Pluggable power converter
By using plug-in connections and guide surfaces, the problem of inconvenient installation of power modules in converters is solved, enabling convenient electrical connections and stable operation.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- XIAMEN KEHUA DIGITAL ENERGY TECH CO LTD
- Filing Date
- 2023-09-18
- Publication Date
- 2026-04-17
AI Technical Summary
The installation, disassembly, or maintenance of power modules in existing converters is inconvenient, especially since the connection between the input bus and the capacitor bus is secured with bolts, resulting in limited operating space and inconvenience.
The system adopts a pluggable connection method. By setting connectors and contact interfaces on the capacitor busbar, the electrode plates of the input busbar can be directly inserted into the contact interfaces to form an electrical connection with the contact pieces. The cooperation of the first and second mating parts ensures that the electrode plates are accurately inserted. At the same time, bending limiting parts and guide surfaces are used to guide and avoid electrode plate deformation and positional deviation.
This makes the installation, disassembly, and maintenance of power modules more convenient, reduces the difficulty of operation, avoids problems such as poor contact between the electrode plates and contacts and shortened lifespan, and improves the stability and reliability of the connection.
Smart Images
Figure CN121886971A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of converters, and more specifically to a pluggable power converter. Background Technology
[0002] Converters are widely used in power systems, rail transportation, military industry, petroleum machinery, new energy vehicles, wind power generation, solar photovoltaic and other fields. They connect the battery system to the power grid to realize bidirectional conversion of electrical energy, control the charging and discharging process of the battery, and perform AC-DC conversion. In the absence of a power grid, they can directly supply power to AC loads. At the same time, NPC (Neutral Point Clamp) or ANPC (Active Neutral Point Clamp) three-level topologies can use IGBT devices with low blocking voltage to increase the DC bus voltage, thereby increasing the AC output voltage and expanding the system power level. Therefore, they are widely used in converters.
[0003] Conventionally, a converter includes a power unit, which generally includes a DC component and a power component. The DC component includes a DC capacitor bank and a capacitor busbar, while the power component includes a power module and a heat sink. The power module is mounted on the heat sink and then connected to the DC busbar through the input busbar.
[0004] Specifically, refer to Figure 1 This diagram illustrates the structure of a power device in the prior art. The power device mainly includes a capacitor busbar 01, a DC capacitor bank 02, an input busbar 03, a power transistor bank 04, an output busbar 05, and a heat sink 06. The input busbar 03, power transistor bank 04, and output busbar 05 constitute the aforementioned power module. This power module is mounted on the heat sink 06, which is an air-cooled heat sink with heat dissipation fins on its back. Therefore, the input busbar 03, power transistor bank 04, and output busbar 05 are all mounted on the front of the heat sink 06. Since the power device outputs three-phase AC power, its power components include three power modules and three corresponding heat sinks 06. Each power module is mounted on one heat sink 06, and the input busbar 03 of each of the three power modules is connected to the capacitor busbar 01.
[0005] Furthermore, the capacitor busbar 01 includes a positive plate, a negative plate, and a neutral plate, which are stacked and separated from each other by an insulating plate. Correspondingly, the input busbar 03 in each power module also includes a positive plate, a negative plate, and a neutral plate, and is connected to the corresponding plates in the capacitor busbar 01. In the prior art, the input busbar 03 and the capacitor busbar 01 are connected by bolts, which makes the installation, disassembly, or maintenance of power components in the power device inconvenient. Summary of the Invention
[0006] The purpose of this invention is to overcome the above-mentioned defects or problems in the prior art and to provide a pluggable power converter, which can connect the input busbar to the capacitor busbar in the correct orientation by plugging and unplugging.
[0007] To achieve the above objectives, the present invention and its preferred embodiments employ the following technical solutions, but the embodiments are not limited to the following solutions:
[0008] A pluggable power converter includes: a DC module comprising a capacitor busbar and a plurality of connectors; the connectors are fixed to the capacitor busbar, and each plate of the capacitor busbar corresponds to at least one connector; the connector has a forward-facing contact interface, and the contact interface has a contact piece electrically connected to the plate of the capacitor busbar corresponding to the connector; at least one power module comprising a mounting base and an input busbar fixed to the mounting base; the input busbar includes plates corresponding to the number and polarity of the capacitor busbars, and accordingly corresponds to each of the connectors; the plates of the input busbar are arranged in a stacked manner, and one of the plates is bent to form a bent portion; and a first mating member fixed to the capacitor busbar and having at least one first pair The system includes a first docking portion and a second docking member, which are fixed to the mounting base and have second docking portions corresponding to each of the first docking portions. The second docking portions are adapted to form a plug-in engagement with the corresponding first docking portions in the front-rear direction. Each electrode plate of the input busbar is configured such that when each of the second docking portions in the power module in which it is located is plugged in with the corresponding first docking portions, it extends into the contact interface of the corresponding connector and contacts the contact piece in the contact interface to form an electrical connection between the input busbar and the capacitor busbar. The system also includes a bending limiting member, which is fixed to the mounting base and closely abuts the bending portion. The second docking member and the bending limiting member are respectively located on both sides of the bending portion in the front-rear direction and are fixed to the mounting base by being fixed to the bending limiting member.
[0009] As a further technical solution, the electrode plates in the input row are arranged in a stacked manner along the left-right direction, and the rear end of at least one electrode plate located on the outermost side is bent in a direction away from the position of other electrode plates, so that the electrode plate forms a base, the bent portion and the insertion portion in sequence from front to back; the base and the insertion portion both extend in the front-back direction, the bent portion connects the base and the insertion portion, and the insertion portion is adapted to extend into the contact interface of the corresponding connector; the bending limiting member is located on the outside of the bent electrode plate in the input row, and it has a fixing portion and a limiting portion corresponding to the extension direction of the base and the bent portion of the bent electrode plate, respectively, and the fixing portion is close to the base corresponding to it, and the limiting portion is close to the bent portion corresponding to it.
[0010] As a further technical solution, the second docking member is located behind the bent portion of the bent electrode plate in the input row, and is fixedly connected to the limiting portion of the bent limiting member in front of the bent portion.
[0011] As a further technical solution, the input row includes three electrode plates, wherein the rear ends of the electrode plates located on the left and right sides are bent to form the bent portion and the insertion portion; corresponding to one input row, at least two second docking members and two bending limiting members are provided, each of the second docking members and one bending limiting member is connected to each other and corresponds to a bent electrode plate.
[0012] As a further technical solution, in the power module, the input row is located on one side of the mounting base in the left-right direction, wherein the input row is located on the first side and the mounting base is located on the second side; the bending limiting member corresponding to the electrode plate located on the second side of the input row is fixed to the mounting base, and is fixed to the bending limiting member corresponding to the electrode plate located on the first side of the input row to cooperate in clamping the input row in the left-right direction.
[0013] As a further technical solution, the first docking member is provided with a forward-facing insertion hole for forming the first docking portion, and the second docking member is provided with a rearward-extending insertion post for forming the second docking portion; each insertion post corresponds to one of the insertion holes and is adapted to form an insertion fit in the front-rear direction; the hole edge of the insertion hole forms an inclined first guide surface, and the end of the insertion post forms an inclined second guide surface, the first guide surface and the second guide surface are adapted to cooperate with each other to guide the insertion post to be inserted into the corresponding insertion hole.
[0014] As a further technical solution, the rear end of each electrode plate of the input row forms an inclined third guide surface, and the edge of the contact interface of the connector forms an inclined fourth guide surface. The third guide surface and the fourth guide surface are adapted to cooperate with each other to guide each electrode plate of the input row to be inserted into the corresponding contact interface of the connector.
[0015] As a further technical solution, the DC module also includes a fixing plate fixed behind the capacitor busbar; the first docking member is located in front of the capacitor busbar and fixed to the fixing plate to clamp and fix it to the capacitor busbar.
[0016] As a further technical solution, the system also includes a frame and a positioning element fixed to the frame; the positioning element is located between the DC module and the power module, and has a first positioning structure on the side facing the DC module and at least one second positioning structure on the side facing the power module, each of the second positioning structures corresponding to one power module; the first positioning structure and the second positioning structure are both composed of two positioning plates arranged opposite each other in the left-right direction, and a positioning groove is formed between the two positioning plates; the DC module and the power module are provided with positioning portions corresponding to the positioning grooves in the first positioning structure and the second positioning structure, and the positioning portions are configured to be limited by the positioning grooves to determine the position of the DC module and the power module relative to the frame in the left-right direction.
[0017] As a further technical solution, it also includes a sliding seat fixed to the frame; the sliding seat is provided with at least one slide rail extending in the front-rear direction; each slide rail corresponds to the number and position of the second positioning structure on the positioning member, and corresponds to one of the power modules; the power module is provided with a sliding part corresponding to the slide rail, the sliding part is adapted to slide along the slide rail, and is limited by the slide rail to determine the position of the power module relative to the frame in the left-right direction.
[0018] As can be seen from the above description of the present invention and its preferred embodiments, compared with the prior art, the technical solution of the present invention and its preferred embodiments have the following beneficial effects due to the adoption of the following technical means:
[0019] Through continuous observation, experimentation, and research, the applicant has found that the reason for the technical problem in the existing technical solution that "the installation, disassembly, or maintenance of the power module is relatively inconvenient" is that the power module is connected to the input busbar and the capacitor busbar by bolt fastening. However, the operating space of the power module in the converter is small, and the bolt fastening method is relatively inconvenient for operators.
[0020] In the relevant technical solution, a connector is installed on the capacitor busbar of the DC module. The connector has a contact interface with a contact piece inside. The contact piece can be electrically connected to the corresponding plate on the capacitor busbar. When installing the power module, the plates of the input busbar of the power module can be extended into the corresponding contact interface in the front-to-back direction, so that the input busbar can form an electrical connection with the corresponding plate on the capacitor busbar through the contact piece inside the contact interface. This connection method allows the input busbar of the power module to be connected to the capacitor busbar of the DC module by direct plug-in. Compared with the bolt locking method, when using this connection method, the staff does not need to tighten the bolts in a confined space, making the installation, disassembly and maintenance of the power module more convenient.
[0021] In addition, a first mating member and a second mating member are provided. The second mating member is fixed on the mounting base. The first and second mating parts of the two members can form a plug-in fit in the front-to-back direction. Through the mutual cooperation of the first and second mating members, the plates of the input busbar on the power module are guided to insert into the contact interface in an accurate posture. Since the input busbar is mounted on the mounting base and the input busbar itself is made of metal, the input busbar may bend during installation, causing a deviation in the positional correspondence between the input busbar and the connector contact interface. This deviation will prevent the plates of the input busbar from extending into the contact interface in the correct posture. Depending on the arrangement of the contact pieces, this may lead to different input... If the total contact area between the input busbar plates and contacts is too small, the current flow area will be too small, which can easily cause the temperature of the contacts and the input busbar plates to rise abnormally. It may also cause the force on the input busbar plates to be concentrated on one or some contacts, resulting in a decrease in the service life of the contacts. However, under the guidance of the first and second mating parts, since the second mating part is fixed to the mounting base and the input busbar is fixed to the mounting base, the positions of the input busbar and the mounting base are fixed. As long as the second mating part can accurately mate with the first mating part, the input busbar plates can be accurately inserted into the corresponding contact interfaces, ensuring the normal connection between the input busbar and the capacitor busbar. The second mating component is designed to be fixed to the mounting base, rather than fixed to the input bar or directly fixed to the input bar. This not only ensures the structural stability of the second mating component, but also avoids stress damage to the input bar caused by the insertion and mating of the second mating component and the first mating component. At the same time, compared to being installed on the input bar, the mounting base itself is not easy to shift or deform, so the position of the second mating component is also fixed, thus ensuring that the relative position of the second mating component and the input bar is fixed.
[0022] Furthermore, one of the electrode plates in the input row is bent to form a bent portion. The second mating member is fixed to the bending limiting member, and each electrode plate of the input row is tightly attached to the bending limiting member, which then fixes it to the mounting base. This ensures that the positions of each electrode plate of the input row and the second mating member relative to the mounting base are fixed, thereby fixing the relative positions of the second mating member and the electrode plates of the input row. In addition, displacement of the electrode plates in the input row can be prevented, and deformation of the electrode plates can be avoided through the cooperation of the second mating member and the bending limiting member, thus reducing assembly errors.
[0023] In the relevant technical solutions and their preferred embodiments, a bending limiting member is provided. The fixing part and the limiting part of the bending limiting member are respectively attached to the base and the bending part of the electrode plate of the input row, and the bending limiting member is fixed to the mounting base. Thus, the bending limiting member can ensure that the position of each electrode plate of the input row is not easily displaced, and can also prevent the deformation of each electrode plate of the input row, thereby ensuring that the relative position of each electrode plate of the input row and the second docking member remains fixed.
[0024] In the relevant technical solutions and their preferred embodiments, the second docking member is fixedly connected to the mounting base by a bending limiting member. The installation position of the second docking member is just located at the bending part of the input row plate, so as to cooperate with the bending limiting member to prevent the input row plate from deforming, thereby getting closer to the insertion part of the input row and avoiding large errors.
[0025] In the relevant technical solutions and their preferred embodiments, the input row is provided with three electrode plates. The rear ends of the electrode plates on the left and right sides are bent to form bending and insertion parts, while the middle electrode plate does not need to be bent. This allows the rear ends of the three electrode plates to be connected to the connector with a certain spacing, and also avoids mutual interference. At the same time, the second mating parts are set at the bending parts of the left and right electrode plates. The two second mating parts can guide the process of inserting the three electrode plates into the connector contact interface.
[0026] In the relevant technical solutions and their preferred embodiments, the two bending limiting members can also cooperate to clamp the three pole plates of the input row, further preventing deformation of the input row and ensuring that the relative position of the second docking member and the input row is fixed.
[0027] In the relevant technical solutions and their preferred embodiments, the first docking member is provided with a plug hole to form a first docking part, and the second docking member is provided with a plug post to form a second docking part. The two can cooperate to form a plug-in fit in the front-back direction. At the same time, a first guide surface and a second guide surface are provided to guide the process of inserting the plug post into the plug hole.
[0028] In the relevant technical solutions and their preferred embodiments, each electrode plate of the input row and the contact interface of the connector respectively form a third guide surface and a fourth guide surface, which cooperate with each other to guide each electrode plate of the input row to be accurately inserted into the contact interface of the connector.
[0029] In the relevant technical solutions and their preferred embodiments, a fixing plate is provided to facilitate the installation of the connector.
[0030] In the relevant technical solutions and their preferred embodiments, a positioning component fixed on the frame is provided. The first positioning structure and the second positioning structure on the positioning component both form positioning grooves. The DC module and the power module can be limited by the positioning grooves in the left and right directions, thereby limiting the position of the DC module and the power module in the left and right directions. Even if the positioning groove has a large positioning tolerance for the DC module and the power module, the determination of this position can lay the foundation for the insertion and mating of the plug-in hole and the plug-in component.
[0031] In the relevant technical solutions and their preferred embodiments, a sliding seat fixed on the frame is provided. The power module can slide back and forth along the slide rail on the sliding seat. At the same time, the sliding seat can also limit the position of the power module in the left and right directions. However, the tolerance of this position limitation is large, and it needs to cooperate with the positioning component, the insertion hole, and the insertion component to ensure that the electrode plate of the input row extends into the corresponding contact interface in the correct posture. Attached Figure Description
[0032] To more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the following description of the embodiments are briefly introduced. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.
[0033] Figure 1 This is a partial structure of a converter in the prior art described in the background section of this specification;
[0034] Figure 2 A partial structural diagram of the pluggable power converter provided in an embodiment of the present invention. Figure 1 ;
[0035] Figure 3 This is a schematic diagram of the structure of the DC module in the pluggable power converter provided in an embodiment of the present invention;
[0036] Figure 4 This is a schematic diagram of the power module structure in a pluggable power converter provided in an embodiment of the present invention. Figure 1 ;
[0037] Figure 5 A partial structural diagram of the pluggable power converter provided in an embodiment of the present invention. Figure 2 ;
[0038] Figure 6 for Figure 5 Enlarged view of the structure of section A;
[0039] Figure 7 for Figure 5 Enlarged view of the structure of section B;
[0040] Figure 8 for Figure 3 A partial structural diagram of the DC module;
[0041] Figure 9 for Figure 8 A structural diagram of section C;
[0042] Figure 10 for Figure 4 A structural diagram of section D;
[0043] Figure 11 This is a schematic diagram of the power module structure in a pluggable power converter provided in an embodiment of the present invention. Figure 2 ;
[0044] Figure 12 for Figure 11 A schematic diagram of the structure of part E in the middle.
[0045] Explanation of key figure labels:
[0046] DC module 10; capacitor busbar 11; connector 12; contact interface 121; fourth guide surface 122; first mating part 13; first mating portion 131; first guide surface 132; clearance groove 133; electrode slot 134; contact piece 14; fixing plate 15;
[0047] Power module 20; mounting base 21; input busbar 22; positive input plate 221; neutral input plate 222; negative input plate 223; third guide surface 224; power transistor assembly 23; output busbar 24; base 25; bending section 26; plug-in section 27;
[0048] Second docking component 30; Second docking part 31; Dating body 32; Second guide surface 33;
[0049] Rack size 40;
[0050] Positioning component 50; First positioning structure 51; Second positioning structure 52; Positioning plate 53; Positioning groove 54; Positioning base 55;
[0051] Sliding seat 60; Slide rail 61;
[0052] Positioning part 71; sliding part 72;
[0053] Bending limit component 80; fixing part 81; limiting part 82. Detailed Implementation
[0054] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are preferred embodiments of the present invention and should not be considered as excluding other embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.
[0055] Unless otherwise expressly defined, the use of terms such as "first," "second," or "third" in the claims, description, and accompanying drawings of this invention is for distinguishing different objects and not for describing a specific order.
[0056] Unless otherwise expressly defined, in the claims, description, and accompanying drawings of this invention, the use of directional terms such as "center," "lateral," "longitudinal," "horizontal," "vertical," "top," "bottom," "inner," "outer," "upper," "lower," "front," "rear," "left," "right," "clockwise," and "counterclockwise" to indicate orientation or positional relationships is based on the orientation and positional relationships shown in the accompanying drawings and is only for the convenience of describing the invention and simplifying the description, and is not intended to indicate or imply that the device or element referred to must have a specific orientation or be constructed and operated in a specific orientation, and therefore should not be construed as limiting the specific scope of protection of this invention.
[0057] Unless otherwise expressly defined, the terms "fixed connection" or "fixed connection" used in the claims, description and drawings of this invention should be interpreted broadly to refer to any connection in which there is no displacement or relative rotation relationship between the two parties, including non-removable fixed connection, detachable fixed connection, integral connection and fixed connection by other means or components.
[0058] In the claims, description and accompanying drawings of this invention, the terms "comprising," "having," and variations thereof are used to mean "including but not limited to."
[0059] This invention provides a pluggable power converter, based on conventional converter circuits and control methods, for achieving bidirectional AC-DC conversion of electrical energy. This embodiment does not improve the basic circuitry, etc., therefore, this part will not be described in detail.
[0060] Reference Figure 2 The power converter includes a frame 40, a DC module 10, a power module 20, a positioning component 50, a sliding seat 60, and a first docking component 13. See also... Figure 10 and Figure 11 The power converter also includes a second docking member 30 and a bending limit member 80.
[0061] The frame 40 is used to fix and install the DC module 10, power module 20, positioning component 50, sliding seat 60, and first docking component 13. It can be designed according to actual needs, and its structure is not limited here. However, it should be able to meet the following requirements: after the above components are installed, the DC module 10 is located in front of the power module 20, the positioning component 50 is located between the DC module 10 and the power module 20, and the sliding seat 60 is located below the DC module 10.
[0062] Reference Figure 3 The DC module 10 mainly includes a DC capacitor bank and a capacitor busbar 11. Several connectors 12 and several first mating parts 13 are fixedly installed on the front side of the capacitor busbar 11, and a fixing plate 15 is fixedly installed on the rear side of the capacitor busbar 11. (Refer to...) Figure 4 The power module 20 mainly includes a mounting base 21, power transistor arrays 23, input busbars 22, and output busbars 24. In this embodiment, the mounting base 21 is a heat sink, the power transistor arrays 23 are IGBT switching transistors, and both the input busbars 22 and output busbars 24 are copper busbars. In this embodiment, three power modules 20 are provided, with each power module 20 corresponding to one phase of the three-phase AC output. However, in other embodiments, other numbers of power modules 20 can be used. For example, the power transistor arrays 23 required for the three-phase AC output can be all placed on one power module 20, requiring only one power module 20 and a corresponding set of input busbars 22. Alternatively, if multiple sets of three-phase AC outputs are needed, multiple sets of power modules 20 can be provided accordingly.
[0063] Reference Figure 5 The frame 40 includes two straight rods arranged in the left-right direction and extending in the up-down direction. The positioning member 50 is a horizontal bar placed between the two straight rods, and both ends of the positioning member 50 are fixed to the two straight rods by bolts. The positioning member 50 has a first positioning structure 51 on the side facing the DC module 10 and at least one second positioning structure 52 on the side facing the power module 20. Each second positioning structure 52 corresponds to one power module 20. In this embodiment, there are three second positioning structures 52 corresponding to three power modules 20.
[0064] Reference Figure 5 and Figure 6Both the first positioning structure 51 and the second positioning structure 52 consist of two positioning plates 53 arranged opposite each other in the left-right direction, forming a positioning groove 54 between the two positioning plates 53. Specifically, in the first positioning structure 51, a positioning plate 53 is respectively provided near the left and right ends of the positioning member 50. The positioning plate 53 has an "L"-shaped bent structure, and its short side is fixedly connected to the rear surface of the crossbar forming the main body of the positioning member 50 by screwing or welding. Its long side extends backward, and the two positioning plates 53 cooperate to form a positioning groove 54 between their long sides. Similarly, in the second positioning structure 52, a positioning groove 54 is formed by the cooperation of two positioning plates 53 according to the position of the corresponding power module 20. Since the size of the power module 20 corresponding to the second positioning structure 52 is smaller, the distance between the two side walls of the positioning groove 54 in the second positioning structure 52 is also smaller.
[0065] At the same time, refer to Figure 3 Positioning portions 71 are formed on the left and right sides of the DC module 10. These positioning portions 71 correspond to the positioning grooves 54 in the first positioning structure 51. That is, the outer edges of the left and right sides of the DC module 10 can be adapted to the two positioning plates 53 in the first positioning structure 51. During installation, the DC module 10 can insert its positioning portions 71 into the positioning grooves 54 of the first positioning structure 51. The positioning portions 71 are then constrained by the positioning grooves 54 to determine the position of the DC module 10 relative to the frame 40 in the left and right direction. Specifically, before installing the DC module 10, the positioning member 50 needs to be fixedly installed to the frame 40, with the first positioning structure 51 facing the rear of the frame 40. After the DC module 10 is positioned by the first positioning structure 51 of the positioning member 50, the DC module 10 is then fixedly installed on the frame 40 by means of screws or other methods.
[0066] Correspondingly, refer to Figure 4 Similar to the DC module 10, each power module 20 also has positioning portions 71 formed on its left and right sides. Specifically, these positioning portions 71 are formed on the mounting base 21 of the power module 20, which is the heat sink body of the power module 20. The positioning portions 71 on the power module 20 can be adapted to the two positioning plates 53 in the corresponding second positioning structure 52, thereby determining the position of the power module 20 relative to the frame 40 in the left-right direction. Specifically, when installing the power module 20, after the power module 20 is positioned by the corresponding second positioning structure 52, the DC module 10 is fixedly installed relative to the frame 40 by means of screws or the like.
[0067] Reference Figure 5 and Figure 7The bottom of the frame 40 is also provided with several crossbars, and the sliding seat 60 is mounted and fixed on these crossbars. The sliding seat 60 is provided with slide rails 61 extending in the front-to-back direction. Each slide rail 61 corresponds to the number and position of the second positioning structures 52 on the positioning member 50, and corresponds to a power module 20. In this embodiment, three sliding seats 60 are provided, and the position of the slide rail 61 on each sliding seat 60 corresponds to a second positioning structure 52. Meanwhile, referring to... Figure 4 The bottom of the power module 20 is provided with a sliding part 72 corresponding to the slide rail 61. The sliding part 72 is adapted to slide along the slide rail 61 and is restricted by the slide rail 61 to determine the position of the power module 20 relative to the frame 40 in the left and right direction.
[0068] It should be understood that, due to the limitations of the manufacturing process, the position of the power module 20 can only be roughly defined by the cooperation between the slide rail 61 and the sliding part 72. Therefore, it is necessary to cooperate with the positioning part 50 to simultaneously determine the positions of the DC module 10 and the power module 20 in order to reduce the error in the relative position between the power module 20 and the DC module 10.
[0069] Reference Figure 3 Several connectors 12 are installed on the DC module 10, and each capacitor busbar 11 has at least one connector 12 corresponding to its plate. Specifically, refer to... Figure 8 and Figure 9 The capacitor busbar 11 of the DC module 10 includes three plates, corresponding to the positive, negative, and neutral terminals respectively. These three plates are stacked and connected to the input power supply via a terminal block at the lower end. As is well known, converters are used to achieve bidirectional conversion between DC and AC; therefore, the DC module 10 needs to be connected to the power module 20. In this embodiment, the electrical connection between the DC module 10 and the power module 20 is achieved through connector 12. The converter provided in this embodiment includes three power modules 20, each of which is connected to the three plates of the capacitor busbar 11 via three connectors 12. Here, refer to... Figure 8 Each power module 20 has three connectors 12, which are respectively designated as positive connector 12, neutral connector 12 and negative connector 12, and are respectively connected to the positive plate, neutral plate and negative plate of capacitor bus 11.
[0070] Specifically, refer to Figure 9Each connector 12 has a forward-facing contact interface 121, which is an elongated slot extending vertically. Within the contact interface 121 is a contact piece 14 electrically connected to the corresponding electrode plate in the capacitor busbar 11. Taking the positive connector 12 as an example, the contact piece 14 within the positive connector 12 is electrically connected to the positive electrode plate in the capacitor busbar 11. Further, the connector 12 can be a finger connector 12, where the metal sheet forms the aforementioned contact piece 14; alternatively, the contact piece 14 within the connector 12 can be a spring-loaded metal sheet, positioned along the extension direction of the contact interface 121, capable of contacting the input busbar 22 on the power module 20 for electrical conduction. An inclined fourth guide surface 122 is formed along the edge of the contact interface 121, with the inclination direction of the fourth guide surface 122 tilting from the outside of the contact interface 121 towards the inside.
[0071] Reference Figure 4 The input row 22 of the power module 20 is fixedly mounted on the upper part of the mounting base 21; see also Figure 10 The input bus 22 includes plates corresponding to the number and polarity of the capacitor bus 11, namely a positive input plate 221, a neutral input plate 222, and a negative input plate 223. Each plate of the input bus 22 corresponds to a connector 12 based on its correspondence with the plates in the capacitor bus 11. Each plate of the input bus 22 is configured to extend in the front-to-back direction into the contact interface 121 of the corresponding connector 12 and contact the contact piece 14 within the contact interface 121 to form an electrical connection between the input bus 22 and the capacitor bus 11. Specifically, the positive input plate is connected to the positive connector 12, the neutral input plate is connected to the neutral connector 12, and the negative input plate is connected to the negative connector 12. The power module 20's input bus 22 is then connected to the capacitor bus 11 via the connector 12. (Refer to...) Figure 8 A fixing plate 15 is fixedly installed at the rear of the capacitor busbar 11, and the connector 12 is located at the front of the capacitor busbar 11 and is fixedly connected to the fixing plate 15 to clamp and fix it to the capacitor busbar 11. Specifically, bolts can be inserted through the capacitor busbar 11, and the fixing plate 15 and the connector 12 can be screwed together accordingly, so that the connector 12 and the fixing plate 15 cooperate to clamp the capacitor busbar 11, thus fixing the connector 12 to the capacitor busbar 11.
[0072] Among them, reference Figure 10The rear end of each electrode plate of the input bar 22 is a flat plate adapted to extend into the corresponding contact interface 121. This flat plate structure can be adapted to the elongated slot-shaped contact interface 121 and increases the contact area between the input bar 22 and the contact piece 14 in the connector 12, facilitating the conduction of large currents. Furthermore, the contact area between the middle neutral electrode plate, i.e., the input neutral plate 222, and the corresponding contact piece 14 in the contact interface 121 is larger than the contact area between the other two electrodes and the corresponding contact pieces 14 in the contact interface 121, thereby improving the current carrying capacity of the input neutral plate 222. And, referring to… Figure 10 The rear ends of each electrode plate of the input row 22 form an inclined third guide surface 224. The third guide surface 224 and the fourth guide surface 122 on the connector 12 are adapted to cooperate with each other to guide each electrode plate of the input row 22 to be inserted into the contact interface 121 of the corresponding connector 12.
[0073] Furthermore, since the rear ends of each plate of the input bus 22 need to be connected to each connector 12, and there is a certain distance between the connectors 12, and the plates of the input bus 22 are stacked at the connection points with the power transistor group 23, some plates of the input bus 22 form a multi-bent shape at the rear. See details... Figure 10 In the input row 22, the electrode plates are arranged in a stacked manner along the left-right direction, and the rear end of at least one outermost electrode plate is bent in a direction away from the position of the other electrode plates, so that the electrode plate forms a base 25, a bent portion 26, and a plug-in portion 27 from front to back. The base 25 and the plug-in portion 27 both extend in the front-back direction. The bent portion 26 connects the base 25 and the plug-in portion 27, and the plug-in portion 27 is adapted to extend into the contact interface 121 of the corresponding connector 12. Specifically, the rear ends of the electrode plates located on the left and right sides are bent to form the bent portion 26 and the plug-in portion 27, that is, the rear ends of the positive input plate and the negative input plate are bent to form the bent portion 26 and the plug-in portion 27. The plug-in portions 27 of the positive input board and the negative input board can be inserted into the contact interface 121 of the corresponding connector 12. The rear end of the neutral input board can also be regarded as forming a plug-in portion 27. However, the neutral input board is not bent like the positive input board or the negative input board. The neutral input board can be separated from the other two plug-in portions 27 by bending the positive input board and the negative input board.
[0074] Reference Figure 11 and Figure 12The bending limiting member 80 is fixed to the mounting base 21 on the outside of the bent electrode plate in the input row 22. It has a fixing part 81 and a limiting part 82 corresponding to the extension directions of the base 25 and the bent portion 26 of the bent electrode plate, respectively. The fixing part 81 is in close contact with its corresponding base 25, and the limiting part 82 is in close contact with its corresponding bent portion 26. Furthermore, in the power module 20, the input row 22 is located on one side of the mounting base 21 in the left-right direction, with the input row 22 on the first side and the mounting base 21 on the second side. The bending limiting member 80 corresponding to the electrode plate on the second side of the input row 22 is fixed to the mounting base 21 and is also fixed to the bending limiting member 80 corresponding to the electrode plate on the first side of the input row 22 to clamp the input row 22 in the left-right direction. In this embodiment, the input row 22 is located on the left side, and the mounting base 21 is located on the right side.
[0075] There are two bending limiting members 80, corresponding to the positive input plate and the negative input plate respectively. They are "L"-shaped components, with a fixing part 81 and a limiting part 82 formed on their two sides respectively. The fixing part 81 of the bending limiting member 80 on the right side is fastened to the mounting base 21 by bolts. The fixing part 81 of the bending limiting member 80 on the left side is connected to the fixing part 81 of the bending limiting member 80 on the right side by bolts, and the bolts pass through the three pole plates of the input row 22 located between the two, so that the two bending limiting members 80 can cooperate to clamp and fix the input row 22. The limiting part 82 of the bending limiting member 80 on the left side is close to and in front of the bending part 26 of the positive input plate, and the second mating part 30 is installed and fixed behind the bending part 26 of the positive input plate by bolts. The limiting part 82 of the bending limiting member 80 on the right side is close to and in front of the bending part 26 of the negative input plate, and the other second mating part 30 is installed and fixed behind the bending part 26 of the negative input plate by bolts. The bending limiting member 80 increases the structural stability of the plates of the input row 22, making it less prone to deformation. Especially when the input row 22 and the connector 12 are connected by a plug-in fit, it can ensure that the plates are not easily deformed during transportation, installation and plug-in processes, thereby ensuring the accurate correspondence between the plates of the input row 22 and the connector 12.
[0076] In practical use, the power module 20 can be placed in the slide rail 61 of the sliding seat 60, and then pushed towards the DC module 10. The power module 20 will fall into the second positioning structure 52, and at the same time, each plate of the input row 22 can be inserted into the corresponding connector 12. Thus, the power module 20 and the DC module 10 are electrically connected through the plug-in connection, eliminating the need for bolts or other fasteners, greatly improving the ease of operation. However, due to manufacturing process limitations, neither the slide rail 61 of the sliding seat 60 nor the positioning structure of the positioning member 50 can guarantee that each plate of the input row 22 will make accurate contact with the contact piece 14 inside the contact interface 121 after being inserted into the contact interface 121 of the connector 12. For example, if the electrode plate of the input bar 22 is slightly tilted, even if it can be inserted into the contact interface 121, it will put too much pressure on the contact piece 14, causing uneven force on the contact piece 14, which will shorten the service life of the contact piece 14; or, if the contact area between the electrode plate of the input bar 22 and the contact piece 14 is too small, it will be easy to overheat when transmitting a large current.
[0077] Therefore, referring to Figure 8 and Figure 9 A first mating part 13 is installed and fixed on the front surface of the capacitor busbar 11; at the same time, refer to Figure 4 and Figure 10 A corresponding second docking part 30 is fixedly installed on the mounting base 21.
[0078] Reference Figure 9 The first docking member 13 is provided with at least one first docking portion 131; see reference Figure 10 The second docking member 30 is provided with a second docking part 31 corresponding to each of the first docking parts 131; the second docking part 31 is adapted to form a plug-in engagement with the corresponding first docking part 131 in the front-back direction; at the same time, each electrode plate of the input row 22 is configured to extend into the contact interface 121 of the corresponding connector 12 when each of the second docking parts 31 in the power module 20 where it is located plugs in with the corresponding first docking parts 131, and to contact the contact piece 14 in the contact interface 121 to form an electrical connection between the input row 22 and the capacitor bus 11.
[0079] Specifically, refer to Figure 8Three first mating parts 13 are provided on the capacitor busbar 11, corresponding to three power modules respectively. Three connectors 12 for each power module are located near the first mating part 13. Two connectors 12 are located on the left and right sides of the first mating part 13, and one connector 12 is located in the middle of the first mating part 13. For this purpose, a clearance groove 133 is provided in the middle of the first mating part 13, allowing the connector 12 to be installed in the middle of the first mating part 13. According to the polarity order of the input busbar 22, the positive connector 12 is located on the left side of the first mating part 13, the negative connector 12 is located on the right side of the first mating part 13, and the neutral connector 12 is located in the middle of the first mating part 13. Since the contact area between the contact piece 14 of the neutral connector 12 and the neutral input plate is relatively large, two plate grooves 134 are also provided above and below the clearance groove 133 on the first mating part 13. The openings of these two plate grooves 134 face forward, allowing the neutral input plate to extend into them. The first docking member 13 has two first docking portions 131 on the left and right sides of the relief groove 133. In this embodiment, the first docking portion 131 is a plug hole, and the hole edge of the plug hole forms an inclined first guide surface 132.
[0080] Correspondingly, refer to Figure 10 In this embodiment, corresponding to one first docking member 13, two second docking members 30 are provided, each second docking member 30 having a second docking portion 31. These two second docking members 30 are respectively mounted on the rear surface of the bent portion 26 of the positive input plate and the negative input plate, and are fixed by screwing with the corresponding bent limiting portion 82. In this embodiment, the second docking member 30 includes a docking body 32, which abuts against the rear surface of the bent portion 26 of the corresponding plate and is screwed with the corresponding bent limiting portion 82. Simultaneously, the rear surface of the docking body 32 extends rearward to form a plug-in post, which forms the second docking portion 31 of the second docking member 30; wherein, the end of the plug-in post has an inclined second guide surface 33. The first guide surface 132 and the second guide surface 33 are adapted to cooperate with each other to guide the plug-in post into the corresponding plug-in hole.
[0081] The pluggable power converter provided in this embodiment has a connector 12 on the capacitor busbar 11 of the DC module 10. The connector 12 has a contact interface 121, and a contact piece 14 is provided in the contact interface 121. The contact piece 14 can be electrically connected to the corresponding plate on the capacitor busbar 11. When installing the power module 20, each plate of the input busbar 22 of the power module 20 can be inserted into the corresponding contact interface 121 in the front-back direction, so that the input busbar 22 can form an electrical connection with the corresponding plate on the capacitor busbar 11 through the contact piece 14 in the contact interface 121. This connection method allows the input busbar 22 of the power module 20 to be connected to the capacitor busbar 11 of the DC module 10 by direct plugging. Compared with the bolt locking method, when using this connection method, the staff does not need to tighten the bolts in a confined space, making the installation, disassembly and maintenance of the power module 20 more convenient. In addition, a first mating member 13 and a second mating member 30 are provided, wherein the second mating member 30 is fixed on the mounting base 21. The first mating portion 131 and the second mating portion 31 of the two are able to form a plug-in fit in the front-back direction. Thus, through the mutual cooperation of the first mating member 13 and the second mating member 30, the plates of the input bar 22 on the power module 20 are guided to be inserted into the contact interface 121 in an accurate posture. Since the input bar 22 is mounted on the mounting base 21, and the input bar 22 itself is made of metal, the input bar 22 may be bent during installation, causing a deviation in the positional correspondence between the input bar 22 and the contact interface 121 of the connector 12. This deviation will cause the plates of the input bar 22 to not be inserted into the contact interface 121 in the correct posture. Depending on the arrangement of the contact pieces 14, this may cause the input bar 22 to be inserted into the contact interface 121 in an incorrect posture. The total contact area between the electrode plate of input bus 22 and the contact piece 14 is too small, resulting in a small current flow area. This can easily cause the temperature of the contact piece 14 and the electrode plate of input bus 22 to rise abnormally. It may also cause the force on the electrode plate of input bus 22 to be concentrated on one or some contact pieces 14, resulting in a decrease in the service life of the contact piece 14. However, under the guidance of the first mating member 13 and the second mating member 30, since the second mating member 30 is fixed to the mounting base 21 and the input bus 22 is fixed to the mounting base 21, the positions of the input bus 22 and the mounting base 21 are fixed. The positions of the second mating member 30 and the mounting base 21 are also fixed. As long as the second mating member 30 can accurately cooperate with the first mating member 13, the electrode plate of input bus 22 can be accurately inserted into the corresponding contact interface 121, ensuring the normal connection between input bus 22 and capacitor bus 11.Specifically, the second docking member 30 is fixedly connected to the mounting base 21, rather than to the input row 22 or directly fixed to the input row 22. This not only ensures the structural stability of the second docking member 30, but also avoids stress damage to the input row 22 caused by the insertion and engagement of the second docking member 30 with the first docking member 13. At the same time, compared to being installed on the input row 22, the mounting base 21 itself is not easily displaced or deformed, so the position of the second docking member 30 is also fixed, thereby ensuring that the relative position of the second docking member 30 and the input row 22 is fixed. Furthermore, one of the electrode plates of the input row 22 is bent to form a bent portion 26. The second mating member 30 is fixed to the bending limiting member 80. Each electrode plate of the input row 22 is tightly attached to the bending limiting member 80, and then fixed to the mounting base 21 by the bending limiting member 80. This ensures that the positions of each electrode plate of the input row 22 and the second mating member 30 relative to the mounting base 21 are fixed, thereby fixing the relative position of the second mating member 30 and each electrode plate of the input row 22. In addition, displacement of the electrode plates of the input row 22 can be avoided, and deformation of the electrode plates of the input row 22 can be avoided through the cooperation of the second mating member 30 and the bending limiting member 80, thereby reducing assembly errors.
[0082] The foregoing description of the specifications and embodiments is intended to explain the scope of protection of this invention, but does not constitute a limitation on the scope of protection of this invention. Modifications, equivalent substitutions, or other improvements to the embodiments of this invention or any component technical feature that can be obtained by those skilled in the art through logical analysis, reasoning, or limited experimentation, based on the teachings of this invention or the foregoing embodiments, in conjunction with common knowledge, general technical knowledge, and / or existing technology, should all be included within the scope of protection of this invention.
Claims
1. A pluggable power converter, characterized in that it comprises: A DC module (10) includes a capacitor busbar (11) and a plurality of connectors (12); the connectors (12) are fixed to the capacitor busbar (11), and each plate of the capacitor busbar (11) corresponds to at least one connector (12); the connector (12) is provided with a contact interface (121) facing forward, and the contact interface (121) is provided with a contact piece (14) electrically connected to the plate of the capacitor busbar (11) corresponding to the connector (12); At least one power module (20) includes a mounting base (21) and an input bus (22) fixed on the mounting base (21); the input bus (22) includes plates corresponding to the number and polarity of the capacitor busbars (11), and forms a corresponding relationship with each of the connectors (12); the plates of the input bus (22) are arranged in a stacked manner, and one of the plates is bent to form a bent portion (26). as well as, The first mating member (13) is fixed to the capacitor busbar (11) and has at least one first mating portion (131); and The second docking member (30) is fixed to the mounting base (21) and has a second docking part (31) corresponding to each of the first docking parts (131); the second docking part (31) is adapted to form a plug-in fit with the corresponding first docking part (131) in the front-back direction; Each plate of the input bar (22) is configured such that when each of the second mating portions (31) in the power module (20) where it is located is inserted into the contact interface (121) of the corresponding connector (12), and contacts the contact piece (14) in the contact interface (121) to form an electrical connection between the input bar (22) and the capacitor busbar (11); It also includes a bending limiting member (80), which is fixed to the mounting base (21) and closely attached to the bending portion (26). The second docking member (30) and the bending limiting member (80) are located on both sides of the bending portion (26) in the front-back direction, and are fixedly connected to the mounting base (21) by the bending limiting member (80).
2. A pluggable power converter as described in claim 1, characterized in that, In the input row (22), each electrode plate is arranged in a stacked manner along the left and right direction, and the rear end of at least one electrode plate located on the outermost side is bent in a direction away from the position of other electrode plates, so that the electrode plate forms a base (25), the bent part (26) and the plug-in part (27) in sequence from front to back; the base (25) and the plug-in part (27) both extend in the front and back direction, the bent part (26) connects the base (25) and the plug-in part (27), and the plug-in part (27) is adapted to extend into the contact interface (121) of the corresponding connector (12). The bending limiting member (80) is located on the outside of the bent electrode plate in the input row (22). It has a fixing part (81) and a limiting part (82) corresponding to the extension direction of the base (25) and the bending part (26) of the bent electrode plate, respectively. The fixing part (81) is close to the base (25) corresponding to it, and the limiting part (82) is close to the bending part (26) corresponding to it.
3. A plug-in power converter as claimed in claim 2, characterized in that The second docking member (30) is located behind the bent portion (26) of the bent electrode plate in the input row (22) and is fixedly connected to the limiting portion (82) of the bent limiting member (80) in front of the bent portion (26).
4. A plug-in power converter as claimed in claim 3, characterized in that The input row (22) includes three electrode plates, wherein the rear ends of the electrode plates located on the left and right sides are bent to form the bent portion (26) and the insertion portion (27); corresponding to one input row (22), at least two second docking members (30) and two bent limiting members (80) are provided, each of the second docking members (30) and one bent limiting member (80) is connected to each other and corresponds to a bent electrode plate.
5. A plug-in power converter as claimed in claim 4, characterized in that In the power module (20), the input row (22) is located on one side of the mounting base (21) in the left-right direction, wherein the input row (22) is located on the first side and the mounting base (21) is located on the second side; the bending limiting member (80) corresponding to the electrode plate located on the second side of the input row (22) is fixed to the mounting base (21) and is fixed to the bending limiting member (80) corresponding to the electrode plate located on the first side of the input row (22) to cooperate in clamping the input row (22) in the left-right direction.
6. A plug-in power converter as claimed in claim 5, characterized in that The first docking member (13) is provided with a forward-facing insertion hole for forming the first docking portion (131), and the second docking member (30) is provided with a rearward-extending insertion post for forming the second docking portion (31); each insertion post corresponds to a insertion hole and is adapted to form an insertion fit in the front-rear direction; the hole of the insertion hole forms an inclined first guide surface (132), and the end of the insertion post forms an inclined second guide surface (33); the first guide surface (132) and the second guide surface (33) are adapted to cooperate with each other to guide the insertion post to be inserted into the corresponding insertion hole.
7. A plug-in power converter as recited in claim 1, wherein, The rear end of each electrode plate of the input row (22) forms an inclined third guide surface (224), and the edge of the contact interface (121) of the connector (12) forms an inclined fourth guide surface (122). The third guide surface (224) and the fourth guide surface (122) are adapted to cooperate with each other to guide each electrode plate of the input row (22) to be inserted into the corresponding contact interface (121) of the connector (12).
8. A plug-in power converter as claimed in claim 6, characterized in that The DC module (10) also includes a fixing plate (15) fixed behind the capacitor busbar (11); the first docking member (13) is located in front of the capacitor busbar (11) and fixed to the fixing plate (15) to clamp and fix it to the capacitor busbar (11).
9. A plug-in power converter according to any one of claims 1-8, characterized in that It also includes a frame (40) and a positioning member (50) fixed to the frame (40); the positioning member (50) is located between the DC module (10) and the power module (20), and has a first positioning structure (51) on the side facing the DC module (10) and at least one second positioning structure (52) on the side facing the power module (20), each second positioning structure (52) corresponding to one power module (20); the first positioning structure (51) and the second positioning structure (52) are both made of The system consists of two positioning plates (53) arranged opposite each other in the left-right direction, with a positioning groove (54) formed between the two positioning plates (53); the DC module (10) and the power module (20) are provided with positioning parts (71) corresponding to the positioning grooves (54) in the first positioning structure (51) and the second positioning structure (52), and the positioning parts (71) are configured to be limited by the positioning grooves (54) to determine the position of the DC module (10) and the power module (20) relative to the frame (40) in the left-right direction.
10. A plug-in power converter as claimed in claim 9, characterized in that It also includes a sliding seat (60) fixed to the frame (40); the sliding seat (60) is provided with at least one slide rail (61) extending in the front-rear direction; each slide rail (61) corresponds to the number and position of the second positioning structure (52) on the positioning member (50) and corresponds to one of the power modules (20); the power module (20) is provided with a sliding part (72) corresponding to the slide rail (61), the sliding part (72) is adapted to slide along the slide rail (61) and is limited by the slide rail (61) to determine the position of the power module (20) relative to the frame (40) in the left-right direction.