Power grid simulator with efficient heat dissipation

Abstract

The invention discloses an efficient heat dissipation power grid simulator, and relates to the technical field of power electronic test equipment. The power grid simulator comprises a case, and an input unit, a power conversion unit, a control unit and an auxiliary unit which are arranged in the case. The case is composed of a ventilation baffle, a side baffle, an upper cover plate and a bottom cover plate which are oppositely arranged. A plurality of parallel insulating plates are arranged in the case, and the length direction of the insulating plates is perpendicular to the ventilation baffle, so that the interior of the case is divided into a plurality of independent ventilation areas. Ventilation grid holes communicated with the ventilation area are formed in the ventilation baffle, and a linear airflow channel is formed. A fan of the auxiliary unit is arranged in the channel and drives airflow to flow in a one-way penetrating mode. Air duct construction, electrical isolation and structure supporting are achieved through integration of the insulating plates, the problems of low heat dissipation efficiency, high insulation safety risk, insufficient mechanical stability and inconvenient maintenance are solved by combining the optimized fan array and the bottom suspension gap, the reliability of equipment is remarkably improved, and the service life of the equipment is remarkably prolonged.

Description

Technical Field

[0001] This application relates to the field of power electronics testing equipment technology, and in particular to a power grid simulator with high-efficiency heat dissipation. Background Technology

[0002] A power grid simulator, also known as an AC power supply or programmable AC power supply, is a key piece of equipment in the research, development, production, and certification testing of renewable energy power generation equipment such as photovoltaic inverters, energy storage converters, electric vehicle charging modules, home appliances, and industrial motors. Its core function is to simulate various normal and abnormal operating conditions of the power grid, such as voltage fluctuations, frequency changes, and harmonic injection, providing a stable, clean, or precisely programmable AC test power supply for the device under test.

[0003] With the rapid development of power electronics technology, modern power grid simulators are evolving towards higher power density, higher dynamic response, and higher output accuracy. This leads to a significant increase in losses and heat generation in their internal power conversion units, such as PFC circuits and inverter bridges, and the integration of processors and drive circuits in the control unit is also becoming increasingly sophisticated. Therefore, efficient and reliable thermal management design has become a core challenge in ensuring long-term stable operation of equipment and improving its reliability and service life.

[0004] Currently, most common cooling solutions for the internal cooling of power grid simulator chassis rely on forced convection fans. However, existing designs typically suffer from the following problems: 1. Crude airflow design and low heat dissipation efficiency: The layout of internal electronic components often prioritizes the convenience of electrical connections without systematically coordinating with the heat dissipation airflow design. The airflow path is disordered, with numerous dead zones and short circuits, preventing cool air from effectively flowing over the main heat-generating components, resulting in low heat dissipation efficiency and prominent local hotspots.

[0005] 2. Complex structure, insulation and safety risks: To fix various circuit boards, such as power boards and control boards, complex metal brackets or beams are often used. This not only increases the weight and assembly complexity, but also brings the risk of insufficient electrical clearance and creepage distance in high voltage and high current working environments, affecting the insulation safety performance of the equipment.

[0006] 3. Conflict between space utilization and maintainability: In order to improve space utilization, circuit boards are often densely arranged, but this will seriously hinder air circulation and make daily maintenance and cleaning of heat dissipation components such as fans and air duct filters extremely difficult.

[0007] 4. Insufficient mechanical stability: The internal modules are usually directly fixed to the chassis wall or simple support components, which are prone to loosening during equipment transportation or operation vibration, affecting the reliability of electrical connections.

[0008] In summary, the existing structural design of power grid simulators struggles to balance heat dissipation efficiency, electrical insulation safety, mechanical stability, and ease of maintenance, thus hindering further improvements in overall equipment performance and reliability. Therefore, an innovative integrated structural layout and heat dissipation design is urgently needed to systematically address these issues. Summary of the Invention

[0009] To address the aforementioned issues, this application provides a power grid simulator with high-efficiency heat dissipation.

[0010] A high-efficiency heat dissipation power grid simulator includes: a chassis and an input unit, a power conversion unit, a control unit, an output unit, and an auxiliary unit disposed within the chassis; the chassis consists of a top cover, a bottom cover, a pair of side baffles, and a pair of ventilation baffles, the ventilation baffles being arranged opposite each other; multiple parallel insulating plates are disposed within the chassis, the length direction of the insulating plates being perpendicular to the two ventilation baffles, dividing the internal space of the chassis into multiple mutually isolated ventilation zones; ventilation baffles have ventilation grid holes, the ventilation grid holes being connected to the ventilation zones to form an airflow path penetrating the interior of the chassis; the auxiliary unit includes multiple fans, the fans being disposed in the airflow path, used to drive airflow into one ventilation baffle through a ventilation grid hole, flow through the ventilation zone, and then exit through a ventilation grid hole in another ventilation baffle; the input unit, power conversion unit, output unit, and control unit are respectively mounted on the side of the insulating plates and located in different ventilation zones.

[0011] Compared to existing technologies, the above-mentioned technical solution utilizes an insulating plate parallel to the airflow direction to divide the interior of the chassis into independent ventilation zones. This, combined with opposing ventilation baffles with perforated grilles, creates a directional, undisturbed, linear, and highly efficient heat dissipation airflow. Simultaneously, the main functional units are suspended on the side of the insulating plate, fully exposed within the airflow duct, effectively increasing the heat dissipation area and reducing airflow resistance. This integrated design fundamentally solves the problems of turbulent airflow and low heat dissipation efficiency in traditional layouts. Furthermore, the insulating plate achieves electrical isolation between units, enhancing safety and structural integrity.

[0012] Furthermore, the plurality of fans are distributed in a rectangular array, with at least two columns in one distribution direction and the number in the other distribution direction matching the number of ventilation areas.

[0013] Compared to existing technologies, by adopting the above technical solution, the distribution of the fan array matches the number of ventilation areas, ensuring that each independent ventilation area receives balanced and sufficient airflow, thus avoiding the formation of cooling dead zones. Setting at least two rows of fans can adapt to potential vertical space divisions within the chassis, such as those blocked by horizontal circuit boards. Airflow is delivered simultaneously from different positions above and below, penetrating obstacles and ensuring that airflow evenly covers the entire ventilation cross-sectional area, significantly improving the uniformity and efficiency of heat dissipation.

[0014] Furthermore, the number of ventilation zones is three, and the fans are arranged in three rows side by side, with two columns arranged horizontally.

[0015] Compared to existing technologies, by adopting the above technical solution, the internal space is divided into three ventilation zones, providing independent heat dissipation channels for the main input, power conversion, and control units, achieving physical separation and targeted cooling. The fan layout corresponds to the three ventilation zones and the possible vertical space within them, making the airflow organization more refined and ensuring that each unit module is in a highly efficient air-cooled environment, further optimizing the overall heat dissipation performance.

[0016] Furthermore, the bottom of the insulating plate is provided with a slot, and a plurality of parallel reinforcing ribs are fixed on the side of the bottom cover plate facing the inside of the chassis. The insulating plate is engaged with the reinforcing ribs through the slot at its bottom, and a cantilever gap is formed between the bottom of the insulating plate and the bottom cover plate.

[0017] Compared with existing technologies, the above-mentioned technical solution enables rapid, accurate positioning and secure installation of the insulation board through the interlocking of the slot and reinforcing rib, enhancing the internal frame's resistance to vibration and impact and improving mechanical stability. Simultaneously, the resulting bottom overhang creates an auxiliary transverse airflow channel, which, combined with the longitudinal main air duct, forms a three-dimensional ventilation network. This promotes air circulation at the bottom of the equipment, eliminates the heat accumulation problem caused by traditional bottom-mounted installations, and improves overall heat dissipation.

[0018] Furthermore, the length direction of the reinforcing rib is perpendicular to the side baffle.

[0019] Compared with existing technologies, by adopting the above technical solution, the reinforcing ribs are set perpendicular to the side baffles, that is, parallel to the general direction of airflow. This layout not only makes the structural stress more reasonable, but also minimizes the obstruction of the reinforcing ribs to the horizontal airflow at the bottom, ensuring the unobstructed flow of the bottom overhang gap as an airflow channel, allowing the cooling airflow to pass through the bottom of the equipment more smoothly.

[0020] Furthermore, an insulating protective plate is fixedly installed on the side of the upper cover plate, bottom cover plate, side baffle plate and ventilation baffle plate facing the inside of the chassis. Multiple insulating protective plates are enclosed to form a frame structure and are fixedly connected to the multiple insulating plates.

[0021] Compared to existing technologies, by adopting the above-mentioned technical solution, the internal frame structure formed by the insulating protective plate, together with the insulating plate, constructs a complete built-in insulating skeleton system. This system completely isolates all major functional units from the metal chassis shell, greatly enhancing the electrical insulation performance and safety level of the equipment. At the same time, this skeleton system significantly improves the structural rigidity and integrity of the entire chassis, ensuring the positional stability of each component during long-term operation or transportation.

[0022] Furthermore, the input unit, power conversion unit, output unit, and control unit are suspended by being mounted on the sides of two adjacent insulating plates.

[0023] Compared to existing technologies, by adopting the above-mentioned technical solution, each functional unit is suspended in the air, exposing all its surfaces, especially the bottom and back, to flowing air, greatly increasing the effective heat dissipation surface area. This installation method completely avoids direct contact between the unit and the inner wall of the chassis, eliminating contact thermal resistance, and allows airflow to circulate around the unit, achieving efficient convective heat transfer, thereby significantly reducing the temperature rise of key heat-generating components.

[0024] Furthermore, a display screen is fixedly installed on the outer side of one of the ventilation baffles.

[0025] Compared with existing technologies, by adopting the above technical solution and integrating the display screen into the ventilation baffle, users are provided with an intuitive and convenient human-machine interface, facilitating status monitoring and parameter setting. This layout makes reasonable use of external panel space, without occupying valuable internal air duct space or circuit board area, thus maintaining the integrity and efficiency of the internal heat dissipation air duct.

[0026] Furthermore, the fan is integrally mounted inside the chassis via a mounting plate, which is detachably connected to the chassis.

[0027] Compared with existing technologies, by adopting the above technical solution, which integrates multiple fans into a single module using a mounting plate, the assembly and disassembly process is greatly simplified. When cleaning, maintenance, or replacement of fans is required, all fans can be operated at once simply by removing the mounting plate, significantly improving maintenance convenience and reducing the later maintenance costs and time of the equipment.

[0028] Furthermore, the distribution of the input unit, power conversion unit, output unit, and control unit within the ventilation area ensures that the airflow passes sequentially through units with different heat generation rates. Compared to existing technologies, by adopting the above technical solution, the layout of each functional unit can be optimized in terms of airflow direction based on its heat generation characteristics. For example, the unit with the highest heat generation can be placed downstream of the airflow to prevent its exhaust hot air from heating subsequent units. This scientific airflow design based on heat source distribution can fully utilize the cooling capacity of the airflow and achieve on-demand allocation of cooling resources, thereby achieving better heat dissipation efficiency and temperature uniformity at the system level.

[0029] In summary, this application includes at least one of the following beneficial technical effects: 1. By dividing independent ventilation areas with insulating boards and cooperating with ventilation baffles to construct straight air ducts, and by suspending functional units on the side of the insulating boards, the integrated design of heat dissipation air ducts and electrical structure layout is realized, which fundamentally solves the problems of airflow turbulence and low heat dissipation efficiency, and improves electrical safety and mechanical integrity.

[0030] 2. The insulating board is fixed by a slot-reinforcing rib structure, forming a bottom suspended gap. Combined with a fan array layout that matches the ventilation area, this not only ensures the installation is firm and vibration-resistant, but also forms a three-dimensional, high-efficiency airflow network that can effectively penetrate internal obstacles (such as horizontal circuit boards), achieving uniform and efficient heat dissipation.

[0031] 3. By constructing an internal insulation frame with an insulating protection plate and adopting a fan mounting plate that can be completely detached, the high-voltage insulation safety level and maintenance convenience of the equipment are improved simultaneously, giving the equipment the characteristics of high reliability, safety and low maintenance cost. Attached Figure Description

[0032] Figure 1 This is a perspective view of this embodiment, mainly showing the chassis; Figure 2 This is a three-dimensional view from another perspective of this embodiment, mainly showing the chassis structure; Figure 3 It is a 3D view of the chassis after the top cover is hidden, mainly showing the internal units of the chassis; Figure 4 It is a 3D view of the chassis behind the hidden bottom cover, mainly showing the reinforcing ribs and slots.

[0033] Explanation of reference numerals in the attached drawings: 1. Input unit; 2. Power conversion unit; 3. Control unit; 4. Output unit; 42. Fan; 5. Chassis; 51. Top cover; 52. Bottom cover; 521. Reinforcing rib; 53. Side baffle; 54. Ventilation baffle; 541. Ventilation grid hole; 55. Insulation board; 551. Slot; 56. Insulation protection board. Detailed Implementation

[0034] The embodiments illustrated in the accompanying drawings are for illustrative purposes only and should not be construed as limiting the scope of protection of this application. Other implementation methods obtained by those skilled in the art based on the described embodiments without inventive effort are all within the scope of protection of this application.

[0035] This embodiment provides a high-efficiency heat dissipation power grid simulator, aiming to solve the problems of low heat dissipation efficiency, poor insulation safety, inconvenient maintenance, and insufficient mechanical stability in the prior art. (Refer to...) Figure 1 , Figure 2 and Figure 3 The system includes a chassis 5 and an input unit 1, a power conversion unit 2, a control unit 3, an output unit 4, and auxiliary units integrated within the chassis 5. The chassis 5 is a hexahedral frame structure, which is enclosed by an upper cover plate 51, a bottom cover plate 52, a pair of side baffles 53, and a pair of ventilation baffles 54. The upper cover plate 51 and the bottom cover plate 52 are arranged vertically opposite each other, the pair of side baffles 53 are arranged horizontally opposite each other, and the pair of ventilation baffles 54 are arranged front-to-back opposite each other, together forming the main body of the equipment's outer shell.

[0036] Reference Figure 3 To optimize internal heat dissipation and ensure electrical safety, multiple parallel insulating plates 55 are installed inside the chassis 5. The longitudinal direction of these insulating plates 55 is perpendicular to the aforementioned pair of ventilation baffles 54, thereby longitudinally dividing the internal space of the chassis 5 into multiple independent compartments, which constitute the ventilation areas of this invention. In a preferred embodiment, two insulating plates 55 are used, thus dividing the internal space into three parallel ventilation areas. Each ventilation area corresponds to an independent airflow channel.

[0037] Reference Figure 1 , Figure 2 and Figure 3 To achieve efficient forced air cooling, a large number of ventilation grilles 541 are provided on each of the pair of ventilation baffles 54. These ventilation grilles 541 are directly connected to the ventilation areas inside the chassis 5, forming an airflow path that runs through the entire device. External cold air can enter through the grilles of one ventilation baffle 54, flow through various ventilation areas, and then be discharged through the grilles of the other ventilation baffle 54 carrying heat.

[0038] Reference Figure 1 , Figure 2 and Figure 3The input unit 1 includes an input filter and PFC circuit; the power conversion unit 2 includes DC / DC and DC / AC power circuits; the control unit 3 includes a main control board and a drive board, serving as the main heat source and functional carrier of the equipment; and the output unit 4 is used to output the processed grid power. These units are arranged in different ventilation areas. Specifically, each unit is fixedly mounted on the opposite sides of two adjacent insulating plates 55 via its housing or mounting bracket. This mounting method allows the main body of each unit to be suspended within the chassis 5, meaning that there is sufficient space around it, especially at the bottom, with the bottom cover 52 of the chassis 5, which greatly reduces airflow resistance.

[0039] Reference Figure 3 Furthermore, to securely and precisely fix the aforementioned multiple insulating plates 55, insulating protective plates 56 are pre-fixed on the surfaces of the upper cover plate 51, bottom cover plate 52, side baffles 53, and ventilation baffles 54 facing the interior of the chassis 5. These insulating protective plates 56 are connected end to end inside the chassis 5, forming a complete rectangular frame structure. The ends of the multiple insulating plates 55 are screwed or snapped into this frame structure of insulating protective plates 56, thereby being firmly locked in the predetermined position, enhancing the rigidity and stability of the entire internal frame.

[0040] Reference Figure 4 Each insulating plate 55 has a downward-opening slot 551 machined on its bottom edge. Correspondingly, multiple parallel reinforcing ribs 521 are welded or cast on the side of the bottom cover plate 52 facing the inside of the chassis 5. The length direction of these reinforcing ribs 521 is set perpendicular to the side baffle 53. During installation, the slots 551 on the bottom of the insulating plate 55 snap into the corresponding reinforcing ribs 521 from top to bottom, achieving quick positioning and fixation. This design ensures the secure installation of the insulating plate 55, preventing loosening during vibration. On the other hand, since the insulating plate 55 is installed on the reinforcing ribs 521 through the slots 551, its bottom naturally separates from the surface of the bottom cover plate 52, forming a bottom overhang gap. This gap becomes part of the bottom transverse airflow channel, combining with the longitudinal air ducts of each ventilation area to form a three-dimensional ventilation network, significantly enhancing airflow and heat dissipation.

[0041] Reference Figure 3The auxiliary unit includes multiple axial fans 42, which drive airflow along the airflow path. In this embodiment, these fans 42 are arranged in a rectangular array on one side of the device. The array distribution satisfies the following characteristics: along the direction parallel to the ventilation baffle 54, the fans 42 are arranged in two columns; along the direction parallel to the insulating plate 55, the fans 42 are arranged in three rows. This two-column, three-row layout design has a clear purpose: since the circuit boards (such as power boards) mounted on the side of the insulating plate 55 are usually horizontally positioned, they vertically divide the ventilation area into upper and lower parts, hindering vertical airflow. By arranging the fans 42 in two columns, they can be directed towards the upper and lower airflow spaces divided by the circuit boards, providing airflow simultaneously, thereby effectively overcoming the obstruction of airflow by the circuit boards and greatly improving the uniformity of ventilation and heat dissipation.

[0042] Reference Figure 3 For ease of maintenance, all fans 42 are initially mounted on a common mounting plate to form a fan 42 module. This mounting plate is then detachably installed in a pre-set position inside the chassis 5 using screws. When cleaning or replacing a fan 42 is required, simply remove the mounting plate to remove all fans 42 as a single unit, making maintenance very convenient.

[0043] Reference Figure 1 Finally, regarding the human-machine interface, a display screen is also fixedly installed on the outside of a ventilation baffle 54 to display the device's working status, parameter settings, and fault information.

[0044] Through the coordinated operation of the above specific structures, the power grid simulator in this embodiment achieves the integration of structural layout and heat dissipation design.

[0045] The implementation principle of this application is as follows: This solution, by setting an insulating plate 55 parallel to the airflow direction, strictly divides the interior of the chassis 5 into multiple independent ventilation zones. In conjunction with the oppositely positioned ventilation baffles 54, it constructs a directional, undisturbed, linear, and efficient airflow path, fundamentally solving the problems of turbulent airflow and dead zones in traditional layouts. The main heat-generating units are suspended on the side of the insulating plate 55, fully exposing them to the airflow duct, and the bottom suspended space gap forms an auxiliary airflow duct, maximizing the heat dissipation area and airflow contact efficiency. The fans 42 adopt a multi-row layout matching the number of ventilation zones, with two specially designed upper and lower rows corresponding to the spaces divided by the horizontal circuit boards, achieving precise compensation and penetration of obstructed airflow and ensuring uniform heat dissipation. Simultaneously, the insulating plate 55 itself serves as a structural skeleton and electrical isolation barrier, combined with the insulating protection plate 56 frame on the inner wall of the chassis 5, physically isolating each high-voltage unit, significantly improving the insulation safety and overall mechanical stability of the equipment. The modular installation design of the fans 42 greatly facilitates later maintenance. In summary, this design, through a highly integrated structural form, simultaneously optimizes heat dissipation performance, electrical safety, structural stability, and maintainability, thereby improving the overall reliability and service life of the power grid simulator.

[0046] The above are merely embodiments of this application and are not intended to limit the scope of protection of this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the scope of protection of this application.

Claims

1. A high-efficiency heat dissipation power grid simulator, characterized in that, include: The chassis (5) and the input unit (1), power conversion unit (2), control unit (3), output unit (4) and auxiliary unit disposed within the chassis (5); The chassis (5) consists of an upper cover plate (51), a bottom cover plate (52), a pair of side baffles (53) and a pair of ventilation baffles (54), which are arranged opposite to each other; The chassis (5) is provided with a plurality of parallel insulating plates (55), the length direction of which is perpendicular to the two ventilation baffles (54), and divides the internal space of the chassis (5) into a plurality of mutually isolated ventilation areas; The ventilation baffle (54) has ventilation grid holes (541) and the ventilation grid holes (541) are connected to the ventilation area to form an airflow passage through the inside of the chassis (5); The auxiliary unit includes multiple fans (42), which are disposed in the airflow passage and are used to drive airflow into the ventilation grid hole (541) of one ventilation baffle (54), flow through the ventilation area, and then discharge from the ventilation grid hole (541) of another ventilation baffle (54). The input unit (1), power conversion unit (2), control unit (3) and output unit (4) are respectively installed on the side of the insulating plate (55) and located in different ventilation areas.

2. The high-efficiency heat dissipation power grid simulator according to claim 1, characterized in that, The plurality of fans (42) are arranged in a rectangular array, with at least two columns in one distribution direction and the number in the other distribution direction matching the number of ventilation areas.

3. The high-efficiency heat dissipation power grid simulator according to claim 2, characterized in that, The number of ventilation zones is three, and the fans (42) are arranged in three rows side by side and in two columns horizontally.

4. The high-efficiency heat dissipation power grid simulator according to claim 1, characterized in that, The bottom of the insulating plate (55) is provided with a slot (551). The bottom cover plate (52) has a plurality of parallel reinforcing ribs (521) fixed on the side facing the inside of the chassis (5). The insulating plate (55) is snapped onto the reinforcing ribs (521) through the slot (551) at its bottom, and a cantilever gap is formed between the bottom of the insulating plate (55) and the bottom cover plate (52).

5. A high-efficiency heat dissipation power grid simulator according to claim 4, characterized in that, The length direction of the reinforcing rib (521) is perpendicular to the side baffle (53).

6. A high-efficiency heat dissipation power grid simulator according to claim 4, characterized in that, The upper cover plate (51), bottom cover plate (52), side baffle (53) and ventilation baffle (54) are all fixedly provided with insulating protection plates (56) on the side facing the inside of the chassis (5). Multiple insulating protection plates (56) are enclosed to form a frame structure and are fixedly connected to the multiple insulating plates (55).

7. A high-efficiency heat dissipation power grid simulator according to claim 1, characterized in that, The input unit (1), power conversion unit (2), control unit (3) and output unit (4) are suspended by being mounted on the sides of two adjacent insulating plates (55).

8. A high-efficiency heat dissipation power grid simulator according to claim 1, characterized in that, A display screen is fixedly installed on the outer side of one of the ventilation baffles (54).

9. A high-efficiency heat dissipation power grid simulator according to claim 1, characterized in that, The fan (42) is mounted inside the chassis (5) by a mounting plate (41), and the mounting plate (41) is detachably connected to the chassis (5).

10. A high-efficiency heat dissipation power grid simulator according to claim 1, characterized in that, The distribution of the input unit (1), power conversion unit (2), control unit (3) and output unit (4) in the ventilation area allows the airflow to pass through units with different heat generation in sequence.

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