-axis, and the other third heat exchange section 63 is close to the fourth side wall 124. The third heat exchange sections 63 are relatively low along the Z-axis and are located directly below the bus capacitor module 33. The airflow from the fourth cooling fans 44 through the third heat exchange sections 63 can dissipate heat from the lower power module 31 and inverter inductor module 32. The two fourth cooling fans 44 can also cooperate with the first cooling fan 41 and the second cooling fan 42 to form a circulating airflow through the lower power module 31 and inverter inductor module 32.

[0058] See Figures 7-8 To improve the heat dissipation efficiency of the upper module, a first air guide shroud 51, a second air guide shroud 52, and a third air guide shroud 53 are also provided. The first air guide shroud 51 at least partially covers the first AC filter module 341 and has a first air vent 511 opposite to the first cooling fan 41, a second air vent 512 facing the rear of the housing 10, and a third air vent 513 facing the first side of the housing 10 along the X-axis. In this embodiment, the first air guide shroud 51 is generally rectangular with a missing corner. A first air vent 511 is formed; a second air guide shroud 52 is at least partially covered on the second AC filter module 342 and has a fourth air vent 521 opposite to the second cooling fan 42, a fifth air vent 522 facing the front of the housing 10 and a sixth air vent 523 facing the first side of the housing 10 along the X-axis. The second air guide shroud 52 is generally rectangular with two missing corners, and the fourth air vent 521 is formed at one of the missing corners; the first air guide shroud 51 and the second air guide shroud 52 are arranged at intervals along the Y-axis. The air inlet side of the third cooling fan 43 faces the rear side of the housing 10 along the Y-axis direction; the axis of the third air guide shroud 53 extends along the Y-axis direction, and the third air guide shroud 53 is at least partially covered on at least one bus capacitor module 33 and opposite to the third cooling fan 43. In this embodiment, the third air guide shroud 53 mainly includes two baffles along the Y-axis direction. The two baffles are located on both sides of the bus capacitor module 33 along the X-axis direction. The air inlet side of the third cooling fan 43 faces the rear side and drives the airflow to flow from back to front through the two bus capacitor modules 33 along the Y-axis.

[0059] In this embodiment, the top plate 13 and the liquid-cooled plate 11 enclose both ends of the frame 12, which means that the liquid-cooled plate 11 has a high thickness and high strength. When the energy storage converter adopts a double-layer structure layout, the existing design is insufficient in ensuring that the support plate 37 supporting the upper module has sufficient structural strength and rigidity. This makes the upper structure prone to deformation, loosening of connections, or damage to components when the equipment is subjected to internal vibrations during normal operation and external impacts and vibrations during transportation and installation. By setting reinforced connection points on the lower high-strength structural components (such as the liquid-cooled plate 11) and forming a multi-point, high-rigidity support and fixing system with the upper support plate 37, this setting significantly improves the support strength and stability of the upper structure, effectively prevents excessive deformation or instability of the upper structure under static load and dynamic excitation, enhances the vibration and impact resistance of the whole machine, and enables the entire energy storage converter to better withstand vibrations from internal working components and mechanical impacts from the external environment, ensuring long-term reliable operation of components. The stable mechanical support structure helps maintain the precise relative positional relationship between components and the reliability of electrical connections.

[0060] In this embodiment, the first, second, and third cooling fans 43 are arranged in separate areas (at both ends of the Y-axis and in the middle of the X-axis), forcing airflow through the bus capacitor module and the AC filter module 34, forming a dual-path heat dissipation of liquid cooling and air cooling in conjunction with the liquid cooling plate 11. When two AC filter modules 34 with similar structures are arranged one after the other along the airflow direction, and the first and second cooling fans 42 are located at both ends blowing air, the existing heat dissipation design is difficult to ensure that the two AC filter modules 34 (especially the components in different positions inside) receive uniform and efficient heat dissipation, and the problem of insufficient local heat dissipation is easily caused by the difference in fan position and airflow attenuation. The first AC filter module 341 and the second AC filter module 342 are at least partially mirror-symmetrical, which improves the heat dissipation efficiency and temperature distribution uniformity of the two AC filter modules 34 as a whole and the key components inside, reduces the operating temperature of the devices, and improves the long-term operational reliability and lifespan of the modules.

[0061] In this embodiment, the first air guide shroud 51 is designed to ensure that the airflow from the first cooling fan 41 is concentrated and blown towards the first AC filter module 341 through the first air outlet 511. After passing over the surface of the first AC filter module 341, part of the airflow passes through the second air outlet 512 and flows along the side wall of the housing 10 along the X-axis direction to the air inlet side of the first cooling fan 41. Part of the airflow passes through the third air outlet 513 to the adjacent bus capacitor module 33 and then returns to the air inlet side of the first cooling fan 41, forming a cycle. The second air guide shroud 52 is designed to... This ensures that the airflow from the second cooling fan 42 is concentrated and blown towards the second AC filter module 342 through the fourth air outlet 521. After flowing over the surface of the second AC filter module 342, the airflow flows along the second side wall of the housing 10 in the X-axis direction through the fifth air outlet 522 to the air inlet side of the second cooling fan 42. Part of the airflow flows to the adjacent bus capacitor module 33 through the sixth air outlet 523 and then returns to the air inlet side of the second cooling fan 42, forming a loop. This shortens the circulation path of the circulating airflow and improves the heat dissipation efficiency of the upper module devices. The axis of the third cooling fan 43 extends along the Y-axis direction. Combined with the third air guide shroud 53, which at least partially covers at least one bus capacitor module 33 and is opposite to the third cooling fan 43, it is more conducive to the complete flow of air over the surfaces of the two bus capacitor modules 33 arranged along the Y-axis direction, thus improving the temperature uniformity of the upper module. The air inlet side of the third cooling fan 43 faces the rear side of the enclosure 10 along the Y-axis direction. Compared with the air inlet side of the third cooling fan 43 facing the front side of the enclosure 10 along the Y-axis direction, it is more conducive to guiding hot air to the front side where the cooling effect is better, thus making it more conducive to the temperature uniformity of the circulating airflow.

[0062] The foregoing description of the specifications and embodiments is intended to explain the scope of protection of this invention, but does not constitute a limitation on the scope of protection of this invention. Modifications, equivalent substitutions, or other improvements to the embodiments of this invention or a portion thereof that can be obtained by those skilled in the art through logical analysis, reasoning, or limited experimentation, based on the teachings of this invention or the foregoing embodiments, in conjunction with common knowledge, general technical knowledge, and / or existing technology, should all be included within the scope of protection of this invention.

Claims

1. An energy storage converter, characterized in that, include The housing (10) has a protective cavity (01) inside, and the protective cavity (01) is provided with a liquid cooling plate (11) extending along the Y-axis. Two energy storage converter units (30) are arranged in the protective cavity (01) along the Y-axis direction; Each energy storage converter unit (30) includes a power module (31) and an inverter inductor module (32) attached to the liquid cooling plate (11), a bus capacitor module (33) located above the power module (31), and an AC filter module (34) located above the inverter inductor module (32); each power module (31) is connected to the corresponding bus capacitor module (33) and inverter inductor module (32); the terminals of the AC filter module (34) and the terminals of the inverter inductor module (32) are close to each other along the Y-axis direction and are both close to the second side of the X-axis direction of the housing (10), and the two are connected by a copper busbar.

2. The energy storage converter as described in claim 1, characterized in that, It also includes an output terminal (22). The housing (10) has a first sidewall (121) on the front side along the Y-axis direction, and the output terminal (22) is embedded in the first sidewall (121). The AC filter module (34) close to the first sidewall (121) along the Y-axis direction is defined as the first AC filter module (341), and the AC filter module (34) away from the first sidewall (121) along the Y-axis direction is defined as the second AC filter module (342). The first AC filter module (341) is provided with a support member (343) below it. The support member (343) is provided with a through channel (3433) extending and penetrating along the Y-axis direction. The second AC filter module (342) is connected to the output terminal (22) through a first copper busbar (02). The first copper busbar (02) penetrates the through channel (3433) and is supported on the support member (343). The support member (343) is also suitable for shielding the electromagnetic interference of the first copper busbar (02).

3. The energy storage converter as described in claim 2, characterized in that, The support member (343) includes a support body (3431) and a plurality of support columns (3432) fixedly connected to the support body (3431) and spaced apart along the Y-axis. The support body (3431) forms the through channel (3433). The support columns (3432) are made of insulating material. The support columns (3432) are fixedly connected to the support body (3431) and fixedly connected to the first copper busbar (02) so that the first copper busbar (02) is spaced apart from the channel wall of the through channel (3433).

4. The energy storage converter as described in claim 3, characterized in that, The portion of the first copper busbar (02) located within the through channel (3433) is covered with an insulating layer (021).

5. The energy storage converter as described in claim 3, characterized in that, The number of the first copper busbars (02) is three, and each first copper busbar (02) is arranged at intervals along the X-axis direction. Each support column (3432) is combined to form three support column columns. Each support column column includes several support columns (3432) arranged at intervals along the Y-axis direction. The support member (343) is also provided with several insulating partitions (3434). The insulating partitions (3434) are located between adjacent support columns (3432) along the X-axis direction. The through channel (3433) has heat dissipation holes (3435) on at least one side of the channel wall along the X-axis direction.

6. The energy storage converter as described in claim 1, characterized in that, It also includes an input terminal (21) and an output terminal (22). The front side of the housing (10) along the Y-axis is provided with a first sidewall (121). The input terminal (21) and the output terminal (22) are both embedded in the first sidewall (121). The bus capacitor module (33) and AC filter module (34) of each energy storage converter unit (30) are fixed on the same support plate (37). The first side and the second side of the housing (10) along the X-axis are respectively provided with a second sidewall (122) and a third sidewall (123). At least two connecting frames (125) protrude from the second sidewall (122) and the third sidewall (123). The support plate (37) is detachably fixed to each connecting frame (125).

7. The energy storage converter as described in claim 6, characterized in that, The housing (10) includes a liquid cooling plate (11), a frame (12) and a top plate (13). The frame (12) has openings at both ends along the Z-axis. The liquid cooling plate (11) and the top plate (13) respectively cover the openings at both ends of the frame (12) along the Z-axis to form the protective cavity (01). The liquid cooling plate (11) is provided with a number of positioning posts (1112) corresponding to the cooling liquid flow channel of the support plate (37) in the middle along the X-axis direction to avoid the liquid cooling plate (11).

8. The energy storage converter as described in claim 7, characterized in that, The liquid cooling plate (11) includes a flow channel processing plate (111) and a cover plate (112). Coolant channels are formed on the flow channel processing plate (111), and the cover plate (112) is fixedly connected to the flow channel processing plate (111) to cooperate in forming coolant channels. The flow channel processing plate (111) is provided with a mounting surface (1111) suitable for contact with the power module (31) and the inverter inductor module (32). The positioning post (1112) is detachably fixedly connected to the flow channel processing plate (111).

9. An energy storage converter as described in claim 2, characterized in that, It also includes a first cooling fan (41), a second cooling fan (42) and a third cooling fan (43); the first cooling fan (41) and the second cooling fan (42) are respectively located at the front and rear ends along the Y-axis direction in the protective cavity (01) and close to the second side along the X-axis direction of the housing (10); the third cooling fan (43) is located between the two bus capacitor modules (33) along the Y-axis direction; the first cooling fan (41), the second cooling fan (42) and the third cooling fan (43) cooperate to form a circulating airflow through the bus capacitor module (33) and the AC filter module (34) of each energy storage converter unit (30); the first AC filter module (341) and the second AC filter module (342) are at least partially mirror-symmetrical.

10. An energy storage converter as described in claim 9, characterized in that, It also includes a first air guide shroud (51), a second air guide shroud (52) and a third air guide shroud (53); the axes of the first cooling fan (41) and the second cooling fan (42) are both inclined relative to the X-axis direction; The first air guide shroud (51) is at least partially covered on the first AC filter module (341) and has a first air outlet (511) opposite to the first cooling fan (41), a second air outlet (512) facing the rear side of the housing (10) and a third air outlet (513) facing the first side of the housing (10) along the X-axis direction. The second air guide shroud (52) is at least partially covered on the second AC filter module (342) and has a fourth air outlet (521) opposite to the second cooling fan (42), a fifth air outlet (522) facing the front side of the housing (10) and a sixth air outlet (523) facing the first side of the housing (10) along the X-axis direction. The first air guide shroud (51) and the second air guide shroud (52) are spaced apart along the Y-axis direction. The axis of the third cooling fan (43) extends along the Y-axis direction. The third air guide shroud (53) is at least partially covered on at least one bus capacitor module (33) and is opposite to the third cooling fan (43).

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