Universal converter box for multiple power sources

Abstract

The invention relates to the technical field of converter box bodies, and discloses a universal converter box body for multiple power sources, which comprises a box body, and the box body is sequentially provided with a middle direct current area A, a power module area B, an electrical switch area C, an external interface area D and a free counterweight area E from top to bottom; a pre-charging contactor and a voltage sensor are arranged in the middle direct current area A; a functional module is arranged on one side of the power module area B; one side of the electrical switch area C is provided with a high-voltage switch, and the other side is provided with an auxiliary switch piece; a standardized interface is arranged in the external interface area D; a mechanical expansion interface is arranged in the middle of the free counterweight area E, and counterweight blocks are mounted on two sides of the free counterweight area E and can adjust the weight and the gravity center of the box body. According to the universal converter box for the multiple power sources, by designing the multi-source compatible frame, the flexible balancing weight, the standardized interface and the integrated interface, universality of a multifunctional converter device can be achieved, the design efficiency is improved, the use cost is reduced, and the device reliability is improved.

Description

Technical Field

[0001] This invention relates to the field of converter housing technology, and in particular to a converter housing applicable to multiple power sources. Background Technology

[0002] To meet the needs of different application scenarios, current new energy locomotives are mainly divided into three major technical routes: "diesel generator + power battery", "power battery", and "hydrogen fuel cell". However, since the converter housing is not shared, different power sources require different converter housings, resulting in a large design workload, low efficiency, low fault tolerance, and high design cost.

[0003] Based on the above problems, the present invention urgently needs to propose a converter housing that is universal for multiple power sources, which can simultaneously meet the installation requirements of three power sources: "diesel generator + power battery", "power battery" and "hydrogen fuel cell". Summary of the Invention

[0004] The purpose of this invention is to provide a universal converter enclosure for multiple power sources, which modularizes and integrates mounting components while reserving installation space. Through an adjustable counterweight design, it meets the functional and weight requirements of different power sources, achieving universality for the converter enclosure; through a standardized interface design, it meets the external interface requirements of different power sources, achieving universality for the converter enclosure.

[0005] The present invention is achieved by the following technical solution: a converter housing for multiple power sources, comprising a housing, wherein the housing is arranged from top to bottom as follows: a middle DC zone A, a power module zone B, an electrical switch zone C, an external interface zone D, and a free counterweight zone E; a pre-charge contactor and a voltage sensor are arranged in the middle DC zone A. A functional module is set on one side of the power module area B. The functional module is divided into three power supply modes: power battery power source, diesel generator + power battery power source, and hydrogen fuel cell + power battery power source. A high-voltage switch is installed on one side of the electrical switch area C. The high-voltage switch is connected to the functional module through a current sensor. The high-voltage switch controls and selects the corresponding circuit according to the power supply mode of the functional module. An auxiliary switch is installed on the other side of the electrical switch area C. The auxiliary switch is mounted on the enclosure through a transition mounting plate. The external interface area D includes a standardized interface, which divides the external interface area D into three regions: front, middle, and rear, named D1, D2, and D3 respectively. The standardized interface in the D1 region is used to connect to the external power source according to the type of external power source. The standardized interface in the D3 region is used for the output of the load cable. The free counterweight zone E is divided into three areas: front, middle, and rear, named E1, E2, and E3 respectively. The E2 area is equipped with a mechanical expansion interface, which has multiple sets according to the type of power source, with each set of mechanical expansion interfaces corresponding to a power source mode. The E1 and E3 areas are equipped with mounting frames, on which counterweights for adjusting the weight and center of gravity of the box are installed.

[0006] More preferably, an installation beam is installed on the bottom plate of the E2 area of ​​the housing, and L-shaped corner brackets are respectively provided at the four corners of the rectangle formed by the two sets of installation beams; the mechanical expansion interface is provided in two sets, one set on the installation beam and the other set on the L-shaped corner brackets.

[0007] More preferably, there are 4 mounting beams, with 2 mechanical expansion interfaces on each mounting beam to form a group of 8; there are 8 L-shaped corner brackets, with 1 mechanical expansion interface on each L-shaped corner bracket to form a group of 8.

[0008] More preferably, eight standardized interfaces are installed.

[0009] Further preferred, the redundant standardized interface is fitted with a cover.

[0010] Furthermore, the standardized interface is equipped with an O-ring for enhanced sealing, achieving an IP68 installation protection level.

[0011] More preferably, the high-voltage switch is electrically connected using a rigid copper busbar connection, a flexible cable connection, or a hybrid connection method combining a rigid copper busbar and a flexible cable.

[0012] More preferably, the counterweight includes a central counterweight body and two L-shaped cantilever brackets on both sides; the vertical arm of the L-shaped cantilever bracket is connected to the side wall of the counterweight body, and the horizontal arm of the L-shaped cantilever bracket has a mounting hole A, through which it is connected to the mounting frame.

[0013] More preferably, the vertical arm of the L-shaped cantilever bracket is provided with a lifting hole.

[0014] More preferably, each of the E1 and E3 areas is provided with 6 sets of mounting frames, and a counterweight is installed between two adjacent mounting frames, for a total of 4 sets; More preferably, two mounting holes B are provided on each side of the mounting frame, and the mounting holes B correspond to the mounting holes A on the L-shaped cantilever bracket. Bolts are inserted into both mounting holes to complete the installation of the counterweight.

[0015] Compared with the prior art, the present invention has the following beneficial technical effects: This invention designs a universal converter housing for multiple power sources. By designing a multi-source compatible framework, flexible counterweights, standardized interfaces, and integrated interfaces, it can realize the universality of multi-functional converter devices, improve design efficiency, reduce usage costs, and enhance device reliability.

[0016] 1. The standardized and expandable interfaces of the converter facilitate rapid adaptation to different power sources, while reducing costs and production complexity.

[0017] 2. The flexible counterweight structure design allows for changes in the overall weight and center of gravity of the device through the installation and removal of the counterweight blocks, facilitating installation and use. The counterweight blocks adopt a modular design, with the main body being a regular cuboid and functional L-shaped support arms welded to both sides. The L-shaped support arms enable portable installation of the counterweight blocks, while the bottom of the housing provides flexible overall weight distribution. Attached Figure Description

[0018] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, for those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0019] Figure 1 This is a schematic diagram of the enclosure structure under a pure electric power source.

[0020] Figure 2 The diagram shows the frame structure of the housing of the present invention; in the diagram, Ⅱ is a high-voltage independent channel and Ⅲ is a low-voltage open cable tray.

[0021] Figure 3 This is a general layout diagram showing the front of the housing of the present invention.

[0022] Figure 4 This is a general layout diagram of the back of the housing of the present invention; in the diagram, A is the central DC zone, B is the power module zone, C is the electrical switch zone, D is the external interface zone, and E is the free counterweight zone.

[0023] Figure 5 This indicates the segmented mounting structure at the transition mounting plate of the present invention; in the figure, Ⅰ represents the housing.

[0024] Figure 6 This is a cross-sectional view showing the structure of the external interface area of ​​the present invention.

[0025] Figure 7 express Figure 6 Enlarged view of the structure of the D2 area; in the figure, blue represents a set of mechanical expansion interfaces, and orange represents a set of mechanical expansion interfaces.

[0026] Figure 8 express Figure 6Enlarged view of the standardized interface structure in the D1 area.

[0027] Figure 9 This is a cross-sectional view showing the structure of the free counterweight region of the present invention.

[0028] Figure 10 This diagram shows the installation structure of the counterweight block of the present invention.

[0029] Figure 11 This is a schematic diagram showing the structure of the counterweight block of the present invention.

[0030] Figure 12 A comparison chart showing the differences in structural layout under different power sources.

[0031] Figure 13 A comparison diagram showing electrical connections under different power sources.

[0032] In the diagram, 1-high voltage switch, 11-mounting beam, 111-L-shaped corner bracket, 12-mechanical expansion interface, 13-standardized interface, 131-end cap, 14-mounting bracket, 141-mounting hole B, 2-functional module, 3-current sensor, 4-auxiliary switch component, 41-transition mounting plate, 5-pre-charge contactor, 6-voltage sensor, 7-counterweight block, 71-counterweight body, 72-L-shaped cantilever bracket, 73-lifting hole, 74-mounting hole A, 8-air-cooled heat dissipation component, 9-insulating support base. Detailed Implementation

[0033] To better understand the above-mentioned objectives, features, and advantages of the present invention, the solutions of the present invention will be further described below. It should be noted that, unless otherwise specified, the embodiments of the present invention and the features thereof can be combined with each other.

[0034] Many specific details are set forth in the following description in order to provide a full understanding of the invention, but the invention may also be practiced in other ways different from those described herein; obviously, the embodiments in the specification are only some embodiments of the invention, and not all embodiments.

[0035] The specific embodiments of the present invention will now be described in detail with reference to the accompanying drawings.

[0036] This invention designs a single enclosure for multiple power sources. While meeting strength and sealing requirements, it designs a universal structural layout, universal electrical connections, and universal cable paths for the converter enclosure based on the converter's circuit topology. By identifying the structural characteristics of key components from different power sources, it enables redundant or interchangeable installation of the converter enclosure. This meets the application needs of multiple power sources ("diesel generator + power battery", "power battery", "hydrogen fuel cell + power battery").

[0037] For ease of reference, "pure electric" will be abbreviated as "pure electric" when powered by "power battery", "oil-electric" when powered by "diesel generator + power battery", and "hydrogen-electric" when powered by "hydrogen fuel cell + power battery".

[0038] 1) The comparison results of the differences between different power sources are shown in Table 1.

[0039] As shown in Table 1, pure electric, oil-electric, and hydrogen-electric converters differ in their external input interfaces, reactor specifications and quantities, main contactor specifications and quantities, voltage sensor quantities, and auxiliary output loads.

[0040] Furthermore, the electrical layout of the pure electric, oil-electric, and hydrogen-electric converters is consistent. (Reference) Figures 3-4 As shown, the converter enclosure is divided from top to bottom into the following sections: A) Central DC Zone, B) Power Module Zone, C) Electrical Switch Zone, D) External Interface Zone, and E) Free Counterweight Zone. Compare the spatial locations of these different sections within the converter enclosure, as follows: Figure 12 .

[0041] In the diagram: ① is a high-voltage switch, ② is a power module, ③ is a current sensor, ④ is an auxiliary switch, ⑤ is a pre-charge contactor, and ⑥ is a voltage sensor.

[0042] according to Figure 12 As can be seen, the traction converter cabinet mainly achieves power supply modes for different power sources (pure electric, oil-electric, and hydrogen-electric) through the flexible configuration of functional module ② and the multi-functional multiplexed electrical interface shown in the figure. When functional module ② uses pure electric power, it achieves pure electric and oil-electric power supply modes; when functional module ② uses hydrogen-electric power, it achieves hydrogen-electric power supply mode. At the same time, the on / off switching of the main circuit under different power sources is achieved through the matching configuration of high-voltage switch ① shown in the figure.

[0043] refer to Figures 1-13 As shown, the specific structural layout of each area is as follows: 1. Intermediate DC Zone A refer to Figure 12 As shown, a pre-charging contactor 5 and a voltage sensor 6 are installed in the middle DC zone A.

[0044] 2. Power Module Area B refer to Figure 12 As shown, a functional module 2 is set on one side of the power module area B. The functional module 2 is divided into three power supply modes: power battery power source, diesel generator + power battery power source, and hydrogen fuel cell + power battery power source.

[0045] 3. Electrical switch area C refer to Figure 1As shown, a high-voltage switch 1 is installed on one side of the electrical switch area C. The high-voltage switch 1 is connected to the functional module 2 through the current sensor 3. The high-voltage switch 1 controls and selects the corresponding circuit according to the power supply mode of the functional module 2. An auxiliary switch 4 is installed on the other side of the electrical switch area C. The auxiliary switch 4 is installed on the enclosure through the transition mounting plate 41. The modular installation of the auxiliary switch 4 is realized, and the interface reuse of this area in the enclosure is completed.

[0046] 3.1 Segmented auxiliary installation structure refer to Figure 5 As shown, the auxiliary switch components 4 and main contactor devices under different power sources are installed on the intermediate transition mounting plate 41 to achieve modularity. Then, the transition mounting plate 41 is installed on the enclosure to realize the reuse of the interface in this area of ​​the enclosure and complete the universal installation under different power sources.

[0047] 3.2 Electrical expansion interface of high voltage switch The high-voltage switch 1 internally employs a rigid copper busbar connection, a flexible cable connection, or a hybrid connection method combining rigid copper busbars and flexible cables for electrical connection. (Reference) Figure 13 As shown, the battery power source adopts a hybrid connection method of rigid copper busbar and flexible cable; the diesel generator + power battery power source adopts a rigid copper busbar connection; and the hydrogen fuel cell + power battery power source adopts a flexible cable connection.

[0048] This selective connection method achieves fixed electrical connections through rigid copper busbar connections, while flexible connections with variable directions enable universal electrical connections for the enclosure under different power source configurations. This satisfies the requirements for flexible configuration of different functional modules and electrical connections under matching configurations of key components.

[0049] 4. External Interface Area D refer to Figures 2-8 As shown, the external interface area D is divided into three areas: front, middle, and rear, named D1, D2, and D3 respectively. The standardized interface 13 in area D1 is used to connect to the external power source according to the type of external power source. The standardized interface 13 in area D3 is used for the output of the load cable.

[0050] Furthermore, such as Figure 6 As shown in Figure 10, area D2 is used to install the air-cooled heat dissipation component 8. The air-cooled heat dissipation component 8 can be mechanically fixed under different power sources through the design of an expandable interface.

[0051] 4.1 Standardized Interface Design refer to Figures 6-8 As shown, the standardized interface 13 in area D1 is used to connect to the external power source according to the type of external power source (power battery, diesel engine, hydrogen fuel). The redundant standardized interface 13 is closed with a stainless steel cover 131.

[0052] Furthermore, eight standardized interfaces 13 are installed. During use, the standardized interfaces 13 are equipped with reinforced O-ring seals to achieve an IP68 protection rating.

[0053] The standardized interface 13 in zone D3 is used for the output of the load cable; at the same time, the insulating support base 9 is set in zones D1 and D3 as the electrical connection break point between the load cable outside the enclosure and the copper busbar inside the enclosure, so as to realize the electrical connection between the external cable and the copper busbar through the standardized interface.

[0054] 4.2 Design of Universal Cable Routes refer to Figure 2 As shown, the interior of the enclosure is divided into a high-voltage independent channel II (red cable tie plate) and a low-voltage open cable tray III (green passageway) to achieve physical isolation between the high-voltage and low-voltage cable channels. Low-voltage cables are arranged in the upper part of the enclosure and on both front beams; high-voltage cables are arranged in the lower part of the enclosure, in the middle, and on both side walls; allowing different power sources to share a single cable path.

[0055] 5. Free counterweight zone E refer to Figures 6-10 As shown, the free counterweight zone E is divided into three areas: front, middle, and rear, named E1, E2, and E3 respectively. The E2 area is equipped with a mechanical expansion interface 12, which has multiple sets according to the type of power source. Each set of mechanical expansion interfaces 12 corresponds to a power source mode. The E1 and E3 areas are equipped with mounting frames 14, on which counterweights 7 are installed for adjusting the weight and center of gravity of the box.

[0056] 5.1 Mechanical Expansion Interface Design The mechanical expansion interface 12 is configured in multiple sets according to the type of power source, with each set of mechanical expansion interface 12 corresponding to a power source mode.

[0057] refer to Figures 6-9 As shown, mounting beams 11 are installed on the bottom plate of area E2 of the enclosure. L-shaped corner fittings 111 are installed at the four corners of the rectangle formed by the two sets of mounting beams 11. Two sets of mechanical expansion interfaces 12 are provided, one set on the mounting beams 11 and the other set on the L-shaped corner fittings 111. There are four mounting beams 11, with two mechanical expansion interfaces 12 on each beam 11, forming a group of eight. There are eight L-shaped corner fittings 111, with one mechanical expansion interface 12 on each L-shaped corner fitting 111, forming a group. Figure 7 As shown, the blue markings represent one set of mechanical expansion interfaces 12, and the orange markings represent another set of mechanical expansion interfaces 12.

[0058] 5.2 Design for Weight and Center of Gravity Adjustment of the Enclosure The counterweight 7 adopts a standardized cuboid design, with the weight of a single block controlled within an easily operable range, making it easy to install without affecting the center of gravity of the box. For example... Figure 11 As shown, symmetrical L-shaped cantilever brackets 72 are integrated on both sides of the counterweight. The vertical arm of the L-shaped cantilever bracket 72 is provided with a lifting hole 73 to serve as a handle for the counterweight 7. The vertical arm of the L-shaped cantilever bracket 72 is provided with a mounting hole A74 for fixing the counterweight 7.

[0059] Six sets of mounting brackets 14 are set in each of the E1 and E3 areas. One counterweight 7 is installed between two adjacent mounting brackets 14. Two mounting holes B141 are opened on each side of the mounting bracket 14. The mounting holes B141 correspond to the mounting holes A74 on the L-shaped cantilever bracket 72. Bolts are inserted into the two mounting holes to complete the installation of the counterweight 7.

[0060] like Figure 10 As shown, by increasing or decreasing the number (1 to 8) and position of the counterweights, the total weight of the converter and the center of gravity temperature under different power sources can be adjusted to meet the weight and center of gravity requirements. Example

[0061] Combined with Table 1 and Figure 12 , 13 As shown, there are 8 high-voltage electrical interfaces in pure electric mode, 4 of which are shared interfaces; 7 high-voltage electrical interfaces in hybrid electric mode, 3 of which are shared interfaces in pure electric mode; and 6 high-voltage electrical interfaces in hydrogen-electric mode, 2 of which are shared interfaces in pure electric mode. Unused interfaces in hybrid and hydrogen-electric modes are blocked. The table below summarizes the high-voltage electrical interfaces for the three modes: Table 2 Definitions of High Voltage Electrical Interfaces

[0062] In pure electric mode, there are 8 high-voltage electrical interfaces. Among them, four sets of electrical interfaces A11, A12, B11, and B12 are shared, and four additional sets of high-voltage electrical interfaces C21, C22, D21, and D22 are added to connect to power battery 21+, power battery 21-, power battery 22+, and power battery 22-, respectively.

[0063] In the hybrid mode, there are 7 high-voltage electrical interfaces. Among them, four sets of electrical interfaces A11, A12, B11, and B12 are shared, and four additional sets of high-voltage electrical interfaces C21, C22, and D21 are added to connect to three power sources: diesel engine U, diesel engine V, and diesel engine W, respectively. A 131 cover is installed on the D22 interface for sealing.

[0064] In hydrogen-electric mode, there are 6 high-voltage electrical interfaces. Among them, four sets of electrical interfaces A11, A12, B11, and B12 are shared, and two additional sets of high-voltage electrical interfaces C21 and C22 are added to connect to the two power sources of fuel cell 1+ and fuel cell 1- respectively. The D21 and D22 interfaces are sealed with 131 covers.

[0065] The above description is merely a specific embodiment of the present invention, enabling those skilled in the art to understand or implement the present invention. Although detailed descriptions have been provided with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments, and they should all be covered within the protection scope of the claims.

Claims

1. A converter housing for multiple power sources, comprising a housing, wherein the housing is arranged from top to bottom as follows: a central DC zone A, a power module zone B, an electrical switch zone C, an external interface zone D, and a free counterweight zone E; a pre-charge contactor (5) and a voltage sensor (6) are provided in the central DC zone A; characterized in that: A functional module (2) is provided on one side of the power module area B. The functional module (2) is divided into three power supply modes: power battery power source, diesel generator + power battery power source, and hydrogen fuel cell + power battery power source. A high-voltage switch (1) is provided on one side of the electrical switch area C. The high-voltage switch (1) is connected to the functional module (2) through a current sensor (3). The high-voltage switch (1) selects the corresponding circuit according to the power supply mode of the functional module (2). An auxiliary switch (4) is provided on the other side of the electrical switch area C. The auxiliary switch (4) is installed on the enclosure through a transition mounting plate (41). The external interface area D includes a standardized interface (13), which divides the external interface area D into three areas: front, middle, and rear, named D1 area, D2 area, and D3 area respectively. The standardized interface (13) in the D1 area is used to connect to the external power source according to the type of external power source. The standardized interface (13) in the D3 area is used for the output of the load cable. The free counterweight zone E is divided into three areas: front, middle and rear, named E1, E2 and E3 respectively. The E2 area is equipped with a mechanical expansion interface (12), which has multiple sets according to the type of power source. Each set of mechanical expansion interfaces (12) corresponds to a power source mode. The E1 and E3 areas are equipped with mounting frames (14), and the mounting frames (14) are equipped with counterweights (7) for adjusting the weight and center of gravity of the box.

2. The universal converter housing for multiple power sources according to claim 1, characterized in that: The bottom plate of the E2 area of ​​the box is equipped with mounting beams (11), and L-shaped corner pieces (111) are respectively provided on the four corners of the rectangle formed by the two sets of mounting beams (11); the mechanical expansion interface (12) is provided in two sets, one set on the mounting beams (11) and the other set on the L-shaped corner pieces (111).

3. The universal converter housing for multiple power sources according to claim 2, characterized in that: There are 4 mounting beams (11), and 2 mechanical expansion interfaces (12) are opened on each mounting beam (11) to form a group of 8; there are 8 L-shaped corner pieces (111), and 1 mechanical expansion interface (12) is opened on each L-shaped corner piece (111) to form a group of 8.

4. The universal converter housing for multiple power sources according to claim 3, characterized in that: The standardized interface (13) has 8 units installed.

5. The universal converter housing for multiple power sources according to claim 4, characterized in that: A cover (131) is installed on the redundant standardized interface (13).

6. The universal converter housing for multiple power sources according to claim 5, characterized in that: The standardized interface (13) is provided with an O-ring for enhanced sealing.

7. The universal converter housing for multiple power sources according to claim 1 or 6, characterized in that: The high-voltage switch (1) is electrically connected by a rigid copper busbar connection, a flexible cable connection, or a hybrid connection of a rigid copper busbar and a flexible cable.

8. The universal converter housing for multiple power sources according to claim 7, characterized in that: The counterweight (7) includes a central counterweight body (71) and two L-shaped cantilever brackets (72) on both sides; the vertical arm of the L-shaped cantilever bracket (72) is connected to the side wall of the counterweight body (71), and the horizontal arm of the L-shaped cantilever bracket (72) is provided with mounting holes A (74), which are connected to the mounting frame (14) through the mounting holes A (74).

9. The universal converter housing for multiple power sources according to claim 8, characterized in that: The vertical arm of the L-shaped cantilever bracket (72) is provided with a lifting hole (73).

10. The universal converter housing for multiple power sources according to claim 9, characterized in that: Each of the E1 and E3 areas is equipped with 6 sets of mounting racks (14), and a counterweight (7) is installed between two adjacent mounting racks (14), for a total of 4 sets; Two mounting holes B (141) are opened on each side of the mounting bracket (14). The mounting holes B (141) correspond to the mounting holes A (74) on the L-shaped cantilever bracket (72). Bolts are inserted through the two mounting holes to complete the installation of the counterweight (7).

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