Liquid cooling bus duct and method of assembling the same

Abstract

This invention relates to the technical field of busbar cooling, and mainly discloses a liquid-cooled busbar and its assembly method. The liquid-cooled busbar includes a main shell plate and auxiliary plates fixed on both sides of the main shell plate. A storage gap for sealed conductor busbars is provided between the main shell plate and the auxiliary plates. At least one set of first flow channels is provided in the area corresponding to the inner contact surface of the conductor busbar within the main shell plate; at least one set of second flow channels is provided in the area corresponding to the outer contact surface of the conductor busbar within the auxiliary plates. The first and second flow channel sets at least cover part of the heat-generating areas on both sides of the conductor busbar. This invention improves upon the problems of poor structural stability, uneven fluid distribution, and weak thermal expansion adaptability of existing liquid-cooled busbars.

Description

Technical Field

[0001] This invention relates to the technical field of busbar cooling, and in particular to a liquid-cooled busbar and its assembly method. Background Technology

[0002] Busbar trunking, as a core transmission component of high-power power distribution systems, is widely used in industrial plants, data centers, and other scenarios. Its conductor busbars generate a large amount of heat during high current-carrying operation. If heat dissipation is not timely, it can easily lead to insulation aging, reduced current-carrying capacity, and even safety hazards.

[0003] Existing busbar trunking systems mostly adopt natural air cooling or single-channel liquid cooling designs, which have problems such as low heat dissipation efficiency and uneven temperature distribution. Some liquid cooling solutions have asymmetrical flow channel layouts, resulting in unbalanced fluid distribution and uneven structural stress. Long-term operation is prone to deformation and leakage due to thermal expansion. In addition, the assembly process is complex and the maintenance is inconvenient, making it difficult to adapt to the requirements of high power and long-term stable operation. Summary of the Invention

[0004] Therefore, the technical problem to be solved by the present invention is that the existing liquid-cooled busbar has poor structural stability, uneven fluid distribution, and weak adaptability to thermal expansion.

[0005] The above-mentioned technical problems are solved by the following technical solution: The present invention proposes a liquid-cooled busbar trunking, which includes a main shell plate and auxiliary plates fixed on both sides of the main shell plate. A storage gap for sealed conductor busbars is provided between the main shell plate and the auxiliary plates. In this case, at least one set of first flow channels is provided in the area corresponding to the inner contact surface of the conductor busbar in the main shell plate; at least one set of second flow channels is provided in the area corresponding to the outer contact surface of the conductor busbar in the auxiliary plates. The first flow channel group and the second flow channel group at least cover part of the heat-generating area on both sides of the conductor busbar.

[0006] In a preferred embodiment of the liquid-cooled busbar trunking of the present invention: a side shell plate is also symmetrically and vertically fixed on the main shell plate, the main shell plate is fixed to the side shell plate by a connecting boss fixed at its top end, the storage gap is formed between the connecting bosses at both ends, and the stacking thickness of the conductor busbar is equal to the gap depth of the storage gap.

[0007] In a preferred embodiment of the liquid-cooled busbar trunking of the present invention: the first flow channel group includes symmetrically arranged flow distribution cavities, which are opened through the main shell plate. The two ends of the flow distribution cavities are symmetrically sealed and fixed with end baffles. A partition group is also provided between the flow distribution cavities. The partition group includes symmetrically arranged partitions. The two ends of the partitions are sealed and inserted into the end baffles, and a buffer barrier gap is formed between the partitions. The end baffle includes a central sealing plate and flow guiding sealing plates symmetrically fixed at its two ends. The central sealing plate seals the two ends of the buffer barrier gap, and the flow guiding sealing plates seal the two ends of the flow distribution cavities.

[0008] In a preferred embodiment of the liquid-cooled busbar trunking of the present invention: an inlet groove and an outlet groove are provided in the middle of the side shell plate, and a first cover plate and a second cover plate are sealed and fixed on the inlet groove and the outlet groove; both the inlet groove and the outlet groove include a connecting port and a flow through port, the diameter of the connecting port is larger than the diameter of the flow through port, and a connecting platform is formed at the junction; both the first cover plate and the second cover plate include a flow channel sealing plate and an isolation boss fixed at its bottom end, a first inlet pipe and a second inlet pipe are symmetrically fixed on the top of the flow channel sealing plate of the first cover plate, and a first outlet pipe and a second outlet pipe are symmetrically fixed on the top of the flow channel sealing plate of the second cover plate.

[0009] In a preferred embodiment of the liquid-cooled busbar trunking of the present invention: a first diverter plate is fixed at the middle of the bottom end of the isolation boss of the first cover plate, and a second diverter plate is fixed at the middle of the bottom end of the isolation boss of the second cover plate; the flow channel sealing plate is fixed on the connecting platform and seals the connecting port; the isolation boss is fixed inside the flow through port and separates the flow through port; the flow through ports separated on both sides are respectively connected to the corresponding inlet and outlet pipes; the first inlet pipe and the first outlet pipe are symmetrical, and the second inlet pipe and the second outlet pipe are symmetrically arranged.

[0010] In a preferred embodiment of the liquid-cooled busbar trunking of the present invention: the first flow divider plate and the second flow divider plate are movably inserted into the flow divider cavity, and a flow equalization plate is fixed in the flow divider cavity parallel to its extension direction, and the first flow divider plate and the second flow divider plate abut against and seal with the flow equalization plate; wherein, the length of the flow equalization plate is greater than the maximum distance between the inlet groove and the outlet groove, and the distance of the flow equalization plate from the top and bottom inner walls of the flow divider cavity is equal.

[0011] In a preferred embodiment of the liquid-cooled busbar trunking of the present invention: a first buffer arc block is symmetrically fixed at the end of the first and second flow distribution plates away from the inlet and outlet channels, and a second buffer arc block is symmetrically arranged at both ends of the flow guide sealing plate located inside the flow distribution cavity; the inner arc surface of the first buffer arc block connects the outer wall of the flow equalization plate with the outer surface of the first and second flow distribution plates; the inner arc surface of the second buffer arc block connects the inner wall of the flow distribution cavity with the outer surface of the flow guide sealing plate.

[0012] In a preferred embodiment of the liquid-cooled busbar trunking of the present invention: the flow equalization plate, the first flow divider plate, and the second flow divider plate separate the internal space of the flow divider cavity, and together with the flow guide sealing plate, form a first flow cavity and a second flow cavity respectively; the first flow cavity includes a first through cavity, and the second flow cavity includes a second through cavity, a rotary cavity, and a third through cavity; wherein, the second through cavity is disposed at both ends of the first through cavity and is separated by the first flow divider plate and the second flow divider plate, the third through cavity is disposed parallel to the side of the first through cavity away from the inlet and outlet slots, and is isolated from the first and second through cavities by the flow equalization plate, and the rotary cavity is directly connected to the second through cavity and the third through cavity; the first through cavity is connected to the first inlet pipe and the first outlet pipe, and the second through cavities at both ends of the first through cavity are connected to the second inlet pipe and the second outlet pipe respectively.

[0013] In a preferred embodiment of the liquid-cooled busbar trunking of the present invention: the auxiliary plate includes a side abutment plate and a sealing shell fixed to its side wall, and at least one set of the sealing shell is provided, forming a second flow channel group between the sealing shell and the side abutment plate; a third inlet pipe and a third outlet pipe are also fixedly connected at both ends of the sealing shell; a plurality of sets of parallel heat dissipation fins are uniformly fixed to the side abutment plate and the outer wall of the sealing shell; connectors are symmetrically fixed to the ends of the side shell plates on both sides, and protective plates are fixed between the connectors, the protective plates are symmetrically arranged, and the conductor busbar is arranged between the protective plates and flush with the connecting end of the conductor busbar.

[0014] To address the aforementioned problems, the present invention also proposes the following technical solution: a liquid-cooled busbar assembly method applicable to the aforementioned liquid-cooled busbar, comprising the following steps: symmetrically welding and fixing side shell plates to the top and bottom of the main shell plate; placing conductor busbars within the storage gap formed on both sides of the main shell plate; installing auxiliary plates on the outside of the conductor busbars to seal the internal conductor busbars; fixing the auxiliary plates to the side shell plates; and after installing connectors at both ends of the side shell plates, sequentially installing protective plates on both sides of the conductor busbars to cover them from both sides.

[0015] The beneficial effects of this invention are as follows: This design achieves balanced fluid distribution and structural stress equilibrium through symmetrically arranged flow dividers and a second flow channel assembly, avoiding localized eddies and stress concentrations caused by asymmetrical layouts and improving operational stability. The dual independent flow channels, combined with a collaborative heat dissipation design, expand the heat dissipation coverage, reduce temperature differences in the conductor busbars, and effectively solve the problem of localized high-temperature accumulation.

[0016] The buffer gap absorbs thermal expansion stress, reduces the risk of leakage due to flow channel deformation, and extends service life. Standardized interfaces and optimized assembly steps simplify the installation process and improve maintenance convenience. The synergistic structure of the flow channel and heat dissipation fins further enhances heat dissipation capabilities, adapting to the long-term stable operation requirements of high-power power distribution scenarios, balancing heat dissipation efficiency and structural reliability. Attached Figure Description

[0017] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings of the embodiments of the present invention will be briefly described below. Obviously, the drawings described below only relate to some embodiments of the present invention and are not intended to limit the present invention. Wherein: Figure 1 A schematic diagram of the distribution of the first flow channel group and the second flow channel group is shown.

[0018] Figure 2 A structural diagram of the side shell plate is shown.

[0019] Figure 3 A schematic diagram of the side shell plate installation is shown.

[0020] Figure 4 A schematic diagram of the distribution of the first flow channel group is shown.

[0021] Figure 5 A structural diagram of the end baffle is shown.

[0022] Figure 6 A schematic diagram of the installation of the first cover plate and the second cover plate is shown.

[0023] Figure 7 The diagram shows the structure of the cover plate and end baffle.

[0024] Figure 8 A diagram of the flow divider cavity structure is shown.

[0025] Figure 9 The structural diagrams of the first and second flow cavities are shown.

[0026] Figure 10 A structural diagram of the auxiliary plate is shown.

[0027] Figure 11 A schematic diagram of the connector and protection plate installation is shown.

[0028] Figure 12 The diagram shows the installation steps for the liquid-cooled busbar trunking. Detailed Implementation

[0029] To enable those skilled in the art to better understand the present invention, the present invention will be further described in detail below with reference to specific embodiments and accompanying drawings.

[0030] The terminology used in this invention is that which is currently widely used in the art in consideration of the function of the invention; however, these terms may vary according to the intent of those skilled in the art, precedent, or new technology in the art. Furthermore, specific terms may be chosen by the applicant, and in such cases, their detailed meanings will be described in the detailed description of the invention. Therefore, the terms used in this specification should not be construed as simple names, but rather based on their meanings and the overall description of the invention.

[0031] Reference Figures 1-12 This embodiment provides a liquid-cooled busbar trunking and its assembly method. This invention is applicable to high-power, high-heat scenarios such as industrial power distribution systems, new energy power plants, and large data centers, and aims to solve problems such as poor structural stability, uneven fluid distribution, and weak thermal expansion adaptability of existing liquid-cooled busbar trunking.

[0032] First, a liquid-cooled busbar trunking is provided, which includes a main shell plate 100 and auxiliary plates 200 fixed on both sides of the main shell plate 100. A storage gap X for a sealed conductor busbar A is provided between the main shell plate 100 and the auxiliary plates 200.

[0033] The main shell plate 100 and the auxiliary plate 200 are both integrally formed from high thermal conductivity aluminum alloy. The width of the storage gap X is designed according to the specifications of the conductor busbar A, which not only ensures that the conductor busbar A can be stably embedded without shaking, but also leaves a small space of 0.5 to 1 mm for heat dissipation. At the same time, the mating surface between the auxiliary plate 200 and the main shell plate 100 is provided with a high temperature resistant silicone rubber sealing gasket to ensure the sealing performance of the storage gap X and prevent external dust and moisture from entering and affecting the insulation performance of the busbar.

[0034] The main shell plate 100 has at least one set of first flow channel group B in the area corresponding to the inner contact surface of the conductor busbar A. The auxiliary plate 200 has at least one set of second flow channel group C in the area corresponding to the outer contact surface of the conductor busbar A. The first flow channel group B and the second flow channel group C at least cover part of the heat-generating area on both sides of the conductor busbar A.

[0035] Among them, the fit error between the first flow channel group B and the inner contact surface of the conductor busbar A is ≤0.1mm, and the second flow channel group C and the outer contact surface are similarly reduced through precision machining. The two flow channels preferentially cover the high heat generation area in the middle of the conductor busbar A, because the heat generation in this area accounts for more than 60%. At the same time, the number of flow channel groups can be increased according to the length of the busbar to achieve full-length heat dissipation coverage.

[0036] Furthermore, to verify the heat dissipation advantages of the flow channel design of this invention, performance tests were conducted. The test conditions were: flow rate 2500A, coolant inlet temperature 25℃, and coolant flow rate 3L / min. The test results are shown in Table 1 below: Table 1 Maximum temperature of conductor busbar (°C) 89.2 62.5 30% Temperature uniformity of conductor busbar (°C) 18.7 7.3 61% Coolant resistance loss (kPa) 12.5 8.3 33.6% Failure rate after 1000 hours of continuous operation 8.3% 0% 100%

[0037] As shown in Table 1 above, the present invention, through the design of "double-sided coverage of the first flow channel group B + coordinated heat dissipation of the second flow channel group C", reduces the maximum temperature of the conductor busbar to 62.5℃, which is far below the 90℃ limit specified in the existing standard. The temperature uniformity is improved by 61%, effectively solving the pain point of "local high temperature accumulation" in the existing solution.

[0038] Furthermore, a side shell plate 300 is symmetrically and vertically fixed on the main shell plate 100. The main shell plate 100 is connected to the side shell plate 300 through a connecting boss 101 fixed at its top end. A storage gap X is formed between the connecting bosses 101 at both ends. The stacking thickness of the conductor busbar A is equal to the gap depth of the storage gap X.

[0039] The connecting boss 101 is a stainless steel protrusion integrally formed with the main shell plate 100. It is fixed to the side shell plate 300 by laser welding, and the welding strength reaches more than 50MPa. The design of the conductor busbar A with equal stacking thickness and gap depth can ensure that the upper and lower surfaces of the busbar are in close contact with the main shell plate 100 and the connecting boss 101 respectively, avoiding poor contact caused by vibration and ensuring stable heat transfer efficiency.

[0040] The first flow channel group B includes symmetrically arranged flow dividers B1, which are opened through the main shell plate 100. Both ends of the flow divider B1 are symmetrically sealed and fixed with end baffles 102.

[0041] The flow divider B1 has a rectangular or U-shaped cross-section and its inner wall is polished to a roughness of ≤Ra0.8μm to reduce fluid resistance. The end baffle 102 is made of corrosion-resistant engineering material and is fixed to the end of the flow divider B1 by bolts or integrated welding.

[0042] To verify the impact of the number and layout of the flow divider B1 on heat dissipation, under the same test conditions: flow rate 2500A, coolant inlet temperature 25℃, and coolant flow rate 3L / min, the heat dissipation performance of flow dividers B1 with different numbers and layouts was compared. The results are shown in Table 2 below. Table 2 Group 1 (Asymmetric) 68.3 10.5 65 7.9 2 groups (symmetrical) 62.5 7.3 82 8.3 3 groups (asymmetric) 55.8 8.7 95 13.6

[0043] As can be seen from Table 2 above, the two sets of symmetrically distributed flow dividers B1 are the optimal solutions: although the resistance of the one asymmetrical configuration is relatively small, the heat dissipation coverage area is only 65%, resulting in poor temperature uniformity; although the coverage area of ​​the three asymmetrical configurations is increased to 95%, the temperature uniformity error increases to 8.7℃ due to the difficulty in achieving uniform fluid distribution, and the dense flow channels cause the resistance loss to soar to 13.6kPa, significantly increasing energy consumption.

[0044] The two symmetrical configurations not only expand the heat dissipation coverage area through dual symmetrical flow channels, but also ensure balanced coolant distribution and structural stress balance, avoiding local eddies or thermal stress concentration caused by asymmetrical layout. They achieve the optimal balance between the highest temperature of the conductor busbar, temperature uniformity and resistance loss, resulting in the best overall heat dissipation performance and operating economy.

[0045] Furthermore, a partition group 103 is also provided between the flow ducts B1. The partition group 103 includes symmetrically arranged partitions 103a. Both ends of the partitions 103a are sealed and inserted into the end baffles 102, and a buffer barrier gap X1 is formed between the partitions 103a.

[0046] The partition 103a is a thin aluminum alloy plate. The part inserted into the end baffle 102 is provided with a sealing strip to achieve complete isolation between the flow dividers B1. The width of the buffer barrier gap X1 is 2-3 mm, which can absorb the thermal expansion of the main shell plate 100 and the flow divider B1 due to temperature changes, avoid flow channel deformation or cracking, and reduce thermal interference between adjacent flow channels.

[0047] A specific test was conducted on "thermal expansion adaptability": the deformation of the flow channel was measured under temperature cycling conditions from -20℃ to 80℃, and the results are shown in Table 3 below: Table 3 -20℃→80℃ (heating stage) 1.8 0.5 72.2% 80℃→-20℃ (cooling stage) 1.5 0.4 73.3% Maximum deformation after 100 cycles 2.3 0.6 73.9%

[0048] The data in Table 3 above show that the "buffer barrier gap X1" of the present invention can effectively absorb the structural stress caused by temperature changes, and the deformation of the flow channel is reduced by more than 70% compared with the existing solution, avoiding the failure of the flow channel seal due to long-term thermal cycling, further verifying the rationality of the structural design.

[0049] Furthermore, the end baffle 102 includes a central sealing plate 102a and flow guiding sealing plates 102b symmetrically fixed at both ends thereof. The central sealing plate 102a seals both ends of the buffer barrier gap X1, and the flow guiding sealing plates 102b seal both ends of the diversion cavity B1.

[0050] The central sealing plate 102a seals the buffer barrier gap X1, preventing external impurities from entering the gap and affecting the thermal expansion absorption effect.

[0051] An inlet groove 301 and an outlet groove 302 are provided in the middle of the side shell plate 300. A first cover plate 301a and a second cover plate 302a are sealed and fixed on the inlet groove 301 and the outlet groove 302.

[0052] The inlet channel 301 and outlet channel 302 are distributed at intervals along the extension direction of the side shell plate 300. The spacing is designed according to the flow channel layout to ensure precise correspondence with the inlet and outlet of the first flow channel group B. The first cover plate 301a and the second cover plate 302a are made of stainless steel and are fixed to the side shell plate 300 by bolts. Anaerobic sealant is applied at the connection to improve long-term sealing reliability.

[0053] Both the inlet channel 301 and the outlet channel 302 include a connection port K1 and a flow through port K2. The diameter of the connection port K1 is larger than the diameter of the flow through port K2. A connecting platform T is formed at the junction. The connecting platform T can position the first cover plate 301a and the second cover plate 302a, and at the same time increase the contact area between the cover plate and the channel body to enhance the sealing effect.

[0054] Both the first cover plate 301a and the second cover plate 302a include a flow channel sealing plate 301a-1 and an isolation boss 301a-2 fixed at its bottom end. A first inlet pipe 301a-3 and a second inlet pipe 301a-4 are symmetrically fixed at the top of the flow channel sealing plate 301a-1 of the first cover plate 301a, and a first outlet pipe 302a-1 and a second outlet pipe 302a-2 are symmetrically fixed at the top of the flow channel sealing plate 301a-1 of the second cover plate 302a.

[0055] Furthermore, the dimensions of the flow channel sealing plate 301a-1 match the connection port K1, and the dimensions of the isolation boss 301a-2 match the through port K2. After insertion, it can separate the internal space of the through port K2 to prevent coolant from flowing between different flow channels. Both the inlet pipe and the outlet pipe adopt standard threaded interfaces, which facilitates quick connection with external pipelines. The pipe body and the flow channel sealing plate 301a-1 are welded and fixed to ensure no leakage.

[0056] A first diverter plate 301a-5 is fixed at the center of the bottom end of the isolation boss 301a-2 on the first cover plate 301a, and a second diverter plate 302a-3 is fixed at the center of the bottom end of the isolation boss 301a-2 on the second cover plate 302a. Both the first diverter plate 301a-5 and the second diverter plate 302a-3 are thin metal plates that can evenly distribute the coolant introduced by the inlet and outlet pipes to the corresponding flow chambers and then evenly discharge it, avoiding uneven heat dissipation caused by local flow concentration; the diverter plate and the isolation boss 301a-2 are integrally formed.

[0057] The flow channel sealing plate 301a-1 is fixed on the connecting platform T and seals the connecting port K1. The isolation boss 301a-2 is fixed inside the flow port K2 and separates the flow port K2. The flow ports K2 separated on both sides are connected to the corresponding inlet and outlet pipes respectively.

[0058] The flow channel sealing plate 301a-1 has a sealing groove on the contact surface with the connecting platform T, and a built-in fluororubber sealing ring to achieve complete sealing of the connection port K1; the isolation boss 301a-2 separates the two channels formed after the flow port K2, which correspond to the first flow cavity B11 and the second flow cavity B12 respectively, to ensure that the coolant enters the different flow cavities for circulation as needed.

[0059] The first inlet pipe 301a-3 and the first outlet pipe 302a-1 are symmetrically arranged, and the second inlet pipe 301a-4 and the second outlet pipe 302a-2 are symmetrically arranged. The symmetrical layout can ensure that the flow path length of the coolant in the flow channel is consistent, avoiding uneven heat dissipation caused by path differences; at the same time, the symmetrical design facilitates the modular splicing of the busbar trunking, and the pipe interface positions on the left and right sides are unified, reducing the difficulty of pipe layout when connecting multiple busbar trunking sections.

[0060] The first diverter plate 301a-5 and the second diverter plate 302a-3 are movably inserted into the diverter cavity B1. A flow equalization plate 104 is fixed within the diverter cavity B1, parallel to its extension direction. The first diverter plate 301a-5 and the second diverter plate 302a-3 abut against the flow equalization plate 104 for sealing. The movable insertion design facilitates disassembly of the diverter plates for cleaning the flow channels during later maintenance. The flow equalization plate 104 is a strip-shaped aluminum alloy plate, fixed to the middle of the diverter cavity B1 by welding. The seal at the abutment point with the diverter plate uses an elastic sealing gasket, which can accommodate assembly errors and ensure no coolant cross-flow.

[0061] The length of the flow equalization plate 104 is greater than the maximum distance between the inlet groove 301 and the outlet groove 302. The distance of the flow equalization plate 104 from the top and bottom inner walls of the flow distribution cavity B1 is equal. The design of equal distance from the inner wall can make the cross-sectional area of ​​the first flow cavity B11 and the second flow cavity B12 the same, ensuring that the flow rates of the two fluids are consistent and further improving the heat dissipation uniformity.

[0062] The first flow divider 301a-5 and the second flow divider 302a-3 are each symmetrically fixed with a first buffer arc block 301a-5a at the ends away from the inlet and outlet slots. The flow guide plate 102b is also symmetrically provided with second buffer arc blocks 102b-1 at both ends inside the flow divider cavity B1. Both the first buffer arc block 301a-5a and the second buffer arc block 102b-1 are arc-shaped rubber blocks or metal arc sheets. Their function is to reduce the local resistance loss of coolant when the flow channel turns or enters and exits the flow divider, avoid the generation of turbulent noise, and protect the inner wall of the flow channel from fluid impact wear. The inner arc surface of the arc block is smoothly connected to the inner wall of the flow channel to ensure smooth fluid flow.

[0063] The inner arc surface of the first buffer arc block 301a-5a connects to the outer wall of the flow equalization plate 104 and the outer surfaces of the first flow divider 301a-5 and the second flow divider 302a-3. The inner arc surface of the second buffer arc block 102b-1 connects to the inner wall of the flow divider cavity B1 and the outer surface of the flow guide plate 102b. This connection design eliminates the sharp corners in the flow channel, preventing coolant from accumulating at the corners or creating dead zones, ensuring no heat dissipation blind spots in the flow channel, while improving the stability of fluid flow and reducing energy consumption during system operation.

[0064] The flow equalization plate 104, the first flow splitter plate 301a-5, and the second flow splitter plate 302a-3 separate the internal space of the flow splitter cavity B1, and together with the flow guide sealing plate 102b, form the first flow cavity B11 and the second flow cavity B12 respectively.

[0065] The first flow chamber B11 and the second flow chamber B12 are independent closed flow channels, which can be circulated with coolant to achieve dual circulation. This not only improves heat dissipation capacity, but also maintains basic heat dissipation through the other flow in the event of a single flow failure, thereby improving system reliability. The flow guide plate 102b seals both ends of the flow splitting chamber B1 to ensure that the two coolants circulate only in their respective flow chambers, without the risk of crossflow.

[0066] The first flow cavity B11 includes a first through cavity B111, and the second flow cavity B12 includes a second through cavity B121, a rotary cavity B122, and a third through cavity B123. The second through cavity B121 is disposed at both ends of the first through cavity B111 and is separated by a first flow divider plate 301a-5 and a second flow divider plate 302a-3. The third through cavity B123 is disposed parallel to the side of the first through cavity B111 away from the inlet slot 301 and the outlet slot 302, and is isolated from the first through cavity B111 and the second through cavity B121 by a flow equalization plate 104. The rotary cavity B122 is directly connected to the second through cavity B121 and the third through cavity B123.

[0067] The first cavity B111 is a straight cavity structure to ensure rapid flow of coolant; the second cavity B121 overlaps with the two ends of the first cavity B111, shortening the path for coolant to enter the flow channel; the rotary cavity B122 is an arc-shaped cavity to achieve smooth turning of coolant; the third cavity B123 is parallel to the first cavity B111 and can cover the area of ​​the diversion cavity B1 far from the inlet and outlet, avoiding heat dissipation dead zones.

[0068] The first passage cavity B111 is connected to the first inlet pipe 301a-3 and the first outlet pipe 302a-1, and the second passage cavities B121 at both ends of the first passage cavity B111 are connected to the second inlet pipe 301a-4 and the second outlet pipe 302a-2, respectively.

[0069] In this scheme, the coolant circulation path is clearly defined: the first path enters the first cavity B111 from the first inlet pipe 301a-3, absorbs heat, and flows out from the first outlet pipe 302a-1; the second path enters the second cavity B121 at one end from the second inlet pipe 301a-4, turns through the rotary cavity B122 to enter the third cavity B123, continues to absorb heat, and flows out from the second cavity B121 at the other end into the second outlet pipe 302a-2.

[0070] The dual-circuit independent circulation can flexibly adjust the single-circuit or dual-circuit operation according to the heat generation power of conductor bus A, taking into account both heat dissipation efficiency and energy saving requirements.

[0071] The auxiliary plate 200 includes a side abutment plate 201 and a sealing shell 202 fixed to its side wall. At least one set of sealing shells 202 is provided, and a second flow channel group C is formed between the sealing shell 202 and the side abutment plate 201.

[0072] Among them, the side plate 201 is a high thermal conductivity aluminum alloy plate, and the contact surface with the outer side of the conductor busbar A is precision polished to ensure a tight fit and reduce contact thermal resistance; the sealing shell 202 is made of stainless steel and is sealed and fixed to the side plate 201 by laser welding to prevent coolant leakage; multiple sets of sealing shells 202 can be set according to the length of the auxiliary plate 200, and multiple sets of second flow channel groups C are connected in parallel to the external cooling system to improve the heat dissipation capacity of the auxiliary plate 200.

[0073] To verify the impact of the number and layout of the second flow channel group C on the heat dissipation effect, under the same test conditions (flow rate 2500A, coolant inlet temperature 25℃, coolant flow rate 3L / min), the heat dissipation performance of different numbers and layouts of the second flow channel group C was compared. The results are shown in Table 4 below: Table 4 Group 1 (Asymmetric) 66.2 75 80 82% 2 groups (symmetrical) 60.1 88 108 100% 3 groups (asymmetric) 54.3 90 135 76%

[0074] As shown in Table 4 above, the optimal solution is the second flow channel group C with two symmetrical configurations: the asymmetrical configuration of the first group not only has insufficient heat dissipation coverage, but also uneven stress on one side of the auxiliary plate, resulting in structural instability; although the heat dissipation per unit time is increased in the three asymmetrical configurations, the structural stress balance of the auxiliary plate is reduced to 76% due to the inability to make the flow channel layout symmetrical, which makes it prone to deformation during long-term operation, and the heat dissipation fin layout is limited by the asymmetrical flow channel, resulting in limited improvement in collaborative efficiency.

[0075] The two symmetrical configurations can achieve uniform distribution of coolant and heat dissipation fins, and the auxiliary plate is subjected to completely balanced forces. This not only reduces the temperature of the conductor busbar to 60.1℃, but also ensures long-term structural stability. It achieves the optimal balance between heat dissipation effect, structural reliability and synergistic efficiency, and its overall performance far exceeds that of the asymmetrical configuration.

[0076] The sealing shell 202 is also fixedly connected to a third inlet pipe 202a and a third outlet pipe 202b at both ends. The interface specifications of the third inlet pipe 202a and the third outlet pipe 202b are the same as those of the first and second inlet pipes, which facilitates unified connection with the external cooling system and reduces pipeline adaptation costs. The pipe body and the sealing shell 202 are fixed by welding, and the connection is inspected for flaws to ensure that there is no risk of leakage.

[0077] Several sets of parallel heat dissipation fins 201a are uniformly fixed on the outer walls of the side plate 201 and the sealing shell 202. The heat dissipation fins 201a are aluminum alloy sheets with a thickness of 0.8 to 1.2 mm and a spacing of 5 to 8 mm between adjacent fins. They are fixed to the outer walls of the side plate 201 and the sealing shell 202 by integral molding or brazing. The fins can increase the contact area between the auxiliary plate 200 and the air, realize the synergistic heat dissipation of "liquid cooling + air cooling", and further improve the heat dissipation efficiency. They are especially suitable for scenarios with good external ventilation.

[0078] Connectors 303 are symmetrically fixed to the ends of the two side shell plates 300, and protective plates 304 are fixed between the connectors 303. The protective plates 304 are symmetrically arranged, and the conductor busbar A is located between the protective plates 304 and flush with the connection end of the conductor busbar A. The connectors 303 are T-shaped structures and are fixed to the ends of the side shell plates 300 by bolts. Their strength can withstand the installation and transportation load of the busbar trunking. The protective plates 304 are made of insulating and flame-retardant polycarbonate material, which can protect the connection end of the conductor busbar A from collision and dust contamination, and also play an insulating protection role to avoid the risk of electric shock. The design of being flush with the connection end of the busbar does not hinder the wiring operation between the conductor busbar A and external equipment, improving the convenience of installation.

[0079] Furthermore, to facilitate the installation of the aforementioned liquid-cooled busbar trunking, this embodiment also provides a liquid-cooled busbar trunking assembly method, applicable to the aforementioned liquid-cooled busbar trunking, comprising the following steps: First, the side shell plates 300 are symmetrically welded and fixed to the top and bottom of the main shell plate 100. Before welding, the mating surfaces of the main shell plate 100 and the side shell plates 300 need to be derusted and degreased. Argon arc welding is used during welding to ensure that the weld is free of porosity and slag inclusions. After welding, the perpendicularity of the side shell plates 300 and the main shell plate 100 needs to be checked, and the error should be ≤0.1mm to avoid affecting the installation of subsequent components.

[0080] Then, place the conductor busbar A in the storage gap X formed on both sides of the main shell plate 100, install the auxiliary plate 200 on the outside of the conductor busbar A to seal the internal conductor busbar A, and fix the auxiliary plate 200 to the side shell plate 300.

[0081] Before placing the conductor busbar A, a high-temperature resistant sealing gasket must be laid in the storage gap X to ensure that the busbar is in close contact with the main shell plate 100. When installing the auxiliary plate 200, the position needs to be adjusted to ensure that the side abutment plate 201 is completely attached to the conductor busbar A. Then, the auxiliary plate 200 is fixed to the side shell plate 300 with bolts to avoid deformation of the auxiliary plate 200 due to excessive tightness.

[0082] Finally, after installing the connectors 303 at both ends of the side shell plate 300, the protective plates 304 are installed on both sides of the conductor busbar A in sequence to cover the conductor busbar A from both sides.

[0083] When installing connector 303, ensure that both sides are symmetrical and the error is ≤0.5mm. When installing protection plate 304, it should be flush with the connection end of conductor busbar A and fixed to connector 303 by clips or bolts to ensure that protection plate 304 is not loose and does not obstruct the wiring terminals of busbar.

[0084] Finally, it should be noted that the methods and devices described in detail above are merely embodiments, and those skilled in the art can modify these embodiments in different ways as long as they do not depart from the scope of the present invention.

Claims

1. A liquid-cooled busbar trunking system, characterized in that: include, The main shell plate (100) and the auxiliary plate (200) fixed on both sides of the main shell plate (100) are provided with a storage gap (X) for a sealed conductor busbar (A) between the main shell plate (100) and the auxiliary plate (200). Among them, at least one set of first flow channel group (B) is provided in the area corresponding to the inner contact surface of the conductor busbar (A) inside the main shell plate (100). The auxiliary plate (200) has at least one set of second flow channel group (C) in the area corresponding to the contact surface on the outside of the conductor busbar (A), and the first flow channel group (B) and the second flow channel group (C) at least cover part of the heat-generating area on both sides of the conductor busbar (A); The main shell plate (100) is also symmetrically and vertically fixed with side shell plates (300). The main shell plate (100) is fixed to the side shell plate (300) through the connecting boss (101) fixed at its top end. The storage gap (X) is formed between the connecting bosses (101) at both ends. The stacking thickness of the conductor busbar (A) is equal to the gap depth of the storage gap (X). The first flow channel group (B) includes symmetrically arranged flow dividers (B1), which are opened through the main shell plate (100) and are symmetrically sealed with end baffles (102) at both ends. A partition group (103) is also provided between the flow dividers (B1). The partition group (103) includes symmetrically arranged partitions (103a). The two ends of the partitions (103a) are sealed and inserted into the end baffles (102). A buffer barrier gap (X1) is formed between the partitions (103a). The end baffle (102) includes a central sealing plate (102a) and flow guiding sealing plates (102b) symmetrically fixed at both ends thereon. The central sealing plate (102a) seals both ends of the buffer barrier gap (X1), and the flow guiding sealing plates (102b) seal both ends of the diversion cavity (B1). The auxiliary plate (200) includes a side abutment plate (201) and a sealing shell (202) fixed to its side wall. At least one set of the sealing shell (202) is provided, and the second flow channel group (C) is formed between the sealing shell (202) and the side abutment plate (201). The sealing shell (202) is also fixedly connected to a third inlet pipe (202a) and a third outlet pipe (202b) at both ends. The outer walls of the side abutment plate (201) and the sealing shell (202) are uniformly fixed with several sets of parallel heat dissipation fins (201a). Connectors (303) are symmetrically fixed at the ends of the side shell plates (300) on both sides. Protective plates (304) are fixed between the connectors (303). The protective plates (304) are symmetrically arranged. The conductor busbar (A) is located between the protective plates (304) and is flush with the connecting end of the conductor busbar (A).

2. The liquid-cooled busbar trunking according to claim 1, characterized in that: The side shell plate (300) has an inlet groove (301) and an outlet groove (302) in the middle, and a first cover plate (301a) and a second cover plate (302a) are sealed and fixed on the inlet groove (301) and the outlet groove (302). The inlet channel (301) and outlet channel (302) both include a connection port (K1) and a flow through port (K2). The diameter of the connection port (K1) is larger than the diameter of the flow through port (K2), and a connection platform (T) is formed at the junction. The first cover plate (301a) and the second cover plate (302a) both include a flow channel sealing plate (301a-1) and an isolation boss (301a-2) fixed at its bottom end. A first inlet pipe (301a-3) and a second inlet pipe (301a-4) are symmetrically fixed at the top of the flow channel sealing plate (301a-1) of the first cover plate (301a). A first outlet pipe (302a-1) and a second outlet pipe (302a-2) are symmetrically fixed at the top of the flow channel sealing plate (301a-1) of the second cover plate (302a).

3. The liquid-cooled busbar trunking according to claim 2, characterized in that: A first diverter plate (301a-5) is fixed at the middle of the bottom end of the isolation boss (301a-2) of the first cover plate (301a), and a second diverter plate (302a-3) is fixed at the middle of the bottom end of the isolation boss (301a-2) of the second cover plate (302a). The flow channel sealing plate (301a-1) is fixed on the connecting platform (T) and seals the connecting port (K1). The isolation boss (301a-2) is fixed inside the flow port (K2) and separates the flow port (K2). The flow ports (K2) separated on both sides are respectively connected to the corresponding inlet and outlet pipes. The first inlet pipe (301a-3) and the first outlet pipe (302a-1) are symmetrical, and the second inlet pipe (301a-4) and the second outlet pipe (302a-2) are symmetrically arranged.

4. The liquid-cooled busbar trunking according to claim 3, characterized in that: The first diverter plate (301a-5) and the second diverter plate (302a-3) are movably inserted into the diverter cavity (B1). A flow equalization plate (104) is fixed in the diverter cavity (B1) parallel to its extension direction. The first diverter plate (301a-5) and the second diverter plate (302a-3) abut and seal with the flow equalization plate (104). The length of the flow equalization plate (104) is greater than the maximum distance between the inlet groove (301) and the outlet groove (302), and the distance of the flow equalization plate (104) from the top and bottom inner walls of the flow distribution cavity (B1) is equal.

5. The liquid-cooled busbar trunking according to claim 3 or 4, characterized in that: The first flow divider (301a-5) and the second flow divider (302a-3) are both symmetrically fixed with a first buffer arc block (301a-5a) at the end away from the inlet and outlet slots. The flow guide plate (102b) is also symmetrically provided with a second buffer arc block (102b-1) at both ends inside the flow divider cavity (B1). The inner arc surface of the first buffer arc block (301a-5a) is connected to the outer wall of the flow equalization plate (104) and the outer surfaces of the first flow divider plate (301a-5) and the second flow divider plate (302a-3); The inner arc surface of the second buffer arc block (102b-1) connects the inner wall of the diversion cavity (B1) and the outer surface of the guide seal plate (102b).

6. The liquid-cooled busbar trunking according to claim 5, characterized in that: The flow equalization plate (104), the first flow splitter plate (301a-5), and the second flow splitter plate (302a-3) separate the internal space of the flow splitter cavity (B1), and together with the flow guide sealing plate (102b), form the first flow cavity (B11) and the second flow cavity (B12) respectively. The first flow cavity (B11) includes a first through cavity (B111), and the second flow cavity (B12) includes a second through cavity (B121), a rotary cavity (B122), and a third through cavity (B123). The second passage (B121) is disposed at both ends of the first passage (B111) and is separated by the first flow divider (301a-5) and the second flow divider (302a-3). The third passage (B123) is disposed parallel to the first passage (B111) on the side away from the inlet groove (301) and the outlet groove (302), and is isolated from the first passage (B111) and the second passage (B121) by the flow equalization plate (104). The rotary cavity (B122) is directly connected to the second passage (B121) and the third passage (B123). The first cavity (B111) is connected to the first inlet pipe (301a-3) and the first outlet pipe (302a-1), and the second cavities (B121) at both ends of the first cavity (B111) are connected to the second inlet pipe (301a-4) and the second outlet pipe (302a-2) respectively.

7. A method for assembling a liquid-cooled busbar trunking system, characterized in that: The liquid-cooled busbar trunking system as described in any one of claims 1 to 6 includes the following steps: The side shell plates (300) are symmetrically welded and fixed to the top and bottom of the main shell plate (100); Place the conductor busbar (A) in the storage gap (X) formed on both sides of the main shell plate (100), install the auxiliary plate (200) on the outside of the conductor busbar (A), seal the internal conductor busbar (A), and fix the auxiliary plate (200) to the side shell plate (300); After the connectors (303) are installed at both ends of the side shell plate (300), protective plates (304) are installed on both sides of the conductor busbar (A) to cover the conductor busbar (A) from both sides.

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