A waterproof high-voltage distribution box that can be quickly inspected and repaired.

Abstract

This invention discloses a waterproof high-voltage distribution box with rapid maintenance capability, relating to the field of high-voltage power distribution equipment. This invention solves the problems of poor space adaptability, inconvenient maintenance, and insufficient protection level of existing high-voltage distribution boxes. The box has a top window and a rear maintenance window, with recessed bosses at the windows. The cover plate has bent edges, and a silicone foam sealing gasket is placed between the two, secured with combination screws. The interior of the box is divided into upper and lower layers by a middle mounting plate, with positive and negative components mounted on the middle and bottom mounting plates respectively. Vulnerable fuses are concentrated at the maintenance windows, and a vent valve is installed on the outer wall of the box. This distribution box is suitable for compact spaces, has good waterproof sealing, and allows for rapid replacement of vulnerable parts, improving electrical safety and making it suitable for power distribution scenarios of new energy equipment.

Description

Technical Field

[0001] This invention belongs to the field of high-voltage power distribution equipment, specifically a waterproof high-voltage distribution box that can be quickly inspected and repaired. It is especially suitable for high-voltage power distribution scenarios in compact spaces such as new energy photovoltaic, energy storage, and new energy vehicle supporting facilities, and the protection level meets the requirements of IP65 and above. Background Technology

[0002] High-voltage distribution boxes are core components for distributing electrical energy in new energy equipment. The industry has clear and high requirements for their waterproof and dustproof protection levels (usually IP65 and above).

[0003] Existing high-voltage distribution boxes are mostly designed as flat metal enclosures with top openings, allowing for equipment installation and maintenance. However, the installation space for new energy equipment is typically quite compact, and the flat enclosure occupies a large amount of space in both length and width, making it difficult to adapt to confined spaces. Furthermore, the top-opening maintenance method requires removing the entire cover, a cumbersome procedure that hinders the rapid replacement of easily damaged parts. Additionally, the sealing structure of existing distribution boxes is mostly a single gasket seal, lacking a positioning structure between the cover and the enclosure, making the gasket prone to shifting and failing to meet the waterproofing requirements of complex outdoor environments. Moreover, the components in existing distribution boxes are mostly arranged in a single layer, with small spacing between positive and negative components, increasing the risk of short circuits and requiring precise positioning during installation, which is difficult. Therefore, developing a high-voltage distribution box that can adapt to compact spaces, enable rapid maintenance, and possess a high level of waterproof protection has become a pressing technical challenge for the industry. Summary of the Invention

[0004] This invention addresses the shortcomings of existing technologies by providing a waterproof high-voltage distribution box that allows for rapid maintenance. It solves the technical problems of poor space adaptability, low maintenance efficiency, insufficient waterproof protection, and high difficulty and safety hazards in the installation of components in existing high-voltage distribution boxes. The invention achieves a unified solution of compact space adaptability, rapid maintenance, high waterproof protection, and safe installation, thus meeting the usage requirements of new energy equipment.

[0005] To solve the above-mentioned technical problems, the present invention is achieved through the following technical solution: A waterproof high-voltage distribution box that can be quickly inspected includes a rear cover plate, a top cover plate, a box body, and a handle. The rear cover plate, top cover plate, and box body are all made of cold-rolled steel plate of the same material, and the surface is galvanized and powder-coated for corrosion protection, making it suitable for complex outdoor use environments.

[0006] The handles are U-shaped metal handles, two in number, symmetrically welded to the outer wall of the enclosure and arranged on the same side as the inspection window. The installation height of the handles matches the center height of the inspection window, which facilitates the handling, installation and maintenance of the enclosure.

[0007] The enclosure is a tall, hollow metal box with a compact design in both length and width, significantly reducing space occupation and adapting to the compact space layout of new energy equipment. The top of the enclosure has a top window, and the rear has a maintenance window. The top window is rectangular and serves as the main window for the overall installation of internal components. The maintenance window is also rectangular with a larger opening area than the top window, serving as a dedicated window for the inspection and replacement of vulnerable parts. Both the top and maintenance windows have integrally formed concave bosses on their edges, which are stepped structures with an inwardly recessed shape. The rear and top covers also have integrally formed bent edges, which are stepped structures with an outwardly protruding shape, fitting perfectly with the concave bosses to achieve precise positioning and alignment between the cover and the enclosure windows, preventing gasket misalignment.

[0008] Silicone foam sealing gaskets are installed between the top window and the top cover plate, and between the inspection window and the rear cover plate. The silicone foam sealing gaskets are closed-cell waterproof structures with a Shore hardness of 30-40 degrees, and perfectly match the contour of the concave boss. The thickness is 5-8mm. The top cover plate and the rear cover plate are fixed to the box body by several evenly distributed combination screws. The combination screws are cross-head pan screws with flat washers and spring washers to prevent loosening. The bent edges, concave bosses and silicone foam sealing gaskets form a triple sealing structure. After compression, the sealing gasket fits into the contact surface, improving the waterproof sealing effect of the distribution box. The protection level can reach IP67.

[0009] An intermediate mounting plate is horizontally welded and fixed inside the enclosure, dividing the internal chamber into two independent upper and lower layers. A bottom mounting plate is horizontally welded and fixed at the bottom of the enclosure. Both the intermediate and bottom mounting plates are made of insulated coated metal plates with an insulation resistance ≥1000MΩ. Positive and negative components are detachably mounted on the intermediate and bottom mounting plates respectively using bolts. This layered installation achieves physical isolation between the positive and negative components, with an isolation gap ≥50mm, to avoid the risk of short circuits.

[0010] The outer wall of the enclosure has threaded mounting holes. The vent valve is an industrial-grade waterproof vent valve, which is fixed in the mounting hole by screwing. The vent valve has a ventilation capacity of 50-100mL / minkPa, a waterproof rating of IP67, and connects the inside and outside of the enclosure. The installation height of the vent valve is higher than the highest arrangement height of the components inside the enclosure to prevent condensation from dripping onto the components. While achieving waterproofing, it also balances the atmospheric pressure inside and outside the distribution box, avoiding damage to the sealing structure due to pressure changes inside the box caused by changes in ambient temperature.

[0011] The vulnerable component inside the enclosure is a high-voltage fuse, which is a high-voltage fuse specifically designed for new energy applications. Its rated voltage is compatible with the distribution box. The fuses are centrally located in the lower section of the enclosure, corresponding to the maintenance window. Workers can operate them directly from behind the enclosure. One end of the fuse is electrically connected to the corresponding electrode components via a copper busbar. The copper busbar is made of pure copper and is tin-plated for corrosion protection. It is fixed to the fuse with bolts. The other end can be detachably installed on the middle or bottom mounting plate with bolts. The fuse can be directly inspected and replaced by opening the rear cover without disassembling other components, enabling rapid maintenance.

[0012] The present invention has the following advantages over the prior art: (1) The tall box structure is compactly designed in the length and width directions, which greatly reduces the space occupation and is suitable for the compact installation space of new energy photovoltaic, energy storage, new energy vehicle supporting equipment, etc. It solves the problem of poor space adaptability of existing flat distribution boxes. In addition, the metal components are treated with anti-corrosion to adapt to the complex outdoor use environment. (2) The split functional design of the top window and the rear maintenance window allows vulnerable parts to be centrally arranged in the corresponding area of ​​the maintenance window. The maintenance window has a large opening area, and vulnerable parts can be quickly replaced directly by opening the rear cover without disassembling other components. The maintenance and replacement time is ≤5 minutes, which is more than 80% more efficient than the existing top maintenance method. (3) The concave boss at the window and the bent edge of the cover plate are fitted together and positioned, and a closed-cell silicone foam sealing gasket and anti-loosening combination screw that match the contour are used to form a triple sealing structure. After the sealing gasket is squeezed, it fits against the contact surface, effectively preventing the sealing gasket from shifting. The waterproof protection level of the distribution box can reach IP67, which meets the protection requirements of complex outdoor use environment. (4) Both the middle mounting plate and the bottom mounting plate inside the box are insulating metal plates, which realize the layered physical isolation of positive and negative components. The isolation distance is ≥50mm and the insulation resistance is ≥1000MΩ. The structure avoids the risk of short circuit and greatly improves the electrical safety performance of the distribution box. (5) A waterproof and breathable valve is installed on the upper part of the box. The installation height is higher than the highest arrangement height of the components. While achieving IP67 waterproofing, the pressure inside and outside the box is balanced in real time to avoid pressure changes from damaging the sealing structure. At the same time, it prevents condensation inside the box from dripping onto the components, ensuring the long-term stable use of the distribution box. (6) The layered installation of components disperses the components, reducing the difficulty of installation and improving the installation efficiency. The two U-shaped handles are symmetrically arranged and matched with the center height of the maintenance window, further improving the convenience of installation and maintenance of the distribution box.

[0013] (7) All components adopt a standardized, detachable connection design, which facilitates production, processing, transportation and subsequent maintenance, and reduces production and usage costs.

[0014] Of course, any product implementing this invention does not necessarily need to achieve all of the advantages described above at the same time. Attached Figure Description

[0015] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the description of the embodiments 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.

[0016] Figure 1 This is a schematic diagram of the overall structure of the distribution box of the present invention; Figure 2 This is a schematic diagram showing the window and protrusion structure of the housing of the present invention; Figure 3 This is a schematic diagram of the sealing connection structure between the cover plate and the box body of the present invention; Figure 4 This is a schematic diagram of the layered installation structure inside the housing of the present invention; Figure 5 This is a schematic diagram of the arrangement of the inspection window and vulnerable parts of the present invention; The attached diagram lists the components represented by each number as follows: 100-Rear cover plate, 101-Top window, 102-Inspection window, 103-Concave boss, 104-Bent edge, 105-Combination screw, 106-Silicone foam sealing gasket; 200-Top cover plate, 201-Intermediate mounting plate, 202-Ventilator, 203-Bottom mounting plate; 300-Enclosure, 301-Fuse, 302-Copper busbar. Detailed Implementation

[0017] 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, and 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.

[0018] In the description of this invention, it should be understood that the terms "top", "upper", "above", "uniformly distributed", etc., which indicate orientation or positional relationship, are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the components or elements referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as limiting this invention.

[0019] The specific embodiments of the present invention will be further described in detail below with reference to the accompanying drawings. In this embodiment, the rated voltage of the distribution box is 10kV, which is suitable for new energy storage equipment, and the protection level requirement is IP67.

[0020] The waterproof high-voltage distribution box of the present invention, which allows for rapid maintenance, comprises a rear cover plate 100, a top cover plate 200, a box body 300, and a handle 400. All metal components are made of cold-rolled steel plates with galvanized and powder-coated anti-corrosion treatment. The box body 300 is designed as a tall structure, with a length of 400mm, a width of 300mm, and a height of 800mm. Compared with the traditional flat box body (length 600mm, width 500mm, height 300mm), it significantly reduces the space occupied in the length and width directions, perfectly adapting to the compact installation space of new energy storage equipment.

[0021] The top window 101 on the top of the enclosure 300 is a rectangular window of 300*200mm, which serves as the main window for component installation. During installation, first unscrew the combination screws 105, open the top cover plate 200, and detachably install the negative component onto the middle mounting plate 201 using M6 bolts. The positive component is detachably installed onto the bottom mounting plate 203 using M6 bolts. The middle mounting plate 201 divides the interior of the enclosure into layers, and the isolation distance between the positive and negative components is 60mm, achieving physical isolation. This structurally eliminates the safety hazard of short circuit due to contact between the positive and negative terminals. At the same time, the layered installation method disperses the components, reduces the difficulty of component installation, and improves installation efficiency.

[0022] After the components are installed, a 6mm thick closed-cell silicone foam sealing gasket 106 with a Shore hardness of 35 is laid on the concave boss 103 of the top window 101. The sealing gasket is perfectly matched with the contour of the concave boss 103. The bent edge 104 of the top cover plate 200 is aligned with the concave boss 103. The top cover plate 200 is threaded to the housing 300 by 12 evenly distributed M5 cross-slot pan head combination screws 105. The combination screws are equipped with flat washers and spring washers to prevent loosening. The fitting structure between the bent edge 104 and the concave boss 103 forms a uniform compression on the silicone foam sealing gasket 106, so that the sealing gasket is tightly attached to the contact surface to ensure the sealing effect.

[0023] The vulnerable component of the distribution box is a 10kV new energy-specific high-voltage fuse 301, of which there are four. They are centrally located in the lower area of ​​the box corresponding to the inspection window 102. The inspection window 102 is a rectangular window of 350*400mm. During routine maintenance, the staff only needs to use a screwdriver to unscrew the 16 M5 combination screws 105 on the back cover plate 100, open the back cover plate 100, and directly observe the working status of the fuse 301. If replacement is required, simply unscrew the M8 fixing bolts at both ends of the fuse 301, disconnect the connection with the copper busbar 302 and the mounting plate, and the fuse 301 can be taken out from the inspection window 102. After replacing the new fuse, the operation is reversed. The entire maintenance and replacement process does not require moving other components, and the operation time can be controlled within 5 minutes, which greatly improves maintenance efficiency.

[0024] After maintenance, the same sealing and fixing method as the top cover plate 200 is adopted. A silicone foam sealing gasket 106 is laid on the concave boss 103 of the maintenance window (102). The bent edge (104) of the rear cover plate 100 is fitted and aligned with the concave boss 103 and fixed by combination screws 105 to ensure the waterproof sealing effect of the maintenance window 102. An M12 threaded mounting hole is opened on the upper part of the outer wall of the box 300. An IP67 waterproof vent valve 202 with a permeability of 80mL / minkPa is fixed in the mounting hole by threading. The installation height of the vent valve is 700mm, which is higher than the maximum arrangement height of the components in the box by 600mm. This can balance the pressure inside and outside the box in real time, avoid the pressure inside the box from rising or falling due to changes in ambient temperature (-40℃~85℃), and prevent damage to the sealing structure. At the same time, it prevents condensation inside the box from dripping onto the components, ensuring the long-term waterproof performance and safety of the distribution box.

[0025] The handle 400 is a U-shaped metal handle. Two handles are symmetrically welded to the outer wall of the enclosure 300 on the same side as the inspection window 102. The installation height is 400mm, which matches the center height of the inspection window 102, making it convenient for staff to move and fix the enclosure during installation and maintenance, thus improving the ease of operation.

[0026] The distribution box in this embodiment has been tested and has a waterproof protection rating of IP67. It can be immersed in 1 meter of water for 30 minutes without water ingress. The replacement time for vulnerable parts is ≤5 minutes, and the insulation resistance of the positive and negative components is ≥1500MΩ, which fully meets the usage requirements of new energy storage equipment.

[0027] The preferred embodiments of the present invention disclosed above are merely illustrative of the invention. These preferred embodiments do not exhaustively describe all details, nor do they limit the invention to the specific implementations described. Clearly, many modifications and variations can be made based on the content of this specification. This specification selects and specifically describes these embodiments to better explain the principles and practical applications of the invention, thereby enabling those skilled in the art to better understand and utilize the invention. The invention is limited only by the claims and their full scope and equivalents.

Claims

1. A waterproof high-voltage distribution box capable of rapid maintenance, characterized in that, Includes a rear cover (100), a top cover (200), a housing (300), and a handle (400); The enclosure (300) is a tall metal enclosure with a top window (101) on the top and an inspection window (102) at the rear. The top window (101) is adapted to cover the top cover plate (200), and the inspection window (102) is adapted to cover the rear cover plate (100). The edges of the top window (101) and the inspection window (102) are integrally formed with concave bosses (103), and the edges of the rear cover plate (100) and the top cover plate (200) are integrally formed with bent edges (104) that fit into the concave bosses (103).

2. The waterproof high-voltage distribution box with rapid maintenance according to claim 1, characterized in that, Silicone foam sealing gaskets (106) are laid between the top window (101) and the top cover plate (200), and between the inspection window (102) and the rear cover plate (100). The silicone foam sealing gaskets (106) have a closed-cell structure and match the contour of the concave boss (103). The top cover plate (200) and the rear cover plate (100) are both threadedly fixed to the box body (300) by a number of evenly distributed combination screws (105).

3. The waterproof high-voltage distribution box with rapid maintenance according to claim 1, characterized in that, The housing (300) has an intermediate mounting plate (201) welded and fixed inside. The intermediate mounting plate (201) divides the internal chamber of the housing (300) into two independent upper and lower layers. The bottom of the housing (300) has a bottom mounting plate (203) welded and fixed at the bottom. Both the intermediate mounting plate (201) and the bottom mounting plate (203) are insulating metal plates. The positive and negative components are detachably mounted on the intermediate mounting plate (201) and the bottom mounting plate (203) respectively by bolts.

4. A waterproof high-voltage distribution box capable of rapid maintenance according to claim 1, characterized in that, An installation hole is provided on the outer side wall of the box (300), and the vent valve (202) is fixed in the installation hole by screwing. The vent valve (202) is a waterproof vent valve and connects the inside and outside of the box (300).

5. A waterproof high-voltage distribution box capable of rapid maintenance according to claim 3, characterized in that, The vulnerable component inside the enclosure (300) is a fuse (301). The fuse (301) is centrally located in the lower part of the enclosure (300) corresponding to the inspection window (102). One end of the fuse (301) is electrically connected to the corresponding electrode component through a copper busbar (302) and fixed by bolts. The other end is detachably installed on the intermediate mounting plate (201) or the bottom mounting plate (203) by bolts.

6. A waterproof high-voltage distribution box capable of rapid maintenance according to any one of claims 1-5, characterized in that, The handle (400) is a U-shaped metal handle. There are two of them, which are symmetrically welded to the outer wall of the box (300) and arranged on the same side as the inspection window (102). The installation height of the handle (400) matches the center height of the inspection window (102).

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