Intelligent thermal management system and method for high-frequency pulse power distribution cabinet

Abstract

This invention discloses an intelligent thermal management system and method for a high-frequency pulse power distribution cabinet, relating to the field of electrical cabinet thermal management technology. The thermal management method, applied to the cabinet body, includes the following steps: Heat dissipation channel operation step: A forced air cooling heat dissipation channel is established through an air inlet and an exhaust fan located on the cabinet body, allowing external air to flow through the electrical components inside the cabinet before being exhausted. Dual-layer filtration step: A dual-layer filter system is installed at the air inlet end of the heat dissipation channel, wherein the filter cloth system uses a continuously replaceable roll-type filter cloth. Adaptive adjustment step: Temperature sensors collect the cabinet interior temperature and ambient temperature parameters. When a preset cleaning trigger condition is met, the controller starts the drive motor, which drives the filter cloth system to perform filter cloth winding and replacement. During replacement, a temporary gap area not covered by the filter cloth appears, providing additional ventilation compensation for heat dissipation inside the cabinet.

Description

Technical Field

[0001] This invention relates to the field of electrical cabinet thermal management technology, specifically to an intelligent thermal management system and method for a high-frequency pulse power distribution cabinet. Background Technology

[0002] High-frequency pulse power supplies are critical power supply equipment in industrial fields such as electrochemical processing, plasma treatment, and metal surface treatment. Their distribution cabinets integrate high-power electrical components such as IGBT full-bridge inverter modules, RCD snubber circuits, and their supporting drive circuits. Under high-frequency switching conditions, the turn-on and turn-off losses of the IGBTs, the forward conduction and reverse recovery losses of the diodes in the RCD snubber circuit, and the ohmic losses generated by the bus current flowing through conductors and connectors collectively constitute significant heat sources within the distribution cabinet. If the heat cannot be dissipated in time, the temperature inside the cabinet will continue to rise, leading to a series of reliability problems such as IGBT module junction temperature exceeding limits, rapid decline in capacitor lifespan, and accelerated aging of insulation materials. In severe cases, this can cause equipment shutdown or even burnout.

[0003] Currently, extensive research has been conducted on the heat dissipation issues of distribution cabinets and electrical cabinets. For example, Chinese utility model patent CN209592750U discloses a distribution box with a temperature control device. Inside the box, it uses an exhaust fan, a heat dissipation chamber, a heat dissipation channel, and a cooling fan mechanism to form two systems: a circulating heat dissipation system and a circulating cooling system. Temperature control within the cabinet is achieved by using a bottom cooling fan to blow air upwards and a top exhaust fan to exhaust air outwards. However, this heat dissipation system operates at a fixed power, and the fan lacks the ability to adjust its speed according to the actual heat load inside the cabinet.

[0004] Chinese utility model patent CN207834856U discloses an intelligent temperature-controlled switch cabinet. It uses a temperature sensor and controller installed inside the cabinet to activate a fan assembly for cooling when the internal temperature exceeds a preset threshold. One side of the cabinet has a louvered fan as an air inlet, and the other side has a fan assembly for exhaust. While this design incorporates temperature sensing and control, its control strategy is limited to simple on / off threshold control. The fans operate between full speed and off, failing to provide continuous speed adjustment and refined thermal management based on dynamic changes in the internal temperature. Furthermore, although the louvered fan structure offers some rain protection, it lacks effective dust filtration capabilities and lacks methods for monitoring filter clogging and an automatic cleaning mechanism.

[0005] Regarding the heat dissipation design of high-frequency pulse transformers, Chinese utility model patent CN204289010U discloses an improved high-frequency pulse transformer. This transformer features left and right variable frequency fans on both sides of the casing to form airflow channels, and air outlets and heat dissipation fins on the casing cover to enhance heat dissipation. However, this solution only optimizes the heat dissipation of the transformer body casing and does not address the thermal management of electrical components such as the IGBT modules and their absorption circuits inside the distribution cabinet that are paired with the transformer.

[0006] Furthermore, in terms of RCD snubber circuit design, existing high-frequency pulse power supplies generally use commercially available fast recovery diode modules to form the snubber circuit. These commercially available fast recovery diode modules are typically packaged with a small number of large chips connected in parallel, resulting in a reverse recovery time of several hundred nanoseconds and a relatively high forward voltage drop. Under high-frequency, high-current pulse conditions, the long reverse recovery time means that the snubber circuit cannot conduct in time to suppress the IGBT turn-off voltage spike, while the high forward voltage drop means that the diode module itself generates significant conduction losses. This not only weakens the voltage spike protection effect of the RCD snubber circuit for the IGBT module but also results in persistently high heat generation inside the distribution cabinet, further burdening the cooling system. Simultaneously, the wiring of existing RCD snubber circuits typically uses wire connections, resulting in a large loop area and high parasitic inductance, further deteriorating the voltage spike suppression effect.

[0007] In summary, existing technologies for thermal management of high-frequency pulse power distribution cabinets have the following shortcomings: First, they lack a systematic design to reduce heat generation within the cabinet from the source, resulting in high power loss in the RCD absorption circuit. Second, the fan speed control strategies for heat dissipation channels are mostly simple threshold switch control or fixed power operation, lacking adaptive continuous adjustment capabilities based on multi-parameter coordination. Third, the air intake filtration system is either missing or uses only a simple static filter structure, which is prone to clogging in high-dust outdoor conditions and lacks clogging monitoring and automatic cleaning methods. Fourth, the various functional components are isolated from each other, lacking a systematic integrated solution from heat source optimization, adaptive adjustment of heat dissipation channels, filter self-cleaning to consumable lifecycle management. Summary of the Invention

[0008] To address the aforementioned technical problems, this invention provides an intelligent thermal management system and method for a high-frequency pulse power distribution cabinet.

[0009] On one hand, this invention provides an intelligent thermal management method for a high-frequency pulse power distribution cabinet, applied to the cabinet body, comprising the following steps: Heat dissipation channel operation steps: A forced air cooling heat dissipation channel is established through the air inlet and exhaust fan on the power distribution cabinet, so that the external air flows through the electrical components inside the cabinet and is then discharged.

[0010] Dual-layer filtration step: A dual-layer filter system is installed at the air inlet of the heat dissipation channel, with a metal filter system as the outer layer and a filter cloth system as the inner layer, to perform two-stage filtration on the air entering the heat dissipation channel; wherein, the filter cloth system adopts a continuously replaceable roll-type filter cloth.

[0011] Adaptive adjustment steps: The temperature inside the cabinet and the ambient temperature parameters are collected by the temperature sensor group, and the pressure difference on both sides of the filter is monitored by the differential pressure sensor. The controller dynamically adjusts the speed of the exhaust fan according to the temperature parameters and the differential pressure signal to maintain the ventilation capacity of the heat dissipation channel.

[0012] Linked self-cleaning steps: When the preset cleaning trigger conditions are met, the controller starts the drive motor, which drives the filter cloth system to perform the winding and replacement of the filter cloth. During the replacement, a gap area that is not covered by the filter cloth temporarily appears, providing additional ventilation compensation for heat dissipation inside the cabinet. The transmission mechanism drives the metal filter in the metal filter system to generate displacement movement, and the relative movement between the metal filter and the wound old filter cloth forms a wiping and cleaning effect on the surface of the metal filter.

[0013] Furthermore, the intelligent thermal management method also includes a step to reduce the heat generated inside the cabinet: a self-made diode assembly is used in the RCD absorption circuit inside the power distribution cabinet. The self-made diode assembly adopts a combination structure of multiple ultra-fast recovery diodes in series and parallel, and adopts a double PCB stacked structure. The space of the positive and negative current paths is tightly fitted to reduce the parasitic inductance of the circuit. The absorption capacitor is integrated between the double PCB stacked structures.

[0014] Furthermore, the preset cleaning triggering conditions adopt a multi-condition joint judgment, including at least one of the following: triggering regular cleaning when the pressure difference exceeds the first threshold, triggering enhanced cleaning when the pressure difference exceeds the second threshold, triggering preventive cleaning when the running timer reaches the preset cycle, and forcibly triggering cleaning when the cabinet temperature exceeds the limit and the exhaust fan has reached the maximum speed.

[0015] Furthermore, the transmission mechanism includes: a reversing gear set disposed on both sides of the supply end of the filter cloth system, a guide shaft of the metal filter system, and a synchronous transmission belt connecting each guide shaft; the outer surface of the guide shaft is provided with a spiral groove, and the displacement seat cooperates with the spiral groove through a follower connector to convert the rotational motion of the guide shaft into the linear motion of the displacement seat carrying the metal filter.

[0016] Furthermore, the linked self-cleaning step also includes: before cleaning, the metal filter screen is pre-rinsed from the inside of the cabinet to the outside of the cabinet through a spray pipe located inside the cabinet; during the wiping and cleaning process, water is sprayed onto the old filter screen cloth through a humidifying water pump to enhance the wiping effect; during the cleaning period, the exhaust fan is kept running to maintain a slight negative pressure inside the cabinet to prevent dust from spreading into the cabinet.

[0017] Furthermore, the intelligent thermal management method also includes a filter consumable management step: the consumption of filter cloth is measured by a rotary encoder, the controller establishes a consumption rate prediction model to predict the remaining available amount and provide graded early warning; at the same time, the cleaning pressure difference recovery rate of the metal filter is calculated based on the pressure difference change before and after each cleaning to assess its performance degradation trend.

[0018] Furthermore, in the filter consumable management step: the controller calculates the consumed length and remaining usable length of the filter cloth based on the roll diameter change at the supply end of the filter cloth system and the cumulative rotation angle collected by the rotary encoder, and predicts the remaining usable days. When the remaining length is lower than a preset threshold, a graded warning is issued. When evaluating the performance of the metal filter, the cleaning frequency is increased when the cleaning differential pressure recovery rate continues to decrease to the first degradation threshold, and a replacement alarm is issued when the rate drops to the second degradation threshold.

[0019] On the other hand, the present invention also provides an intelligent thermal management system for a high-frequency pulse power distribution cabinet, comprising: The distribution cabinet has an air inlet; an exhaust fan is installed on the cabinet, forming a forced air cooling channel with the air inlet; a dual-layer filter system is located at the air inlet of the cooling channel, including an outer metal filter system and an inner filter cloth system, the filter cloth system including a continuously replaceable roll-type filter cloth; a temperature sensor group is used to collect the temperature parameters inside the cabinet and the ambient temperature; a differential pressure sensor is used to monitor the pressure difference across the filter; a drive motor is used to drive the filter cloth system to perform filter cloth winding and replacement, and through a transmission mechanism, it drives the metal filter in the metal filter system to generate displacement movement, so that the metal filter and the old filter cloth generate relative movement to form a wiping cleaning; a controller is connected to the temperature sensor group, differential pressure sensor, exhaust fan and drive motor, adjusts the speed of the exhaust fan according to the temperature parameters and differential pressure signal, and starts the drive motor to perform linkage self-cleaning when the preset cleaning trigger conditions are met.

[0020] Furthermore, the metal filter system also includes a displacement seat for carrying the metal filter; the filter cloth system also includes a discharge bucket for releasing the filter cloth and a winding bucket for collecting the filter cloth; the transmission mechanism includes a reversing gear set, a guide shaft, and a synchronous transmission belt connecting each guide shaft at both ends of the discharge bucket, and the guide shaft drives the displacement seat to move up and down with the metal filter through the cooperation of the spiral groove on its outer surface and the follower connector.

[0021] Furthermore, the intelligent thermal management system also includes a communication module for remotely transmitting thermal management status information to the operation and maintenance management platform to achieve remote monitoring and parameter distribution; and a rotary encoder installed at the supply end of the filter cloth system for measuring the consumption of filter cloth.

[0022] The beneficial effects of this invention include: First, the present invention achieves two-stage filtration of the air entering the cabinet by setting a dual-layer filter system consisting of a metal filter system and a filter cloth system at the air inlet end of the heat dissipation channel, effectively preventing external dust from entering the power distribution cabinet and ensuring the safe operation of electrical components.

[0023] Secondly, this invention simultaneously drives the winding and replacement of the filter cloth and the displacement movement of the metal filter by a drive motor. The relative movement between the metal filter and the old filter cloth is used to wipe and clean the metal filter. Only a single drive source is needed to complete the linkage self-cleaning of the double-layer filter. The structure is simple and highly reliable.

[0024] Third, the present invention monitors the thermal environment inside the cabinet and the filter blockage status in real time through a temperature sensor group and a differential pressure sensor. The controller dynamically adjusts the fan speed and automatically triggers the cleaning program based on multiple parameter signals, realizing the adaptive adjustment of the heat dissipation channel and maintaining good heat dissipation and ventilation capabilities for a long time without manual intervention.

[0025] Fourth, this invention uses a self-made diode assembly to replace a commercially available diode module. By utilizing the low forward voltage drop characteristics of the ultrafast recovery diode and the low parasitic inductance design of the double PCB stacked structure, the power loss of the RCD absorption circuit and the heat generation inside the distribution cabinet are reduced from the source, creating more favorable conditions for heat dissipation management.

[0026] Fifth, this invention uses a rotary encoder and differential pressure sensor to accurately measure the consumption of filter cloth and quantitatively assess the performance degradation of metal filter screens. Combined with a consumption rate prediction model, it provides graded early warning and achieves intelligent management of filter consumables throughout their entire life cycle.

[0027] Sixth, the present invention remotely transmits thermal management status information to the operation and maintenance management platform through a communication module, supports remote monitoring, fault alarms and parameter distribution, and facilitates the clustered management of multiple devices. Attached Figure Description

[0028] Figure 1 This is a schematic diagram of the overall structure of the power distribution cabinet of the present invention (solid line portion).

[0029] Figure 2 This is a schematic diagram of the airflow path of the heat dissipation channel and the internal layout of the temperature control feedback in the power distribution cabinet of the present invention.

[0030] Figure 3 This is a schematic diagram of the overall structure of the double-layer filter linkage mechanism of the present invention.

[0031] Figure 4 This is a schematic diagram of the self-made diode assembly of the present invention.

[0032] Figure 5This is a schematic diagram of the structure of the double-layer filter linkage mechanism of the present invention after a portion has been removed.

[0033] Figure 6 This is a schematic diagram of the filter cloth in operation according to the present invention.

[0034] Figure 7 This is a block diagram of the overall functional architecture of the intelligent thermal management system of the present invention.

[0035] Figure 8 This is the RCD absorption circuit diagram of the present invention.

[0036] Figure 9 This is a flowchart of the filter cleaning control trigger judgment and execution process of the present invention.

[0037] Figure 10 This is a flowchart illustrating the intelligent management process of the filter's entire lifecycle in this invention.

[0038] Figure 11 This is a physical image of the self-made diode assembly of this invention.

[0039] Numbering on the map: 1. Distribution cabinet body; 2. Self-made diode assembly; 2a. Double PCB stacked structure; 2b. Flat copper busbar; 2c. Absorption capacitor; 2f. Insulation isolation layer; 1a. Inspection door; 1c. Air inlet; 10. Exhaust fan; 17. Temperature sensor group; 17a. Cabinet internal temperature sensor; 17b. Ambient temperature sensor; 18. Controller; 11. Metal filter system; 12. Filter cloth system; 12c. Filter cloth; 12a. Discharge bucket; 12b. Flexible closing cover; 12d. Guide strip; 12e. Rewind bucket; 11a. Base; 11b. Displacement seat; 11c. Metal filter; 11d. Guide shaft; 11e. Follower connector; 16. Differential pressure sensor; 14. Reversing gear set; 15. Synchronous transmission belt; 19. Communication module; 20. Rotary encoder; 23. Cloud management platform. Detailed Implementation

[0040] It should be noted that, unless otherwise specified, the embodiments and features described in this application can be combined with each other. The following will refer to the appendix... Figure 1 To be continued Figure 11 The present invention will be described in detail with reference to the embodiments.

[0041] This invention provides an intelligent thermal management system and method for a high-frequency pulse power distribution cabinet.

[0042] I. Overall System Composition The intelligent thermal management system of this invention uses the distribution cabinet 1 as the basic mounting carrier, see [link / reference]. Figure 1 , Figure 2 The distribution cabinet 1 is installed on the side of the high-frequency pulse transformer body, and its interior contains IGBT full-bridge inverter modules and their supporting RCD absorption circuits and other electrical components.

[0043] This invention first optimizes the diode assembly in the RCD absorption circuit from the perspective of reducing heat generation inside the cabinet: a self-made diode assembly 2 is used to replace the commercial diode module. The self-made diode assembly 2 employs a series-parallel combination structure of multiple ultrafast recovery diodes (see circuit topology). Figure 8 The selected ultrafast recovery diode has a reverse recovery time of tens of nanoseconds (typically 15~35ns), which can promptly conduct the absorption circuit at the moment of IGBT turn-off, significantly improving the suppression effect of voltage spikes. At the same time, the forward voltage drop of the ultrafast recovery diode is significantly lower than that of the fast recovery diode, and the power loss of the diode assembly itself is greatly reduced, thereby reducing the heat generation inside the distribution cabinet 1 from the source.

[0044] In terms of structural design, the self-made diode assembly 2 adopts a dual PCB stacked structure 2a, see [reference needed]. Figure 4 Multiple ultrafast recovery diodes are soldered onto the upper and lower PCB layers, which are electrically interconnected via a flat copper busbar 2b. The dual-PCB stacked structure ensures that the positive and negative current paths of the absorption circuit are spatially close and in opposite directions, significantly reducing parasitic inductance by minimizing the current loop area. The flat copper busbar 2b has a larger aspect ratio than traditional round-section conductors, further reducing conductor self-inductance and mutual inductance between adjacent conductors while maintaining the same current carrying capacity. The absorption capacitor 2c is directly integrated between the dual-PCB stacked structures 2a, eliminating the need for external connections and further shortening the current path of the absorption circuit.

[0045] Through the low-loss design and compact circuit structure of the self-made diode assembly 2, the present invention achieves two improvements in electrical performance: First, the peak voltage suppression capability of the RCD absorption circuit is significantly enhanced, which can withstand voltage surges of higher amplitude and improve the operational safety of the IGBT power module; Second, the power loss of the diode assembly is greatly reduced, and the total heat generation inside the distribution cabinet 1 is reduced accordingly, creating more favorable heat dissipation conditions for the intelligent thermal management system.

[0046] Based on reducing the heat generated inside the cabinet, this invention further constructs an intelligent thermal management system on the distribution cabinet 1 to dissipate the remaining heat inside the cabinet.

[0047] Therefore, the present invention constructs a heat dissipation channel on the power distribution cabinet 1, see [reference]. Figure 2 , Figure 3The distribution cabinet 1 has an inspection door 1a on the front and an air inlet 1c at the bottom. An exhaust fan 10 is installed at the high position on each of the two side walls, forming a forced air cooling channel from bottom to top. The distribution cabinet 1 is equipped with a temperature sensor group 17, including an internal temperature sensor 17a and an ambient temperature sensor 17b. The controller 18 adjusts the speed of the exhaust fans 10 in real time according to the temperature difference between the inside and outside of the cabinet, achieving basic adaptive adjustment of the heat dissipation channel.

[0048] However, high-frequency pulse power distribution cabinets typically operate in outdoor high-dust environments. If the heat dissipation channel lacks a filter, external dust will enter the cabinet 1 with the airflow, adhering to the electrical components and the surface of the heat sink 5. This not only reduces heat dissipation efficiency but may also cause insulation failure, short circuits, and other malfunctions. Therefore, an effective dust filter barrier needs to be installed at the air intake end of the heat dissipation channel.

[0049] Therefore, the present invention provides a double-layer filter system on one side wall of the power distribution cabinet 1 or on both side walls. The system uses a metal filter system 11 as the outer layer and a filter cloth system 12 as the inner layer. External air must pass through the metal filter system 11 and the filter cloth system 12 in sequence to complete two stages of filtration before it can enter the heat dissipation channel and flow through the electrical components inside the cabinet.

[0050] Among them, the metal filter system 11 (see Figure 5 The system includes a base 11a fixed to the side wall of the cabinet, a square frame displacement seat 11b that can move up and down along the base 11a, a metal filter screen 11c supported on the displacement seat 11b, four guide shafts 11d located at the four corners to drive the displacement seat 11b to move up and down, and four follower connectors 11e that link and couple the displacement seat 11b with the guide shafts 11d. Each follower connector 11e is positioned corresponding to a single guide shaft 11d, with one end fixed to the displacement seat 11b and the other end having a pin or roller that mates with the spiral groove on the outer surface of the guide shaft 11d and is embedded in the groove of the guide shaft 11d. When the guide shaft 11d is driven to rotate, the spiral contour of the groove forces the follower connector 11e to move axially, thereby converting the rotational motion of the guide shaft 11d into the linear motion of the displacement seat 11b. The groove contour of the guide shaft 11d is divided into three sections: a bottom horizontal section, a middle spiral rising section, and a top horizontal section (see [reference]). Figure 5 These correspond to the initial waiting position, variable speed lifting cleaning stroke, and top stopping wiping function of the metal filter 11c, respectively.

[0051] The filter cloth system 12 uses roll-type filter cloth 12c as the filter medium, and together with the discharge bucket 12a at the supply end and its elastic closing cover 12b, the guide strip 12d that guides the filter cloth's path, and the winding bucket 12e at the collection end, it forms a continuously replaceable filter barrier.

[0052] Differential pressure sensors 16 are installed on both sides of the filter to monitor the degree of clogging in real time. The signal from the differential pressure sensors 16 is connected to the controller 18. When dust accumulation on the filter causes an increase in differential pressure, the controller 18 gradually increases the speed of the exhaust fan 10 to compensate. When the fan compensation reaches its limit, the automatic cleaning and replacement of the filter needs to be initiated.

[0053] To address this, the present invention employs a dual-layer filter screen linkage self-cleaning mechanism driven by a single drive motor 13. This drive motor 13 is connected to the winding drum 12e, driving the winding drum 12e to rotate and collect the old filter cloth 12c. Simultaneously, the tension of the filter cloth 12c causes the discharge drum 12a to passively rotate and release the new filter cloth 12c, achieving continuous roll-type replacement of the filter cloth 12c. Furthermore, by setting reversing gear sets 14 at each end of the discharge drum 12a, power is transmitted to the corresponding side guide shaft 11d, and then synchronously transmitted to the other side guide shaft 11d via a synchronous transmission belt 15. Thus, the four guide shafts 11d rotate synchronously with the discharge drum 12a, thereby transmitting power to four follower connectors 11e to drive the displacement seat 11b, which in turn carries the metal filter screen 11c in a lifting and lowering motion.

[0054] During the aforementioned linkage process, the active upward movement of the metal filter 11c creates a relative motion of contact and separation with the old filter cloth 12c. The old filter cloth 12c continuously wipes the surface of the metal filter 11c, peeling off the attached dust. To further enhance the wiping effect, a humidifying water pump 8 sprays water onto the old filter cloth 12c to moisten it, giving the wiping process a wet cleaning effect and further improving the dust removal capability.

[0055] It is worth noting that during the transition phase of filter cloth replacement (see...) Figure 6 When the old filter cloth 12c is rolled up, it needs to overcome the elastic force of the elastic closing cover 12b. The elastic force of the elastic closing cover 12b is used to seal the filter cloth 12c tightly onto the base 11a. After the filter cloth 12c is rolled up and the elastic closing cover 12b is lifted, a gap area will temporarily appear that is not covered by the filter cloth. This gap temporarily reduces the resistance of the filter section, forming a channel expansion effect, allowing external air to pass more smoothly through the metal filter 11c into the cabinet, providing additional ventilation compensation for heat dissipation inside the cabinet (since this is when heat is concentrated and accumulated inside the cabinet, the additional compensation can improve the situation instantly). During this process, the elastic closing cover 12b is briefly opened due to the change in filter cloth tension. After the new filter cloth is in place, it is closed again, restoring the double-layer filtration state.

[0056] Furthermore, to track and manage the status of filter consumables, this invention installs a rotary encoder 20 on the rotating shaft of the discharge tank 12a to measure the consumed length of the filter cloth 12c in real time. This allows the controller 18 to accurately determine the remaining usable amount of the filter cloth 12c and predict and warn of its consumption rate. Simultaneously, the controller 18 evaluates the cleaning and recovery effect of the metal filter 11c and tracks its performance degradation trend by recording the pressure difference changes before and after each cleaning.

[0057] In addition, the present invention is provided with a communication module 19, which is used to remotely transmit the thermal management status information of the equipment to the operation and maintenance management platform, so as to realize remote monitoring, fault alarm and parameter distribution, and facilitate the clustered management of multiple devices.

[0058] In summary, the intelligent thermal management system of the present invention (see overall functional architecture) Figure 7 By reducing heat generation at the source through self-made low-loss diode components, and through multi-level functional integration such as core heat dissipation channels, double-layer filter barriers, linkage self-cleaning mechanisms, and full life cycle management of consumables, the high-frequency pulse power distribution cabinet achieves adaptive adjustment of heat dissipation channels and long-term reliable operation under harsh outdoor conditions.

[0059] II. RCD Absorption Circuit and Self-made Diode Assembly 2.1 Circuit Topology of Self-Made Diode Assembly The RCD snubber circuit is connected between the positive and negative terminals of the DC bus of the IGBT full-bridge inverter module and consists of a self-made diode assembly 2 and a snubber capacitor 2c. The self-made diode assembly 2 internally adopts a series-parallel combination topology of multiple ultra-fast recovery diodes, wherein the number of series groups is determined according to the required peak voltage to withstand, and the number of parallel groups is determined according to the peak current.

[0060] In a preferred embodiment, each series-connected ultrafast recovery diode is connected in parallel with a voltage-equalizing resistor to ensure that each stage shares the reverse voltage evenly in the off state; each parallel branch is connected in series with a current-limiting inductor or a current-equalizing resistor to suppress current imbalance caused by differences in forward voltage drop between branches.

[0061] 2.2 Dual PCB Stacked Busbar Structure The core principle of the dual-PCB stacked structure 2a is that current flows in one direction through the upper PCB and returns in the opposite direction through the lower PCB. The resulting magnetic flux largely cancels each other out, minimizing the equivalent current loop area and significantly reducing parasitic inductance. The flat copper busbar 2b uses a flat cross-section with a width-to-thickness ratio greater than 5, resulting in lower self-inductance and skin effect losses under the same current carrying capacity. The reduction in parasitic inductance reduces the induced voltage spike during IGBT turn-off and accelerates the response speed and improves the damping characteristics of the absorption circuit, suppressing voltage oscillations.

[0062] In a preferred embodiment, an insulating isolation layer 2f, which combines insulation and thermal conductivity, is provided between the two PCB layers of the dual PCB stacked structure 2a to avoid localized hot spots. The entire dual PCB stacked structure 2a is attached to the surface of the heat sink 5 using a thermally conductive interface material, eliminating the need for a separate heat sink 5, further simplifying the structure and reducing the loop area.

[0063] III. Adaptive Adjustment of Heat Dissipation Channels 3.1 Heat dissipation channel configuration Based on the heat dissipation channel described in Part 1, the exhaust fan 10 is driven by a variable speed DC brushless motor, which supports PWM or analog voltage speed regulation. The speed regulation range is 20% to 100% of the rated speed, and an independent speed feedback signal line is configured for fault detection.

[0064] 3.2 Multi-parameter coordinated adjustment logic The controller 18 continuously collects parameters such as the cabinet temperature Tin, ambient temperature Tout, pressure difference ΔP across the filter, fan speed n, and radiator surface temperature Ts (optional), and performs the following adaptive adjustments: During normal operation, the controller 18 dynamically calculates the minimum required intake airflow based on the heat balance equation Qmin = Pdiss / (ρ × Cp × ΔTallow), and determines the fan speed by comparing it with the current ventilation capacity. When sufficient airflow is available, it operates in an energy-saving low-speed mode. Here, Pdiss is the total power dissipation inside the cabinet, ρ is the air density, Cp is the specific heat capacity of air at constant pressure, and ΔTallow is the maximum allowable temperature rise inside and outside the cabinet.

[0065] When dust accumulates on the filter screen, causing ΔP to increase, the controller 18 uses a PID closed-loop strategy to gradually increase the fan speed to compensate; if the speed increases too quickly in a short period of time (such as exceeding 40% of the rated speed within 30 minutes), the cleaning program is scheduled in advance.

[0066] When the fan speed reaches its rated value but still cannot meet the heat dissipation requirements, the controller 18 forcibly triggers the filter cleaning program. During the cleaning process, after the old filter cloth is rolled up and removed, and before the new filter cloth is fully in place, the resistance of the filter section is temporarily reduced, creating a channel expansion effect and providing additional ventilation compensation for heat dissipation inside the cabinet. After cleaning is completed, the ΔP value is re-detected and the fan speed is adjusted back. The parameter trajectory of the entire adjustment process is recorded for self-learning optimization.

[0067] 3.3 Fan Failure Redundancy Strategy Each side of the power distribution cabinet 1 is equipped with an exhaust fan 10, which work together under normal conditions. When the controller 18 detects a failure of one fan, it immediately increases the speed of the other fan to the highest speed to maintain heat dissipation, while lowering the cleaning trigger threshold and increasing the cleaning frequency to compensate for the decrease in heat dissipation margin, and sends a fault alarm through the communication module 19.

[0068] 3.4 Extreme Temperature Protection When the temperature inside the cabinet exceeds the emergency protection threshold Tmax, the controller 18 can send a power reduction operation request to the main control system through the communication module 19 to reduce heat generation at the source. In extremely low temperature environments, when the water temperature approaches the freezing point, the system suspends the water washing function and relies solely on dry airflow to maintain heat dissipation, and appropriately relaxes the cleaning trigger threshold.

[0069] IV. Dual-layer filter linkage self-cleaning system 4.1 Metal Filter System In a preferred embodiment, the groove cross-section is T-shaped or dovetail-shaped to prevent it from coming off, and a polytetrafluoroethylene or oil-impregnated nylon low-friction bushing is provided between the follower connector 11e and the groove.

[0070] 4.2 Filter Cloth System Based on the filter cloth system 12 described in Part 1, a constant force spring tensioner is provided in the discharge bin 12a to maintain stable tension, and a ratchet check mechanism is provided in the winding bin 12e to prevent the dirty filter cloth from loosening in the reverse direction. During normal operation, the elastic closing cover 12b keeps the filter cloth tightly attached to the outer wall of the metal filter displacement seat 11b, achieving double-layer filtration. The filter cloth 12c is guided by the guide strip 12d on the inner wall of the cabinet. The guide strip and the filter cloth attached to it have both heat insulation and anti-condensation functions on the inner surface of the side wall.

[0071] In a preferred embodiment, the guide strip 12d has a stepped cross section and an arc transition section at the corner, and the surface is provided with longitudinal guide microgrooves to guide the discharge of condensate.

[0072] 4.3 Power Transmission and Linkage Mechanism Based on the linkage mechanism described in Part 1, the drive motor 13 is equipped with a forward and reverse rotation control module to realize the reciprocating motion of the metal filter screen, and a torque limiter is provided between the output shaft and the winding drum to achieve jamming protection. The synchronous transmission belt 15 adopts a toothed belt structure with an embedded steel wire reinforcement layer, and is equipped with a spring-preloaded automatic tensioning pulley to compensate for thermal expansion and contraction and wear elongation.

[0073] 4.4 Cleaning Triggering and Execution Controller 18 triggers cleaning based on the signal from differential pressure sensor 16 using a multi-condition joint judgment (see...). Figure 9 ): Regular cleaning is triggered when the differential pressure exceeds the first threshold P1, enhanced cleaning is triggered when it exceeds the second threshold P2, preventive cleaning is triggered when the running timer reaches cycle T, and forced cleaning is triggered when the cabinet temperature exceeds the limit and the fan has reached its maximum speed.

[0074] The cleaning process is executed sequentially: the drive motor 13 starts, the winding drum 12e rotates to collect the old filter cloth 12c, the release drum 12a passively rotates to release the new filter cloth, the metal filter screen 11c actively rises under the drive of the guide shaft 11d, and generates relative motion with the old filter cloth 12c to form a wiping effect, and the humidifying water pump 8 sprays water to moisten the old filter cloth to enhance the wiping effect. The controller 18 records parameters for strategy optimization.

[0075] In a further preferred embodiment, a spray pipe 9 is also provided inside the distribution cabinet 1 (see...). Figure 9 The spray pipe 9 is installed inside the cabinet of the metal filter 11c, with its spray direction set from the inside of the cabinet to the outside. Before the cleaning sequence is started, the controller 18 first drives the spray pipe 9 to pre-rinse the metal filter 11c, using water flow to wash away loose dust adhering to the surface of the metal filter from the inside to the outside of the cabinet, preventing dust from falling onto the electrical components inside the cabinet and causing secondary pollution during subsequent wiping. After the pre-rinse is completed, the following steps are executed in sequence: starting the drive motor 13, rewinding and replacing the filter cloth, wet wiping, and lifting and cleaning the metal filter. The spray pipe 9 and the wet water pump 8 can share the same water supply line or be set up independently. The spray pressure and duration are adaptively adjusted by the controller 18 based on the pressure difference reading before cleaning. By adding a pre-rinsing stage with spray pipe 9, the cleaning process forms a three-stage progressive cleaning process of "spray pre-rinse - wiping main wash - lifting and rinsing in stages", and is combined with a triple anti-secondary pollution mechanism: First, the spray direction is from the inside of the cabinet to the outside of the cabinet, and the dust-laden water flow is far away from electrical components; Second, the wet filter cloth forms a dynamic interception barrier on the outside of the metal filter, capturing the fine dust scattered during the rinsing process; Third, the exhaust fan 10 continues to operate during the cleaning period, keeping the cabinet in a slightly negative pressure state, and the airflow always flows from the outside of the cabinet to the inside of the cabinet, further preventing dust from spreading into the cabinet.

[0076] V. Intelligent Management of the Filter's Entire Lifecycle 5.1 Filter Cloth Consumable Management The controller 18 calculates the initial roll diameter, filter cloth thickness, and cumulative rotation angle collected by the rotary encoder 20 (see...). Figure 10 The consumed length and remaining usable length are accurately calculated using the roll diameter decreasing model L = Σ(2π × ri × Δθi), and cross-validated by the torque feedback of the drive motor 13. Here, ri is the real-time roll diameter of the released bucket 12a at the i-th sampling moment, and Δθi is the rotation angle increment detected by the rotary encoder 20 within the corresponding sampling interval. As the filter cloth is continuously released, the roll diameter ri decreases successively, therefore the single-turn release length corresponding to each sampling is different, and accurate measurement is achieved by summing. The controller 18 establishes a consumption rate prediction model based on each cleaning as the sampling point to predict the remaining usable days. When the remaining days are below a preset threshold, a graded warning is issued, and a replacement reminder is pushed through the communication module 19.

[0077] 5.2 Performance Evaluation of Metal Filters The controller 18 records the differential pressure readings before and after each cleaning, and calculates the cleaning differential pressure recovery rate η = (ΔPbefore - ΔPafter) / (ΔPbefore - ΔP0) × 100%. Where ΔPbefore is the differential pressure across the filter before cleaning, ΔPafter is the differential pressure across the filter after cleaning, and ΔP0 is the baseline differential pressure when the filter is initially installed (in brand new condition). A higher η value indicates a better recovery effect of cleaning on the filter's airflow capacity; a continuously decreasing η value indicates irreversible degradation of the metal filter's performance. When the average η value after multiple consecutive cleanings falls below the first degradation threshold η1, the cleaning frequency is automatically increased to compensate for the performance decline; when the average η value further drops to the second degradation threshold η2, a replacement alarm is issued. After replacement, the baseline is reset via the reset button on the controller 18 panel or the communication module 19, starting a new round of lifecycle tracking.

[0078] 5.3 Self-optimization and remote management of operating parameters Based on historical operating data, the controller 18 automatically optimizes parameters such as cleaning trigger threshold, spray duration, timed cleaning cycle, and single roll-up length of the filter cloth. The communication module 19 supports standard industrial communication protocols (such as Modbus RTU / TCP, 4G / 5G, or LoRa) to upload thermal management status information to the cloud management platform 23, enabling cluster management functions such as centralized monitoring of multiple devices, cross-device comparative analysis, remote parameter distribution, and consumable inventory scheduling.

[0079] VI. Variations It should be noted that this embodiment is only one of the preferred embodiments of the present invention, and various modifications and improvements can be made without departing from the technical solution of the present invention.

[0080] Regarding the RCD snubber circuit, the number of series and parallel stages of the ultrafast recovery diodes can be flexibly configured according to the voltage and current ratings of the specific IGBT module. The number of PCB layers in the dual-PCB stacked structure is not limited to two. Flat copper busbars can be replaced with copper braided strips or multi-layer copper foil stacked structures. The snubber capacitor can be a film capacitor or a ceramic capacitor.

[0081] Regarding the heat dissipation channels, infrared temperature sensor arrays or thermocouple arrays can be arranged on the surface of the heat sink 5 and on the IGBT device housing to achieve more refined temperature zone monitoring. Air guide plates can be added inside the cabinet to preferentially guide cooling air to the areas with the highest heat generation. Auxiliary heat dissipation methods can be added to the heat dissipation channels, such as heat pipes installed at the bottom of the heat sink 5.

[0082] Regarding the linkage mechanism of the double-layer filter screen, the groove of the guide shaft 11d can adopt other contour forms such as sine curves and trapezoidal waves; the power transmission can be replaced by gear transmission, chain transmission, etc.; the elastic device of the elastic closing cover 12b can be replaced by springs, pneumatic devices, or electromagnetic devices instead of torsion springs. The installation position of the linkage mechanism is not limited to the left and right side walls. The guide strip 12d can be further integrated with electric heating wires to preheat and prevent freezing of the filter cloth in extremely low temperature environments. The displacement drive mechanism of the metal filter screen 11c is not limited to the cooperation method between the spiral groove of the guide shaft 11d and the follower connector 11e. For example, the lifting and lowering movement of the displacement seat 11b can be directly pushed by an electric push rod (linear actuator). One end of the electric push rod is fixed to the side wall of the cabinet or the base 11a, and the other end is connected to the displacement seat 11b. The extension stroke and speed are directly controlled by the controller 18. For example, a vertical rack can be fixed to the side of the displacement seat 11b, and the linear motion of lifting and lowering can be achieved by the rotation of the gear meshing with it. The gear can be driven by the discharge bucket 12a through the reversing gear set 14 to maintain mechanical linkage. In the above alternative drive methods, the coordination of metal filter screen lifting and filter screen winding can be achieved by mechanical transmission, or by the controller 18 coordinating the action timing and speed of the two independent drive sources through electrical signals.

[0083] In terms of filter lifecycle management, the consumption rate model can employ machine learning methods such as deep learning to process long-term series data. The cloud management platform 23 can integrate a digital twin model to simulate and extrapolate the operating status of the thermal management system.

[0084] To prevent secondary pollution, solenoid valves and pressure sensors can be added to the cleaning water circuit to achieve closed-loop control of the spray pressure. The water supply for the humidifying pump 8 and spray pipe 9 can utilize a circulating water system. A collection tank at the bottom of the cabinet collects cleaning wastewater, which is then reused after sedimentation and filtration. This system is suitable for water-scarce areas or outdoor environments without a regular water supply. Antistatic agents or surfactants can also be added to the cleaning water to reduce the adhesion of dust to the metal filter surface, thereby improving the cleaning effect.

[0085] The metal filter screen 11c can be made of corrosion-resistant materials such as stainless steel 304 or 316L, and the mesh size can be selected from 40 to 200 mesh according to the dust particle size distribution. The filter cloth 12c can be made of materials such as polyester fiber, polypropylene fiber, or glass fiber, and the basis weight and air permeability are determined according to the filtration accuracy and heat dissipation and ventilation requirements. In addition to open roll material, the filter medium of the filter cloth system 12 can also be a closed annular filter belt. The annular filter belt forms a circulation loop through the release tank 12a and the winding tank 12e. After passing through the metal filter screen wiping area, the filter belt enters the water tank immersion or airflow blowing cleaning area to remove the adsorbed dust before returning to the working position, which can significantly reduce filter material consumption.

[0086] The above description is merely a specific example of the present invention and does not constitute any limitation on the present invention. Obviously, those skilled in the art, after understanding the content and principles of the present invention, may make various modifications and changes in form and detail without departing from the principles and structure of the present invention; however, these modifications and changes based on the spirit of the present invention are still within the scope of protection of the claims of the present invention.

Claims

1. A method for intelligent thermal management of a high-frequency pulse power distribution cabinet, applied to the cabinet body (1), characterized in that, Includes the following steps: Heat dissipation channel operation steps: A forced air cooling heat dissipation channel is established through the air inlet (1c) and exhaust fan (10) located on the power distribution cabinet (1); Dual-layer filtration step: A dual-layer filter system is set at the air inlet end of the heat dissipation channel, with a metal filter system (11) as the outer layer and a filter cloth system (12) as the inner layer, to perform two-stage filtration on the air entering the heat dissipation channel; wherein, the filter cloth system (12) adopts a roll-type filter cloth (12c) that can be continuously replaced. Adaptive adjustment steps: The temperature inside the cabinet and the ambient temperature parameters are collected by the temperature sensor group (17), the pressure difference on both sides of the filter is monitored by the differential pressure sensor (16), and the controller (18) dynamically adjusts the speed of the exhaust fan (10) according to the temperature parameters and the differential pressure signal to maintain the ventilation capacity of the heat dissipation channel. Linked self-cleaning steps: When the preset cleaning trigger conditions are met, the controller (18) starts the drive motor (13), which drives the filter cloth system (12) to perform the winding and replacement of the filter cloth (12c). During the replacement, a gap area not covered by the filter cloth temporarily appears, providing additional ventilation compensation for heat dissipation in the cabinet. The metal filter (11c) in the metal filter system (11) is driven by the transmission mechanism to generate displacement movement. The relative movement between the metal filter (11c) and the wound old filter cloth (12c) forms a wiping and cleaning on the surface of the metal filter (11c).

2. The intelligent thermal management method according to claim 1, characterized in that, It also includes a step to reduce the heat generated inside the cabinet: a self-made diode assembly (2) is used in the RCD absorption circuit inside the power distribution cabinet (1). The self-made diode assembly (2) adopts a multi-group ultra-fast recovery diode series-parallel combination structure and a double PCB stacked structure (2a). The space of the positive and negative current paths is tightly fitted to reduce the parasitic inductance of the circuit. The absorption capacitor (2c) is integrated between the double PCB stacked structure (2a).

3. The intelligent thermal management method according to claim 1, characterized in that, The preset cleaning triggering conditions adopt multiple conditions for joint judgment, including at least one of the following: triggering regular cleaning when the pressure difference exceeds the first threshold, triggering enhanced cleaning when the pressure difference exceeds the second threshold, triggering preventive cleaning when the running timer reaches the preset cycle, and forcibly triggering cleaning when the cabinet temperature exceeds the limit and the exhaust fan (10) has reached the maximum speed.

4. The intelligent thermal management method according to claim 1, characterized in that, The transmission mechanism includes: a reversing gear set (14) disposed on both sides of the supply end of the filter cloth system (12), a guide shaft (11d) of the metal filter system (11), and a synchronous transmission belt (15) connecting each guide shaft (11d); the outer surface of the guide shaft (11d) is provided with a spiral groove, and the displacement seat (11b) cooperates with the spiral groove through the follower connector (11e) to convert the rotational motion of the guide shaft (11d) into the linear motion of the displacement seat (11b) carrying the metal filter (11c).

5. The intelligent thermal management method according to claim 1, characterized in that, The linkage self-cleaning step also includes: before cleaning, the metal filter screen (11c) is pre-washed from the inside of the cabinet to the outside of the cabinet through the spray pipe (9) located inside the cabinet body (1); during the wiping and cleaning process, water is sprayed onto the old filter cloth (12c) through the humidifying water pump (8) to enhance the wiping effect; during the cleaning period, the exhaust fan (10) is kept running to keep the cabinet in a slightly negative pressure state to prevent dust from spreading into the cabinet.

6. The intelligent thermal management method according to claim 1, characterized in that, It also includes filter consumable management steps: the consumption of filter cloth (12c) is measured by rotary encoder (20), the controller (18) establishes a consumption rate prediction model to predict the remaining available amount and provide graded early warning; at the same time, the cleaning pressure difference recovery rate of metal filter (11c) is calculated based on the pressure difference change before and after each cleaning to assess its performance degradation trend.

7. The intelligent thermal management method according to claim 6, characterized in that, In the filter consumable management steps: the controller (18) calculates the consumed length and remaining usable length of the filter cloth (12c) based on the change in roll diameter at the supply end of the filter cloth system (12) and the cumulative rotation angle collected by the rotary encoder (20), and predicts the remaining usable days. When the remaining length is lower than the preset threshold, a warning is issued in stages. When evaluating the performance of the metal filter (11c), the cleaning frequency is increased when the cleaning differential pressure recovery rate continues to decrease to the first degradation threshold, and a replacement alarm is issued when the rate drops to the second degradation threshold.

8. An intelligent thermal management system for a high-frequency pulse power distribution cabinet, characterized in that, include: The power distribution cabinet (1) has an air inlet (1c) on it. An exhaust fan (10) is installed on the cabinet (1) of the power distribution cabinet and forms a forced air cooling heat dissipation channel with the air inlet (1c); A dual-layer filter system is provided at the air inlet end of the heat dissipation channel, including a metal filter system (11) as the outer layer and a filter cloth system (12) as the inner layer; the filter cloth system (12) includes a roll-type filter cloth (12c) that can be continuously replaced. Temperature sensor group (17) is used to collect the temperature parameters inside the cabinet and the ambient temperature. Differential pressure sensor (16) is used to monitor the pressure difference across the filter screen; The drive motor (13) is used to drive the filter cloth system (12) to perform the winding and replacement of the filter cloth (12c), and through the transmission mechanism, it drives the metal filter (11c) in the metal filter system (11) to generate displacement movement, so that the metal filter (11c) and the old filter cloth (12c) generate relative movement to form wiping and cleaning. The controller (18) is connected to the temperature sensor group (17), differential pressure sensor (16), exhaust fan (10) and drive motor (13) by signal connection. It adjusts the speed of exhaust fan (10) according to temperature parameters and differential pressure signal, and starts drive motor (13) to perform linkage self-cleaning when preset cleaning trigger conditions are met.

9. The intelligent thermal management system according to claim 8, characterized in that, The metal filter system (11) further includes a displacement seat (11b) for carrying the metal filter (11c); the filter cloth system (12) further includes a discharge bucket (12a) for releasing the filter cloth (12c) and a winding bucket (12e) for collecting the filter cloth (12c); the transmission mechanism includes a reversing gear set (14) disposed at both ends of the discharge bucket (12a), a guide shaft (11d) and a synchronous transmission belt (15) connecting each guide shaft (11d). The guide shaft (11d) drives the displacement seat (11b) to carry the metal filter (11c) to move up and down through the cooperation of the spiral groove on its outer surface and the follower connector (11e).

10. The intelligent thermal management system according to claim 8, characterized in that, It also includes a communication module (19) for remotely transmitting thermal management status information to the operation and maintenance management platform to realize remote monitoring and parameter distribution; and a rotary encoder (20) installed at the supply end of the filter cloth system (12) for measuring the consumption of filter cloth (12c).

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