A high-voltage artificial network system and equipment

Abstract

This invention relates to the field of artificial power network technology, specifically to a high-voltage artificial power network system and equipment. It includes a DC decoupling network module integrating decoupling capacitors and discharge resistors for power protection; and a DC load network module electrically interconnected with the DC decoupling network module via cables, integrating a multi-stage resistor array, a heat exchanger system, control components, and a cooling subsystem. The cooling subsystem is configured for water-air heat exchange or water-water heat exchange based on the current output stage of the multi-stage resistor array. This invention features efficient heat dissipation and precise temperature control, real-time closed-loop temperature monitoring, and over-temperature alarms for safety. It can promptly observe localized temperature rises and water levels caused by poor cable contact. Connecting to a host computer via a communication module allows for real-time monitoring by the host computer software, and interlocking protection is implemented with the power supply equipment and the tested equipment, simplifying maintenance.

Description

Technical Field

[0001] This invention relates to the field of electrical performance testing technology, specifically to a high-voltage artificial network system and equipment. Background Technology

[0002] With the development of high-voltage electrical systems in electric vehicles (such as 1500V DC), the requirements for electrical performance testing of on-board components are becoming increasingly stringent. International standard ISO 21498-2 explicitly requires testing equipment to accurately simulate the dynamic impedance characteristics (including resistance and inductance parameters) of the vehicle's power supply system and battery to verify the reliability of components under real-world operating conditions. However, existing testing equipment suffers from the following key problems: Heat dissipation bottleneck: Traditional high-voltage artificial networks (such as 200A continuous current rating) generate significant heat during testing. If air cooling is used, the efficiency is insufficient and can easily lead to temperature runaway, affecting test accuracy and equipment lifespan; if water cooling is used, existing equipment lacks integrated and efficient thermal management design (such as a linkage mechanism between heat exchanger and temperature monitoring).

[0003] Limitations of dynamic simulation: A single resistance range is difficult to cover complex test scenarios (such as the need for multiple ranges of 10mΩ / 25mΩ / 100mΩ), and the lack of collaborative design with decoupling networks leads to impedance simulation deviations (such as the need for inductance values ​​to be stable at 2–2.5μH).

[0004] Security and flexibility deficiencies: Insufficient insulation performance: The resistor and the housing (i.e., housing 40) need to withstand a withstand voltage test of 3500V / 1min, but the existing structure is prone to insulation failure due to leakage of cooling medium; Poor equipment mobility: Large-sized testing systems (such as 720mm×580mm×700mm) are fixed in place, making it difficult to adapt to the needs of laboratory layout adjustments.

[0005] The industry urgently needs a portable high-voltage testing system that integrates forced water cooling, adjustable impedance at multiple levels, and high insulation protection. Summary of the Invention

[0006] To address the shortcomings of existing technologies, this invention discloses a high-voltage artificial network system and equipment to solve the aforementioned problems.

[0007] This invention is achieved through the following technical solution: In a first aspect, the present invention provides a high-voltage artificial network system, comprising: The DC decoupling network module integrates decoupling capacitors and discharge resistors to achieve power supply protection; The DC load network module is electrically interconnected with the DC decoupling network module via cables, and integrates a multi-stage resistor array, a heat exchanger system, control components, and a cooling subsystem. The cooling subsystem is configured for water-air heat exchange or water-water heat exchange based on the current output of the multi-level resistor array.

[0008] Furthermore, the control components include a temperature sensor, a current sensor, a water level monitor, an alarm indicator light, and a processor.

[0009] Furthermore, the heat exchanger system includes a heat exchanger, an inlet, and an outlet, and temperature sensors are installed at the inlet and outlet.

[0010] Furthermore, the cooling subsystem is equipped with an air-cooling device or a water-cooling device, which is located above the heat exchanger.

[0011] Furthermore, the temperature acquisition unit is connected to a temperature sensor. When the inlet and outlet temperatures exceed the set values ​​of the temperature acquisition unit, the processor controls the alarm indicator light to issue an alarm fault message.

[0012] Secondly, the present invention provides a high-voltage artificial network device, including a movable DC decoupling network device and a movable DC load network device.

[0013] Furthermore, the movable DC decoupling network device includes a shielded box and copper busbars, with wheels at the bottom of the shielded box.

[0014] Furthermore, the copper busbar is mounted on the shielding box.

[0015] Furthermore, the movable DC load network device includes a load housing, a heat exchanger system, a control unit, and a cooling subsystem, all of which are housed within the load housing.

[0016] Furthermore, a switch button is installed on the front panel of the load cell for starting and stopping the heat exchanger system; The front panel of the load box is equipped with a rubber socket for collecting the voltage at the output terminal, which is used to connect voltage measuring equipment.

[0017] The beneficial effects of this invention are as follows: 1. High-efficiency heat dissipation and precise temperature control A forced water cooling + air cooling combined heat exchange system is adopted (the heat exchanger is circulated with deionized water + the top fan delivers air), which enables the resistor to quickly dissipate heat energy when it is working continuously at a high temperature of 400℃ (200A current), avoiding the risk of heat accumulation in traditional air cooling solutions. Built-in temperature closed-loop monitoring chain (inlet and outlet temperature sensors → panel data collector → top alarm indicator) to detect cooling performance in real time, and provide immediate alarm for over-temperature, ensuring safe and reliable testing process (such as the standard requirement of 1500V / 200A continuous operation).

[0018] 2. Accurate simulation of dynamic impedance in multiple scenarios It offers three resistance values: 10mΩ, 25mΩ, and 100mΩ (accuracy ±2%). Supports differentiated current carrying capacity: 600A for 10mΩ range, 400A for 25mΩ range, and 200A for 100mΩ range. Currently, it can achieve continuous high current carrying capacity for all ranges and can meet the continuous current carrying capacity of up to 800A for various ranges according to the requirements, satisfying test scenarios from normal to extreme. The system inductance is stably maintained at 2–2.5μH, and works in conjunction with the DN 1510 decoupling network (10mF capacitor + 4kΩ discharge resistor) to accurately reproduce the dynamic characteristics of the vehicle power supply system.

[0019] 3. High-level electrical safety protection The resistor and the housing (i.e., the casing 40) are isolated by an insulator and cooled by deionized water, achieving double insulation protection. The insulation resistance is >10MΩ and has passed the 3500V / 1min withstand voltage test (without flashover breakdown). With an IP20 protection rating, it effectively prevents the risk of short circuits caused by the intrusion of external foreign objects.

[0020] 4. Modular and portable operation Both the DN 1510 network (620mm×466mm×540mm) and the 200A main network (720mm×580mm×700mm) are equipped with casters, allowing for flexible deployment in the laboratory; The front panel integrates a voltage monitoring rubber socket, a heat exchange system start / stop switch, and a temperature acquisition device, simplifying the testing process and reducing maintenance costs. Attached Figure Description

[0021] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, 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.

[0022] Figure 1 This is a circuit diagram of a high-voltage artificial network system; Figure 2 This is the electrical diagram of a DC load network module; Figure 3This is a circuit diagram of a high-voltage artificial network system. Figure 4 This is an electrical diagram of a DC load network module variant; In the picture: 10 is the decoupling capacitor, 20 is the power device, 30 is the built-in current probe, and 40 is the housing. Detailed Implementation

[0023] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, 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 only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0024] In one embodiment, the present invention provides a high-voltage artificial network system, including... The DC decoupling network module integrates decoupling capacitors and discharge resistors to output a continuously flowing current that meets the requirements of electrical performance testing. The DC load network module is electrically interconnected with the DC decoupling network module via a copper busbar, and integrates a multi-stage resistor array, a heat exchanger system, control components, and a cooling subsystem. The cooling subsystem is configured for water-air heat exchange or water-water heat exchange based on the current output of the multi-level resistor array.

[0025] The control components in this embodiment include a temperature sensor, an alarm indicator light, and a processor.

[0026] In this embodiment, the heat exchanger system includes a heat exchanger, an inlet, and an outlet, and temperature sensors are installed at the inlet and outlet.

[0027] In this embodiment, the cooling subsystem is equipped with an air-cooling device, which is located above the heat exchanger.

[0028] In this embodiment, the temperature acquisition unit is connected to a temperature sensor. When the inlet and outlet temperatures exceed the set values ​​of the temperature acquisition unit, the processor controls the alarm indicator light to issue an alarm fault message.

[0029] The present invention also provides a high-voltage artificial network device, including a movable DC decoupling network device and a movable DC load network device.

[0030] The movable DC decoupling network device in this embodiment includes a shielded box and a copper busbar, and the bottom of the shielded box is equipped with wheels.

[0031] In this embodiment, the DC decoupling network module is installed inside the shielded box, and the copper busbar is installed on the shielded box.

[0032] The portable DC load network device in this embodiment includes a load housing, a heat exchanger system, a control unit, and a cooling subsystem, all of which are housed within the load housing.

[0033] In this embodiment, a switch button is installed on the front panel of the load box for starting and stopping the heat exchanger system; a rubber socket for collecting the voltage at the output terminal is installed on the front panel of the load box for connecting voltage measuring equipment.

[0034] This embodiment will be described and illustrated using two examples, as follows: Example 1 (refer to) Figure 1 The diagram shows a topology (water-to-water heat exchange) of a high-voltage artificial network system. Decoupling capacitor 10 is integrated into the DC decoupling network module, connected in parallel with a discharge resistor at the power input for power protection. Power devices 20 are located in the DC load network module, controlling the switching of a multi-level resistor array to configure different current levels. A built-in current probe 30 is mounted on the internal copper busbar of the DC load network module for real-time acquisition of system current data. The housing 40 serves as the system's grounding protection terminal. Decoupling capacitor 10 and the load circuit are electrically isolated from the housing 40 through an insulation structure to ensure electrical safety during high-voltage testing.

[0035] about Figure 2 , Figure 2This is the electrical diagram of the DC load network module, showcasing the complex control and monitoring system within. The system ensures the safety and accuracy of high-voltage testing through a multi-layered monitoring mechanism: First, the temperature control and alarm system installs high-precision temperature sensors at the heat exchanger inlet and outlet, connected to a temperature monitoring instrument on the tank panel. This, along with an infrared temperature sensor, collects real-time copper busbar temperature data. Once the temperature exceeds a preset safety threshold, the processor triggers a red alarm indicator on the top of the tank, emitting an audible and visual alarm signal. Second, the liquid level alarm system uses a liquid level sensor inside the expansion tank to monitor the deionized water storage status. When the liquid level is too low, the yellow alarm light on the front panel activates an audible and visual alarm, prompting the operator to replenish the liquid. For power monitoring, the system integrates a Hall effect current sensor to collect loop current and displays the value visually through an energy meter. Furthermore, the system is equipped with a 485-to-Ethernet module and related aviation connectors for real-time communication with the host computer software and external data monitoring. Finally, the front panel of the enclosure integrates a switch button for controlling the start and stop of the heat exchange system, a power indicator light, and a rubber socket for safely connecting external voltage measuring equipment, thus achieving comprehensive closed-loop monitoring and convenient operation of the entire high-voltage artificial network system. It demonstrates the electrical control logic and signal monitoring connections of each functional component within the DC load network module, rather than the topology or mechanical location of the main circuit. Specifically, the "multi-stage resistor array" serves as the load under test. Figure 2 The electrical parameters are represented by sampling circuits, specifically the "loop current sampling" unit in the lower left corner (configured with a Hall sensor to monitor the loop current of the resistor array) and the "copper busbar temperature infrared sampling" unit in the lower middle section (used to monitor the real-time temperature of the copper busbars connecting the resistor array). The "heat exchanger system" and "cooling subsystem" are represented in the electrical diagram as the connections between the actuators and the security monitoring components, corresponding to... Figure 2 The central "water-cooled internal circulation" module (which includes a water pump circuit to drive the water flow), the "inlet PT100" and "outlet PT100" terminals connected to the temperature monitoring instrument (used to monitor the temperature difference between the inlet and outlet of the heat exchanger), and the "level switch" and alarm indicator circuit on the right (used to monitor the state of the cooling medium and perform over-temperature / low level alarms) together form a closed-loop control network for the resistor array and cooling system.

[0036] Specifically, Figure 2In the diagram, the upper left corner "AC220V, L, N, PE" represent the live wire, neutral wire, and ground wire of a 220V AC power supply, respectively; "QF1" is the main circuit breaker; the "three-hole socket" is for external power supply access; "H1" and its adjacent "power indicator light" indicate the power status; "SB6" and "start switch" are buttons to control the "water pump," and the annotation "water-cooled internal circulation" explains the driving method of the cooling circuit; the "liquid level switch" and "L105" on the right side of the diagram are connected to "HL(R)2" and "yellow alarm light - liquid level," forming a liquid level safety monitoring circuit; the "inlet PT100" and "outlet PT100" in the middle represent temperature sensors installed at the inlet and outlet of the heat exchanger, connected to the "temperature monitoring instrument" (annotated "to monitor the internal temperature of the cabinet"), through " The AL1 / AL2 / AL3 output terminals control HL(R)1 and the red alarm light (temperature) to achieve over-temperature alarm; the Hall sensor in the lower left corner works with the energy meter (note: "to achieve current monitoring" and "loop current sampling") to collect current data; the 485 to Ethernet module connects to the instrument via twisted-pair shielded cable (numbers 1001-1004), note: "to achieve external data communication"; the infrared temperature sensor and copper busbar temperature infrared sampling below demonstrate the non-contact temperature measurement logic for the main circuit copper busbar; the switching power supply and its outputs DC15V+ / COM / DC15V- provide DC power to the sensors; the block diagram of the front panel function modules in the lower right corner visually illustrates the physical layout of the energy meter, level gauge, inspection instrument, and various indicator lights on the equipment panel.

[0037] about Figure 3 , Figure 3 This section showcases a modified topology of a high-voltage artificial network system, primarily composed of a DC decoupling network module and a multi-stage DC load network. On the left side of the system is the DN-1510 DC decoupling network, which connects a 1500V, 10mF decoupling capacitor CS2 and a 5kΩ / 500W discharge resistor RS2 in parallel between the HV+IN and HV-IN input terminals. This provides power protection and outputs a stable current that meets electrical performance testing requirements. On the right side is the DC load network, where a multi-stage resistor array of 50mΩ, 100mΩ, and 200mΩ is connected in parallel on the HV+ side to meet the continuous current carrying requirements from 200A to 600A, depending on the stage of the resistor. In the load loop, a 500nH and a 1uH inductor are connected in series, along with a 220nF ground filter capacitor, ensuring the system inductance remains stably around 2.2μH, thus accurately replicating the dynamic impedance characteristics of the vehicle's power supply system. In addition, the circuit diagram clearly marks the GND grounding terminal, and the resistors are connected to the chassis through insulators to ensure that the circuit can pass the 3500V withstand voltage test under 1500V high voltage conditions, thus guaranteeing the overall electrical safety protection level.

[0038] about Figure 4 , Figure 4 The electrical control system of the modified DC load network module was demonstrated. Based on achieving accurate testing of high-voltage artificial networks, this system focuses on enhancing heat dissipation monitoring and safety protection functions: specifically, the "multi-stage resistor array" serves as the main circuit load. Figure 4 The electrical and physical parameters of the resistor array are represented by sampling circuits, namely the "loop current sampling" circuit in the lower left corner (configured with Hall sensor 2001 to monitor the loop current of the resistor array), the "copper busbar temperature infrared sampling" circuit in the lower middle, and the "voltage monitoring port protection" circuit (connected to the HV+ / HV- terminals of the copper busbar). These units together constitute real-time monitoring of the current flow status and heat generation of the resistor array. The "heat exchanger system" is represented in the electrical diagram by the "inlet water PT100" and "outlet water PT100" sensor interfaces connected to the temperature monitoring instrument, used to monitor the inlet and outlet temperature difference of the heat exchanger in real time to evaluate the heat exchange efficiency. The "cooling subsystem" specifically corresponds to the "water pump" (labeled as water-cooled internal circulation) drive circuit in the middle of the diagram, the "electronic fan" (labeled as cooling fan) drive circuit on the right, and the "liquid level switch" monitoring circuit. These electrical components together constitute the drive control and closed-loop safety protection logic of the "water-air heat exchange" mode in this embodiment. Most of the power supply and monitoring symbols in the diagram (such as AC220V, QF1, PT100, temperature monitoring instrument, HL alarm light, etc.) are... Figure 2 The meaning remains the same. Its unique features include: a newly added "electronic fan" and its annotation "cooling fan" on the right, powered by a "24V / 600W switching power supply," forming a water-fan coordinated cooling system together with the "water pump"; a newly added "voltage monitoring port protection" circuit diagram below, detailing that "copper busbar (HV+)" and "copper busbar (HV-)" are connected to the output terminals of "Monitoring 1 (red)" and "Monitoring 2 (black)" via "5A fuse terminals," and equipped with "PE (shielding layer)" grounding, clarifying the safety protection structure for voltage acquisition; furthermore, the annotations such as "twisted pair shielded cable" and "sheet metal LINK connector" in the diagram further clarify the specific form of the system's anti-interference wiring and physical interfaces, ensuring the integrity and feasibility of the electrical connection scheme. First, the system uses high-precision temperature sensors installed at the heat exchanger inlet and outlet, along with a temperature monitoring instrument and infrared temperature sensor on the enclosure panel, to monitor the water and copper busbar temperatures in the loop in real time. When the temperature exceeds a safe threshold, a red over-temperature alarm indicator is triggered, emitting an audible and visual alarm. Second, the system uses a level switch in the expansion tank to monitor the deionized water level in real time. If the level is too low, a yellow alarm light indicates an abnormal level. For core heat exchange control, the system integrates a water-cooled internal circulation system consisting of an electronic fan and a water pump. The processor dynamically adjusts the fan speed and system start / stop based on real-time temperature data to achieve efficient heat dissipation. Simultaneously, the system incorporates a Hall current sensor to sample the loop current. The data is displayed visually via an energy meter and communicates in real-time with a host computer and external data sources via a 485-to-Ethernet module. Furthermore, the system has a dedicated voltage monitoring port protection circuit to ensure the safety of voltage signal acquisition at the output terminals. Finally, the front panel of the enclosure integrates power indicator lights, a start switch, and a monitoring instrument, providing a user-friendly interface and enabling comprehensive closed-loop control of the high-voltage testing environment.

[0039] More specifically, the system achieves a high degree of integration between internal monitoring and external communication by integrating a 485 to Ethernet module. For internal monitoring, the module uses signal lines labeled 1001 to 1004, with twisted-pair shielded cables, to electrically connect to the A and B ports of the energy meter and temperature monitoring instrument. This wiring method, protected by a PE shield, effectively enhances anti-interference capabilities under high-current testing environments, thereby accurately achieving real-time acquisition of current monitoring and multi-channel temperature data. For external data communication, the module is equipped with a dedicated Ethernet interface and securely connected via a sheet metal connector, supporting real-time transmission of collected electrical performance and thermal management data to host computer software for remote monitoring. Furthermore, the communication unit is independently powered by 15V+ and COM DC power supplies, ensuring electrical isolation and stable operation between the data transmission link and the high-voltage main circuit, ultimately constructing a complete intelligent monitoring and external data communication system.

[0040] System Composition 1. Module Configuration DC decoupling network module: Built-in 10mF decoupling capacitor (1500V withstand voltage) and 4kΩ discharge resistor (1kW power). Natural air cooling structure, dimensions 620mm×466mm×540mm. Electrical interfaces: HV+IN / OUT, HV-IN / OUT (connect to load network).

[0041] DC load network module:

[0042] Rated current capacity: 600A for 10mΩ range, 400A for 25mΩ range, and 200A for 100mΩ range. Currently, it can meet the 200A test requirements for all three ranges simultaneously.

[0043] The cabinet dimensions are 820mm×600mm×1908mm (increased volume to accommodate water-to-water heat exchange).

[0044] 2. Cooling subsystem (water-to-water heat exchange) Double-plate heat exchanger, deionized water circulation flow rate ≥20L / min.

[0045] Rated power: 8kW, heat dissipation power: 200mΩ, 200A.

[0046] 3. Control and Safety The front panel is equipped with a rubber socket voltage measurement interface and an emergency stop switch for the heat exchange system.

[0047] Processor-linked control: When the water temperature exceeds 70℃, the resistor power supply is shut off and an audible and visual alarm is triggered.

[0048] The grounding terminal features a dual redundancy design (enclosure grounding point + terminal metal ring).

[0049] 4. Electrical performance The system inductance is 2.5μH (the path is shortened by direct connection through the copper busbar).

[0050] Insulation resistance: Resistance-to-casing (i.e., housing 40) > 100MΩ (tested with a 2500V megohmmeter).

[0051] Frequency response characteristics (10Hz~150kHz): 10mΩ, 25mΩ, 50mΩ, 100mΩ correspond to standard ISO 21498-2.

[0052] Example 2 (refer to) Figure 3 The diagram illustrates another topology for a high-voltage artificial network system (water-air heat exchange). System Composition 1. Module Configuration DC decoupling network module: Built-in 10mF decoupling capacitor (1500V withstand voltage) and 4kΩ discharge resistor (1kW power). Natural air-cooled structure, dimensions 620mm×466mm×540mm. Electrical interfaces: HV+IN / OUT, HV-IN / OUT (connect to load network).

[0053] DC load network module: Multi-position resistor array (HV+ side R1=50mΩ, R2=100mΩ, R3=200mΩ; HV- side symmetrical).

[0054] Rated current capacity: 600A for 50mΩ range / 400A for 100mΩ range / 600A for 200mΩ range (continuous).

[0055] The box measures 1300mm×1000mm×1909mm and has casters at the bottom.

[0056] 2. Cooling subsystem (water-air heat exchange) A temperature sensor is installed at the inlet of the heat exchanger system, and the outlet temperature is set to a threshold of 65℃.

[0057] Dual-fan forced cooling: The fan speed is adjusted in 3 levels according to the water temperature (low speed starts at 40℃, full speed at 60℃).

[0058] Rated power: 72kW, heat dissipation power: 200mΩ, 600A.

[0059] Air duct design: The air outlet is equipped with a 30° inclined baffle to direct hot air to the ground (avoiding direct airflow into the operating area).

[0060] Dual-fan forced cooling: The fan speed is adjusted in 3 levels according to the water temperature (low speed starts at 40℃, full speed at 60℃).

[0061] 3. Control and Safety The temperature sensor monitors the temperature difference between the inlet and outlet in real time, and the processor triggers the red alarm indicator on the top when the temperature exceeds the limit.

[0062] All terminals are equipped with grounded metal terminals (connected to the housing), with an IP20 protection rating.

[0063] 4. Electrical performance The system inductance is 2.2μH.

[0064] Insulation withstand voltage: 3500V / 50Hz / 1min between resistance and housing (i.e., chassis 40) without breakdown.

[0065] Measured impedance (10kHz): 0.166Ω for the 50mΩ range (tolerance ±10%).

[0066] The commonalities of the above embodiments are as follows: 1. Dynamic Impedance Simulation The impedance characteristics of the metering network can be realized by shorting different resistor combinations (such as shorting the AD / BE / CF ports with AN 21498-2); the impedance characteristics of the vehicle battery can be simulated by selecting different resistor levels.

[0067] Impedance deviation within the 10Hz~150kHz frequency band is <±10% (measured data compared with theoretical values).

[0068] 2. Innovation in security protection Interface protective cover: It adopts a quick-release transparent cover, which can prevent electric shock without obscuring the interface markings.

[0069] Insulating sleeve: made of silicone material, heat resistant to 200℃, insulation resistance >1GΩ after covering unused terminals.

[0070] 3. Optimization of mobile structure The casters are equipped with brakes, and the housing has lifting holes (compatible with handling equipment).

[0071] A shock-absorbing pad is installed between the copper busbar and the enclosure to prevent the connection from loosening during movement.

[0072] Comparison of effects of each example Comparison table of heat exchanger characteristics

[0073] The modular design enables rapid switching between 200A and 600A systems, and the cooling solution can be configured as needed; the grounding and interface protection system is compatible with both models, reducing production complexity; actual test data shows that the voltage fluctuation is <±3% in the ISO 21498-2 standard test.

[0074] The high-voltage artificial network system, designated AN21498-2-200 (Example 1), and the high-voltage artificial network system, designated AN80300-600 (Example 2), are examples of such systems.

[0075] This embodiment will describe the device using two examples, as follows: Example 3: In this example, the fan is installed above the resistive element inside the housing to provide cooling air for the heat exchanger.

[0076] The following protective devices are installed on the 200A high-voltage artificial network (serial number AN 21498-2): The temperature control and alarm system has temperature sensors installed at the inlet and outlet of the heat exchanger, a temperature collector installed on the panel of the housing, and an alarm indicator light installed on the top of the housing. When the temperature at the inlet and outlet exceeds the set value of the temperature collector, the alarm indicator light will issue an alarm fault message. A switch button is installed on the front panel of the enclosure for starting and stopping the heat exchange system of the resistance element; The front panel of the enclosure is equipped with a rubber socket for collecting the voltage at the output terminal, which is used to connect voltage measuring equipment.

[0077] The high-voltage artificial network (the high-voltage artificial network system in this embodiment) is composed of a DN 1510 DC decoupling network and a 200A high-voltage artificial network (AN 21498-2), and the specific parameters are shown in the table below: Table 1

[0078] Example 4, its electrical principle is as follows Figure 4As shown. Mechanically, the 600A DC load network uses casters for movement at the bottom, and the resistors are mounted inside the enclosure. The resistors are connected to the enclosure via insulators, ensuring insulation between the resistors and the enclosure.

[0079] The fan is installed above the resistive elements inside the housing to provide cooling air for the heat exchanger.

[0080] The following protection devices are installed on the 600A DC load artificial network (the high-voltage artificial network system in this embodiment): The temperature control and alarm system has temperature sensors installed at the inlet and outlet of the heat exchanger, a temperature collector installed on the panel of the housing, and an alarm indicator light installed on the top of the housing. When the temperature at the inlet and outlet exceeds the set value of the temperature collector, the alarm indicator light will issue an alarm fault message. A switch button is installed on the front panel of the enclosure for starting and stopping the heat exchange system of the resistance element; The front panel of the enclosure is equipped with a rubber socket for collecting the voltage at the output terminal, which is used to connect voltage measuring equipment.

[0081] The DC load artificial network (the high-voltage artificial network system in this embodiment) is composed of a DN 1510 DC decoupling network and a 600A DC load artificial network (the high-voltage artificial network system in this embodiment), and the specific parameters are shown in the table below: Table 2

[0082] In one specific embodiment, as a preferred solution of this embodiment, the temperature control acquisition and alarm system adopts a multi-level temperature monitoring and alarm mechanism. Specifically, high-precision temperature sensors are installed at both the inlet and outlet of the resistor for real-time detection of water temperature changes. A multi-functional monitoring instrument is configured on the cabinet panel. The first channel of this instrument displays the copper busbar temperature data acquired by the infrared temperature sensor in real time. The second and third channels dynamically monitor and display the temperature values ​​of the inlet and outlet, respectively. The fourth channel is responsible for monitoring the ambient temperature inside the cabinet, ensuring comprehensive coverage of key temperature control areas. In addition, a conspicuous alarm indicator light is installed on the top of the cabinet. Once the temperature of the inlet and outlet exceeds the preset safety threshold, the temperature acquisition unit will trigger the alarm circuit, and the indicator light will immediately emit an audible and visual alarm signal to prompt the operator to handle the abnormal situation in a timely manner.

[0083] Regarding the liquid level alarm system, a sensitive liquid level sensor is installed inside the expansion tank to continuously monitor the storage status of deionized water. When the liquid level is detected to be below the safety limit, the liquid level alarm light on the front panel of the tank will activate an audible and visual alarm, reminding the user to replenish deionized water in time. Operators can add sufficient deionized water through the replenishment port; the alarm signal will automatically deactivate once the liquid level returns to normal. It should be noted that the pressure relief valve of the expansion tank must be manually opened during the replenishment process to ensure operational safety and system balance.

[0084] The front panel of the enclosure features clearly marked power buttons for controlling the start and stop of the resistance element heat exchange system, providing a convenient operating interface for users. An integrated copper busbar current sensor inside the enclosure collects current data in real time and displays the current value visually on a power meter, facilitating user monitoring of the system's power status. Additionally, a dedicated rubber socket is installed on the right side panel of the enclosure for safe and reliable connection to external voltage measuring equipment, enabling real-time acquisition of voltage signals from the output terminals and further enhancing the overall system's monitoring capabilities.

[0085] In summary, this invention has the advantages of efficient heat dissipation and precise temperature control; A forced water cooling + air cooling combined heat exchange system is adopted (the heat exchanger is circulated with deionized water + the top fan delivers air), which enables the resistor to quickly dissipate heat energy when it is working continuously at a high temperature of 400℃ (600A current), avoiding the risk of heat accumulation in traditional air cooling solutions. Built-in temperature closed-loop monitoring chain (inlet and outlet temperature sensors → panel data collector → top alarm indicator) to detect cooling performance in real time, and provide immediate alarm for over-temperature, ensuring safe and reliable testing process (such as the standard requirement of 1500V / 200A continuous operation).

[0086] This invention has the advantage of accurate simulation of dynamic impedance in multiple scenarios; It offers three resistance values: 10mΩ, 25mΩ, and 100mΩ (accuracy ±2%). Supports differentiated current throughput capabilities: 600A for the 10mΩ range, 400A for the 25mΩ range, and 200A for the 100mΩ range, meeting testing scenarios from normal to extreme. The system inductance is stably maintained at 2–2.5μH, and works in conjunction with the DN 1510 decoupling network (10mF capacitor + 4kΩ discharge resistor) to accurately reproduce the dynamic characteristics of the vehicle power supply system.

[0087] This invention has the advantage of high-level electrical safety protection; The resistor and the housing (i.e., the casing 40) are isolated by an insulator and cooled by deionized water, achieving double insulation protection. The insulation resistance is >10MΩ and has passed the 3500V / 1min withstand voltage test (without flashover breakdown). With an IP20 protection rating, it effectively prevents the risk of short circuits caused by the intrusion of external foreign objects.

[0088] This invention has the advantages of being modular and portable; Both the DN 1510 network (620mm×466mm×540mm) and the 200A main network (800mm×600mm×1908mm) are equipped with casters, allowing for flexible deployment in the laboratory; The front panel integrates a voltage monitoring rubber socket, a heat exchange system start / stop switch, and a temperature acquisition device, simplifying the testing process and reducing maintenance costs.

[0089] 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 the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A high-voltage artificial network system, characterized in that, include The DC decoupling network module integrates decoupling capacitors and discharge resistors to achieve power supply protection; The DC load network module is electrically interconnected with the DC decoupling network module via cables, and integrates a multi-stage resistor array, a heat exchanger system, control components, and a cooling subsystem. The cooling subsystem is configured for water-air heat exchange or water-water heat exchange based on the current output of the multi-level resistor array.

2. The high-voltage artificial network system according to claim 1, characterized in that, The control components include a temperature sensor, a current sensor, a water level monitor, an alarm indicator light, and a processor.

3. A high-voltage artificial network system according to claim 2, characterized in that, The heat exchanger system is equipped with a heat exchanger, an inlet, and an outlet, and temperature sensors are installed at the inlet and the outlet.

4. A high-voltage artificial network system according to claim 1, characterized in that, The cooling subsystem is equipped with an air-cooling device or a water-cooling device, which is located above the heat exchanger.

5. A high-voltage artificial network system according to claim 3, characterized in that, The temperature acquisition unit is connected to a temperature sensor. When the temperature at the inlet and outlet exceeds the set value of the temperature acquisition unit, the processor controls the alarm indicator light to issue an alarm fault message.

6. A high-voltage artificial network device, comprising a high-voltage artificial network system as described in any one of claims 1 to 5, characterized in that, It includes a portable DC decoupling network device and a portable DC load network device.

7. A high-voltage artificial network device according to claim 6, characterized in that, The movable DC decoupling network device includes a shielded box and copper busbars, with wheels at the bottom of the shielded box.

8. A high-voltage artificial network device according to claim 7, characterized in that, The copper busbar is installed on the shielding box.

9. A high-voltage artificial network device according to claim 6, characterized in that, The movable DC load network device includes a load housing, a heat exchanger system, a control unit, and a cooling subsystem, all of which are housed within the load housing.

10. A high-voltage artificial network device according to claim 9, characterized in that, A switch button is installed on the front panel of the load cell for starting and stopping the heat exchanger system; The front panel of the load box is equipped with a rubber socket for collecting the voltage at the output terminal, which is used to connect voltage measuring equipment.

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