Compact water-cooling power unit structure
By employing water-cooled heat dissipation and a compact power unit structure, the problems of large size and low power density associated with air-cooled heat dissipation methods are solved, achieving high power density and miniaturization, improving environmental adaptability and service life, and making it suitable for power drive boxes in rail transit and mining trucks.
Patent Information
- Application Number
- CN202511780848.5
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-11-28
- Publication Date
- 2026-02-27
AI Technical Summary
Existing air-cooled power units have drawbacks in rail transit and mining truck power drive boxes, such as large size, low power density, high noise, low heat dissipation capacity, poor environmental adaptability, and short service life, which cannot meet the requirements of high power miniaturization.
It adopts water cooling and compact structural design, with IGBT modules arranged on both sides. The water cooling plate has a cooling medium flow channel inside. Thermal grease is applied between the IGBT module and the water cooling plate. It utilizes the ANPC three-level topology to make full use of space to arrange unit pulse boards and supporting capacitors. Temperature sensors are set up to monitor the temperature, and the bus fixing and signal wiring are optimized.
It achieves a doubling of power density, reduces noise, improves environmental adaptability and service life, and meets the requirements of high-power miniaturization for power drive boxes in rail transit and mining trucks.
Smart Images
Figure CN121584980A_ABST
Abstract
Description
TECHNICAL FIELD
[0001] The present application relates to the technical field of rail transit bidirectional converter and mine truck power drive box, and particularly relates to a compact water-cooled power unit structure. BACKGROUND
[0002] The power unit refers to a functional module for converting electric energy by using power electronic devices, and generally mainly includes a radiator, an IGBT, a driving board, a unit pulse board, a direct current bus, an alternating current bus, a support capacitor, a current sensor and the like. The electric energy form conversion and control are realized through rectification, filtering, inversion and the like, and the core device inside is an IGBT (insulated gate bipolar transistor). Since a large amount of heat is generated during the operation of the IGBT, the power unit can adopt air cooling or water cooling to dissipate heat. The rail transit bidirectional converter and the mine truck power drive box are both modularly designed by being equipped with multiple power units to improve power, and therefore, the power unit is a main component of the rail transit bidirectional converter and the mine truck power drive box. At present, with the rapid development of the rail transit and power drive industries, the structure of the bidirectional converter and the mine truck power drive box is required to be higher and higher, that is, to be both high in power and small in size. At the present stage, as a main component, the power unit adopting the traditional air cooling dissipates heat, and has defects of large volume, low power density, large noise, low upper limit of heat dissipation capacity, poor environmental adaptability and short service life in the application of the rail transit bidirectional converter and the mine truck power drive box. The water cooling dissipates heat by taking water or cooling liquid as a cooling medium, and has advantages of high heat dissipation efficiency, small radiator volume, high power density, small noise, strong environmental adaptability, long service life and low maintenance cost due to the fact that the specific heat capacity and the thermal conductivity of the water or the cooling liquid are far greater than those of air. Therefore, the power unit adopting the water cooling and a more compact structure design is a development trend at the present stage.
[0003] Therefore, it is necessary to provide a compact water-cooled power unit structure. SUMMARY
[0004] In view of the problems in the prior art, the present application provides a compact water-cooled power unit structure, which adopts the water cooling and a more compact structure design, and the IGBT is arranged on two sides. In the case of little change in volume, the power density is doubled, and the defects of the power unit adopting the traditional air cooling, such as large volume, low power density, large noise, low upper limit of heat dissipation capacity, poor environmental adaptability and short service life, can be well solved, so that the rail transit bidirectional converter and the mine truck power drive box using the power unit of the present application can be both high in power and small in size.
[0005] In order to achieve the above object, the present application is realized by the following technical scheme: a compact water-cooled power unit structure, comprising a shell, a core, the core comprising a water-cooled plate, an IGBT module, a unit pulse plate and a support capacitor; The core is installed inside the shell, the periphery and the inside of the core are provided with the water-cooled plate, the inside of the water-cooled plate is provided with a cooling medium flow channel, the front part of the water-cooled plate is provided with a water inlet and a water outlet, the water inlet and the water outlet are connected with a water cooling system outside the power unit, the left and right sides of the water-cooled plate are provided with hexagonal steel columns connected with the inner wall of the shell to support the installation of the water-cooled plate, the IGBT module adopts six in number and is uniformly fixed on the upper and lower sides of the water-cooled plate. A driving plate is arranged on the upper part of the front end of each IGBT module, the driving plate is electrically connected with the gate electrode of the IGBT module, each driving plate is provided with a second signal terminal, the unit pulse plate is fixed on the metal plate arranged between the water inlet and the water outlet at the front part of the water-cooled plate, the front part of the unit pulse plate is provided with a power terminal and a first signal terminal, the power terminal is electrically connected with a control power source outside the power unit, the first signal terminal is electrically connected with a main control board of the whole system, the upper and lower sides of the unit pulse plate are respectively provided with three third signal terminals, the third signal terminals are connected with the second signal terminals on the six driving plates one by one. The terminal of the IGBT module on the upper layer of the water-cooled plate is electrically connected with a first DC bus and a first AC bus, the first DC bus and the first AC bus are arranged at the top of the IGBT module, the terminal of the IGBT module on the lower layer of the water-cooled plate is electrically connected with a second DC bus and a second AC bus, the second DC bus and the second AC bus are arranged at the bottom of the IGBT module on the lower layer of the water-cooled plate, The support capacitor comprises a first support capacitor and a second support capacitor, the first support capacitor and the second support capacitor are arranged alternately between the rear part of the water-cooled plate and the upper and lower DC buses, the purpose is to make full use of the space between the rear part of the water-cooled plate and the upper and lower DC buses, the capacitor terminals of the two first support capacitors are electrically connected with the first DC bus by screws, the other end of the first support capacitor passes through the hole arranged at the corresponding position of the second DC bus and is fixed by a nut, the capacitor terminals of the two second support capacitors are electrically connected with the second DC bus by screws, the other end of the second support capacitor passes through the hole arranged at the corresponding position of the first DC bus and is fixed by a nut; discharge resistors are arranged between the positive and zero of the first DC bus and the second DC bus and between the zero and the negative.
[0006] Preferably, the IGBT module and the water-cooled plate need to be coated with heat-conducting silicone grease to reduce the contact thermal resistance between the IGBT module and the water-cooled plate.
[0007] Preferably, the IGBT module adopts an ANPC three-level topology structure, and the IGBT module adopts single-phase output.
[0008] Preferably, the water-cooled plate is provided with a temperature sensor electrically connected with the unit pulse plate, the temperature of the water-cooled plate is monitored in real time, the unit pulse plate obtains the signal and analyzes the signal transmitted to the main control board of the whole system through the first signal terminal, the working pulse signal of the unit pulse plate is controlled by the program of the main control board, and the starting and stopping of the IGBT module are controlled.
[0009] Preferably, the shell comprises a front plate, an upper cover, a bottom plate, a left metal support, a right metal support, a handle and a buckle, the front plate, the upper cover, the bottom plate, the front plate, the left metal support and the right metal support are installed through screws, the handle is arranged on the front plate of the shell, the left metal support and the right metal support are respectively provided with the buckle, and the rear part of the shell is provided with an insulating rear plate.
[0010] Preferably, the upper and lower surfaces of the water-cooled plate are respectively fixed with busbar fixing clamps and support insulators, the DC bus is clamped and fixed, relative movement between the DC bus and the IGBT module in a vibration environment is prevented, the top end of the busbar fixing clamp at the lower part of the water-cooled plate abuts against the bottom plate in the shell, and the function of auxiliary supporting the water-cooled plate is achieved.
[0011] Preferably, the rear part of the power unit is provided with positive, zero and negative output copper bars, the positive, zero and negative output ends of the first DC bus and the second DC bus are connected in parallel from top to bottom; the insulating rear plate is arranged at the rear part of the unit and connected with the rear parts of the left metal support and the right metal support through screws, and is used for fixing the positive, zero and negative output copper bars and the output ends of the first AC bus and the second AC bus.
[0012] Preferably, the positive, zero and negative output copper bars are electrically connected with the DC main loop of the bidirectional current conversion device or the mine card power drive box; the first current sensor and the second current sensor are respectively fixed at the rear part of the insulating rear plate through the output ends of the first AC bus and the second AC bus, are electrically connected with the unit pulse plate, and are used for detecting the output or input AC current value.
[0013] Preferably, the output ends of the first AC bus and the second AC bus are respectively fixed with first AC output copper bars and second AC output copper bars, and other components in the whole system outside the power unit, such as electric reactors, are electrically connected.
[0014] In summary, the application provides a compact water-cooled power unit structure, adopts a water-cooled heat dissipation mode, the water-cooled plate is horizontally arranged, a cooling medium flow channel is arranged in the water-cooled plate, water inlets and outlets are arranged at the front part of the water-cooled plate and connected with a water cooling system outside the power unit, heat conducted to the water-cooled plate by the IGBT module is taken away by the rapidly flowing cooling medium; hexagonal steel columns are arranged at the left and right sides of the water-cooled plate and connected with left and right metal support frames to support the water-cooled plate; the IGBT module adopts an ANPC three-level topology structure and is fixed on the upper and lower surfaces of the water-cooled plate to be single-phase output; In order to make full use of the space in the shell, the unit pulse board is fixed on the metal plate fixedly arranged between the water inlet and the water outlet at the front of the water-cooled plate, the front of the unit pulse board is provided with power connection terminals, first signal connection terminals and a control power supply outside the power unit and a main control board of the whole system, and the upper and lower portions are respectively provided with three third signal connection terminals which are connected with the second signal connection terminals on the driving boards of the six IGBT modules arranged on the upper and lower water-cooled plates in one-to-one correspondence, so that the length of the signal line is reduced, the electromagnetic interference is reduced, and the probability of signal transmission error is reduced. The first direct current bus and the first alternating current bus are arranged on the top of the IGBT module on the upper layer of the water-cooled plate and are electrically connected with the connection terminals of the IGBT module, the second direct current bus and the second alternating current bus are arranged on the top of the IGBT module on the lower layer of the water-cooled plate and are electrically connected with the connection terminals of the IGBT module, and the upper and lower surfaces of the water-cooled plate are respectively fixed with bus fixed clamps and support insulators for clamping and fixing the direct current bus, preventing the direct current bus and the IGBT module from moving relatively in a vibration environment to damage the connection terminals on the IGBT module and improving the anti-vibration performance of the unit. The top end of the bus fixed clamp at the lower portion of the water-cooled plate abuts against the bottom plate in the shell and plays a role of auxiliary support for the water-cooled plate, in order to make full use of the space between the rear portion of the water-cooled plate and the upper and lower direct current buses, the support capacitors are arranged between the rear portion of the water-cooled plate and the upper and lower direct current buses, the first direct current bus is electrically connected with the capacitor connection terminals of the two first support capacitors by using screws, the other end stud of the first support capacitor passes through the hole arranged at the corresponding position of the second direct current bus and is fixed by a nut, the second direct current bus is electrically connected with the capacitor connection terminals of the two second support capacitors by using screws, and the other end stud of the second support capacitor passes through the hole arranged at the corresponding position of the first direct current bus and is fixed by a nut. Positive, zero and negative output copper bars are arranged at the rear portion of the unit and are connected in parallel with the positive, zero and negative output ends of the first and second direct current buses, respectively, an insulating rear plate is arranged at the rear portion of the unit and is connected with the left and right metal support members at the rear portion by screws and is used for fixing the positive, zero and negative output copper bars and the output ends of the first and second alternating current buses, and the positive, zero and negative output copper bars are electrically connected with the direct current main circuit of the bidirectional current conversion device or the mine card power drive box. The first and second current sensors are respectively fixed at the rear portion of the insulating rear plate by passing through the output ends of the first and second alternating current buses and are electrically connected with the unit pulse board and are used for detecting the output or input alternating current value. BRIEF DESCRIPTION OF DRAWINGS
[0015] Figure 1 It is a perspective view of the power unit according to the present application. Figure 2 It is a rear portion structure diagram of the power unit according to the present application. Figure 3 is the power unit shell structure schematic diagram of the present application; Figure 4 is the power unit internal movement structure schematic diagram of the present application; Figure 5 is the busbar fixing clamp, support insulator structure schematic diagram of the present application; Figure 6 is the movement structure section schematic diagram of the present application; Figure 7 is the DC bus and AC bus output end structure schematic diagram of the present application; Figure 8 is the signal terminal structure schematic diagram of the present application; Figure 9 is the support capacitor installation structure schematic diagram of the present application in the top view state; Figure 10 is the power unit circuit principle schematic diagram of the present application; Figure 11 is the power unit heat dissipation process schematic diagram of the present application; In the figure: shell 1, movement 2, front plate 11, upper cover 12, bottom plate 13, left sheet metal support 14, right sheet metal support 15, handle 16, buckle hand 17, insulating back plate 18; Water-cooled plate 21, IGBT module 22, unit pulse plate 23, water inlet 24, water outlet 25, hexagonal steel column 26, drive plate 27, second signal terminal 28, sheet metal bottom plate 29; Power terminal 30, first signal terminal 31, third signal terminal 32, first DC bus 33, first AC bus 34, second DC bus 35, second AC bus 36; First support capacitor 41, second support capacitor 42, capacitor terminal 43, discharge resistor 44, temperature sensor 5, busbar fixing clamp 52, support insulator 53; Positive, zero, negative output copper bar 54 provided at the rear of the power unit; positive, zero, negative output end of the first DC bus and the second DC bus 55; First current sensor 56, second current sensor 57, first AC output copper bar 61, second AC output copper bar 62. DETAILED DESCRIPTION
[0016] The present application will be further described below in conjunction with the drawings.
[0017] As Figures 1 to 11 shown: The present application is mainly composed of a shell 1 and a core 2. The shell 1 comprises a front plate 11, an upper cover 12, a bottom plate 13, a left metal support 14, a right metal support 15, a handle 16, and a buckle 17. The core 2 comprises a water-cooled plate 21, an IGBT module 22, a driving plate 27, a unit pulse plate 23, a temperature sensor 5, a hexagonal steel column 26, a bus fixed clamp 52, a support insulator 53, a first DC bus 33, a second DC bus 35, a first AC bus 34, a second AC bus 36, a first support capacitor 41, a second support capacitor 42, a discharge resistor 44, an insulating back plate 18, a first current sensor 56, a second current sensor 57, a first AC output copper bar 61, a second AC output copper bar 62, and positive, zero, and negative output copper bars 54 arranged at the back of the power unit.
[0018] Referring to Figure 4 The water-cooled plate 21 is horizontally arranged, and a cooling medium flow channel is arranged inside the water-cooled plate 21. The water-cooled plate 21 is provided with a water inlet 24 and a water outlet 25 at the front, which are connected with a water cooling system outside the power unit. The heat conducted to the water-cooled plate 21 by the IGBT module 22 is taken away by the fast-flowing cooling medium. Hexagonal steel columns 26 are arranged at the left and right sides of the water-cooled plate 21 and connected with the left and right metal support frames to support the water-cooled plate 21. Referring to Figure 1 , 4 , 8, 9, the IGBT module 22 adopts an ANPC three-level topology structure and is fixed on the upper and lower surfaces of the water-cooled plate 21 for single-phase output. The IGBT module 22 and the water-cooled plate 21 need to be coated with thermal conductive silicone grease to reduce the contact thermal resistance between the IGBT module 22 and the water-cooled plate 21 and improve the heat conduction efficiency. A driving plate 27 is arranged at the front end of each IGBT module 22. The driving plate 27 is electrically connected with the gate of the IGBT module 22. A second signal terminal 28 is arranged on each driving plate 27. In order to make full use of the space in the shell, a unit pulse plate 23 is fixed on the metal bottom plate 13 arranged between the water inlet 24 and the water outlet 25 at the front of the water-cooled plate 21. A power terminal 30 and a first signal terminal 31 are arranged at the front of the unit pulse plate 23 and electrically connected between the control power source outside the power unit and the main control board of the whole system. Three third signal terminals 32 are arranged on the upper and lower parts of the unit pulse plate 23, respectively, and are connected with the second signal terminals 28 on the driving plates 27 of the six IGBT modules 22 arranged on the upper and lower parts of the water-cooled plate 21, one by one, so as to reduce the length of the signal line, reduce electromagnetic interference, and reduce the probability of signal transmission error. Referring to Figure 1 , 4As shown in Figs. 6, 7 and 9, the water-cooled plate 21 is provided with a temperature sensor 5 electrically connected to the unit pulse plate 23 to monitor the temperature of the water-cooled plate 21 in real time. Once the temperature exceeds the normal range due to a fault, the unit pulse plate 23 receives a signal and sends the signal to the main control board of the whole system through the first signal terminal 31. Upon receiving the fault signal, the main control board stops sending working pulse signals to the unit pulse plate 23 in the power unit according to the pre-set program, so that the IGBT stops working, thereby avoiding damage to the IGBT module 22 caused by over-temperature; Referring to Figure 4 、 5 As shown in Figs. 6, 7 and 9, the first DC bus 33 and the first AC bus 34 are electrically connected to the top of the IGBT module 22 on the upper layer of the water-cooled plate 21 and the terminal of the IGBT module 22, and the second DC bus 35 and the second AC bus 36 are electrically connected to the top of the IGBT module 22 on the lower layer of the water-cooled plate 21 and the terminal of the IGBT module 22. The water-cooled plate 21 is fixed with a bus fixing clamp 52 and a support insulator 53 on the upper and lower surfaces, respectively, to clamp and fix the DC bus, prevent relative movement between the DC bus and the IGBT module 22 in a vibrating environment, and damage the terminal on the IGBT module 22, thereby improving the anti-vibration performance of the unit. The top end of the bus fixing clamp 52 on the lower part of the water-cooled plate 21 abuts against the bottom plate 13 in the shell 1, thereby assisting in supporting the water-cooled plate 21. To fully utilize the space between the rear part of the water-cooled plate 21 and the upper and lower DC buses, the support capacitors are arranged between the rear part of the water-cooled plate 21 and the upper and lower DC buses. The first DC bus 33 is electrically connected to the capacitor terminals of the two first support capacitors 41 by screws, the other end of the first support capacitor 41 passes through the hole provided at the corresponding position of the second DC bus 35, and is fixed by a nut. The second DC bus 35 is electrically connected to the capacitor terminals of the two second support capacitors 42 by screws, and the other end of the second support capacitor 42 passes through the hole provided at the corresponding position of the first DC bus 33, and is fixed by a nut. Discharge resistors 44 are arranged between the positive and zero of the DC bus, and between the zero and the negative. Referring to Figure 2 、 7 As shown in Figs. 6, 7 and 9, the unit rear part is provided with positive, zero and negative output copper bars 54, which are connected in parallel to the positive, zero and negative output ends 55 of the first DC bus 33 and the second DC bus 35. The rear insulating plate 18 is connected to the rear parts of the left and right metal support members 14 and 15 by screws, and is used to fix the positive, zero and negative output copper bars 54 of the power unit, and the output ends of the first AC bus 34 and the second AC bus 36. Referring to Figure 2As shown, the positive, zero, and negative output copper busbars 54 are electrically connected to the DC main circuit of the bidirectional converter or the mining truck power drive box; the first current sensor 56 and the second current sensor 57 pass through the output ends of the first AC busbar 34 and the second AC busbar 36 respectively and are fixed to the rear of the insulating rear plate 18, and are electrically connected to the unit pulse board 23 to detect the output or input AC current value. See Figure 2 , 3 As shown, the output ends of the first AC bus 34 and the second AC bus 36 are respectively fixed with the first AC output copper bus 61 and the second AC output copper bus 62, which facilitates electrical connection with other components in the entire system, such as reactors, outside the power unit; the bottom plate 13 is connected to the bottom of the left sheet metal support 14 and the right sheet metal support 15, the front plate 11 is connected to the front of the left sheet metal support 14 and the right sheet metal support 15, and the top cover 12 is connected to the top of the left sheet metal support 14 and the right sheet metal support 15; in order to facilitate the handling or installation of the power unit, the housing 1 is provided with a handle 16 and a latch 17.
[0019] In summary, the technical effects achieved by this patent are as follows: A water-cooled heat dissipation method is adopted, with the water-cooled plate 21 arranged horizontally. A cooling medium flow channel is provided inside the water-cooled plate 21. An inlet 24 and an outlet 25 are provided at the front of the water-cooled plate 21, connecting it to the external water cooling system of the power unit. The rapidly flowing cooling medium removes the heat transferred from the IGBT module 22 to the water-cooled plate 21. Hexagonal steel columns 26 are provided on the left and right sides of the water-cooled plate 21, connected to left and right sheet metal support frames to support the water-cooled plate 21. The IGBT module 22 adopts an ANPC three-level topology structure, fixed on the upper and lower sides of the water-cooled plate 21, each with a single-phase output. To make full use of the space inside the housing 1, the unit pulse board 23 is fixed on the sheet metal base plate 1315 arranged between the water inlet 24 and the water outlet 25 at the front of the water-cooled plate 21. The front of the unit pulse board 23 is provided with a power terminal 30 and a first signal terminal 31, which are electrically connected to the external control power supply of the power unit and the main control board of the entire system. The upper and lower parts are respectively provided with three third signal terminals 32, which are respectively connected to the second signal terminals 28 on the drive boards of the six IGBT modules 22 arranged at the top and bottom of the water-cooled plate 21, thereby reducing the signal line length, reducing electromagnetic interference, and reducing the probability of signal transmission errors. The first DC bus 33 and the first AC bus 34 are electrically connected to the top of the IGBT module 22 and the wiring terminal of the IGBT module 22 on the upper layer of the water-cooled plate 21, and the second DC bus 35 and the second AC bus 36 are electrically connected to the top of the IGBT module 22 and the wiring terminal of the IGBT module 22 on the lower layer of the water-cooled plate 21; the upper and lower surfaces of the water-cooled plate 21 are respectively fixed with a bus fixing clamp 52 and a support insulator 53, which are used for clamping and fixing the DC bus, preventing the relative movement between the DC bus and the IGBT module 22 in the vibration environment from damaging the wiring terminal on the IGBT module 22, and improving the anti-vibration performance of the unit; The top end of the bus fixing clamp 52 on the lower part of the water-cooled plate 21 abuts against the bottom plate 13 in the shell 1, and plays a role of auxiliary supporting the water-cooled plate 21; in order to fully utilize the space between the rear part of the water-cooled plate 21 and the upper and lower DC buses, the support capacitors are arranged between the rear part of the water-cooled plate 21 and the upper and lower DC buses, the first DC bus 33 is electrically connected to the capacitor wiring terminal of the two first support capacitors 41 by using screws, the other end stud of the first support capacitor 41 passes through the hole arranged at the corresponding position of the second DC bus 35 and is fixed by a nut, the second DC bus 35 is electrically connected to the capacitor wiring terminal of the two second support capacitors 42 by using screws, and the other end stud of the second support capacitor 42 passes through the hole arranged at the corresponding position of the first DC bus 33 and is fixed by a nut; Positive, zero and negative output copper bars 54 are arranged on the rear part of the unit, and the positive, zero and negative output ends 55 of the first DC bus 33 and the second DC bus 35 are connected in parallel from top to bottom; an insulating back plate 18 is arranged on the rear part of the unit and is connected to the rear part of the left metal support 14 and the right metal support 15 by screws, which is used for fixing the positive, zero and negative output copper bars 54, and the output ends of the first AC bus 34 and the second AC bus 36; the positive, zero and negative output copper bars are electrically connected to the DC main circuit of the bidirectional current conversion device or the mine card power drive box; The first current sensor 56 and the second current sensor 57 are respectively fixed on the rear part of the insulating back plate 18 by passing through the output ends of the first AC bus 34 and the second AC bus 36, and are electrically connected to the unit pulse plate 23, which is used for detecting the output or input AC current value.
[0020] The embodiments in the application are only used for describing the application, and do not constitute a limitation on the scope of claims, and other substantially equivalent alternatives that can be thought by those skilled in the art are within the protection scope of the application.
Claims
1. A compact water-cooled power unit structure, characterized in that, It includes a housing (1) and a mechanism (2). The mechanism (2) includes a water-cooled plate (21), an IGBT module (22), a unit pulse board (23), and a supporting capacitor. The core (2) is installed inside the housing (1). The core (2) is surrounded and the interior is equipped with a water-cooled plate (21). The water-cooled plate (21) is equipped with a cooling medium flow channel. The front of the water-cooled plate (21) is equipped with a water inlet (24) and a water outlet (25). The water inlet (24) and the water outlet (25) are connected to the water cooling system outside the power unit. Hexagonal steel columns (26) are set on the left and right sides of the water-cooled plate (21) and connected to the inner wall of the housing (1) to support the installation of the water-cooled plate (21). The IGBT module (22) is made of six and is evenly fixed on the upper and lower sides of the water-cooled plate (21). Each IGBT module (22) has a driver board (27) on its upper front end. The driver board (27) is electrically connected to the gate of the IGBT module (22). Each driver board (27) has a second signal terminal (28). The unit pulse board (23) is fixed on the sheet metal base plate (29) arranged between the water inlet (24) and the water outlet (25) at the front of the water-cooled plate (21). The unit pulse board (23) has a power terminal (30) and a first signal terminal (31) at its front. The power terminal (30) is electrically connected to the control power supply outside the power unit. The first signal terminal (31) is electrically connected to the main control board of the entire system. The unit pulse board (23) has three third signal terminals (32) on its upper and lower sides respectively. The third signal terminals (32) are connected one-to-one with the second signal terminals (28) on the six driver boards (27). The terminals of the IGBT module (22) on the upper layer of the water-cooled plate (21) are electrically connected to the first DC bus (33) and the first AC bus (34). The first DC bus (33) and the first AC bus (34) are located on the top of the IGBT module (22). The terminals of the IGBT module (22) on the lower layer of the water-cooled plate (21) are electrically connected to the second DC bus (35) and the second AC bus (36). The second DC bus (35) and the second AC bus (36) are located at the bottom of the IGBT module (22) on the lower layer of the water-cooled plate (21). The supporting capacitors include a first supporting capacitor (41) and a second supporting capacitor (42). The first supporting capacitor (41) and the second supporting capacitor (42) are arranged alternately between the upper and lower DC buses at the rear of the water-cooled plate (21). The first DC bus (33) is electrically connected to the capacitor terminals (43) of the two first supporting capacitors (41) using screws. The stud at the other end of the first supporting capacitor (41) passes through the hole set at the corresponding position of the second DC bus (35) and is fixed by a nut. The second DC bus (35) is electrically connected to the capacitor terminals (43) of the two second supporting capacitors (42) using screws. The stud at the other end of the second supporting capacitor (42) passes through the hole set at the corresponding position of the first DC bus (33) and is fixed by a nut. Discharge resistors (44) are provided between the positive and zero of the first DC bus (33) and the second DC bus (35), and between zero and negative.
2. The compact water-cooled power unit structure according to claim 1, characterized in that, Thermal grease needs to be applied between the IGBT module (22) and the water-cooled plate (21) to reduce the contact thermal resistance between the IGBT module (22) and the water-cooled plate (21).
3. The compact water-cooled power unit structure according to claim 1, characterized in that, The IGBT modules (22) on both the upper and lower sides of the water-cooled plate (21) form an ANPC three-level topology and adopt single-phase output.
4. The compact water-cooled power unit structure according to claim 1, characterized in that, The water-cooled plate (21) is equipped with a temperature sensor (5) which is electrically connected to the unit pulse board (23) to monitor the temperature of the water-cooled plate (21) in real time. The unit pulse board (23) receives the signal and analyzes it, and transmits it to the main control board of the whole system through the first signal terminal (31). The main control board program control unit pulse board (23) sends working pulse signals to control the IGBT module (22) to start and stop.
5. The compact water-cooled power unit structure according to claim 1, characterized in that, The housing (1) includes a front plate (11), a top cover (12), a bottom plate (13), a left sheet metal support (14), a right sheet metal support (15), a handle (16), and a latch (17). The front plate (11), the top cover (12), the bottom plate (13), the front plate (11), the left sheet metal support (14), and the right sheet metal support (15) are connected by screws. The front plate (11) of the housing (1) is provided with a handle (16), and the left sheet metal support (14) and the right sheet metal support (15) are respectively provided with latches (17). The rear part of the housing (1) is provided with an insulating rear plate (18).
6. The compact water-cooled power unit structure according to claim 5, characterized in that, The water-cooled plate (21) is fixed with a busbar fixing clip (52) and a support insulator (53) on its upper and lower sides, respectively, to clamp and fix the DC busbar, and prevent the DC busbar from moving relative to the IGBT module (22) in the vibration environment and damaging the wiring terminals on the IGBT module (22). The top of the busbar fixing clip (52) at the lower part of the water-cooled plate (21) abuts against the bottom plate (13) in the housing (1), which plays the role of assisting in supporting the water-cooled plate (21).
7. A compact water-cooled power unit structure according to claim 5, characterized in that, The power unit is provided with positive, zero and negative output copper busbars (54) at the rear, which connect the positive, zero and negative output terminals (55) of the first DC bus (33) and the second DC bus (35) in parallel. The insulating rear plate (18) is provided at the rear of the unit and is connected to the rear of the left sheet metal support (14) and the right sheet metal support (15) by screws. It is used to fix the positive, zero and negative output copper busbars (54) of the power unit, as well as the output terminals of the first AC bus (34) and the second AC bus (36).
8. A compact water-cooled power unit structure according to claim 7, characterized in that, The positive, zero, and negative output copper busbars (54) of the power unit are electrically connected to the DC main circuit of the bidirectional converter or the mining truck power drive box; the first current sensor (56) and the second current sensor (57) pass through the output ends of the first AC bus (34) and the second AC bus (36) respectively and are fixed to the rear of the insulating rear plate (18), and are electrically connected to the unit pulse board (23) to detect the output or input AC current value.
9. A compact water-cooled power unit structure according to claim 8, characterized in that, The first AC bus (34) and the second AC bus (36) are respectively fixed with a first AC output copper bus (61) and a second AC output copper bus (62) to facilitate electrical connection with other components in the entire system outside the power unit, such as reactors.