Liquid-cooled large-capacity terminal bus and assembling method thereof

Abstract

The application discloses a liquid-cooled large-capacity terminal bus and an assembling method thereof. Ground wire row grooves and a plurality of phase row grooves are formed in an aluminum profile shell, and ground wire rows and phase rows are inserted into the grooves. Upper supports are arranged at both ends of the aluminum profile shell, and the ground wire rows and the phase rows are pressed and covered in the aluminum profile shell through the upper supports. An insulating film is laid in the aluminum profile shell, and the insulating film extends from one side of the aluminum profile shell to the other side. The insulating film is sequentially laid along the ground wire row grooves and the phase row grooves. The ground wire rows and the phase rows in the liquid-cooled large-capacity terminal bus are directly installed in the ground wire row grooves and the phase row grooves of the aluminum profile shell through the insulating film. At this time, the heat generated by the ground wire rows and the phase rows is directly conducted to the aluminum profile shell. Three liquid cooling grooves are arranged in the aluminum profile shell and staggered with four groups of phase row grooves. Refrigerant liquid enters from a liquid cooling input joint, flows through the liquid cooling grooves, and then flows out from a liquid cooling output joint, so that the temperature rise of the phase rows in the phase row grooves is reduced.

Description

Technical Field

[0001] This invention belongs to the field of terminal busbar technology, and specifically relates to a liquid-cooled large-capacity terminal busbar and its assembly method. Background Technology

[0002] A terminal busbar is typically a power distribution device consisting of copper conductors and an aluminum profile shell. It supplies power to specific equipment via matching plug-in boxes and other devices.

[0003] Existing terminal busbars typically consist of an aluminum profile shell, copper busbars, and an insulating support. The copper busbars are mounted inside the aluminum profile shell via the insulating support. Traditional terminal busbars are generally cooled by flowing air. Air cooling is easily affected by the external environment. The higher the temperature of the external environment, the worse the air cooling effect becomes, making it difficult to achieve safe operation of small busbars with high current. Summary of the Invention

[0004] The purpose of this invention is to provide a liquid-cooled large-capacity terminal busbar and its assembly method, which uses liquid cooling to reduce the temperature rise of the phase busbar in the terminal busbar.

[0005] To solve the above technical problems, the present invention provides a liquid-cooled large-capacity terminal busbar, including an aluminum profile shell, wherein a ground wire slot and a plurality of phase slots are provided inside the aluminum profile shell;

[0006] Ground busbars and phase busbars are respectively inserted into the ground busbar slot and the plurality of phase busbar slots;

[0007] The aluminum profile housing is provided with upper brackets at both ends, and the ground busbar and multiple phase busbars are pressed into the aluminum profile housing by the upper brackets.

[0008] An insulating film is laid inside the aluminum profile shell. The insulating film extends from one side of the aluminum profile shell to the other side, and the insulating film is laid sequentially along the ground wire groove and the multiple phase grooves.

[0009] The insulating film extends from one end of the aluminum profile housing to the other end;

[0010] A liquid cooling tank is provided in the aluminum profile shell between adjacent phase row slots, and a refrigerant is circulated in the liquid cooling tank to reduce the temperature rise of the phase row in the phase row slot.

[0011] Preferably, the liquid cooling tank is a square cavity that extends along the length of the aluminum profile shell, and both ends of the liquid cooling tank are sealed with plugs, so that the liquid cooling tank forms a closed cavity.

[0012] Preferably, the bottom of the aluminum profile shell is provided with multiple water pipe joints, which pass through the aluminum profile shell and communicate with the liquid cooling tank;

[0013] Each set of liquid cooling tanks is equipped with two water pipe joints, one of which is a liquid cooling input joint and the other is a liquid cooling output joint. The refrigerant enters from the liquid cooling input joint, flows through the liquid cooling tank, and then flows out from the liquid cooling output joint.

[0014] Preferably, an insulating film extends from one side of the aluminum profile housing to the other side and lays the ground wire groove and multiple phase wire grooves, thereby insulating the ground wire and multiple phase wires through the insulating film.

[0015] Preferably, multiple insulating films are stacked and extend from one side of the aluminum profile housing to the other, and the ground wire groove and multiple phase grooves are laid, so that the ground wire and multiple phases are insulated by the insulating films.

[0016] Preferably, both the ground wire slot and the phase slot are U-shaped slots for inserting the ground wire and multiple phase slots, wherein the ground wire slot and the phase slot are narrow on the outside and wide on the inside, and the slot openings are chamfered.

[0017] Preferably, each of the ground wire slots and the phase slots is provided with insulating pressure blocks at both ends.

[0018] Preferably, both sides of the aluminum profile shell are provided with tailing clamping strips, which tightly adhere the insulating film to the inner wall of the aluminum profile shell.

[0019] Preferably, both sides of the aluminum profile shell are provided with tailing clamping strips, which tightly adhere the insulating film to the inner wall of the aluminum profile shell.

[0020] The present invention also provides a method for assembling a liquid-cooled large-capacity terminal bus, comprising the following steps:

[0021] Step A: Film pretreatment. First, the insulating film is heated with hot air. Then, under the action of the stainless steel pillars of the mold, five semi-circular grooves are formed, corresponding to the lower edges of the ground busbar and the four phase busbars, respectively. Cold air is used to cool and shape the insulating film.

[0022] Step B: Then, place the pre-treated film into the aluminum profile shell, and align the five semi-circular grooves with the ground wire slot and the four phase slots opened inside the aluminum profile shell, respectively.

[0023] Step C: Next, insert the ground busbar and the four phase busbars into the ground busbar slot and the phase busbar slot respectively. At this time, the ground busbar and the four phase busbars are inserted into the ground busbar slot and the phase busbar slot under the wrapping of the insulating film.

[0024] Step D: The edges of the aluminum profile shell end face are treated with a scraper, and the end face is expanded in a U-shape using a hydraulic tool to give it an expansion arc so that the insulating film does not contact the edges.

[0025] Step E: Then install the finishing clamping strip on both sides of the aluminum profile shell, pressing the edge of the insulating film, so that the finishing clamping strip tightly adheres the edge of the insulating film to the aluminum profile shell;

[0026] Step F: Next, seal both ends of the liquid cooling tank with plugs to form a closed cavity; the refrigerant enters from the liquid cooling inlet, flows through the liquid cooling tank and then flows out from the liquid cooling outlet, thereby reducing the temperature rise of the phase pack in the phase pack tank;

[0027] Step G: Next, install the upper bracket on top of the aluminum profile shell so that it covers and fixes the ground busbar and the four phase buses;

[0028] Step H: Finally, secure the middle of the cable tie to the upper bracket with screws; wrap both ends around to the bottom of the aluminum profile shell and connect them to the aluminum profile shell with locking bolts.

[0029] Overall, the beneficial effects of the above-described technical solutions conceived by this invention compared with the prior art are as follows:

[0030] The ground busbar and multiple phase busbars in this liquid-cooled high-capacity terminal busbar are directly installed in the ground busbar slots and multiple phase busbar slots of the aluminum profile shell through an insulating film. At this time, the heat generated by the ground busbar and multiple phase busbars is directly conducted to the aluminum profile shell. The aluminum profile shell has three liquid cooling tanks and four sets of phase busbar slots arranged alternately. The refrigerant enters from the liquid cooling inlet, flows through the liquid cooling tank, and flows out from the liquid cooling outlet, thereby reducing the temperature rise of the phase busbars in the phase busbar slots. Attached Figure Description

[0031] Figure 1 This is a first-view structural schematic diagram of a liquid-cooled large-capacity terminal bus provided by the present invention;

[0032] Figure 2 This is a schematic diagram of the structure of a liquid-cooled large-capacity terminal bus provided by the present invention from a second perspective;

[0033] Figure 3 This is a structural schematic diagram of the aluminum profile shell provided by the present invention;

[0034] Figure 4 This is a front view of a liquid-cooled large-capacity terminal bus provided by the present invention;

[0035] Figure 5 This is a cross-sectional view of the location of a water pipe joint for a large-capacity liquid-cooled terminal busbar provided by the present invention;

[0036] Figure 6 This is a cross-sectional view of the locking bolt position of a large-capacity liquid-cooled terminal busbar provided by the present invention.

[0037] The meanings of the markings in the attached diagram are as follows:

[0038] In the diagram: 1. Aluminum profile shell; 2. Ground busbar; 3. Phase busbar; 4. Upper bracket; 5. Insulating film; 6. Liquid cooling tank; 7. Plug; 8. Water pipe joint; 9. Insulating pressure block; 10. Finishing clamping strip; 11. Cable tie; 12. Locking bolt; 101. Ground busbar groove; 102. Phase busbar groove. Detailed Implementation

[0039] The present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments. The advantages and features of the present invention will become clearer from the following description and claims. It should be noted that the drawings are all in a very simplified form and use non-precise proportions, and are only used to facilitate and clarify the illustration of the embodiments of the present invention.

[0040] In the description of this invention, it should be understood that the terms "center", "longitudinal", "lateral", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0041] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art will understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0042] Example

[0043] This invention provides a liquid-cooled, high-capacity terminal busbar. Please refer to [link / reference]. Figure 1-3The device includes an aluminum profile shell 1, in which a ground wire slot 101 and multiple phase slots 102 are formed; ground wire busbars 2 and phase busbars 3 are respectively inserted into the ground wire slot 101 and the multiple phase slots 102; upper supports 4 are respectively provided at both ends of the aluminum profile shell 1, and the ground wire busbars 2 and the multiple phase busbars 3 are pressed into the aluminum profile shell 1 by the upper supports 4; an insulating film 5 is laid inside the aluminum profile shell 1, the insulating film 5 extends from one side of the aluminum profile shell 1 to the other side, and the insulating film 5 is laid sequentially along the ground wire slot 101 and the multiple phase slots 102; the insulating film 5 extends from one end of the aluminum profile shell 1 to the other end.

[0044] Furthermore, a liquid cooling tank 6 is provided in the aluminum profile shell 1 between adjacent phase row grooves 102, and a refrigerant is circulated in the liquid cooling tank 6, thereby reducing the temperature rise of the phase row 3 in the phase row groove 102.

[0045] The ground busbar 2 and multiple phase busbars 3 in the liquid-cooled high-capacity terminal busbar are directly installed in the ground busbar groove 101 and multiple phase busbar grooves 102 of the aluminum profile shell 1 through the insulating film 5. At this time, the heat generated by the ground busbar 2 and multiple phase busbars 3 is directly conducted to the aluminum profile shell 1. The aluminum profile shell 1 is provided with three liquid cooling grooves 6 and four sets of phase busbar grooves 102 arranged alternately. The refrigerant enters from the liquid cooling inlet joint, flows through the liquid cooling groove, and flows out from the liquid cooling outlet joint, thereby reducing the temperature rise of the phase busbars in the phase busbar grooves 102.

[0046] Specifically, such as Figure 4 and Figure 5 As shown, the liquid cooling tank 6 is a square cavity that extends along the length of the aluminum profile shell 1, and both ends of the liquid cooling tank 6 are sealed by plugs 7, so that the liquid cooling tank 6 forms a closed cavity.

[0047] Furthermore, such as Figure 6 As shown, the bottom of the aluminum profile shell 1 is provided with multiple water pipe joints 8, which pass through the aluminum profile shell 1 and are connected to the liquid cooling tank 6; each group of liquid cooling tanks 6 is provided with two water pipe joints 8, one of which is a liquid cooling input joint and the other is a liquid cooling output joint. The refrigerant enters from the liquid cooling input joint, flows through the liquid cooling tank 6 and then flows out from the liquid cooling output joint.

[0048] In some embodiments, an insulating film 5 extends from one side of the aluminum profile housing 1 to the other side and lays the ground wire groove 101 and a plurality of phase grooves 102, thereby insulating the ground wire 2 and the plurality of phases 3 through the insulating film 5.

[0049] In some embodiments, multiple insulating films 5 are stacked and extend from one side of the aluminum profile housing 1 to the other, and the ground wire groove 101 and multiple phase grooves 102 are laid, so that the ground wire 2 and multiple phase 3 are insulated by the insulating films 5.

[0050] Furthermore, both the ground wire slot 101 and the phase slot 102 are U-shaped slots for inserting the ground wire 2 and multiple phase wires 3. The ground wire slot 101 and the phase slot 102 are narrow on the outside and wide on the inside, and the slot openings are chamfered to guide the pressing of the ground wire 2 or the phase wire 3, and allow slight deformation of the bottom of the ground wire 2 or the phase wire 3 and the insulating film 5 without affecting the clamping force of the U-shaped slot on the ground wire 2 or the phase wire 3.

[0051] Specifically, each of the ground wire slots 101 and the phase slots 102 is provided with an insulating pressure block 9 at both ends, and the ground wire 2 or the phase wire 3 is pressed into the ground wire slots 101 and the phase slots 102 by the insulating pressure block 9.

[0052] Specifically, both sides of the aluminum profile shell 1 are provided with tailing clamping strips 10, which tightly attach the insulating film 5 to the inner wall of the aluminum profile shell 1 to meet the insulation distance requirements.

[0053] Furthermore, each set of upper brackets 4 is equipped with cable ties 11, the middle of which is fixedly connected to the upper bracket 4 by screws; both ends are wrapped around to the bottom of the aluminum profile shell 1 and connected to the aluminum profile shell 1 by locking bolts 12.

[0054] In some embodiments, the bottom of the aluminum profile housing 1 is provided with two nut grooves, and a locking nut is slidably connected in the nut groove. The locking bolt 12 passes through the cable tie 11 and is connected to the locking nut in the nut groove, so that the upper bracket 4 is pressed onto the ground busbar 2 and multiple phase busbars 3 by the cable tie 11.

[0055] In some embodiments, the upper bracket 4 is provided with a plurality of copper busbar slots, and the ground busbar 2 and the plurality of phase busbars 3 are correspondingly inserted into the copper busbar slots.

[0056] The present invention also provides a method for assembling a liquid-cooled large-capacity terminal bus, comprising the following steps:

[0057] Step A: Film pretreatment. First, the insulating film 5 is heated with hot air. Then, under the action of the stainless steel column of the mold, five semi-circular grooves are formed, corresponding to the lower edges of the ground wire 2 and the four phase wires 3 respectively. The insulating film 5 is then cooled with cold air to set its shape.

[0058] Step B: Then, the pre-treated film is placed inside the aluminum profile shell 1, and the five semi-circular grooves correspond to the ground wire slot 101 and the four phase slots 102 opened inside the aluminum profile shell 1, respectively.

[0059] Step C: Next, insert the ground busbar 2 and the four phase busbars 3 into the ground busbar slot 101 and the phase busbar slot 102 respectively. At this time, the ground busbar 2 and the four phase busbars 3 are inserted into the ground busbar slot 101 and the phase busbar slot 102 under the wrapping of the insulating film 5.

[0060] Step D: The edges of the aluminum profile shell 1 end face are treated with a scraper, and the end face is expanded in a U-shape using a hydraulic tool to give it an expansion arc so that the insulating film 5 does not contact the edges.

[0061] Step E: Then install the finishing clamping strip 10 on both sides of the aluminum profile shell 1, and press the edge of the insulating film 5, so that the finishing clamping strip 10 tightly adheres the edge of the insulating film 5 to the aluminum profile shell 1.

[0062] Step F: Next, the plugs 7 are used to seal both ends of the liquid cooling tank 6, so that the liquid cooling tank 6 forms a closed cavity; the refrigerant enters from the liquid cooling inlet connector, flows through the liquid cooling tank 6 and then flows out from the liquid cooling outlet connector, thereby reducing the temperature rise of the phase row 3 in the phase row tank 102.

[0063] Step G: Next, install the upper bracket 4 on top of the aluminum profile shell 1 so that it covers and fixes the ground busbar 2 and the four phase busbars 3;

[0064] Step H: Finally, fix the middle part of the cable tie 11 to the upper bracket 4 with screws; wrap both ends around to the bottom of the aluminum profile shell 1 and connect them to the aluminum profile shell 1 with locking bolts 12.

[0065] The ground busbar and multiple phase busbars in this liquid-cooled high-capacity terminal busbar are directly installed in the ground busbar slots and multiple phase busbar slots of the aluminum profile shell through an insulating film. At this time, the heat generated by the ground busbar and multiple phase busbars is directly conducted to the aluminum profile shell. The aluminum profile shell has three liquid cooling tanks and four sets of phase busbar slots arranged alternately. The refrigerant enters from the liquid cooling inlet, flows through the liquid cooling tank, and flows out from the liquid cooling outlet, thereby reducing the temperature rise of the phase busbars in the phase busbar slots.

[0066] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A liquid-cooled high-capacity terminal busbar, characterized in that, It includes an aluminum profile shell (1), and the aluminum profile shell (1) has a ground wire groove (101) and a plurality of phase grooves (102). Ground busbars (2) and phase busbars (3) are respectively inserted into the ground busbar slot (101) and the plurality of phase busbar slots (102); The aluminum profile shell (1) is provided with upper brackets (4) at both ends, and the ground busbar (2) and multiple phase busbars (3) are pressed into the aluminum profile shell (1) by the upper brackets (4); An insulating film (5) is laid inside the aluminum profile shell (1). The insulating film (5) extends from one side of the aluminum profile shell (1) to the other side, and the insulating film (5) is laid sequentially along the ground wire groove (101) and the multiple phase grooves (102). The insulating film (5) extends from one end of the aluminum profile shell (1) to the other end; A liquid cooling tank (6) is provided in the aluminum profile shell (1) between adjacent phase row tanks (102), and a refrigerant is circulated in the liquid cooling tank (6) to reduce the temperature rise of the phase row (3) in the phase row tank (102).

2. The liquid-cooled large-capacity terminal busbar according to claim 1, characterized in that, The liquid cooling tank (6) is a square cavity that extends along the length of the aluminum profile shell (1), and both ends of the liquid cooling tank (6) are sealed by plugs (7) to form a closed cavity.

3. The liquid-cooled large-capacity terminal busbar according to claim 2, characterized in that, The bottom of the aluminum profile shell (1) is provided with multiple water pipe joints (8), and the water pipe joints (8) pass through the aluminum profile shell (1) and are connected to the liquid cooling tank (6); Each of the liquid cooling tanks (6) is equipped with two water pipe joints (8), one of which is a liquid cooling input joint and the other is a liquid cooling output joint. The refrigerant enters from the liquid cooling input joint, flows through the liquid cooling tank (6) and then flows out from the liquid cooling output joint.

4. The liquid-cooled large-capacity terminal busbar according to claim 1, characterized in that, An insulating film (5) extends from one side of the aluminum profile shell (1) to the other side and lays the ground wire groove (101) and multiple phase grooves (102), and the insulating film (5) insulates the ground wire (2) and multiple phases (3).

5. A liquid-cooled large-capacity terminal busbar according to claim 1, characterized in that, Multiple insulating films (5) are stacked and used to extend from one side of the aluminum profile shell (1) to the other side, and to lay the ground wire groove (101) and multiple phase grooves (102), thereby insulating the ground wire (2) and multiple phases (3) through the insulating films (5).

6. A liquid-cooled large-capacity terminal busbar according to claim 1, characterized in that, The ground wire slot (101) and the phase slot (102) are both U-shaped slots used to insert the ground wire (2) and multiple phase wires (3). The ground wire slot (101) and the phase slot (102) are both narrow on the outside and wide on the inside, and the slot openings are chamfered.

7. A liquid-cooled large-capacity terminal busbar according to claim 1, characterized in that, Insulating blocks (9) are provided at both ends of each of the ground wire slots (101) and the phase slots (102).

8. A liquid-cooled large-capacity terminal busbar according to claim 1, characterized in that, Both sides of the aluminum profile shell (1) are provided with tailing clamping strips (10), and the insulating film (5) is tightly attached to the inner wall of the aluminum profile shell (1) by the tailing clamping strips (10).

9. A liquid-cooled large-capacity terminal busbar according to claim 1, characterized in that, Each of the upper brackets (4) is equipped with cable ties (11), the middle of which is fixedly connected to the upper bracket (4) by screws; both ends are wrapped around to the bottom of the aluminum profile shell (1) and connected to the aluminum profile shell (1) by locking bolts (12).

10. A method for assembling a liquid-cooled, high-capacity terminal busbar, characterized in that, Includes the following steps: Step A: Film pretreatment. First, the insulating film (5) is heated with hot air. Then, five semi-circular grooves are formed under the action of the stainless steel column of the mold, corresponding to the lower edge of the ground line (2) and the four phase line (3), respectively. The insulating film (5) is then cooled with cold air to set its shape. Step B: Then, the pre-treated film is placed inside the aluminum profile shell (1), and the five semi-circular grooves correspond to the ground wire slot (101) and the four phase slots (102) opened inside the aluminum profile shell (1). Step C: Next, insert the ground busbar (2) and the four phase busbars (3) into the ground busbar slot (101) and the phase busbar slot (102) respectively. At this time, the ground busbar (2) and the four phase busbars (3) are inserted into the ground busbar slot (101) and the phase busbar slot (102) under the wrapping of the insulating film (5). Step D: The corners of the end face of the aluminum profile shell (1) are treated with a scraper, and the end face is expanded in a U-shape using a hydraulic tooling to give it an expansion arc so that the insulating film (5) does not contact the corners; Step E: Then install the finishing clamping strip (10) on both sides of the aluminum profile shell (1) and press the edge of the insulating film (5) so that the finishing clamping strip (10) tightly adheres the edge of the insulating film (5) to the aluminum profile shell (1). Step F: Next, the plugs (7) are used to seal both ends of the liquid cooling tank (6) so that the liquid cooling tank (6) forms a closed cavity; the refrigerant enters from the liquid cooling inlet connector, flows through the liquid cooling tank (6) and then flows out from the liquid cooling outlet connector, thereby reducing the temperature rise of the phase pack (3) in the phase pack tank (102); Step G: Next, install the upper bracket (4) on top of the aluminum profile shell (1) so that it covers and fixes the ground busbar (2) and the four phase busbars (3). Step H: Finally, the middle part of the cable tie (11) is fixedly connected to the upper bracket (4) by screws; the two ends are wrapped around to the bottom of the aluminum profile shell (1) and connected to the aluminum profile shell (1) by locking bolts (12).

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