Liquid-cooled modular converter and cabinet thereof

Abstract

The application provides a liquid-cooled modular converter and a cabinet thereof, and belongs to the field of power conversion devices.The cabinet of the liquid-cooled modular converter comprises a cabinet body, a partition layer is arranged in the cabinet body and is used for dividing the space in the cabinet body into an upper space and a lower space, the left and right sides of the partition layer are connected with the left and right side walls of the cabinet body, respectively, and the front and back sides of the partition layer are connected with the front and back side walls of the cabinet body, respectively, and spaces for wiring and air flow are left between the front and back sides of the partition layer and the front and back side walls of the cabinet body, and the lower space of the cabinet body is provided with a liquid cooling plate, and the length direction of the liquid cooling plate is in the same direction as the front-back direction of the cabinet body.The liquid-cooled modular converter comprises the cabinet mentioned above.The application rearranges the internal elements of the cabinet of the liquid-cooled modular converter, enhances the heat dissipation effect, and improves the space utilization.

Description

Technical Field

[0001] The present invention belongs to the field of power conversion devices, and particularly relates to a liquid-cooled modular converter and its chassis. Background Art

[0002] With the wide application of clean energy, more and more energy storage devices are being constructed for wind power generation and solar power generation. The core device in the energy storage device is the energy storage converter, which generally has a modular structure for convenient installation and replacement.

[0003] The main function of the energy storage converter is to convert alternating current into direct current to charge the battery during the low load period of the power grid, and convert the battery direct current into alternating current to feed back to the power grid during the peak period. Some components inside the energy storage converter generate a large amount of heat. If the waste heat generated by these components cannot be discharged in time, it is easy to cause the internal temperature of the energy storage converter to rise, affecting the efficiency and the service life of the device. However, with the continuous increase in usage requirements, pursuing higher power density and smaller volume has become an industry trend, but this poses higher challenges to heat dissipation.

[0004] The existing Chinese patent application with publication number CN120811080A discloses an energy storage converter. The energy storage converter includes a chassis, electrical components, and a refrigeration component. A closed inner cavity is formed inside the chassis, and the electrical components and the refrigeration component are arranged inside the inner cavity; the refrigeration component includes a heat exchange device (i.e., a liquid-cooled plate) and a air supply device (i.e., a fan). The heat exchange device is used to directly cool the power components and inductance components, and is installed on the front side wall inside the chassis. Together with the air supply device, it can make the air inside the chassis circulate along the left, rear, right, and front directions. The electrical components are arranged in three layers. Most of the components on the bottom layer are high-heat-generating components, and the power components and inductance components with the most heat generation are directly arranged on the heat exchange device.

[0005] The existing energy storage converter uses a combination of a liquid-cooled plate and a fan for heat dissipation, aiming to minimize the volume of the entire energy storage converter while meeting the heat dissipation requirements. However, this layout form is not reasonable enough. It not only results in poor heat dissipation effect, but also wastes the internal space of the chassis and is not conducive to miniaturization design. The reasons are as follows: First, with the liquid cooling plate positioned at the front, the inverter inductors mounted on it are also positioned at the front. The relatively large height of the inverter inductors easily obstructs the wiring path between other components and the front wall of the chassis, requiring wiring to be routed, resulting in low space utilization within the chassis. Furthermore, the increased wiring length leads to increased resistance and thus increased heat generation. Second, the air inside the chassis primarily flows horizontally, requiring space for airflow and fan installation in these directions. Simultaneously, space must be reserved at the front of the chassis to avoid external interfaces on the front wall, further reducing space utilization. This necessitates arranging electrical components in three layers, making it difficult to control the overall height. Third, to control the overall height, this energy storage converter chooses to reduce the height of the second layer and compress the space at the bottom. This requires the second layer to avoid the inverter inductors, thus allowing... The area for mounting components is further reduced. On the other hand, the reduced space at the bottom layer is not conducive to the heat dissipation of high-heat-generating components at the bottom. Fourth, with the increase in the number of electrical component layers, the fans in the chassis are prone to neglecting the heat dissipation needs of the upper layers after meeting the heat dissipation needs of the lower layers, which is not conducive to the high-intensity use of the energy storage converter. Fifth, the fans force the air on the left side of the chassis to flow to the right by suction. However, this makes it impossible to control the direction of air flow and make it difficult to effectively and accurately dissipate heat from components with high heat generation. Sixth, for components such as inverter inductors and IGBT boards that generate extremely high heat, relying solely on liquid cooling plates for bottom heat dissipation is far from sufficient. The upper part of these components and the wiring harnesses and conductors connected to them also generate a lot of heat. If air cooling is not specifically designed for these locations, these locations are prone to becoming bottlenecks in heat dissipation. Summary of the Invention

[0006] The purpose of this invention is to provide a liquid-cooled modular converter to solve the technical problems in the prior art where the unreasonable internal layout of energy storage converters leads to poor heat dissipation and serious space waste.

[0007] Another object of the present invention is to provide a chassis for a liquid-cooled modular converter to solve the same technical problems when applied to a liquid-cooled modular converter.

[0008] To achieve the above objectives, the technical solution of the liquid-cooled modular converter provided by this invention is as follows: A liquid-cooled modular converter includes a housing and components disposed within the housing. The housing has a partition dividing the interior space into an upper and lower space. The left and right sides of the partition are connected to the left and right side walls of the housing, respectively. Space for wiring and airflow is left between the front and rear sides of the partition and the front and rear side walls of the housing, respectively. A liquid-cooled plate, attached to the bottom wall of the housing, is disposed on one side of the lower space in the left-right direction. The length direction of the liquid-cooled plate is the same as the front-rear direction of the housing. The components include inductive elements attached to the upper side of the liquid-cooled plate and arranged in the front-rear direction. At least two fans for forward airflow are disposed on the rear side wall of the housing. One fan is positioned in the lower space corresponding to the liquid-cooled plate to blow air onto the inductive elements on the liquid-cooled plate. At least a portion of the airflow area of ​​one fan is above the partition to blow air into the upper space.

[0009] The beneficial effect is that the liquid-cooled modular converter provided by this invention belongs to the invention of changing the relationship between elements. In this liquid-cooled modular converter, the liquid cooling plate is first placed on one side of the enclosure in the left-right direction. This prevents larger components mounted on the liquid cooling plate from obstructing the wiring path between other components and the front wall of the enclosure. Simultaneously, the front end of the liquid cooling plate can be positioned close to or against the front wall of the enclosure. The inlet and outlet of the liquid cooling plate can be directly installed on the front wall of the enclosure without the need for additional piping. Secondly, the components inside the enclosure are distributed across only two layers. This reduction in the number of layers not only allows for better control of the overall height but also makes it easier for the fan to reach components on each layer. Furthermore, it allows for more space in the lower section, which is more conducive to heat dissipation of high-heat components. Thirdly, the fan is positioned on the rear wall of the enclosure. This not only utilizes the space that is difficult to occupy on the front of the enclosure but also facilitates a dedicated air-cooling design for the upper part of the inductors on the liquid cooling plate, resulting in better heat dissipation. Finally, the fan blows air into the enclosure, ensuring that the airflow is more accurately delivered to the components requiring heat dissipation.

[0010] As a further improvement, the lower side of the partition has a constraint piece that extends continuously or intermittently in the front-back direction. The space between the constraint piece and one side wall of the housing is used to accommodate inductive components. The space can form an air duct for airflow guidance when in use.

[0011] The beneficial effect is that after a clear airflow channel is formed, the airflow blowing towards the inductor is not easily dispersed, which can ensure that the components far away from the fan can also receive a sufficiently strong air cooling effect.

[0012] As a further improvement, the partition includes a crossbeam extending in the left and right direction, as well as a duct cover and a partition. The duct cover includes a top plate and a side plate located on one side of the top plate. The side plate is provided with perforations or slots for the crossbeam to pass through. The top plate of the duct cover is attached to the upper side of the crossbeam, and the side plate faces downward and forms the constraint piece. The partition is located on one side of the duct cover and is attached to the upper side of the crossbeam.

[0013] The beneficial effects are that the above structures can all be processed from sheet metal by stamping, which reduces processing difficulty and cost on the one hand, and reduces weight on the other.

[0014] As a further improvement, for the fan whose blowing area is at least partially higher than the partition, the upper half of its blowing area corresponds to the upper space and the lower half corresponds to the lower space. A high-heat-generating element is provided at the rear position of the upper space that can be blown by the fan, and low-heat-generating elements or elements with their own heat dissipation structures are provided at the remaining positions of the upper space.

[0015] The beneficial effects are as follows: The aforementioned fan takes into account the heat dissipation of both the upper and lower spaces. Since the upper space mostly contains low-heat-generating components or components with built-in heat dissipation, it is sufficient for the fan to blow only a portion of its airflow into the upper space. The remaining airflow from the fan is blown into the lower space to enhance its heat dissipation capacity, thus not wasting the fan's efficiency. Furthermore, high-heat-generating components are placed in a rear position in the upper space where they can be reached by the fan, allowing them to be directly exposed to the airflow, further improving the full utilization of the fan.

[0016] As a further improvement, the fan corresponding to the liquid cooling plate is the first fan, and the fan that blows air into both the upper and lower spaces is the second fan. The second fan is located in the middle of the left-right direction inside the box. A third fan is set on the side of the second fan away from the first fan. The blowing area of ​​the third fan corresponds only to the lower space. Low-heating elements are set in the front part of the lower space that can be blown by the second fan, and high-heating elements are set in the remaining parts of the lower space.

[0017] The beneficial effects are: this layout fully considers the characteristics of the lower space having many high-heat-generating components and high heat dissipation requirements, sending most of the air volume to the lower space while also taking into account the heat dissipation requirements of the upper space. Moreover, through the arrangement of the heat-generating components, especially for the second fan, the heat dissipation pressure on the upper and lower spaces is balanced, ensuring a good overall heat dissipation effect.

[0018] To achieve the above objectives, the technical solution for the chassis of the liquid-cooled modular converter provided by this invention is as follows: A chassis for a liquid-cooled modular converter includes a chassis body. Inside the chassis body, there is a partition that divides the internal space into an upper space and a lower space. The left and right sides of the partition are connected to the left and right side walls of the chassis body, respectively. The front and rear sides of the partition are respectively provided with space between them and the front and rear side walls of the chassis body for wiring and airflow. In the lower space of the chassis body, a liquid cooling plate for heat dissipation of inductor components is provided on one side in the left-right direction and is attached to the bottom wall of the chassis body. The length direction of the liquid cooling plate is the same as the front-rear direction of the chassis body. At least two fans for forward airflow are provided on the rear side wall of the chassis body. One fan is arranged in the lower space corresponding to the position of the liquid cooling plate so as to blow air onto the inductor components on the liquid cooling plate during use. At least part of the airflow area of ​​the fan is higher than the partition so as to blow air onto the upper space.

[0019] The beneficial effect is that the chassis of the liquid-cooled modular converter provided by this invention belongs to the invention of changing the relationship of elements. In this liquid-cooled modular converter, the liquid cooling plate is first placed on one side of the enclosure in the left-right direction. This prevents larger components mounted on the liquid cooling plate from obstructing the wiring path between other components and the front wall of the enclosure. Simultaneously, the front end of the liquid cooling plate can be positioned close to or against the front wall of the enclosure. The inlet and outlet of the liquid cooling plate can be directly installed on the front wall of the enclosure without the need for additional piping. Secondly, the components inside the enclosure are distributed across only two layers. This reduction in the number of layers not only allows for better control of the overall height but also makes it easier for the fan to reach components on each layer. Furthermore, it allows for more space in the lower section, which is more conducive to heat dissipation of high-heat components. Thirdly, the fan is positioned on the rear wall of the enclosure. This not only utilizes the space that is difficult to occupy on the front of the enclosure but also facilitates a dedicated air-cooling design for the upper part of the inductors on the liquid cooling plate, resulting in better heat dissipation. Finally, the fan blows air into the enclosure, ensuring that the airflow is more accurately delivered to the components requiring heat dissipation.

[0020] As a further improvement, the lower side of the partition has a constraint piece that extends continuously or intermittently in the front-back direction. The space between the constraint piece and one side wall of the housing is used to accommodate inductive components. The space can form an air duct for airflow guidance when in use.

[0021] The beneficial effect is that after a clear airflow channel is formed, the airflow blowing towards the inductor is not easily dispersed, which can ensure that the components far away from the fan can also receive a sufficiently strong air cooling effect.

[0022] As a further improvement, the partition includes a crossbeam extending in the left and right direction, as well as a duct cover and a partition. The duct cover includes a top plate and a side plate located on one side of the top plate. The side plate is provided with perforations or slots for the crossbeam to pass through. The top plate of the duct cover is attached to the upper side of the crossbeam, and the side plate faces downward and forms the constraint piece. The partition is located on one side of the duct cover and is attached to the upper side of the crossbeam.

[0023] The beneficial effects are that the above structures can all be processed from sheet metal by stamping, which reduces processing difficulty and cost on the one hand, and reduces weight on the other.

[0024] As a further improvement, for the fan whose blowing area is at least partially higher than the partition, the upper half of its blowing area corresponds to the upper space and the lower half corresponds to the lower space. The rear part of the upper space that can be blown by the fan is used to set high-heat-generating elements, and the remaining part of the upper space is used to set low-heat-generating elements or elements with their own heat dissipation structures.

[0025] The beneficial effects are as follows: The aforementioned fan takes into account the heat dissipation of both the upper and lower spaces. Since the upper space mostly contains low-heat-generating components or components with built-in heat dissipation, it is sufficient for the fan to blow only a portion of its airflow into the upper space. The remaining airflow from the fan is blown into the lower space to enhance its heat dissipation capacity, thus not wasting the fan's efficiency. Furthermore, high-heat-generating components are placed in a rear position in the upper space where they can be reached by the fan, allowing them to be directly exposed to the airflow, further improving the full utilization of the fan.

[0026] As a further improvement, the fan corresponding to the liquid cooling plate is the first fan, and the fan that blows air into both the upper and lower spaces is the second fan. The second fan is located in the middle of the left-right direction inside the housing. A third fan is set on the side of the second fan away from the first fan. The blowing area of ​​the third fan corresponds only to the lower space. The front part of the lower space that can be blown by the second fan is used to set low-heating elements, and the remaining part of the lower space is used to set high-heating elements.

[0027] The beneficial effects are: this layout fully considers the characteristics of the lower space having many high-heat-generating components and high heat dissipation requirements, sending most of the air volume to the lower space while also taking into account the heat dissipation requirements of the upper space. Moreover, through the arrangement of the heat-generating components, especially for the second fan, the heat dissipation pressure on the upper and lower spaces is balanced, ensuring a good overall heat dissipation effect. Attached Figure Description

[0028] Figure 1 This is a schematic diagram of the overall structure of one embodiment of the liquid-cooled modular converter in this invention; Figure 2 This is an exploded view of one embodiment of the liquid-cooled modular converter in this invention; Figure 3 This is a schematic diagram of the structure of the liquid-cooled modular converter in one embodiment of the present invention, with the chassis cover and front side wall removed; Figure 4 This is a front view of the chassis with the front sidewall removed in one embodiment of the liquid-cooled modular converter of the present invention; Figure 5 This is a schematic diagram of the chassis structure with the cover and left side wall of the chassis removed in one embodiment of the liquid-cooled modular converter of the present invention; Figure 6 This is a schematic diagram of the chassis partition structure in one embodiment of the liquid-cooled modular converter of the present invention; Figure 7 This is a right-side view of an embodiment of the liquid-cooled modular converter in this invention, cut from the first fan. Figure 8 This is a schematic diagram of the liquid-cooled modular converter of the present invention from a rear oblique upward view after removing the cover and housing. Figure 9 This is a rear view of an embodiment of the liquid-cooled modular converter in this invention after removing the cover and housing. Figure 10 This is a right-side view, cut from the second fan, of one embodiment of the liquid-cooled modular converter in this invention; Figure 11 This is a right-side view of an embodiment of the liquid-cooled modular converter in this invention, cut from the third fan. Figure 12 This is a top view of an embodiment of the liquid-cooled modular converter in this invention with the casing cover removed, showing the component arrangement in the upper space; Figure 13 This is a top view of an embodiment of the liquid-cooled modular converter in this invention, with the components in the upper space removed. Figure 14 This is a top view of an embodiment of the liquid-cooled modular converter in this invention, with the partition and the structure above the partition removed, showing the component arrangement in the lower space; Figure 15 This is a schematic diagram of the front oblique downward view of an embodiment of the liquid-cooled modular converter in this invention, with the cover and housing removed. Figure 16 This is a schematic diagram of the liquid-cooled modular converter of the present invention from a front oblique upward view after removing the cover and housing.

[0029] Explanation of reference numerals in the attached figures: 1. Enclosure; 2. Enclosure Cover; 3. Sealing Ring; 4. AC External Terminal; 5. Communication Interface; 6. Non-Electrical Interface; 7. Indicator Light; 8. DC External Terminal; 9. DC Disconnect Switch; 10. Grounding Bolt; 11. Vent Valve; 12. Water Inlet; 13. Water Outlet; 14. Handle; 15. Crossbeam; 16. Air Duct Cover; 161. Top Plate; 162. Side Plate; 163. Through-slot; 17. Partition; 18. Connecting Feet; 19. Liquid Cooling Plate; 20. AC Inductor; 21. First Fan; 22. Second Fan; 23. 24. Third fan; 25. First bracket; 26. Opening; 27. Second bracket; 28. Third bracket; 29. ​​DC capacitor board; 30. AC contactor and capacitor board; 31. AC EMI board; 32. Main control board; 33. Power supply board; 34. BCU module; 35. DC disconnect switch; 36. DC fuse; 37. DC contactor; 38. Filter capacitor; 39. IGBT device; 40. IGBT adapter board; 41. IGBT driver board; 42. Elevation plate; 43. Support plate; 44. Conductor busbar. Detailed Implementation

[0030] The present invention will be further described in detail below with reference to the embodiments.

[0031] The basic concept of this invention is to arrange the liquid cooling plates in the liquid-cooled modular converter along the front-to-back direction and use a blower to blow air from back to front to form air circulation inside the chassis. This ensures better cooling effect while saving space inside the chassis and also facilitates wiring.

[0032] Specific embodiments of the liquid-cooled modular converter provided by this invention: This liquid-cooled modular converter includes a chassis and components arranged within the chassis. The chassis structure is as follows: Figure 1 and Figure 2 As shown, it includes a box body 1 and a box cover 2 fixed to the upper side of the box body 1. The box body 1 and the box cover 2 are connected by screws and a sealing ring 3 is provided.

[0033] The front side of the enclosure 1 is a panel for arranging various external connectors. The panel is equipped with AC external terminal 4, communication interface 5, non-electrical interface 6, indicator light 7, DC external terminal 8, operating handle of DC disconnect switch 33, grounding bolt 10, vent valve 11, water inlet 12, water outlet 13 and handle 14.

[0034] See appendix Figure 3 Appendix Figure 4 and appendix Figure 5The enclosure 1 has a partition that divides it into an upper space and a lower space. The partition is positioned slightly above the lower space, making the height of the upper space less than that of the lower space. The left and right sides of the partition are connected to the left and right side walls of the enclosure 1, respectively. The front and rear sides of the partition are respectively provided with space between them and the front and rear side walls of the enclosure 1 for wiring and airflow. Specifically, the space between the front side of the partition and the front side wall of the enclosure 1 is mainly for the passage of wire harnesses or conductive busbars 42, to avoid various terminals, and for vertical airflow. The space between the rear side of the partition and the rear side wall of the enclosure 1 is mainly for the passage of wire harnesses or conductive busbars 42, for the installation of fans, and for vertical airflow.

[0035] Space is left on both the front and rear sides of the partition, making full use of the space inside the enclosure 1, especially the front side, which is used to avoid various terminals and cannot be occupied. This allows these two spaces to play a greater role and saves extra space inside the enclosure 1. On this basis, the left and right sides of the partition are connected to the left and right side walls of the enclosure 1, respectively. This allows for a larger upper surface area of ​​the partition and a larger area in the upper space of the enclosure 1 for installing components. Therefore, all components can be arranged in two layers of space, making the internal layout of the energy storage converter more compact. This is beneficial for controlling the size of the energy storage converter and for using a limited number of fans to heat up more components, thus improving the heat dissipation effect.

[0036] The lower side of the partition has a constraint plate that extends continuously or intermittently in the front-back direction. The space between the constraint plate and one side wall of the housing 1 can form an air duct for airflow guidance during use, so as to provide more efficient air cooling for the components arranged in the air duct.

[0037] In this embodiment, see Appendix Figure 6 The partition includes a horizontal beam 15 extending in the left-right direction, a duct cover 16, and a partition 17. The duct cover 16 includes a top plate 161 and a side plate 162 located on one side of the top plate 161. The side plate 162 is provided with through holes or slots 163 for the horizontal beam 15 to pass through. The top plate 161 of the duct cover 16 is attached to the upper side of the horizontal beam 15 and fixed to the horizontal beam 15 with screws. The side plate 162 faces downwards and forms the aforementioned constraint piece. The partition 17 is located on one side of the duct cover 16 and is attached to the upper side of the horizontal beam 15 and fixed to the horizontal beam 15 with screws. The horizontal beam 15 is a stamped sheet metal part, and its two ends are fixedly connected with connecting feet 18 with screw mounting holes for easy fixed connection with the housing 1. This arrangement allows the entire partition to be processed using sheet metal, which is less difficult to process and results in a lighter overall weight.

[0038] In other embodiments, the partition includes a crossbeam 15 and a partition plate 17 attached to its upper side. The left and right sides of the partition plate 17 are respectively connected to the left and right side walls of the housing 1. The restraining piece is another sheet-like structure welded or bolted to the lower side of the partition plate 17 or the lower side of the crossbeam 15. In other embodiments, the partition may also include only the partition plate 17 and the restraining piece fixed to its lower side. The left and right sides of the partition plate 17 are bent to form flanges with mounting holes for direct fixation to the housing 1. To enhance the strength of the partition plate 17, reinforcing ribs can be stamped on the partition plate 17.

[0039] See appendix Figure 3 A liquid cooling plate 19 is installed at the bottom of the lower space of the housing 1, corresponding to the aforementioned air duct. In this embodiment, the liquid cooling plate 19 is specifically arranged on the right side of the bottom of the lower space of the housing 1. The length direction of the liquid cooling plate 19 is the same as the front-rear direction of the housing 1. Figure 7 The inductors are attached to the upper side of the liquid cooling plate 19 and arranged in the front-to-back direction. In this embodiment, the inductors specifically refer to three AC inductors 20, which are independent of each other and arranged at intervals. In other embodiments, the inductors can also be inverter inductors.

[0040] The AC inductor 20 generates a large amount of heat. Directly mounting this component onto the liquid cooling plate 19 allows the strong cooling capacity of the liquid cooling plate 19 to quickly absorb the heat it generates. With the liquid cooling plate 19 positioned to one side of the enclosure 1 in the left-right direction, the front end of the liquid cooling plate 19 can be close to the front wall of the enclosure 1. This allows the inlet 12 and outlet 13 on the liquid cooling plate 19 to be directly installed on the front wall of the enclosure 1 without the need for liquid cooling pipes, facilitating the installation of the liquid cooling plate 19. At the same time, the inductor component occupies less space on the front wall of the enclosure 1. Whether in the lower or upper space, wiring between the connectors on the front wall does not need to be routed, improving space utilization and saving space to a certain extent.

[0041] Three fans are arranged at intervals along the left and right direction on the rear side wall inside the housing 1. The first fan 21 is positioned in the lower space corresponding to the liquid cooling plate 19 to blow air onto the inductor components on the liquid cooling plate 19. (See attached diagram.) Figure 7The first fan 21 is fixed to the rear side wall of the housing 1 by the first bracket 24. The first bracket 24 extends forward and positions the first fan 21 entirely within the air duct. The air blown out by the first fan 21 is constrained by the constraint plate, allowing it to flow forward along the air duct to the maximum extent. It then passes through the gaps between the AC inductors 20 and the side wall of the housing 1, and between the AC inductors 20 and the air duct cover plate 16, dissipating heat from the AC inductors 20, IGBT devices 37, and the connected wiring harnesses and conductors 42. In this way, the AC inductors 20 and IGBTs are cooled not only at their bottoms but also at their tops. More importantly, the wiring harnesses and conductors 42 connected to them and arranged along the gaps receive strong and stable air cooling.

[0042] Combined with appendix Figure 8 The second fan 22 and the third fan 23 are fixed to the rear side wall inside the housing 1 by the second bracket 25 and the third bracket 26, respectively. The second bracket 25 and the third bracket 26 are shorter in the front-to-back direction, allowing the second fan 22 and the third fan 23 to be arranged close to the rear side wall of the housing 1 with only a small ventilation gap. The first bracket 24 is longer in the front-to-back direction, allowing the first fan 21 to enter the air duct. All brackets are sheet metal parts. The part of the first bracket 24 connecting the rear side wall of the housing 1 and the first fan 21 is a vertical plate. This plate has a through-hole 241 machined on it to reduce weight and provide a path for airflow.

[0043] See appendix Figure 4 and in conjunction with the appendix Figure 9 Appendix Figure 10 and appendix Figure 11 The second fan 22 is located to the left of the first fan 21, and the upper half of its blowing area corresponds to the upper space and the lower half corresponds to the lower space, so that the air blown by the second fan 22 can enter both the upper and lower spaces. The third fan 23 is located on the side of the second fan 22 away from the first fan 21, and its blowing area corresponds only to the lower space, so that most of the air blown by the third fan 23 enters the lower space.

[0044] See appendix Figure 12 Appendix Figure 13 and appendix Figure 14 In addition to the AC inductor 20, the components inside the enclosure 1 also include a DC capacitor board 27, an AC contactor and capacitor board 28, an AC EMI board 29, a main control board 30, a power supply board 31, a BCU module 32, a DC disconnect switch 33, a DC fuse 34, a DC contactor 35, a filter capacitor 36, IGBT devices 37, an IGBT adapter board 38, an IGBT driver board 39, etc.

[0045] The DC capacitor board 27 is located in the rear of the lower space, excluding the air duct, so that it can be blown by both the second fan 22 and the third fan 23. The DC capacitor board 27 is a component that generates less heat than the AC inductor 20 and the IGBT device 37, but still generates a relatively large amount of heat. Being blown by both the second fan 22 and the third fan 23 at the same time ensures its good heat dissipation capacity.

[0046] See appendix Figure 11 The DC fuse 34 and DC contactor 35 are arranged front and back in the lower space and can be blown by the third fan 23. Since the third fan 23 blows almost all of the air volume to the lower space, after passing the DC capacitor board 27, there is still a considerable amount of air volume blown to the DC fuse 34 and DC contactor 35, so that these two components can also get good heat dissipation.

[0047] See appendix Figure 10 The AC contactor is positioned towards the rear in the upper space and is directly exposed to the airflow from the second fan 22. The AC contactor also generates heat easily, which is directly dissipated by the airflow from the second fan 22. Apart from this, the other components in the upper space generate relatively little heat. The airflow from the second fan 22 diffuses outwards, then spreads downwards or bounces back after encountering the side wall of the housing 1, forming an airflow covering the upper space to dissipate heat from the components there. A filter capacitor 36 is positioned forward of the second fan 22 in the lower space. The filter capacitor 36 generates relatively little heat, reducing the heat dissipation pressure at that location. Apart from the filter capacitor 36, the other components in the lower space generate significant heat.

[0048] This arrangement fully utilizes the airflow from the three fans, maximizing the air-cooling capacity of the liquid-cooled modular converter and thus improving heat dissipation. It also indirectly increases space utilization. Furthermore, the larger lower space accommodates more heat-generating components, while the smaller upper space houses fewer heat-generating components. This provides more space for heat dissipation in the heat-generating components, ensuring balanced heat dissipation and further enhancing overall cooling efficiency.

[0049] In summary, the solution is as follows: First, the lower space is designated as the primary heat dissipation area, where most high-heat-generating components are located. The majority of the fan's airflow is also directed to this lower space to fully utilize its large size. Second, one fan's airflow area corresponds to both the upper and lower spaces, allowing some of the airflow to enter the upper space and dissipate heat from the low-heat-generating components there, thus achieving balanced heat dissipation for all components. Third, high-heat-generating components are placed in the upper space at the rear where they are accessible by the fan, maximizing the fan's airflow. Finally, for fans that also dissipate heat from the upper space, low-heat-generating components are placed in the lower space at the front, reducing the heat dissipation pressure in those areas. In this way, all high-heat-generating components receive direct airflow from the fans, ensuring effective heat dissipation, while the fans also provide cooling for all low-heat-generating components.

[0050] The high-heat-generating elements and low-heat-generating elements are determined according to the relative heat generation of the elements in the liquid-cooled modular converter. There is a relative difference in heat generation between the two, but they do not specifically represent a particular element. During use, the high-heat-generating elements and low-heat-generating elements can be arranged as needed.

[0051] In other embodiments, at least two fans for forward airflow can be installed on the rear side wall inside the housing 1. One fan is positioned in the lower space corresponding to the liquid cooling plate 19 to blow air onto the inductors on the liquid cooling plate 19, and the other fan has at least a portion of its airflow area above the partition to blow air onto the upper space. Specifically, it is necessary to ensure that the air duct corresponds to one fan, and one of the remaining fans needs to blow air onto the upper space. This fan can blow air only onto the upper space, or it can blow air onto both the upper and lower spaces simultaneously. Other fans can be arranged separately as needed.

[0052] See appendix Figure 3 and in conjunction with the appendix Figure 15 The bottom of the lower space of the housing 1 is also provided with a raised plate 40 to provide a mounting base for the components. The raised plate 40 is a stamped sheet metal part, and its upper side is flush with the upper side of the liquid cooling plate 19. The raised plate 40 is located between the liquid cooling plate 19 and the other side wall of the housing 1. The IGBT adapter board 38 is mounted on the raised plate 40 and also on the liquid cooling plate 19. The aforementioned filter capacitor 36 is mounted on the IGBT adapter board 38. There are three IGBT devices 37. The three IGBT devices 37 are arranged back and forth at intervals and attached to the upper side of the liquid cooling plate 19, and are connected to the IGBT adapter board 38. The IGBT adapter board 38 is equipped with an IGBT driver board 39 at the corresponding position of the IGBT device 37. Since the IGBT device 37 is also a device that generates a lot of heat, directly attaching it to the liquid cooling plate 19 can meet its heat dissipation requirements.

[0053] See appendix Figure 13 Appendix Figure 14 and attached Figure 16 The DC disconnect switch 33 is installed at the front of the lower space on the side away from the liquid cooling plate 19, adjacent to or against the front wall of the enclosure 1, so that its operating handle can extend out of the front wall of the enclosure 1. See Appendix Figure 14 The conductive busbar 42, connected from the DC external terminal 8, is first connected to the DC disconnect switch 33, and then extends from the DC disconnect switch 33 to the DC fuse 34 located directly behind the DC disconnect switch 33 in the lower space. The DC fuse 34 is connected to the DC contactor 35 behind it via the conductive busbar 42. The direct contactor is connected to the corresponding two connection terminals on the IGBT adapter board 38 via the conductive busbar 42. The DC disconnect switch 33 can form a clear break on the DC connection side, thereby ensuring safe use.

[0054] The DC disconnect switch 33 is relatively tall, and gaps are left at corresponding positions for the shim plate 40, IGBT adapter plate 38, and partition. In order to leave gaps on the partition, the length of the foremost crossbeam 15 is shortened, and the crossbeam 15 cannot continue to extend to connect with the side wall of the housing 1. In order to support the crossbeam 15, in this embodiment, a support plate 41 is fixedly connected to the bottom of the housing 1. The thickness direction of the support plate 41 is parallel to the front-to-back direction, and the upper end of the support plate 41 extends upward and is fixedly connected to the crossbeam 15. The support plate 41 is located directly behind the DC disconnect switch 33.

[0055] The IGBT adapter board 38 has three sets of connection terminals for wiring, which are respectively connected to three AC inductors 20. Taking DC input and AC output as an example, the DC power is converted into three-phase AC power after passing through the IGBT devices 37 on the IGBT adapter board 38, and the three-phase AC power is respectively connected to the three AC inductors 20. The IGBT adapter board 38 is directly connected to the DC capacitor board 27 through the busbar 42, and the three AC inductors 20 are also connected to the DC capacitor board 27 by wiring harnesses.

[0056] See appendix Figure 12 The AC contactor and capacitor board 28 are located at the rear of the upper space. Three sets of AC contactors are installed on it, and three AC inductors 20 are connected to the three sets of AC contactors upward through wire harnesses.

[0057] The AC EMI board 29 is located in the upper space at the position corresponding to the air duct. The AC contactor and capacitor board 28 are connected to the AC EMI board 29 through the conductive bar 42. The front end of the AC EMI board 29 is close to the front side wall of the housing 1 and is connected to the three AC external terminals 4 through the three conductive bars 42 respectively.

[0058] The main control board 30 and the BCU module 32 are located at the front of the upper space. The main control board 30 and the BCU module 32 are located in the upper space because they generate less heat, and the front placement is to facilitate their connection with the communication interface 5 and to facilitate wiring operations.

[0059] In addition, the power supply board 31 is also located in the upper space. It is positioned on the side away from the AC EMI board 29 and towards the rear. This is mainly because there is suitable space for this position. The power supply board 31 has its own cooling fan, so the need for heat dissipation is relatively small.

[0060] In this embodiment, the liquid cooling plate 19 provides the most efficient cooling to quickly dissipate heat from the power components and inductors. Simultaneously, the liquid cooling plate 19 is positioned close to the lower side wall of the housing 1, carrying away some of the heat from the side wall, giving the side wall, especially the lower portion, good heat absorption capacity. Thus, the air flowing in the lower space inside the housing 1 primarily impacts the lower portion of the side wall. This air, primarily used for cooling high-heat-generating components, is also at a higher temperature and cools rapidly upon contact with the lower part of the side wall, facilitating subsequent air-cooling cycles. In this way, the liquid cooling plate 19 not only utilizes its upper surface but also fully utilizes its lower surface, using the side wall of the housing 1 as its heat-conducting structure, maximizing the heat dissipation capacity of the liquid cooling plate 19.

[0061] Most of the components in the upper space are low-heat components, generating less heat. The air flowing in the upper space is also at a lower temperature. After impacting the upper part of the side wall of the enclosure 1, the air transfers heat to the side wall of the enclosure 1, and then dissipates into the surrounding environment mainly through the side wall of the enclosure 1. This matches the heat dissipation requirements of the components in the upper space.

[0062] In addition, there is some vertical airflow between the upper and lower spaces, mainly from the front and rear sides of the partition. Because the lower space has a larger airflow, some air flows upwards from the front of the partition. When the heat absorption capacity of the lower part of the side wall of housing 1 is insufficient, the warmer air from the lower space can enter the upper space to dissipate heat through the upper part of the side wall of housing 1 and the natural heat dissipation of the lid 2, ensuring balanced heat dissipation from top to bottom. After the air from the lower space flows upwards into the upper space, air from the upper space correspondingly flows downwards into the lower space from the rear to balance the air pressure.

[0063] Specific embodiments of the chassis for the liquid-cooled modular converter provided by this invention: The chassis has the same structure as the chassis in the aforementioned liquid-cooled modular converter, so it will not be described again.

[0064] Finally, it should be noted that the above descriptions are merely preferred embodiments of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still make modifications to the technical solutions described in the foregoing embodiments without creative effort, or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A liquid-cooled modular converter, characterized in that, The device includes a housing and components housed within it. The housing has a partition dividing the interior space into an upper and lower space. The left and right sides of the partition are connected to the left and right side walls of the housing, respectively. Space is left between the front and rear sides of the partition and the front and rear side walls of the housing for wiring and airflow. A liquid cooling plate, attached to the bottom wall of the housing, is located on one side of the lower space in the left-right direction. The length of the liquid cooling plate is in the same direction as the front-back direction of the housing. The components include inductive components attached to the upper side of the liquid cooling plate and arranged in the front-back direction. At least two fans for forward airflow are located on the rear side wall of the housing. One fan is positioned in the lower space corresponding to the liquid cooling plate to blow air onto the inductive components on the liquid cooling plate. At least part of the airflow area of ​​one fan is above the partition to blow air into the upper space.

2. The liquid-cooled modular converter according to claim 1, characterized in that, The lower side of the partition has a constraint plate that extends continuously or intermittently in the front-to-back direction. The space between the constraint plate and one side wall of the housing is used to accommodate inductive components. The space can form an air duct for airflow guidance when in use.

3. The liquid-cooled modular converter according to claim 2, characterized in that, The partition includes a horizontal beam extending in the left and right direction, as well as a duct cover and a partition. The duct cover includes a top plate and a side plate located on one side of the top plate. The side plate is provided with perforations or slots for the horizontal beam to pass through. The top plate of the duct cover is attached to the upper side of the horizontal beam, and the side plate faces downward and forms the constraint piece. The partition is located on one side of the duct cover and is attached to the upper side of the horizontal beam.

4. The liquid-cooled modular converter according to any one of claims 1-3, characterized in that, For the fan whose blowing area is at least partially higher than the partition, the upper half of its blowing area corresponds to the upper space and the lower half corresponds to the lower space. A high-heat-generating element is provided in the rear position of the upper space that can be blown by the fan, and low-heat-generating elements or elements with their own heat dissipation structures are provided in the remaining positions of the upper space.

5. The liquid-cooled modular converter according to claim 4, characterized in that, The fan corresponding to the liquid cooling plate is the first fan, and the fan that blows air into both the upper and lower spaces is the second fan. The second fan is located in the middle of the left-right direction inside the box. A third fan is set on the side of the second fan away from the first fan. The blowing area of ​​the third fan corresponds only to the lower space. Low-heating elements are set in the front part of the lower space that can be blown by the second fan, and high-heating elements are set in the remaining parts of the lower space.

6. A chassis for a liquid-cooled modular converter, characterized in that, The enclosure includes a cabinet with a partition dividing the interior space into an upper and lower space. The left and right sides of the partition are connected to the left and right side walls of the cabinet, respectively. Space is left between the front and rear sides of the partition and the front and rear side walls of the cabinet for wiring and airflow. A liquid cooling plate for heat dissipation of inductors is installed on one side of the lower space in the left-right direction, which is attached to the bottom wall of the cabinet. The length direction of the liquid cooling plate is the same as the front-back direction of the cabinet. At least two fans for forward airflow are installed on the rear side wall of the cabinet. One fan is located in the lower space corresponding to the position of the liquid cooling plate so that it can blow air onto the inductors on the liquid cooling plate during use. At least part of the airflow area of ​​the other fan is higher than the partition so that it can blow air into the upper space.

7. The chassis of the liquid-cooled modular converter according to claim 6, characterized in that, The lower side of the partition has a constraint plate that extends continuously or intermittently in the front-to-back direction. The space between the constraint plate and one side wall of the housing is used to accommodate inductive components. The space can form an air duct for airflow guidance when in use.

8. The chassis of the liquid-cooled modular converter according to claim 7, characterized in that, The partition includes a horizontal beam extending in the left and right direction, as well as a duct cover and a partition. The duct cover includes a top plate and a side plate located on one side of the top plate. The side plate is provided with perforations or slots for the horizontal beam to pass through. The top plate of the duct cover is attached to the upper side of the horizontal beam, and the side plate faces downward and forms the constraint piece. The partition is located on one side of the duct cover and is attached to the upper side of the horizontal beam.

9. The chassis of the liquid-cooled modular converter according to any one of claims 6-8, characterized in that, For the fan whose blowing area is at least partially higher than the partition, the upper half of its blowing area corresponds to the upper space and the lower half corresponds to the lower space. The rear part of the upper space that can be blown by the fan is used to install high-heat-generating elements, and the remaining part of the upper space is used to install low-heat-generating elements or elements with their own heat dissipation structures.

10. The chassis of the liquid-cooled modular converter according to claim 9, characterized in that, The fan corresponding to the liquid cooling plate is the first fan, and the fan that blows air into both the upper and lower spaces is the second fan. The second fan is located in the middle of the left-right direction inside the housing. A third fan is located on the side of the second fan away from the first fan. The blowing area of ​​the third fan corresponds only to the lower space. The front part of the lower space that can be blown by the second fan is used to install low-heating elements, and the remaining part of the lower space is used to install high-heating elements.

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