Converter side module easy to dissipate heat and working method thereof

Abstract

The invention relates to the technical field of heat dissipation of converter cabinets, in particular to a converter side module easy to dissipate heat. The power unit group comprises a plurality of first power modules and a plurality of second power modules which are mounted on the mounting base surface; the plurality of first power modules are arranged along a first direction to form a first module column, a first heat dissipation gap is formed between two adjacent first power modules, and the plurality of second power modules are arranged along the first direction to form a second module column. According to the invention, the double rows of parallel power modules are arranged on the heat dissipation base, and the through-type first heat dissipation main channel is constructed between the two rows of modules, so that a traditional'series connection long path 'heat dissipation mode is converted into a'parallel connection short path' heat dissipation mode; by means of the negative pressure suction effect formed in the trunk line, cold air is driven to directly penetrate through module gaps and be rapidly discharged out of the middle trunk line, fluid resistance is greatly reduced, and the accumulation effect of heat between modules is eliminated.

Description

Technical Field

[0001] This invention relates to the field of converter cabinet heat dissipation technology, and in particular to a converter side module that is easy to dissipate heat and its working method. Background Technology

[0002] As the core power conversion device in a wind power generation system, the converter integrates a large number of power modules. During operation, the power modules generate a significant amount of heat. If this heat cannot be dissipated in time, it will lead to excessively high junction temperatures, thereby affecting the operational stability and lifespan of the converter.

[0003] In existing technologies, power modules are typically arranged in a compact matrix, lacking specially designed heat dissipation channels between modules. This arrangement has the following drawbacks: ① Severe heat accumulation effect: Due to the lack of effective physical spacing between modules, the heat emitted by adjacent modules overlaps, causing a severe "heat island effect" in the modules located in the central area of ​​the arrangement, where the local junction temperature can easily exceed the critical value. ② Inefficient heat dissipation path: Existing air-cooling systems mostly use a large-area sweeping airflow method, resulting in significant resistance when air flows through densely packed power units. Limited by the module casing, cool air has difficulty penetrating the small gaps between modules, leading to low heat exchange efficiency and a large amount of hot air remaining on the module sidewalls. ③ Uneven airflow distribution: In traditional series airflow systems, the temperature of cool air increases after absorbing heat from the front-row modules, resulting in a smaller temperature difference for the rear-row modules, a decreasing trend in heat dissipation effect, and an inability to guarantee the uniformity of the overall module temperature.

[0004] Therefore, how to design a module layout that can both ensure power density and provide a smooth heat dissipation path is an urgent problem to be solved in the current converter structure design. Summary of the Invention

[0005] In this section, as well as in the abstract and title of this application, some simplifications or omissions may be made to avoid obscuring the purpose of this section, the abstract, and the title of this application, and such simplifications or omissions shall not be used to limit the scope of the invention.

[0006] To address the shortcomings of existing converter side modules, such as low heat dissipation efficiency and easy accumulation of hot air, one objective of this invention is to provide a converter side module that is easy to dissipate heat.

[0007] To achieve the above objectives, the present invention adopts the following technical solution: a converter side module that is easy to dissipate heat, comprising: a heat dissipation base with a mounting base on its top surface; a power unit group, comprising a plurality of first power modules and a plurality of second power modules mounted on the mounting base; wherein the plurality of first power modules are arranged along a first direction to form a first module column, and a first heat dissipation gap is formed between two adjacent first power modules; the plurality of second power modules are arranged along the first direction to form a second module column, and a second heat dissipation gap is formed between two adjacent second power modules; the first module column and the second module column are arranged parallel to each other in the first direction; and a first heat dissipation channel is located between the first module column and the second module column, and is connected to the first heat dissipation gap and the second heat dissipation gap respectively.

[0008] As a preferred embodiment of the easily heat-dissipating converter side module of the present invention, wherein: the first heat dissipation gap includes a counter-type gap and a through-type gap; the counter-type gap is aligned with the side wall of the second power module, the through-type gap is aligned with the second heat dissipation gap in the lateral direction, and the counter-type gap and the through-type gap are arranged alternately in the extension direction of the first heat dissipation channel.

[0009] As a preferred embodiment of the easily heat-dissipating converter side module of the present invention, it further includes: a stacked busbar, which is mounted above the first heat dissipation trunking, and the stacked busbar is connected to the first power module and the second power module respectively; a first PCB board, which is disposed on the first module column and connected to the pins of the first power module; and a second PCB board, which is disposed on the second module column and connected to the pins of the second power module.

[0010] As a preferred embodiment of the easily heat-dissipating converter side module of the present invention, the heat dissipation base includes a plurality of heat dissipation fins arranged along the first direction, and a bottom heat dissipation gap is formed between two adjacent heat dissipation fins; a second heat dissipation channel is provided at one end of the bottom heat dissipation gap, and the second heat dissipation channel is arranged along the first direction; a third heat dissipation channel is provided at the other end of the bottom heat dissipation gap, and the third heat dissipation channel is arranged along the first direction; wherein, the second heat dissipation channel is connected to the first heat dissipation gap, and the third heat dissipation channel is connected to the second heat dissipation gap.

[0011] As a preferred embodiment of the heat-dissipating converter side module of the present invention, the top surfaces of the first power module and the second power module are provided with inwardly recessed heat dissipation recesses, the length of which is greater than the width of the first PCB board or the second PCB board.

[0012] As a preferred embodiment of the easily heat-dissipating converter side module of the present invention, both the first power module and the second power module include an insulating shell made of polyphenylene sulfide material, and a copper thermally conductive substrate is embedded at the bottom of the insulating shell.

[0013] As a preferred embodiment of the easily heat-dissipating converter side module of the present invention, wherein: an extension frame is provided on the top of the heat dissipation base, and a third PCB board is disposed on the extension frame, the third PCB board being located above the first PCB board or the second PCB board.

[0014] As a preferred embodiment of the easily heat-dissipating converter side module of the present invention, it further includes a module base and a U-shaped frame disposed on the module base. The heat dissipation base has a connecting surface parallel to the heat sink, and the connecting surface is connected to the U-shaped frame so that the heat dissipation base is fixed to the module base by the U-shaped frame.

[0015] As a preferred embodiment of the heat-dissipating converter side module of the present invention, wherein: a capacitor is provided on the top of the module base, a composite busbar is provided between the capacitor and the first power module, and an output busbar is provided on the heat dissipation base and connected to the second power module.

[0016] The advantages of this invention's easily heat-dissipating converter side module are as follows: By setting two parallel rows of power modules on the heat dissipation base and cleverly constructing a through-type first heat dissipation channel between the two rows of modules, the traditional "series long path" heat dissipation is transformed into a "parallel short path" heat dissipation mode; by utilizing the negative pressure suction effect formed in the channel, cold air is driven to pass directly through the gaps between the modules and quickly discharged from the middle channel, which greatly reduces fluid resistance and eliminates the heat accumulation effect between the modules; combined with the alternating arrangement design of "opposed" and "straight-through" gaps, the air volume distribution of each module along the path is effectively balanced, fundamentally solving the problem of uneven temperature rise and local heat islands inside high power density equipment, and significantly improving the thermal stability and overall service life of the converter under high load operation.

[0017] To address the shortcomings of existing converter side-side modules, such as low heat dissipation efficiency and easy accumulation of hot air, another objective of this invention is to provide a method for operating a converter side-side module.

[0018] To achieve the above objectives, the present invention adopts the following technical solution: a converter machine-side module operating method, comprising the following steps: the first power module and the second power module generate heat during operation, part of which is conducted to the heat dissipation base, and the other part of which is accumulated in the first heat dissipation gap, the second heat dissipation gap, and the heat dissipation recess; the first heat dissipation main channel, the second heat dissipation main channel, and the third heat dissipation main channel, which are parallel to each other, are simultaneously ventilated by the exhaust assembly, so that a negative pressure environment is generated inside each heat dissipation main channel at the same time; under the action of the synchronous negative pressure, the hot air located in the middle of the second direction of the power module flows into the middle first heat dissipation main channel and is drawn outward, and the hot air located at both ends of the second direction of the power module, as well as the hot air from the bottom heat dissipation gap, respectively flows into the second heat dissipation main channel and the third heat dissipation main channel at both ends and is drawn outward simultaneously.

[0019] The beneficial effects of the converter machine-side module operation method of the present invention are the same as those of the converter machine-side module that is easy to dissipate heat, and will not be repeated here. Attached Figure Description

[0020] To more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the following description of the embodiments will be briefly introduced. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0021] Figure 1 This is a schematic diagram of the heat dissipation base and power unit assembly of the present invention.

[0022] Figure 2 This is a schematic diagram of the structure of the first power module and the second power module of the present invention.

[0023] Figure 3 This is a schematic diagram of the structure of the first module column and the second module column of the present invention.

[0024] Figure 4 This is a schematic diagram of the structure of the counter-clamping type gap and the through type gap of the present invention.

[0025] Figure 5 This is a schematic diagram of the structure of the stacked busbar, the first PCB board, and the second PCB board of the present invention.

[0026] Figure 6 For the present invention Figure 5 Enlarged schematic diagram of point G in the middle.

[0027] Figure 7 This is a schematic diagram of the structure of the second and third heat dissipation channels of the present invention.

[0028] Figure 8This is a schematic diagram of the heat dissipation recess of the present invention.

[0029] Figure 9 This is a schematic diagram of the structure of the heat dissipation recess and the first PCB board of the present invention.

[0030] Figure 10 This is a schematic diagram of the extension frame and the third PCB board of the present invention.

[0031] Figure 11 This is a schematic diagram of the module base and U-shaped frame of the present invention.

[0032] Figure 12 This is a schematic diagram of the overall structure of the present invention.

[0033] Figure 13 This is a schematic diagram of the converter module and exhaust assembly of the present invention. Detailed Implementation

[0034] To make the objectives, features and advantages of the present invention more apparent and understandable, the specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings.

[0035] Many specific details are set forth in the following description in order to provide a full understanding of the invention. However, the invention may also be practiced in other ways different from those described herein, and those skilled in the art can make similar extensions without departing from the spirit of the invention. Therefore, the invention is not limited to the specific embodiments disclosed below.

[0036] Secondly, the term "one embodiment" or "embodiment" as used herein refers to a specific feature, structure, or characteristic that may be included in at least one implementation of the present invention. The phrase "in one embodiment" appearing in different places in this specification does not necessarily refer to the same embodiment, nor is it a single or selective embodiment that is mutually exclusive with other embodiments.

[0037] Example 1

[0038] Reference Figures 1-4This embodiment provides a converter machine-side module that is easy to dissipate heat, which includes: a heat dissipation base 100, the top surface of which is provided with a mounting base A; a power unit group 200, which includes a plurality of first power modules 201 and a plurality of second power modules 202 mounted on the mounting base A; wherein, the plurality of first power modules 201 are arranged along a first direction X to form a first module column B1, and a first heat dissipation gap 203 is formed between two adjacent first power modules 201; the plurality of second power modules 202 are arranged along the first direction X to form a second module column B2, and a second heat dissipation gap 204 is formed between two adjacent second power modules 202; the first module column B1 and the second module column B2 are arranged parallel to each other in the first direction X; and a first heat dissipation channel C1, which is located between the first module column B1 and the second module column B2, and is connected to the first heat dissipation gap 203 and the second heat dissipation gap 204 respectively.

[0039] The heat dissipation base 100 is the core load-bearing structure of the converter's machine-side module, and its top surface has a flat mounting base A. Power unit groups 200 are arranged on mounting base A, consisting of multiple first power modules 201 and multiple second power modules 202. As shown in Figure 2, in terms of spatial arrangement, all the first power modules 201 are arranged sequentially along the first direction X, thus constructing a first module column B1. To ensure airflow, adjacent first power modules 201 are not tightly fitted together, but rather have a clearly defined first heat dissipation gap 203. Similarly, multiple second power modules 202 are also arranged parallel to each other along the first direction X to form a second module column B2, and a second heat dissipation gap 204 is formed between adjacent modules. The first module column B1 and the second module column B2 are arranged parallel to each other on mounting base A, forming a double-column layout.

[0040] This design includes a centrally located heat dissipation channel C1 between the first module column B1 and the second module column B2. This channel C1 is physically connected to the first heat dissipation gap 203 and the second heat dissipation gap 204 on either side.

[0041] In actual use, when the modules generate heat, the hot air accumulated between the first module row B1 and the second module row B2 can converge towards the center through their respective heat dissipation gaps and enter the first heat dissipation channel C1. This layout changes the heat dissipation dead zone problem caused by the compact stacking of traditional converter modules.

[0042] Furthermore, the first heat dissipation gap 203 includes a counter-type gap 203a and a through-type gap 203b; the counter-type gap 203a is aligned with the side wall of the second power module 202, and the through-type gap 203b is aligned with the second heat dissipation gap 204 in the lateral direction. In the extension direction of the first heat dissipation channel C1, the counter-type gap 203a and the through-type gap 203b are arranged alternately.

[0043] like Figure 4 As shown, the first heat dissipation gap 203 is further divided into a counter-type gap 203a and a straight-through gap 203b. The counter-type gap 203a is aligned with the sidewall of the opposite second power module 202, while the straight-through gap 203b is directly aligned laterally with the opposite second heat dissipation gap 204. In terms of arrangement, the counter-type gaps 203a and straight-through gaps 203b are arranged alternately along the extension direction of the first heat dissipation main channel C1. This alternating design can disrupt the airflow within the main channel, creating turbulence, thereby further improving heat exchange efficiency and balancing the airflow distribution of the entire module array.

[0044] Example 2

[0045] Reference Figure 5 This embodiment provides a converter side module that is easy to dissipate heat, which also includes a stacked busbar 300, which is mounted above the first heat dissipation channel C1. The stacked busbar 300 is connected to the first power module 201 and the second power module 202 respectively; a first PCB board 205, which is disposed on the first module column B1 and connected to the pin 207 of the first power module 201; and a second PCB board 206, which is disposed on the second module column B2 and connected to the pin 207 of the second power module 202.

[0046] In terms of electrical connection and spatial layout, the first PCB board 205 and the second PCB board 206 are horizontally positioned over the top of the first module column B1 and the second module column B2, respectively. The first PCB board 205 is electrically connected to the pins 207 extending upward from the first power module 201 through openings or solder joints on it, and the second PCB board 206 is similarly connected to the second power module 202, thereby realizing the drive control of the two columns of power modules.

[0047] Specifically, the stacked busbar 300 adopts an overhead structure design, positioned directly above the first heat dissipation main channel C1, with its horizontal height slightly higher than or equal to the height of the first PCB board 205 or the second PCB board 206. The stacked busbar 300, through its laterally extending connection terminals, crosses or avoids the PCB board, and is electrically connected to the main power circuits of the first power module 201 and the second power module 202 on both sides. This layout, with the drive boards (first PCB board 205, second PCB board 206) positioned on both sides and the main power busbar (stacked busbar 300) centrally overhead, achieves separation of strong and weak currents, effectively reducing electromagnetic interference.

[0048] In terms of heat dissipation coordination, the stacked busbar 300, the first PCB board 205 and the second PCB board 206 together form a relatively shielded "top cover" structure, which echoes the heat dissipation base 100 at the bottom.

[0049] Specifically, by installing a stacked busbar 300 above the first heat dissipation duct C1, the top of the first heat dissipation duct C1 is physically limited. When the external exhaust assembly 700 is working, this arrangement helps to create a more stable negative pressure environment within the first heat dissipation duct C1, forcing cold air to enter from the heat dissipation gaps on the side of the module, thereby enhancing the heat exchange effect of scouring the sidewalls of the module.

[0050] Furthermore, this arrangement of mounting the stacked busbar 300 above the first heat dissipation channel C1 creates a certain vertical gap between the stacked busbar 300 and the first heat dissipation channel C1. On one hand, the high-speed airflow flowing through the first heat dissipation channel C1 can simultaneously carry away the Joule heat generated by the stacked busbar 300 during the transmission of large currents; on the other hand, this gap prevents direct heat conduction between the busbar and the module, thus providing thermal isolation.

[0051] Example 3

[0052] Reference Figures 5-7 This embodiment provides a converter machine-side module that is easy to dissipate heat. The heat dissipation base 100 includes a plurality of heat sinks 101 arranged along the first direction X. A bottom heat dissipation gap 101a is formed between two adjacent heat sinks 101. A second heat dissipation channel C2 is provided at one end of the bottom heat dissipation gap 101a, and the second heat dissipation channel C2 is arranged along the first direction X. A third heat dissipation channel C3 is provided at the other end of the bottom heat dissipation gap 101a, and the third heat dissipation channel C3 is arranged along the first direction X. The second heat dissipation channel C2 is connected to the first heat dissipation gap 203, and the third heat dissipation channel C3 is connected to the second heat dissipation gap 204.

[0053] The heat dissipation base 100 is not a single solid structure; it integrates a microchannel heat dissipation system. Specifically, the heat dissipation base 100 includes multiple heat sinks 101 evenly spaced along the first direction X (module arrangement direction), with the gaps between adjacent heat sinks 101 forming the bottom heat dissipation gap 101a. This finned design greatly increases the heat exchange surface area of ​​the base, enabling rapid transfer of heat from the bottom of the power module to the base and into the flowing air.

[0054] The system employs a three-channel heat dissipation architecture—a primary channel C2, a secondary channel C3, and a primary channel C1—to create a spatially integrated "one main, two auxiliary" structure. Specifically, at both ends of the bottom heat dissipation gap 101a, the second and third heat dissipation channels C2 and C3 are respectively routed along the first direction X. These two channels are parallel to the primary heat dissipation channel C1, which is located between the two modules (i.e., the first module column B1 and the second module column B2), forming an exhaust path covering the entire width of the base.

[0055] The second heat dissipation channel C2 is vertically connected to the first heat dissipation gap 203 above, while the third heat dissipation channel C3 is connected to the second heat dissipation gap 204. This multi-channel interconnection design enables the construction of a "three-dimensional airflow field".

[0056] In actual use, when the exhaust assembly 700 is working, the negative pressure not only acts on the gaps between modules, but also extends into the heat dissipation base 100 through the second and third heat dissipation channels C3. External cold air is drawn into the bottom heat dissipation gap 101a, absorbs heat from the base substrate as it flows through the heat sink 101, and then merges into the second and third heat dissipation channels C3 on both sides. By splitting the hot airflow at the bottom with the hot airflow on the side (first heat dissipation channel C1), the airflow saturation of a single air duct is effectively reduced. The high-temperature airflow generated by the bottom heat dissipation gap 101a and the high-temperature airflow generated by the first heat dissipation gap 203 and the second heat dissipation gap 204 flow independently in their respective channels and eventually merge and discharge. This layered airflow method avoids secondary accumulation of hot air above the base and significantly improves the cooling rate of the bottom of the power module.

[0057] Example Verification: To verify the substantial progress of the "dual-row three-channel" layout of the present invention in suppressing the heat island effect and improving the thermal decoupling capability between modules, comparative tests were conducted in a high and low temperature damp heat test simulation chamber (experimental scenario: simulating the extreme high temperature (50℃) environment of a wind farm, and the converter operating under 1.2 times rated power overload conditions). The results are shown in Table 1 below: Table 1

[0058] Based on the experimental data shown in Table 1, the specific beneficial effects of the "double-row, three-lane" layout scheme are as follows: (1) Eliminating heat accumulation and reducing core junction temperature: The highest junction temperature of the experimental group was significantly reduced by 26.1℃ compared to the control group. The reason is that the first heat dissipation channel C1 constructs a low-flow-resistance pressure relief and diffusion zone between the two rows of power modules (B1 / B2). The heat in the central area of ​​the control group was severely accumulated due to the lack of lateral channels; while in this application, the heat of each power module is quickly drawn into the first heat dissipation channel C1 through the nearby first heat dissipation gap 203 and second heat dissipation gap 204 and carried away by the exhaust assembly 700, which significantly improves the upper limit of heat dissipation.

[0059] (2) Achieving excellent heat dissipation uniformity and extending the overall lifespan: In the comparison group, the temperature difference between modules reached as high as 22.1℃, with a significant "hot center, cold edge" heat island phenomenon, which would lead to premature failure of the central module. The temperature difference between modules in the experimental group of this application was only 5.3℃. This proves that the second heat dissipation trunk line C2, the third heat dissipation trunk line C3 and the first heat dissipation trunk line C1 form a symmetrical three-trunk parallel network, so that the power unit located at any position in the two columns of modules has an equal heat dissipation surface and heat exchange air volume, which greatly improves the consistency of the converter module and the overall working life.

[0060] (3) Enhanced system thermal robustness: The thermal interference coefficient was significantly reduced from 0.35 to 0.08, proving that this scheme achieves thermal decoupling between power modules through physical trunk isolation and negative pressure diversion. When one of the modules experiences instantaneous overload and heat generation, the resulting temperature rise energy is immediately captured and discharged by the heat dissipation trunk, without causing significant heat conduction interference to adjacent modules, thus ensuring the operational stability of the power electronic system under high power conditions.

[0061] Example 4

[0062] Reference Figures 8-9 This embodiment provides a converter side module that is easy to dissipate heat, including a heat dissipation recess 208 on the top surface of a first power module 201 and a second power module 202. The length of the heat dissipation recess 208 is greater than the width of the first PCB board 205 or the second PCB board 206.

[0063] The top surfaces of the first power module 201 and the second power module 202 are not completely flat; instead, they each have inwardly recessed heat dissipation recesses 208. These heat dissipation recesses 208 physically break the flush structure of the module tops, forming a semi-open air buffer cavity. Furthermore, the length of the heat dissipation recess 208 is designed to be greater than the width of the first PCB board 205 or the second PCB board 206 covering it.

[0064] like Figure 9 As shown, the length of the heat dissipation recess 208 in the first direction X is configured as H1, and the length of the first PCB board 205 or the second PCB board 206 in the first direction X is configured as H2, with the relationship between the two satisfying: H1 > H2. This H1 > H2 setting ensures that even after the driver PCB board (first PCB board 205 or second PCB board 206) is installed, a through-flow transverse airflow channel can still be formed between the PCB board and the top surface of the module because the length of the heat dissipation recess 208 extends beyond the shielding range of the PCB board (first PCB board 205 or second PCB board 206).

[0065] The heat dissipation recess 208 is interconnected with the first heat dissipation gap 203, the second heat dissipation gap 204, and the first heat dissipation main channel C1. When the heat dissipation main channel generates a suction effect, hot air is not only discharged from the side of the module, but can also pass through the heat dissipation recess 208 under the PCB board, effectively avoiding heat accumulation on the top surface of the module (first power module 201 and second power module 202) caused by the PCB board (first PCB board 205 or second PCB board 206), and at the same time, the airflow reduces the operating temperature of the drive circuit board.

[0066] Furthermore, both the first power module 201 and the second power module 202 include an insulating shell 201a made of polyphenylene sulfide material, and a copper thermally conductive substrate 201b is embedded at the bottom of the insulating shell 201a.

[0067] The insulating shells 201a of the first power module 201 and the second power module 202 are made of polyphenylene sulfide (PPS). PPS has excellent thermal stability, high strength and chemical corrosion resistance, and can maintain structural stability under the complex electromagnetic field and temperature rise environment generated by high frequency and high current on the converter side, avoiding thermal deformation that affects the duct size.

[0068] At the bottom of the insulating shell 201a, a copper thermally conductive substrate 201b is fixed by integral molding or fastening. Copper, as an excellent heat conductor, has a thermal conductivity much higher than that of the shell material. This combination of "PPS shell + copper substrate" allows the Joule heat generated by the power chip inside the module to be quickly and evenly conducted to the heat dissipation base 100 at the bottom through the copper substrate, and then exchanged with the airflow through the heat sink 101 inside the base.

[0069] In summary, this embodiment solves the problem of "top-level heat dissipation blind spot" under dense arrangement of electronic components by introducing "ultra-wide" heat dissipation recesses 208 on the top surface of the first power module 201 and the second power module 202; at the same time, by utilizing the stability of PPS material and the high thermal conductivity of copper substrate, "vertical efficient introduction" and "horizontal auxiliary export" of heat are realized, ensuring the heat dissipation requirements of the core power unit of the converter in all aspects.

[0070] When manufacturing the plastic frame of the IGBT module (i.e., the insulating shell 201a of the first power module 201 and the second power module 202), there are usually a variety of materials available, such as polyamide (PA), polybutylene terephthalate (PBT), polyethylene terephthalate (PET), polyphthalamide (PPA), polyphenylene sulfide (PPS), etc.

[0071] To verify the optimal material selection for the 201a insulating housing of the power module on the converter side, five commonly used engineering plastics for power electronic device packaging—polyamide (PA), polybutylene terephthalate (PBT), polyethylene terephthalate (PET), polyphthalamide (PPA), and polyphenylene sulfide (PPS)—were selected. Their mechanical properties, thermal properties, electrical insulation properties, and molding process properties were compared and tested. Specific performance parameters are shown in Table 2 below.

[0072] Table 2

[0073] As can be seen from the performance data comparison of five commonly used engineering plastics in Table 2, polyphenylene sulfide (PPS) shows significant advantages in all core indicators.

[0074] Specifically, PPS exhibits the highest flexural modulus, tensile strength, and flexural strength among the five materials. The converter-side module must withstand significant tightening pressure during assembly and faces high-frequency vibrations during wind turbine operation. PPS's superior structural rigidity effectively prevents mechanical deformation of the casing, preventing pin 207 misalignment and damage to internal bonding wires. More importantly, this high resistance to deformation ensures that the geometry of the heat dissipation gap and the first heat dissipation channel C1 maintains design accuracy under complex stress, guaranteeing the stability of the wind field.

[0075] In terms of thermal properties, PPS has a heat distortion temperature exceeding 260°C, and its melting point is well-suited to the high-temperature operating environment of the converter. In contrast, PA exhibits high hygroscopicity and poor dimensional stability at high temperatures, while PBT suffers from significantly insufficient heat resistance. Because this embodiment incorporates a copper thermally conductive substrate 201b embedded at the bottom of the insulating shell 201a, Table 1 shows that the linear expansion coefficient of PPS is more compatible with that of copper. This significantly reduces thermal stress generated during alternating heating and cooling cycles, preventing interface cracking due to differences in expansion rates and ensuring structural integrity at high temperatures.

[0076] According to the data in Table 2, PPS has a tracking index (CTI) of 400V, which is on par with other high-performance engineering plastics in the table, sufficient to meet the insulation requirements of the converter's 1140V high-voltage operating conditions. Crucially, PPS has extremely low water absorption (significantly better than PA and PPA), ensuring that its 400V CTI value will not decrease due to absorption of environmental moisture. In the high-humidity environment of wind farms, PPS can prevent insulation failure problems such as leakage and tracking, and its insulation reliability has stronger long-term stability than materials that are more prone to moisture absorption.

[0077] In terms of molding process, PPS exhibits excellent melt flow rate and molding shrinkage, balancing molding efficiency and dimensional accuracy. This allows the insulating shell 201a with irregularly shaped structures such as the heat dissipation recess 208 in this invention to be precision injection molded and perfectly adapted to the embedding process of the copper thermally conductive substrate 201b. Compared to the less-than-ideal creep resistance of PET, PPS can maintain a tight fit for a long time after injection molding, meeting the high consistency requirements of mass production.

[0078] In summary, polyphenylene sulfide (PPS) is the optimal material for manufacturing the insulating shell 201a of the power module of the converter side module of this invention. Its comprehensive performance can fully meet all the requirements of the power module in terms of structural stability, high temperature resistance, electrical insulation and process adaptability, providing core material-level protection for the reliable operation of the module.

[0079] Example Verification: To verify the effect of the heat dissipation recess 208 of this solution on improving the thermal environment of sensitive components, a specific temperature rise test was conducted on the working environment of thermistor components such as electrolytic capacitors in the drive circuit. The results are shown in Table 3 below: Table 3

[0080] As shown in Table 3, this solution has produced unexpected technical effects in addressing the industry pain point of heat accumulation in the enclosed space on the drive side: (1) Constructing a “horizontal air corridor”: The experimental group utilized the heat dissipation recess 208 formed by the height difference to create an additional heat dissipation path between the top surfaces of the first PCB board 205, the second PCB board 206, the first power module 201, and the second power module 202. Driven by the negative pressure gradient, this space forms a dynamic cold air curtain, continuously introducing the heat accumulated on the top layer into the first heat dissipation channel C1 in the center, breaking the heat dissipation deadlock of the “windless zone on the top layer”.

[0081] (2) Significantly improved control loop reliability: Experimental data shows that the ambient temperature of the first PCB board 205 and the second PCB board 206 decreased sharply from 92℃ to 68℃. This effectively avoids the electrolytic capacitors in the drive circuit from drying out and failing due to long-term high temperature. Without adding additional cooling components, it significantly extends the reliability life of sensitive components, which is a remarkable and substantial improvement.

[0082] Example 5

[0083] Reference Figures 10-11 This embodiment provides a converter side module that is easy to dissipate heat, including a heat dissipation base 100 with an extension frame 400 on the top, and a third PCB board 401 disposed on the extension frame 400. The third PCB board 401 is located above the first PCB board 205 or the second PCB board 206.

[0084] The heat dissipation base 100 has an extension frame 400 extending upwards from its top edge or a specific location. This extension frame 400 serves as a support, and a third PCB board 401 is mounted on top of it. From a vertical projection angle, the third PCB board 401 is located above the aforementioned first PCB board 205 or second PCB board 206, thus forming a stacked architecture of three or more PCB boards within a limited horizontal projection area. This vertical stacking design allows for the physical separation of power drive circuits (first PCB board 205, second PCB board 206) from signal processing or logic control circuits (third PCB board 401). The vertical height difference provided by the extension frame 400 not only provides ample installation and heat dissipation space for the electronic components on the lower first PCB board 205 and second PCB board 206, but also utilizes the upward-extending cool airflow of the first heat dissipation channel C1 to provide auxiliary cooling for the third PCB board 401.

[0085] The third PCB board 401 is raised by the extension bracket 400, which increases the physical distance between it and the high-current power module and the stacked busbar 300 below, effectively reducing electromagnetic coupling interference and improving the transmission quality of control signals.

[0086] Furthermore, it also includes a module base 500, a U-shaped frame 501 disposed on the module base 500, and a heat dissipation base 100 having a connecting surface D parallel to the heat sink 101. The connecting surface D is connected to the U-shaped frame 501 so that the heat dissipation base 100 is fixed to the module base 500 by the U-shaped frame 501.

[0087] To ensure the reliability of the converter's operation under the vibration environment of the wind turbine, this embodiment also introduces a stable base fixing system. Specifically, the converter's machine-side module also includes an integral module base 500, which serves as the foundation for the entire unit's installation. The U-shaped frame 501 is preferably made of a material with excellent vibration resistance.

[0088] The heat dissipation base 100 has connecting surfaces D on both sides or at the bottom, parallel to the internal heat sink 101. These connecting surfaces D are precisely connected to the inner side or support end of the U-shaped frame 501 via fasteners. The heat dissipation base 100 is suspended or fixed to the module base 500 via the U-shaped frame 501. This fixing method allows for a certain buffer margin between the heat dissipation base 100 and the module base 500, and the opening structure of the U-shaped frame 501 does not obstruct the second and third heat dissipation channels C3 at both ends of the heat dissipation base 100. Simultaneously, the design of the connecting surfaces D parallel to the heat sink 101 ensures that installation stress does not cause deformation of the internal airflow channels of the heat dissipation base 100, guaranteeing the mechanical stability of the heat dissipation structure and the consistency of the airflow channels.

[0089] In summary, this embodiment achieves "three-dimensional" integration of the control circuit through the extension frame 400, expanding the control function without increasing the module's footprint. At the same time, by utilizing the scientific cooperation between the U-shaped frame 501 and the connecting surface D of the heat dissipation base 100, a robust mounting base that can withstand high-frequency vibrations without interfering with the heat dissipation airflow is constructed, comprehensively improving the industrial practicality of the machine-side module.

[0090] Example 6

[0091] Reference Figure 12 This embodiment provides a converter side module that is easy to dissipate heat, including a capacitor 600 disposed on the top of the module base 500, a composite busbar 601 disposed between the capacitor 600 and the first power module 201, and an output busbar 602 disposed on the heat dissipation base 100 and connected to the second power module 202.

[0092] A capacitor 600 (such as a support capacitor or absorption capacitor) is installed on the top of the module base 500. The capacitor 600 serves as the energy storage unit of the machine-side module and is located adjacent to the power unit group 200. A composite busbar 601 (also known as a stacked DC busbar) is provided between the capacitor 600 and the first power module 201.

[0093] The composite busbar 601 directly connects the positive and negative output terminals of the capacitor 600 to the DC input terminals of the first power module 201 and the second power module 202. By adopting a composite stacked structure, this busbar can not only carry large currents, but also utilize the mutual inductance cancellation effect between the positive and negative plates to greatly reduce the parasitic inductance of the DC circuit, suppress voltage spikes in the power modules during high-speed switching, and ensure electrical safety.

[0094] Among them, the composite busbar 601 is horizontally mounted above the heat dissipation base 100. Its spatial position avoids the aforementioned heat dissipation channel, which not only ensures the electrical insulation distance, but also makes use of the gap between modules for a compact arrangement.

[0095] An output bus 602 is located on one side of the heat sink base 100 (typically the side furthest from the DC input terminal). This output bus 602 is directly fixed to the mounting position on the heat sink base 100 and is electrically connected to the AC output terminal of the second power module 202. Furthermore, the close contact between the output bus 602 and the heat sink base 100 allows heat generated during high current transmission to be directly conducted to the heat sink base 100 and dissipated by the heat sink 101 and heat dissipation gaps inside the base. The output bus 602 enables unified collection of the AC output terminals of the generator-side modules, facilitating subsequent cable connections to the generator rotor or stator and improving the standardization of the overall assembly.

[0096] In summary, this embodiment, through the scientific layout of the composite busbar 601 and the output busbar 602, constructs a "shortest path" power flow from the capacitor 600 to the power module and then to the output terminal, effectively reducing line losses and electromagnetic interference. Simultaneously, spatially coupling these high-current carriers with a base and trunk structure possessing efficient heat dissipation capabilities ensures the thermal stability of the entire power chain under continuous high-current conditions, further enhancing the reliability of the converter's machine-side modules.

[0097] Example 7

[0098] Reference Figures 1-13 This embodiment provides a method for operating a converter machine-side module, including the following steps: the first power module 201 and the second power module 202 generate heat during operation. Part of the heat is conducted to the heat dissipation base 100, and the other part of the heat accumulates in the first heat dissipation gap 203, the second heat dissipation gap 204, and the heat dissipation recess 208. The exhaust assembly 700 simultaneously exhausts the parallel first heat dissipation channel C1, the second heat dissipation channel C2, and the third heat dissipation channel C3, so that a negative pressure environment is generated inside each heat dissipation channel at the same time. Under the action of the synchronous negative pressure, the hot air located in the middle of the second direction Y of the power module flows into the middle first heat dissipation channel C1 and is drawn outward. The hot air located at both ends of the second direction Y of the power module, as well as the hot air from the bottom heat dissipation gap 101a, respectively flow into the second heat dissipation channel C2 and the third heat dissipation channel C3 at the two ends and are drawn outward simultaneously.

[0099] Inside a wind power converter cabinet, multiple converter-side modules are typically arranged in a matrix or stacked configuration within the cabinet's interior. (Refer to...) Figure 13 In the figure, (a1) is the front view of the converter cabinet and (a2) is the rear view of the converter cabinet. The entire cabinet forms a relatively closed heat exchange space. Its specific working steps and principles are as follows: Step 1 is heat generation and initial conduction. When the converter is under load, the power devices such as IGBTs inside the first power module 201 and the second power module 202 frequently switch, generating a large amount of Joule heat. Part of the heat is directly conducted to the heat dissipation base 100 and its internal heat sink 101 through the copper heat-conducting substrate 201b at the bottom of the module. The other part of the heat is dissipated through the side wall and top surface of the module and accumulates in the first heat dissipation gap 203, the second heat dissipation gap 204 and the heat dissipation recess 208 located on the top of the module, forming a layer of temperature rise air to be extracted.

[0100] Step two involves constructing a multi-channel synchronous negative pressure environment. This is achieved by using an exhaust assembly 700 (such as a centrifugal fan or axial fan unit) installed at the top or rear of the converter cabinet to simultaneously exhaust the first heat dissipation channel C1, the second heat dissipation channel C2, and the third heat dissipation channel C3, which are parallel to each other in each machine-side module.

[0101] like Figure 13 As shown in (a2), the exhaust assembly 700 creates a significant pressure gradient between the cabinet's internal cavity and the external environment, resulting in a uniform negative pressure environment within each heat dissipation duct at the same time scale. Compared to traditional positive pressure blowing, this "negative pressure suction" has the advantages of more guided airflow direction and less likelihood of creating turbulent dead zones.

[0102] Step three is the implementation of the three-dimensional heat dissipation path. Under the action of synchronous negative pressure, the hot air around the module migrates according to the principle of "nearest inflow and shortest path": the hot air located in the middle of the power module in the second direction Y (lateral) directly flows into the first heat dissipation channel C1 located between the two rows of modules and is drawn outward along the axial direction of the channel; the hot air located at both ends of the power module in the second direction Y, as well as the hot air from the bottom heat dissipation gap 101a inside the heat dissipation base 100 (this part of the air has absorbed the heat of the heat sink 101), respectively flow into the second heat dissipation channel C2 and the third heat dissipation channel C3 at both ends and are drawn outward synchronously. Due to the existence of the heat dissipation recess 208, even under the shielding of the first PCB board 205 and the second PCB board 206, the heat accumulated on the top layer can flow into the first heat dissipation channel C1 in the middle along the horizontal airflow formed by the recess.

[0103] Step four involves balancing the airflow of multiple parallel modules. Multiple unit-side modules are installed on the inverter cabinet. Through the reasonable pressure drop distribution of the exhaust assembly 700, the airflow in each main duct is adaptively balanced. Since the first heat dissipation duct C1, the second heat dissipation duct C2, and the third heat dissipation duct C3 are parallel and interconnected, the system can automatically balance the air resistance of each path. When a module generates instantaneous high heat, the expansion of the heated air at that location accelerates the negative pressure suction effect, ensuring that the heat accumulation point receives compensatory airflow distribution.

[0104] like Figure 13 As shown in (a1), external cold air enters through the air inlet at the front door of the cabinet, is "drawn in" by the negative pressure windows (heat dissipation gaps) on the surface of each module, passes through the module surface to carry away heat, enters the main duct, and is finally discharged through the air outlet at the rear of the cabinet, forming an efficient and orderly heat exchange circulation system.

[0105] In summary, this solution, through the synergy of "multi-channel synchronous negative pressure" and "multi-path local convergence," greatly shortens the residence time of hot air inside the cabinet, significantly reduces the mutual thermal impact when multiple power modules are densely arranged, and ensures the thermal balance of the converter under high-power operation.

[0106] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention, and all such modifications or substitutions should be covered within the scope of the claims of the present invention.

Claims

1. A converter side module that facilitates heat dissipation, characterized in that: include, A heat dissipation base (100) has a mounting base (A) on its top surface; The power unit group (200) includes a plurality of first power modules (201) and a plurality of second power modules (202) mounted on the mounting base (A). In this configuration, a plurality of first power modules (201) are arranged along a first direction (X) to form a first module column (B1), and a first heat dissipation gap (203) is formed between two adjacent first power modules (201). A plurality of second power modules (202) are arranged along the first direction (X) to form a second module column (B2), and a second heat dissipation gap (204) is formed between two adjacent second power modules (202). The first module column (B1) and the second module column (B2) are arranged parallel to each other in the first direction (X). The first heat dissipation channel (C1) is located between the first module column (B1) and the second module column (B2), and is connected to the first heat dissipation gap (203) and the second heat dissipation gap (204) respectively.

2. The converter side module with easy heat dissipation as described in claim 1, characterized in that: The first heat dissipation gap (203) includes a counter-type gap (203a) and a straight-through gap (203b); The counter-type gap (203a) is aligned with the side wall of the second power module (202), and the straight-through gap (203b) is aligned with the second heat dissipation gap (204) in the lateral direction. In the extension direction of the first heat dissipation channel (C1), the counter-type gap (203a) and the straight-through gap (203b) are arranged alternately.

3. The easily heat-dissipating converter side module as described in claim 1 or 2, characterized in that: It also includes, A stacked busbar (300) is mounted above the first heat dissipation trunk line (C1), and the stacked busbar (300) is connected to the first power module (201) and the second power module (202) respectively. The first PCB board (205) is disposed on the first module column (B1) and connected to the pin (207) of the first power module (201); The second PCB board (206) is disposed on the second module column (B2) and connected to the pin (207) of the second power module (202).

4. The easily heat-dissipating converter side module as described in claim 1 or 2, characterized in that: The heat dissipation base (100) includes a plurality of heat dissipation fins (101) arranged along the first direction (X), and a bottom heat dissipation gap (101a) is formed between two adjacent heat dissipation fins (101). A second heat dissipation channel (C2) is provided at one end of the bottom heat dissipation gap (101a), and the second heat dissipation channel (C2) is arranged along the first direction (X); A third heat dissipation channel (C3) is provided at the other end of the bottom heat dissipation gap (101a), and the third heat dissipation channel (C3) is arranged along the first direction (X); The second heat dissipation channel (C2) is connected to the first heat dissipation gap (203), and the third heat dissipation channel (C3) is connected to the second heat dissipation gap (204).

5. The converter side module with easy heat dissipation as described in claim 3, characterized in that: The top surfaces of the first power module (201) and the second power module (202) are provided with inwardly recessed heat dissipation recesses (208), the length of which is greater than the width of the first PCB board (205) or the second PCB board (206).

6. The easily heat-dissipating converter side module as described in any one of claims 1, 2, and 5, characterized in that: Both the first power module (201) and the second power module (202) include an insulating shell (201a) made of polyphenylene sulfide material, and a copper thermally conductive substrate (201b) is embedded at the bottom of the insulating shell (201a).

7. The easily heat-dissipating converter side module as described in claim 3, characterized in that: The top of the heat dissipation base (100) is provided with an extension frame (400), and a third PCB board (401) is provided on the extension frame (400). The third PCB board (401) is located above the first PCB board (205) or the second PCB board (206).

8. The converter side module with easy heat dissipation as described in claim 4, characterized in that: It also includes a module base (500) and a U-shaped frame (501) disposed on the module base (500). The heat dissipation base (100) has a connecting surface (D) parallel to the heat sink (101). The connecting surface (D) is connected to the U-shaped frame (501) so that the heat dissipation base (100) is fixed to the module base (500) by the U-shaped frame (501).

9. The easily heat-dissipating converter side module as described in claim 8, characterized in that: A capacitor (600) is provided on the top of the module base (500), a composite busbar (601) is provided between the capacitor (600) and the first power module (201), and an output busbar (602) is provided on the heat dissipation base (100) and connected to the second power module (202).

10. A method for operating a converter machine-side module, characterized in that: include, The first power module (201) and the second power module (202) generate heat during operation. Part of the heat is conducted to the heat sink base (100), and the other part of the heat is accumulated in the first heat dissipation gap (203), the second heat dissipation gap (204) and the heat dissipation recess (208). The exhaust assembly (700) simultaneously exhausts the first heat dissipation channel (C1), the second heat dissipation channel (C2) and the third heat dissipation channel (C3) that are parallel to each other, so that a negative pressure environment is generated inside each heat dissipation channel at the same time. Under the action of synchronous negative pressure, the hot air located in the middle of the second direction (Y) of the power module flows into the first heat dissipation channel (C1) in the middle and is drawn outward. The hot air located at both ends of the second direction (Y) of the power module, as well as the hot air from the bottom heat dissipation gap (101a), flows into the second heat dissipation channel (C2) and the third heat dissipation channel (C3) at both ends respectively and is drawn outward synchronously.

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