Two-way control liquid cooling energy storage high-voltage control inverter box and method

Abstract

The invention provides a two-way control liquid cooling energy storage high-voltage control inverter box and method. The inverter box comprises an inverter box body; a first control loop and a second control loop are arranged in the inverter box body, the first control loop is used for controlling the first battery cluster, the second control loop is used for controlling the second battery cluster, and the first battery cluster and the second battery cluster are both composed of a plurality of battery packs; two integrated busbars, a battery control unit and an inversion module are also arranged in the inversion box body; the two busbars are respectively connected with the direct current electrical components of the first control loop and the second control loop, and the inversion module is respectively and correspondingly connected with the two busbars through a first circuit breaker and a second circuit breaker; and the first circuit breaker and the second circuit breaker are arranged on the inverter box body. The problems that in the prior art, a plurality of high-voltage control loops are separately arranged, so that the occupied space is large, the number of connecting wire harnesses is large, and the heat dissipation performance is poor due to integration of the plurality of high-voltage control loops are solved.

Description

TECHNICAL FIELD

[0001] The application belongs to the technical field of energy storage, and particularly relates to a dual-path controlled liquid-cooled energy storage high-voltage control inverter box and method. BACKGROUND

[0002] The statements in this section merely provide background information related to the application and do not necessarily constitute prior art.

[0003] In recent years, the battery cell technology continues to break through, the energy density is continuously improved, and the single-box nominal capacity of the energy storage system presents a stepwise rising trend. The market demand for high-energy, high-density and low-cost energy storage products is increasingly urgent, which promotes the development of the energy storage system in the direction of larger capacity and higher integration.

[0004] In the prior art, the common 20-foot standard container type energy storage system adopts a configuration mode of 52 battery cells per battery pack, and the system capacity is generally lower than 5MWh. In order to further increase the single-box capacity to 5MWh or even higher, the energy density needs to be greatly improved, and the typical method includes increasing the number of battery cells in the battery pack to 104, and correspondingly improving the system voltage and power level. However, this way causes the number of battery clusters to increase, resulting in a fold increase in high-voltage distribution and control loops. The method of independently configuring a high-voltage control box for each cluster in the traditional scheme not only occupies a large amount of space, but also increases the system complexity and the scale of cable connections, causing layout redundancy, cost increase and reliability risk.

[0005] In view of the above problems, the prior art adopts a discrete design for the high-voltage control loop, with each cluster corresponding to an independent loop. Although this method is beneficial to the isolation and control between clusters, it also leads to a large box size, a large number of wire harnesses, and inconvenient installation and maintenance, making it difficult to effectively improve the system capacity in a limited space. SUMMARY

[0006] In view of the above problems, the application provides a dual-path controlled liquid-cooled energy storage high-voltage control inverter box and method, which solves the problems of large occupied space and a large number of connection wire harnesses caused by the discrete arrangement of multiple high-voltage control loops in the prior art, and also solves the problem of poor heat dissipation caused by the integration of multiple high-voltage control loops.

[0007] In order to achieve the above purpose, the application is implemented by the following technical solutions: The first aspect of the present application provides a two-way controlled liquid-cooled energy storage high-voltage control inverter box, comprising: an inverter box body; a first control circuit and a second control circuit are arranged in the inverter box body, the first control circuit is used for controlling a first battery cluster, the second control circuit is used for controlling a second battery cluster, the first battery cluster and the second battery cluster are both composed of a plurality of battery packs, the battery pack is made of 104 battery cells in series; two integrated busbars, a battery control unit and an inverter module are further arranged in the inverter box body; the two busbars are respectively connected with direct current electrical components of the first control circuit and the second control circuit, the inverter module is correspondingly connected with the two busbars through a first circuit breaker and a second circuit breaker; the first circuit breaker and the second circuit breaker are arranged on the inverter box body; the battery control unit is connected with a first relay in the first control circuit and a second relay in the second control circuit respectively.

[0008] As a further implementation manner, a first Hall sensor is installed at a direct current negative line end of the first control circuit, a first fuse is installed at a direct current positive line end of the first control circuit, a first relay and a voltage and current collection point are arranged on the busbar connected with the direct current positive line end and the direct current negative line end, and the first relay and the voltage and current collection point are both connected with the battery control unit.

[0009] As a further implementation manner, a direct current positive line end and a direct current negative line end of the second control circuit; a second Hall sensor is installed at the direct current negative line end of the second control circuit, a second fuse is installed at the direct current positive line end, a second relay and a voltage and current collection point are arranged on the busbar connected with the direct current positive line end and the direct current negative line end, and the second relay and the voltage and current collection point are both connected with the battery control unit.

[0010] As a further implementation manner, the busbar is an integrated copper busbar.

[0011] As a further implementation manner, the first fuse and the second fuse both include an electronic fuse and a mechanical fuse arranged in series to realize double protection.

[0012] As a further implementation manner, the inverter box further comprises an intelligent equalization module, the intelligent equalization module is an active equalization module, the intelligent equalization module is connected with the first battery cluster and the second battery cluster respectively, and is used for equalizing energy of the first battery cluster and the second battery cluster.

[0013] As a further implementation manner, the inverter box is further provided with a liquid cooling heat dissipation system, the liquid cooling heat dissipation system comprises a first liquid cooling plate, a second liquid cooling plate, a first water nozzle and a second water nozzle, the first liquid cooling plate and the second liquid cooling plate are respectively embedded with the waterproof shell of the inverter box body and are fixed through waterproof pull-riveting, and the first liquid cooling plate and the second liquid cooling plate respectively cool the first control circuit and the second control circuit, the first liquid cooling plate and the first water nozzle are connected through a cooling control device, the second liquid cooling plate and the second water nozzle are connected through a cooling control device, and the first water nozzle and the second water nozzle are arranged on the inverter box body.

[0014] As a further implementation manner, the inverter box body is provided with a bottom fixing wing plate and a side fixing wing plate for fixing the whole inverter box body, and the inverter box body is further provided with a handle, a wire outlet base, a waterproof communication LAN port, a communication port, a lamp switch button, a fault indicator light, an operation indicator light and positive and negative electrode bases.

[0015] In a second aspect, the application further provides a control method of the liquid cooling energy storage high-voltage control inverter box with double control circuits, which comprises the following steps: S1: Real-time monitoring of the voltage, current and residual power of each battery cluster through the voltage and current collection points of the first control circuit and the second control circuit; S2: When the difference value of the residual power of the battery cluster between the first battery cluster and the second battery cluster is greater than 3%, the battery control unit starts the active balancing module to perform dynamic energy balancing between the first battery cluster and the second battery cluster; S3: When the first control circuit or the second control circuit detects an overcurrent, overvoltage or short circuit fault, the battery control unit triggers the first fuse or the second fuse within 5 ms and controls the mechanical fuse to act, and controls the relay of the fault cluster to be disconnected within 10 ms, so as to realize the rapid isolation of the fault cluster.

[0016] As a further implementation manner, the first control circuit and the second control circuit are independently cooled through the first liquid cooling plate and the second liquid cooling plate, the temperature of the first liquid cooling plate and the second liquid cooling plate is monitored in real time through the cooling control device, and the temperature difference is controlled within ±3.5 DEG C.

[0017] Compared with the prior art, the application has the advantages and positive effects that: The application completes the control and detection of the battery cluster end by integrating the high-voltage power distribution inverter box of the first control loop and the second control loop, built-in battery control unit, relay, circuit breaker, and completes the independent control of two battery clusters in the energy storage system with the inverter module; the two battery clusters are independently controlled by the double control loops, the mutual influence between the clusters is avoided, the charge and discharge management, state monitoring and fault isolation of each battery cluster can be carried out independently, and the system operation reliability and fault tolerance are significantly improved. The traditional dispersed confluence is changed into the integrated copper busbar, a large number of cable connections in the traditional scheme are reduced, the impedance is reduced by 40%, the contact resistance is reduced, the connection looseness and local overheating risk are reduced, and the stability and safety of the electrical connection are improved, and the maintenance is facilitated.

[0018] The application sets the first fuse and the second fuse at the direct current positive pole incoming line end, when serious overload or short circuit fault occurs in the loop, the fuse can be fused quickly, the fault current is effectively cut off, the accident is prevented from expanding, and the expensive battery pack and the electrical equipment at the rear end are protected from damage. The first relay and the second relay are arranged on the busbar and are directly controlled by the battery control unit, active and accurate management of the loop on-off is realized. When the system detects insulation fault, overcurrent or needs maintenance, the battery control unit can actively send a command to break the relay, electrical isolation is realized, and double protection is provided for the operator and the equipment. The first Hall sensor and the second Hall sensor are installed at the direct current negative pole incoming line end, and are used for lossless and high-precision measurement of the loop current.

[0019] The application adopts the first liquid cooling plate and the second liquid cooling plate to independently cool the first control loop and the second control loop, avoids the thermal coupling and mutual interference between different power units, ensures that each heat generating unit can obtain direct and efficient cooling effect, and fundamentally solves the performance decline problem caused by heat accumulation. The temperature of the first liquid cooling plate and the second liquid cooling plate is accurately managed by the cooling control device, and the system temperature difference is controlled within an extremely high precision of ± 3.5 DEG C. Through the modular design, the maintenance or replacement of a single loop will not affect the normal operation of another loop, and the maintainability and usability of the system are greatly improved. BRIEF DESCRIPTION OF DRAWINGS

[0020] The drawings accompanying the specification of the application form a part of the application and serve to further understand the application. The schematic embodiments of the application and the description thereof are used to explain the application, and do not constitute an improper limitation on the application.

[0021] Figure 1 It is a schematic diagram of the liquid-cooled energy storage high-voltage control inverter box of the application. In the figure: 1, inverter box; 2, bottom fixed wing plate; 3, first water nozzle; 4, second water nozzle; 5, handle; 6, outgoing line base; 7, side fixed wing plate; 8, waterproof communication LAN port; 9, communication port; 10, first circuit breaker; 11, second circuit breaker; 12, DC positive pole incoming line end; 13, DC negative pole incoming line end; 14, with lamp switch button; 15, fault indicator light; 16, running indicator light. DETAILED DESCRIPTION

[0023] It should be noted that the following detailed description is illustrative only, and is intended to provide further description of the application. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs.

[0024] It is also important to note that the terms used herein are not intended to limit the exemplary embodiments to the specific embodiments described herein, but rather, are intended to provide further description of the exemplary embodiments according to the present application. As used herein, unless otherwise indicated, the use of the singular includes the plural and back again; and, also, it is understood that the terms "comprise" and / or "comprising," when used in this specification, specify the presence of stated features, steps, operations, devices, components and / or combinations thereof, but do not preclude the presence or addition of one or more other features, steps, operations, devices, components and / or combinations thereof. Example 1 The present embodiment provides a double-path controlled liquid-cooled energy storage high-voltage control inverter box, as shown in the figure Figure 1The application discloses a high-voltage power distribution inverter box, and shows that the high-voltage power distribution inverter box comprises an inverter box body 1; a first control circuit and a second control circuit are arranged in the inverter box body 1, the first control circuit is used for controlling a first battery cluster, the second control circuit is used for controlling a second battery cluster, the first battery cluster and the second battery cluster each comprise a plurality of battery packs, and each battery pack is made of 104 battery cells connected in series; two integrated busbars, a battery control unit and an inverter module are further arranged in the inverter box body 1; the two busbars are connected with direct-current electrical components of the first control circuit and the second control circuit respectively, the inverter module is connected with the two busbars through a first circuit breaker 10 and a second circuit breaker 11 respectively, the first circuit breaker 10 and the second circuit breaker 11 are arranged on the inverter box body 1, and the battery control unit is connected with a first relay in the first control circuit and a second relay in the second control circuit respectively. The high-voltage power distribution inverter box integrating the first control circuit and the second control circuit, the built-in battery control unit, the relays and the circuit breakers complete control and detection of the battery cluster end, cooperate with a 450KW inverter module, and complete independent control of two battery clusters in an energy storage system. The application adopts the double control circuits to independently control the two battery clusters, avoids mutual influence between the clusters, can realize that charging and discharging management, state monitoring and fault isolation of each battery cluster are independently performed, and significantly improves system operation reliability and fault tolerance capability. The traditional dispersed bus is changed into a busbar of a one-piece copper busbar, a large number of cable connections in the traditional scheme are reduced, impedance is reduced by 40%, contact resistance is reduced, connection looseness and local overheating risks are reduced, electrical connection stability and safety are improved, and maintenance is facilitated.

[0025] As a further implementation, a first Hall sensor is installed at the DC negative input terminal 13 of the first control circuit, and a first fuse is installed at the DC positive input terminal 12 of the first control circuit. A first relay and voltage / current acquisition points are installed on the busbars connected to both the DC positive input terminal 12 and the DC negative input terminal 13. Both the first relay and the voltage / current acquisition points are connected to the battery control unit. The first fuse at the DC positive input terminal 12 allows for rapid melting and interruption of the fault current in the event of a severe overload or short circuit, preventing the accident from escalating and protecting the expensive battery pack and electrical equipment from damage. The first relay on the busbar, directly controlled by the battery control unit, enables proactive and precise management of the circuit's on / off state. When the system detects an insulation fault, overcurrent, or requires maintenance, the battery control unit can proactively issue a command to disconnect the relay, achieving electrical isolation and providing dual protection for operators and equipment. The first Hall sensor at the DC negative input terminal 13 is used for non-destructive, high-precision measurement of the circuit current. Hall effect sensors offer advantages such as wide measurement range, fast response, and isolation from the circuit under test. They provide accurate and reliable current data to the battery control unit, forming the foundation for battery state estimation, energy management, and fault diagnosis. Dedicated voltage and current acquisition points are installed on the busbar, providing a direct and reliable voltage sampling interface to ensure accurate voltage monitoring. Combined with Hall effect current sensors, the battery control unit can acquire real-time voltage and current parameters of the circuit, enabling precise power calculation and energy statistics.

[0026] As a further implementation, the second control circuit has a DC positive input terminal 12 and a DC negative input terminal 13. A second Hall sensor is installed at the DC negative input terminal 13, and a second fuse is installed at the DC positive input terminal 12. Second relays and voltage / current acquisition points are installed on the busbars connected to both the DC positive and DC negative input terminals 12 and 13. These relays and acquisition points are connected to the battery control unit. The second fuse at the DC positive input terminal 12 allows for rapid melting and interruption of the fault current in the event of a severe overload or short circuit, preventing the accident from escalating and protecting the expensive battery pack and electrical equipment from damage. The second relay on the busbar, directly controlled by the battery control unit, enables proactive and precise management of the circuit's on / off state. When the system detects an insulation fault, overcurrent, or requires maintenance, the battery control unit can proactively issue a command to disconnect the relay, achieving electrical isolation and providing dual protection for operators and equipment. A second Hall effect sensor is installed at the DC negative input terminal 13 for non-destructive, high-precision measurement of the loop current. A dedicated voltage and current acquisition point is set on the busbar, providing a direct and reliable voltage sampling interface for the system and ensuring accurate voltage monitoring. Combined with the Hall effect current sensor, the battery control unit can acquire the loop's voltage and current parameters in real time, enabling precise power calculation and energy statistics.

[0027] As a further implementation, the busbar is a one-piece copper busbar. Replacing the traditional distributed busbar with a one-piece copper busbar, which has good conductivity and low resistivity, reduces the number of cable connections required in traditional solutions. This lowers contact resistance and also reduces the risk of loose connections and localized overheating. As a further implementation, both the first and second fuses include an electronic fuse and a mechanical fuse connected in series to achieve dual protection.

[0028] As a further implementation, the inverter box also includes an intelligent balancing module, which is an active balancing module. This module is connected to both the first and second battery clusters to balance their energy. Specifically, the active balancing module can directly transfer energy between the first and second battery clusters with an efficiency greater than 85%, transferring energy from the cluster with higher charge to the cluster with lower charge. This effectively solves the problem of inconsistent energy decay caused by slight differences in internal resistance, temperature, and initial capacity between battery clusters, allowing the system to release more capacity. This significantly extends the system's effective discharge time and cycle life.

[0029] As a further implementation, the inverter box is also equipped with a liquid cooling system, which includes a first liquid cooling plate, a second liquid cooling plate, a first water nozzle 3, and a second water nozzle 4. The first and second liquid cooling plates are respectively embedded in the waterproof shell of the inverter box 1 and fixed by waterproof rivets, and respectively cool the first control circuit and the second control circuit. The first liquid cooling plate and the first water nozzle 3 are connected by a cooling control device, and the second liquid cooling plate and the second water nozzle 4 are connected by a cooling control device. Both the first water nozzle 3 and the second water nozzle 4 are located on the inverter box 1. Specifically, by using the first and second liquid cooling plates to independently cool the first and second control circuits, a parallel heat dissipation architecture of "cluster division" is realized. This design avoids thermal coupling and mutual interference between different power units, ensuring that each heat-generating unit can obtain a direct and efficient cooling effect, fundamentally solving the performance degradation problem caused by heat accumulation. By precisely adjusting each cooling circuit through a cooling control device, accurate temperature management of critical components is achieved, keeping the system temperature difference within an extremely high precision of ±3.5℃. Modular cooling ensures that maintenance or replacement of one circuit will not affect the normal operation of another, greatly improving the system's maintainability and availability.

[0030] As a further implementation, the inverter enclosure 1 is provided with a bottom fixing wing plate 2 and a side fixing wing plate 7 for fixing the entire inverter enclosure 1; the inverter enclosure 1 is also provided with a handle 5, a cable outlet base 6, a waterproof communication LAN port 8, a communication port 9, an illuminated switch button 14, a fault indicator light 15, a running indicator light 16, and positive and negative terminal bases; the cable outlet base 6 is an AC output terminal for connecting AC electrical equipment or the power grid; the waterproof communication LAN port 8 is used to connect to the network to realize data interaction with the terminal; the communication port 9 is used to connect multiple inverters in series and transmit binary data signals; the positive and negative terminal bases are used to connect the DC positive terminal and DC negative terminal of the energy storage battery cluster; the illuminated switch button 14 is used to start or stop the inverter; the fault indicator light 15 and the running indicator light 16 are used to display the real-time operating status of the inverter.

[0031] Example 2 This embodiment provides a control method for a dual-channel controlled liquid-cooled energy storage high-voltage control inverter box, including the following steps: S1: Real-time monitoring of the voltage, current and remaining charge of each battery cluster through the voltage and current acquisition points of the first and second control loops; S2: When the difference in remaining charge between the first battery cluster and the second battery cluster is greater than 3%, the battery control unit activates the active balancing module to perform dynamic energy balancing between the first battery cluster and the second battery cluster. S3: When the first control circuit or the second control circuit detects an overcurrent, overvoltage, or short-circuit fault, the battery control unit triggers the first fuse or the second fuse within 5ms and controls the mechanical fuse to operate. At the same time, it controls the relay of the fault cluster to disconnect within 10ms, thereby achieving rapid isolation of the fault cluster.

[0032] As a further implementation, the first control loop and the second control loop are cooled independently by the first liquid cooling plate and the second liquid cooling plate, and the temperature of the first liquid cooling plate and the second liquid cooling plate are monitored in real time by the cooling control device, and the temperature difference is controlled within ±3.5℃.

[0033] While the specific embodiments of the present invention have been described above in conjunction with the accompanying drawings, this is not intended to limit the scope of protection of the present invention. Those skilled in the art should understand that various modifications or variations that can be made by those skilled in the art without creative effort based on the technical solutions of the present invention are still within the scope of protection of the present invention.

Claims

1. A dual-channel controlled liquid-cooled energy storage high-voltage control inverter, characterized in that, include: An inverter enclosure is provided; the inverter enclosure is provided with a first control circuit and a second control circuit, the first control circuit is used to control a first battery cluster, and the second control circuit is used to control a second battery cluster, both of which are composed of multiple battery packs; the inverter enclosure is also provided with two integrated busbars, a battery control unit, and an inverter module; the two busbars are respectively connected to the DC electrical components of the first control circuit and the second control circuit, and the inverter module is respectively connected to the two busbars through a first circuit breaker and a second circuit breaker; the first circuit breaker and the second circuit breaker are provided on the inverter enclosure; the battery control unit is respectively connected to a first relay in the first control circuit and a second relay in the second control circuit.

2. The dual-channel controlled liquid-cooled energy storage high-voltage control inverter box as described in claim 1, characterized in that, A first Hall sensor is installed at the DC negative input terminal of the first control circuit, and a first fuse is installed at the DC positive input terminal of the first control circuit. A first relay and a voltage and current acquisition point are provided on the busbars connected to the DC positive input terminal and the DC negative input terminal. The first relay and the voltage and current acquisition point are both connected to the battery control unit.

3. The dual-channel controlled liquid-cooled energy storage high-voltage control inverter box as described in claim 2, characterized in that, The second control circuit has a DC positive input terminal and a DC negative input terminal; a second Hall sensor is installed on the DC negative input terminal of the second control circuit, a second fuse is installed on the DC positive input terminal, and a second relay and a voltage and current acquisition point are provided on the busbars connected to the DC positive input terminal and the DC negative input terminal, and the second relay and the voltage and current acquisition point are connected to the battery control unit.

4. The dual-channel controlled liquid-cooled energy storage high-voltage control inverter box as described in claim 3, characterized in that, The busbar is an integral copper busbar.

5. The dual-channel controlled liquid-cooled energy storage high-voltage control inverter box as described in claim 3, characterized in that, Both the first and second fuses include an electronic fuse and a mechanical fuse connected in series to achieve dual protection.

6. The dual-channel controlled liquid-cooled energy storage high-voltage control inverter box as described in claim 1, characterized in that, The inverter box is also equipped with an intelligent balancing module, which is an active balancing module. The intelligent balancing module is connected to the first battery cluster and the second battery cluster respectively, and is used to balance the energy of the first battery cluster and the second battery cluster.

7. The dual-channel controlled liquid-cooled energy storage high-voltage control inverter box as described in claim 1, characterized in that, The inverter box is also equipped with a liquid cooling system, which includes a first liquid cooling plate, a second liquid cooling plate, a first water nozzle, and a second water nozzle. The first liquid cooling plate and the second liquid cooling plate are respectively embedded in the waterproof shell of the inverter box and fixed by waterproof rivets, and respectively cool the first control circuit and the second control circuit. The first liquid cooling plate and the first water nozzle are connected by a cooling control device, and the second liquid cooling plate and the second water nozzle are connected by a cooling control device. Both the first water nozzle and the second water nozzle are located on the inverter box.

8. The dual-channel controlled liquid-cooled energy storage high-voltage control inverter box as described in claim 1, characterized in that, The inverter enclosure is equipped with a bottom fixing wing plate and a side fixing wing plate for fixing the entire inverter enclosure; the inverter enclosure is also equipped with a handle, a cable outlet base, a waterproof communication LAN port, a communication port, an illuminated switch button, a fault indicator light, a running indicator light, and positive and negative terminal bases.

9. The control method for a dual-path controlled liquid-cooled energy storage high-voltage control inverter box as described in any one of claims 1-8, characterized in that, Includes the following steps: S1: Real-time monitoring of the voltage, current and remaining charge of each battery cluster through the voltage and current acquisition points of the first and second control loops; S2: When the difference in remaining charge between the first battery cluster and the second battery cluster is greater than 3%, the battery control unit activates the active balancing module to perform dynamic energy balancing between the first battery cluster and the second battery cluster. S3: When the first control circuit or the second control circuit detects an overcurrent, overvoltage, or short-circuit fault, the battery control unit triggers the first fuse or the second fuse within 5ms and controls the mechanical fuse to operate. At the same time, it controls the relay of the fault cluster to disconnect within 10ms, thereby achieving rapid isolation of the fault cluster.

10. The operating method of a dual-path controlled liquid-cooled energy storage high-voltage control inverter box as described in claim 9, characterized in that, The first control loop and the second control loop are cooled independently by the first liquid cooling plate and the second liquid cooling plate. The temperature of the first liquid cooling plate and the second liquid cooling plate is monitored in real time by the cooling control device, and the temperature difference is controlled within ±3.5℃.

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