A backup power supply system

Abstract

This patent application discloses a backup power system, including a housing. The backup power system is connected to an ATS module system via an automatic load management system and employs a permanent magnet generator set. The housing is a metal shell and also includes an engine and a generator. The engine is encased in a first air guide shroud, and a cooling fan is provided on the cooling air intake side of the engine and / or generator. The generator is encased in a second air guide shroud. An inverter is also included, with a dedicated heat dissipation structure within the housing for housing the inverter. A muffler assembly is further included, with an independent exhaust structure within the housing for housing the muffler assembly. The backup power system of this invention can achieve decoupling of speed and frequency through power electronic control, ensuring the engine always operates in the optimal fuel consumption range. Furthermore, the engine and generator form an integrated or independent air duct, the inverter has a dedicated heat dissipation structure, and the muffler assembly has an independent exhaust structure, resulting in a high-efficiency and effective heat dissipation system.

Description

Technical Field

[0001] This invention relates to the field of generator set technology, and more specifically to a backup power system. Background Technology

[0002] Backup power supplies are devices that provide emergency power support, primarily functioning when mains power is interrupted or voltage is unstable. The core function of these devices is to ensure that critical electrical equipment continues to operate even in the event of grid anomalies, protecting daily life from disruption or minimizing losses caused by power outages.

[0003] The engine speed and output frequency of the existing backup power supply are fixedly coupled and cannot be flexibly adjusted according to load requirements, causing the engine to often operate in a non-optimal fuel consumption range. In addition, the cooling system of the backup power supply adopts an open or simple air duct structure, with the engine and generator sharing the same heat dissipation space in the housing or the air ducts being chaotically connected. The cooling air flows disorderly in the housing, with vortex dead zones, making it impossible to accurately dissipate heat for the heat characteristics of different components, which easily leads to local overheating. Summary of the Invention

[0004] To overcome the shortcomings of the prior art, the purpose of this invention is to provide a backup power system. The backup power system of this invention can achieve decoupling of speed and frequency through power electronic control, so that the engine always works in the optimal fuel consumption range. Moreover, the engine and generator form an integrated or independent air duct. The AC-DC-AC inverter circuit system controller is equipped with a dedicated heat dissipation structure, and the muffler assembly is equipped with an independent exhaust structure. The resulting heat dissipation system has high heat dissipation efficiency and good heat dissipation effect.

[0005] The technical solution adopted in this invention is as follows:

[0006] A backup power system includes a housing with a first air inlet on one side and a first air outlet on the other side. It is connected to an Automatic Load Management (ATS) module system via an Automatic Load Management System. The backup power system uses a permanent magnet inverter generator set. The housing is a metal casing. The system also includes:

[0007] An engine and a generator are installed inside the housing and are connected by a drive. The engine is covered by a first air guide shroud. A cooling fan is provided on the cooling air intake side of the engine and / or generator. The generator is covered by a second air guide shroud. The first air guide shroud and the second air guide shroud are connected or separated and independent.

[0008] AC-DC-AC inverter circuit system controller, the housing is equipped with a dedicated heat dissipation structure for accommodating the AC-DC-AC inverter circuit system controller;

[0009] A muffler assembly is used to reduce the noise of exhaust gas from the engine. The housing is provided with an independent exhaust structure for accommodating the muffler assembly. The independent exhaust structure is arranged on the side of the housing near the first exhaust port.

[0010] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0011] 1. The backup power system of this invention adopts a permanent magnet generator set, which is a new type of backup power product. The permanent magnet generator set, combined with frequency conversion control technology, achieves decoupling of speed and frequency through power electronic control, ensuring the engine always operates in the optimal fuel consumption range. Connected to the Automatic Load Management System (ATS) module system, it activates and switches to the backup power system in the event of mains power interruption, voltage loss, undervoltage, or frequency abnormality, ensuring uninterrupted operation of electrical equipment.

[0012] 2. In this invention, the engine is enclosed by a first air guide shroud, and the generator is enclosed by a second air guide shroud. If the first and second air guide shrouds are connected, a fully continuous cooling air duct is formed. Under the negative pressure of the cooling fan, cooling air enters the housing from the first air inlet on one side of the housing and flows sequentially through the first and second air guide shrouds, or sequentially through the second and first air guide shrouds, to cool the engine and generator, or sequentially through the generator and engine. Then, it flows through the muffler assembly for further cooling and finally exits from the first exhaust vent on the other side of the housing. This process forms a... The integrated, continuous cooling airflow design allows for rapid and orderly airflow within the housing, resulting in better heat dissipation. If the first and second air guide shrouds are separated, independent cooling airflow channels are formed within each shroud. On one hand, under the negative pressure of the cooling fan, cooling air enters the housing from the first air inlet on one side of the housing and enters the first air guide shroud to cool the engine. On the other hand, cooling air also enters the second air guide shroud to cool the engine. This design, with independent cooling airflow channels for the engine and generator, provides even better cooling for both components.

[0013] 3. The AC-DC-AC inverter circuit system controller is a heat-generating component. Its core power components generate a lot of heat during the power conversion process. The enclosure is equipped with a dedicated heat dissipation structure to house the AC-DC-AC inverter circuit system controller. Independent heat dissipation of the AC-DC-AC inverter circuit system controller can effectively control the operating temperature of the AC-DC-AC inverter circuit system controller and ensure the stable operation of the AC-DC-AC inverter circuit system controller.

[0014] 4. Muffler assembly: Used to reduce the noise of exhaust gas from the engine. The muffler assembly has a high temperature. The housing has an independent exhaust structure to house the muffler assembly, which can effectively reduce heat radiation and accumulate in the housing. It is arranged near the first exhaust port of the housing, so that the exhaust gas after being treated by the muffler assembly can be quickly discharged from the first exhaust port, resulting in better heat dissipation.

[0015] 5. The backup power system of the present invention, especially the household backup power system, is usually installed outdoors. The enclosure is made of metal, which gives it sufficient strength and a longer service life, and makes it less prone to aging.

[0016] In a preferred embodiment of the present invention, the dedicated heat dissipation structure includes a first partition plate disposed inside the housing near the first air inlet, the first partition plate and the first air inlet side of the housing forming an air intake cavity, the first partition plate being provided with a first ventilation opening, and the AC-DC-AC inverter circuit system controller being located inside the air intake cavity.

[0017] In this solution, a first partition is set inside the housing near the first air inlet, and the AC-DC-AC inverter circuit system controller is set in the air intake cavity formed by the first partition and the first air inlet on the housing. After the cooling air enters the air intake cavity through the first air inlet, it first cools and dissipates heat to the AC-DC-AC inverter circuit system controller, resulting in good heat dissipation.

[0018] In a preferred embodiment of the present invention, the AC-DC-AC inverter circuit system controller is mounted on the first partition, and an inverter cooling air duct is formed between the AC-DC-AC inverter circuit system controller and the first partition. One side of the inverter cooling air duct is connected to the first ventilation port, and the other side is connected to the first air inlet on the housing.

[0019] In this design, an inverter cooling duct is formed between the AC-DC-AC inverter circuit system controller and the first partition. After the cooling air enters the air intake cavity from the first air inlet, it will all flow through the inverter cooling duct and then enter the housing from the first ventilation port. The cooling air flows rapidly in the cooling duct and carries away the heat generated by the AC-DC-AC inverter circuit system controller, resulting in a significant heat dissipation effect on the AC-DC-AC inverter circuit system controller.

[0020] In a preferred embodiment of the present invention, the dedicated heat dissipation structure includes a first heat dissipation shroud disposed on the top or side of the housing, the AC-DC-AC inverter circuit system controller being installed in the first heat dissipation shroud, the first heat dissipation shroud being provided with a second air inlet and a second air outlet, and a cooling fan being provided at the second air inlet and / or the second air outlet.

[0021] In this solution, the AC-DC-AC inverter circuit system controller is installed in the first heat dissipation shroud at the top or side of the housing. The AC-DC-AC inverter circuit system controller in the first heat dissipation shroud is cooled by the cooling fan at the second air inlet and / or the second air outlet, resulting in high heat dissipation efficiency.

[0022] In a preferred embodiment of the present invention, the independent exhaust structure includes a second partition disposed in the housing near the first exhaust port, the second partition and the first exhaust port side of the housing forming an exhaust chamber, the second partition being provided with a second vent, and the silencer assembly being located in the exhaust chamber.

[0023] In this design, a second partition is installed inside the housing near the first exhaust vent. The second partition separates the muffler assembly into the exhaust chamber, which effectively reduces the heat radiation from the muffler assembly to one side of the housing. The exhaust gas after being silenced by the muffler assembly can be quickly discharged through the first exhaust vent. In addition, under the action of the cooling fan, the air inside the housing is discharged outward through the second vent, which can also carry the exhaust gas discharged by the muffler assembly and the radiated heat to the first exhaust vent.

[0024] In a preferred embodiment of the present invention, the muffler assembly includes a first muffler, a second muffler, and an exhaust pipe connected in sequence. The first muffler is connected to the engine exhaust port through an intake pipe, and the exhaust pipe is provided with a plurality of exhaust ports.

[0025] In this design, the muffler assembly adopts a multi-stage silencing structure consisting of a first muffler and a second muffler, resulting in excellent silencing performance.

[0026] In a preferred embodiment of the present invention, the generator is provided with an exhaust fan, which is arranged opposite to the second vent.

[0027] In this design, an exhaust fan mounted on the generator, positioned opposite the second vent, draws cooling air into the housing to cool the engine and generator. Meanwhile, the exhaust fan forces the hot air inside the housing to be quickly expelled through the second vent. This cooling structure effectively improves heat dissipation efficiency.

[0028] In a preferred embodiment of the present invention, the independent exhaust structure includes a second heat dissipation hood, a silencer assembly located inside the second hood, and the second air guide hood, the first air guide hood, and the second heat dissipation hood are connected in sequence. The exhaust port of the second heat dissipation hood faces and is close to the first exhaust port of the housing.

[0029] In this design, the independent exhaust structure employs a second heat dissipation hood. The second air guide hood, the first air guide hood, and the second heat dissipation hood are connected in sequence. Cooling air enters the housing from the first air inlet and flows sequentially through the second air guide hood, the first air guide hood, and the second heat dissipation hood, respectively, to cool the generator, engine, and muffler. Finally, it is discharged from the exhaust port of the second heat dissipation hood to the first exhaust port of the housing. With this independent exhaust structure, the heat dissipation of the generator, engine, and muffler assembly is arranged along the same airflow path. The cooling airflow cools the generator, engine, and muffler assembly sequentially, forming a directional heat dissipation path. The muffler assembly is located at the end of the airflow path, and the heat it generates is directly discharged after being guided by the second heat dissipation hood, effectively reducing the diffusion of heat to the engine and generator side.

[0030] As a preferred embodiment of the present invention, an exhaust hood with one open side is provided. The open side of the exhaust hood is close to or abuts against the first exhaust port of the housing. The other side of the exhaust hood is connected to the second heat dissipation hood. The exhaust pipe of the muffler assembly extends into the exhaust hood and has several exhaust ports.

[0031] In this design, an exhaust hood with an open side is provided, and the exhaust pipe of the muffler assembly extends into the exhaust hood. The exhaust gas, after being silenced by the muffler assembly, is directly discharged to the first exhaust port through several exhaust ports on the exhaust pipe. The exhaust hood is separated from the second heat dissipation hood, which can further separate the discharged exhaust gas, create positive pressure in the exhaust hood, and quickly discharge it to the first exhaust port, preventing exhaust gas from flowing back or heat from radiating into the box.

[0032] In a preferred embodiment of the present invention, the independent exhaust structure includes a third heat dissipation shroud disposed at the top of the housing above the generator, or disposed on one side of the housing alongside the generator, and the silencer assembly is located within the third heat dissipation shroud.

[0033] In this design, the third heat dissipation shroud is located at the top of the housing above the generator, or on one side of the housing alongside the generator. This shortens the distance between the muffler assembly and the engine, thereby reducing the length of the exhaust pipe between the muffler assembly and the engine. This prevents exhaust gases from dissipating a large amount of heat into the backup power supply housing through the exhaust pipe. At the same time, placing the third heat dissipation shroud above or alongside the generator makes full use of the space around the generator, reducing the space occupied by the muffler assembly on the outside of the generator set. This makes the component layout inside the backup power supply housing more compact and effectively reduces the overall volume of the backup power supply.

[0034] In a preferred embodiment of the present invention, the side panel of the first air inlet and / or the first air outlet of the housing includes a first protective plate and a second protective plate. The first protective plate and the second protective plate are provided with a plurality of air holes, and the air holes between the first protective plate and the second protective plate are staggered.

[0035] In this design, the side panels of the first air inlet and / or the first air outlet of the enclosure are composed of a first protective plate and a second protective plate to prevent debris from outside the enclosure from entering the enclosure. The staggered arrangement of the air holes between the first and second protective plates also provides a waterproof effect.

[0036] In a preferred embodiment of the present invention, a protective net is further provided between the first protective plate and the second protective plate.

[0037] In this design, a protective net is installed between the first and second protective plates to further prevent debris or insects from entering the container, resulting in better protection.

[0038] In a preferred embodiment of the present invention, the first air guide shroud and the second air guide shroud are separated and independent. The second air guide shroud has a second air inlet on the side away from the engine. An intake fan is provided on the generator near the second air inlet. The second air guide shroud has a second exhaust vent on the side near the engine. The second air inlet extends to the side or bottom of the housing through an air intake pipe.

[0039] In this design, the first and second air guide shrouds are separated and independent, with independent cooling air ducts forming inside each shroud. On one hand, under the negative pressure of the cooling fan, cooling air enters the housing from the first air inlet on one side of the housing and then enters the first air guide shroud to cool the engine. On the other hand, under the action of the intake fan, cooling air enters the second air guide shroud from the side or bottom of the housing through the air intake pipe and the second air inlet to cool the engine, and then exits into the housing from the second exhaust outlet, and finally exits from the first exhaust outlet on the housing. This form of forming independent cooling air ducts for the engine and generator provides better cooling for both the engine and generator.

[0040] In a preferred embodiment of the present invention, when the second air inlet extends to the bottom of the box through the air inlet pipe, a shield with one open side is provided at the bottom of the box. The two ends of the shield are connected to the bottom of the box, and a cooling air inlet gap is formed between the two sides of the shield and the bottom of the box.

[0041] In this design, a shield with one open side is provided at the bottom of the enclosure. On the one hand, the two ends of the shield are connected to the bottom of the enclosure, forming a support beam structure at the bottom of the enclosure to support and strengthen it. On the other hand, a cooling air intake gap is formed between the two sides of the shield and the bottom of the enclosure. Cooling air can enter through the intake gap, and then enter the second air guide shroud through the intake duct and the second air inlet to dissipate heat from the generator. The shield can also effectively prevent debris from directly entering the intake duct. Sufficient intake gaps can be formed on both sides of the shield to ensure sufficient cooling air intake.

[0042] In a preferred embodiment of the present invention, the backup power system is a household backup power system.

[0043] In a preferred embodiment of the present invention, the automatic load management subsystem collects the current of each output channel at different levels and calculates the total generator power Pn. The output channels at different levels include uncontrolled channels and multiple controlled channels at different levels. Based on the overload status and duration of the total generator power Pn, each controlled channel is closed sequentially in ascending order of its level until the total generator power Pn < 90%. When the margin of the total generator power Pn is sufficient, each controlled channel that was closed due to overload can be automatically reopened.

[0044] This solution achieves refined power monitoring and management of uncontrolled channels and multiple controlled channels of different levels by collecting the current of each output channel at different levels and calculating the total generator power Pn. When the total generator power Pn is overloaded, the system can sequentially shut down each controlled channel in ascending order of level until the total generator power Pn drops below 90%. This tiered load control strategy avoids frequent start-stop cycles caused by instantaneous fluctuations and ensures that the continuous power supply to critical loads (uncontrolled channels) is unaffected. Simultaneously, when the margin of the total generator power Pn is sufficient, the system can automatically reopen the controlled channels that were shut down due to overload, restoring power to non-critical loads without manual intervention. This significantly improves power supply continuity and the system's intelligence level, achieving dynamic balancing and automated control of load management.

[0045] In a preferred embodiment of the present invention, the automatic load management subsystem is also used to automatically shut down the corresponding controlled channel when the single-channel current of the controlled channel at different levels exceeds its respective set current threshold and duration, and to restore it within a set time after removing the corresponding load; and to shut down the controlled channel when a short circuit is detected in any controlled channel, and to restore it within a set time after removing the corresponding load.

[0046] In this solution, by monitoring the single-channel current of each controlled channel, the system can automatically shut down the corresponding controlled channel when the current exceeds its set current threshold and duration, preventing local overload from damaging the backup power supply and load. After removing the corresponding load, the system can automatically restore power to the channel within a set time, reducing the workload of manual troubleshooting and restoration. Furthermore, when a short circuit is detected in any controlled channel, the system shuts down that channel and automatically restores it after the fault is cleared. This multi-dimensional safety protection system not only ensures the overall operational safety of the backup power supply but also provides independent protection for each load channel, comprehensively improving the reliability of the power supply system and the safety of the equipment. Attached Figure Description

[0047] Figure 1 This is a schematic diagram of the structure of Embodiment 1 of the present invention;

[0048] Figure 2 This is a structural schematic diagram of Embodiment 1 of the present invention (concealing one side and top of the box);

[0049] Figure 3 This is another structural schematic diagram of Embodiment 1 of the present invention (hiding one side and top of the box);

[0050] Figure 4 This is a structural schematic diagram of Embodiment 1 of the present invention (concealing one side, top, and part of the bottom of the box);

[0051] Figure 5 This is a schematic diagram of the side plate portion of the first air inlet and the first air outlet in Embodiment 1 of the present invention;

[0052] Figure 6 This is a structural schematic diagram of Embodiment 2 of the present invention (concealing one side and top of the box);

[0053] Figure 7 This is a structural schematic diagram of Embodiment 2 of the present invention (concealing the sides and top of the box);

[0054] Figure 8 This is a schematic diagram of the structure of Embodiment 3 of the present invention;

[0055] Figure 9 This is a structural schematic diagram of Embodiment 3 of the present invention (hiding the sides and top of the box);

[0056] Figure 10 This is a structural schematic diagram of Embodiment 3 of the present invention (concealing the sides, top, and top of the first heat dissipation shroud);

[0057] Figure 11 This is a schematic diagram of the dedicated heat dissipation structure in Embodiment 3 of the present invention;

[0058] Figure 12 This is a structural schematic diagram of Embodiment 4 of the present invention (concealing the sides and top of the box);

[0059] Figure 13 This is another structural schematic diagram of Embodiment 4 of the present invention (hiding the sides and top of the box);

[0060] Figure 14 This is a structural schematic diagram of Embodiment 5 of the present invention (concealing the sides and top of the box);

[0061] Figure 15 This is a schematic diagram of the structure of the bottom of the housing, the second air guide shroud, and the air inlet duct in Embodiment 5 of the present invention;

[0062] Figure 16 This is a cross-sectional view along the AA direction of Embodiment 5 of the present invention.

[0063] The reference numerals in the attached drawings include: housing 1, first air inlet 101, first air outlet 102, first protective plate 103, second protective plate 104, protective net 105, vent 106, baffle plate 107, engine 2, generator 3, first air guide shroud 4, second air guide shroud 5, inverter 6, first partition 7, air intake chamber 701, first vent 702, inverter cooling air duct 703, muffler assembly 8, first muffler 801, second muffler 802, exhaust pipe 803, second partition 9, exhaust chamber 901, second vent 902, annular cover 903, and exhaust fan 10.

[0064] Second heat dissipation cover 11, exhaust cover 12.

[0065] First heat sink shroud 13, second air inlet 131, second air outlet 132, cooling fan 14, third air guide shroud 15, third air inlet 108.

[0066] The third heat dissipation cover 16, the opening 161.

[0067] 17. Intake fan, 501. Second air inlet, 502. Intake duct, 18. Shield, 19. Intake gap, 20. Fourth air inlet, 21. Detailed Implementation

[0068] Typical embodiments embodying the features and advantages of the present invention will be specifically described in the following description. It should be understood that the present invention can have various variations in different embodiments without departing from the scope of the present invention, and the descriptions and illustrations herein are for illustrative purposes only and not intended to limit the present invention.

[0069] In the description of this application, the terms "first", "second", etc. are used only for the convenience of describing this application and simplifying the description, and are not intended to indicate or imply that the structure referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this application.

[0070] Example 1

[0071] See Figure 1 , Figure 2As shown, this embodiment discloses a backup power system, particularly a household backup power system, including a housing 1. The housing 1 is a metal shell. In some other specific embodiments, the housing 1 can also be made of high-strength, aging-resistant engineering plastic. The housing 1 has a first air inlet 101 on one side and a first air outlet 102 on the other side. The backup power system also includes an automatic load management subsystem. The automatic load management system is connected to the ATS module system to achieve connection with the power distribution system. The ATS module system is an automatic transfer switch (ATS). The backup power system uses a permanent magnet generator set and also includes an engine 2 and a generator 3 installed in the housing 1. The engine 2 and the generator 3 are connected by a drive. The engine 2 is wrapped with a first air guide shroud 4, and the generator 3 is wrapped with a second air guide shroud 5. The first air guide shroud 4 and the second air guide shroud 5 are connected. The generator 3 is located near the first air inlet 101. A cooling fan is provided on the cooling air intake side of the generator 3. The engine 2 is located near the first air outlet 102. In some other specific embodiments, the engine 2 may be located near the first air inlet 101, the engine 3 may have a cooling fan on the air intake side, and the generator 3 may be located near the first air outlet 102.

[0072] The automatic load management subsystem collects the current of output channels at different levels and calculates the total generator power Pn. These output channels include uncontrolled channels and multiple controlled channels at different levels. Based on the overload status and duration of the total generator power Pn, the subsystem sequentially shuts down controlled channels in ascending order of their level until the total generator power Pn < 90%. When the total generator power Pn has sufficient margin, the subsystem automatically reopens the controlled channels that were shut down due to overload. The automatic load management subsystem also automatically shuts down the corresponding controlled channel when the single-channel current exceeds its set current threshold and duration, and restores it within a set time after removing the corresponding load. Similarly, if a short circuit is detected in any controlled channel, the subsystem shuts down that channel and restores it within a set time after removing the corresponding load. In some specific embodiments, the automatic load management subsystem includes a load selection module, uncontrolled channels, and multiple controlled channels of different levels. The load selection module has a built-in current transformer. The different levels of controlled channels can be manually set according to requirements. Taking three controlled channels as an example, the uncontrolled channel is S0, and the three controlled channels are S1, S2, and S3. S0 has the highest priority, is not controlled by the load selection module, and provides continuous power. S1–S3 are controlled channels, and their on / off state is independently controlled by the load selection module through relays. The current of S0–S3 is collected in real time through the current transformer, the total power Pn is calculated, and protection logic is executed in combination with voltage and frequency parameters, as detailed below:

[0073] Load distribution logic:

[0074] Normal operating conditions: S1–S3 are activated sequentially in the order of S1→S2→S3.

[0075] Overload conditions:

[0076] Total power Pn>100% for 120s: Turn off in sequence S3→S2→S1 until total power Pn<90%.

[0077] Total power Pn > 105% for 30 seconds: Turn off in sequence S3 → S2 → S1 until total power Pn < 90%.

[0078] Total power Pn > 115% for 6 seconds: Turn off sequentially in the order of S3 → S2 → S1 until total power Pn < 90%.

[0079] Single-path protection:

[0080] S1 current > 30A for 10s: S1 is turned off, and it recovers 3s after the load is removed.

[0081] S2 / S3 current > 20A for 10s: shut down the corresponding channel, and restore 3s after the load is removed.

[0082] Short circuit protection: If a short circuit is detected in any of the S1–S3 channels, the channel will be shut down immediately and will recover 3 seconds after the load is removed.

[0083] Recovery logic: After the channel is shut down due to overload, the load selection module records the load power at the time of shutdown, determines the total power margin of the generator, and if it is sufficient, automatically reopens the channel.

[0084] Electrical parameter protection (taking 120V 60Hz as an example)

[0085] Undervoltage protection: If U < 90%Un (108V) for 8 seconds, disconnect S1–S3.

[0086] Overvoltage protection: If U>110%Un (132V) lasts for 1 second, S1–S3 will be disconnected.

[0087] Underfrequency protection: f < 54Hz for 8 seconds, then disconnect S1–S3.

[0088] Overclocking protection: If f>65Hz lasts for 1 second, S1–S3 will be disconnected.

[0089] Status indication:

[0090] When channels S1–S3 are operating normally, the green indicator light will remain constantly on.

[0091] The indicator light flashes when overloaded, and goes out after the protection trips, with no output from the socket.

[0092] The automatic load management subsystem using this solution has the following advantages:

[0093] Priority guarantee: By setting S0 as an uncontrolled channel, it is not controlled by the load selection module and continues to supply power; S1-S3 are controlled channels, and their on / off state is independently controlled by the load selection module through relays. This hierarchical architecture ensures that after critical loads are connected to S0, they will not be cut off due to power management strategies under any overload conditions, fundamentally guaranteeing the power supply continuity of core electrical equipment.

[0094] Stepped overload protection: Three protection thresholds are set according to different overload levels of total power Pn: Pn>100% for 120s, Pn>105% for 30s, and Pn>115% for 6s. Controlled channels are shut down sequentially in the order of S3→S2→S1 until Pn<90%. The lighter the overload, the longer the response time; the more severe the overload, the faster the response. This stepped shutdown strategy effectively distinguishes between temporary fluctuations and continuous overloads, avoiding frequent start-stops caused by instantaneous power changes. At the same time, loads are cut off in reverse order of priority, maximizing the preservation of power supply to important loads.

[0095] Multi-dimensional protection: Integrating overload, short circuit, and voltage / frequency anomaly protection, it includes: 1) global power overload protection, monitoring total power Pn; 2) single-channel current protection, automatically shutting down the corresponding channel if S1 current > 30A for 10s or S2 / S3 current > 20A for 10s; 3) short circuit protection, immediately cutting off any channel detected with a short circuit; and 4) electrical parameter protection, covering undervoltage (<108V / 8s), overvoltage (>132V / 1s), underfrequency (<54Hz / 8s), and overfrequency (>65Hz / 1s). These multi-dimensional protections are independent yet synergistic, comprehensively ensuring the safety of the backup power supply and load equipment.

[0096] Intelligent recovery: Power supply is automatically restored after fault troubleshooting, which significantly improves power supply continuity and enables intelligent operation of load management.

[0097] like Figure 5As shown, the side panels of the first air inlet 101 and the first air outlet 102 of the housing 1 include a first protective plate 103 and a second protective plate 104 arranged from the inside to the outside of the housing 1. A protective net 105 is also provided between the first protective plate 103 and the second protective plate 104. Several air holes 106 arranged in a horizontal and vertical array are opened on the first protective plate 103 and the second protective plate 104. The air holes 106 between the second protective plate 104 and the first protective plate 103 are staggered. A protective net 105 is also provided between the first protective plate 103 and the second protective plate 104. In some specific embodiments, a shielding plate 107 is provided on one side of each air hole 106 to block the air hole 106. Preferably, the shielding plates 107 on the first protective plate 103 and the second protective plate 104 are located in the space between them. The shielding plate 107 on the second protective plate 104 is inclined from bottom to top or arc-shaped, and the shielding plate 107 on the first protective plate 103 is inclined from top to bottom or arc-shaped. In some other embodiments, the shielding plate 107 may also be located on the other side of the first protective plate 103 or the second protective plate 104. When the shielding plate 107 on the second protective plate 104 is on the outside, the shielding plate 107 is inclined from top to bottom or arc-shaped.

[0098] AC-DC-AC inverter circuit system controller, such as Figure 3 As shown, the AC-DC-AC inverter circuit system controller is the inverter 6, which belongs to the prior art and will not be described in detail in the embodiment. The housing 1 is provided with a dedicated heat dissipation structure for accommodating the inverter 6. In this embodiment, the dedicated heat dissipation structure includes a first partition 7 disposed in the housing 1 near the first air inlet 101. The first partition 7 and one side of the first air inlet 101 on the housing 1 form an air intake cavity 701. The first partition 7 is provided with a first ventilation opening 702. The inverter 6 is located in the air intake cavity 701. The inverter 6 is mounted on the first partition 7, and an inverter cooling air duct 703 is formed between the inverter 6 and the first partition 7. One side of the inverter cooling air duct 703 is connected to the first ventilation opening 702, and the other side is connected to the first air inlet 101 on the housing 1.

[0099] The muffler assembly 8 is used to reduce the noise of the exhaust gas from the engine 2. The housing 1 has an independent exhaust structure for housing the muffler assembly 8, and this independent exhaust structure is arranged near the first exhaust port 102 of the housing 1. Figure 2 , Figure 4As shown, in this embodiment, the independent exhaust structure includes a second partition 9 disposed inside the housing 1 near the first exhaust port 102. The second partition 9 and one side of the first exhaust port 102 on the housing 1 form an exhaust chamber 901. The second partition 9 is provided with a second vent 902. The engine 2 is provided with an exhaust fan 10, which is arranged opposite to the second vent 902. The muffler assembly 8 is located inside the exhaust chamber 901. The muffler assembly 8 includes a first muffler 801, a second muffler 802, and an exhaust pipe 803 connected in sequence. The first muffler 801 is connected to the exhaust port of the engine 2 through an intake pipe. The exhaust pipe 803 is provided with several exhaust ports. In some other embodiments, depending on the need for noise reduction, the muffler assembly 8 may consist of one muffler, three mufflers, etc.

[0100] In some specific embodiments, an annular cover 903 is provided at the second vent 902 of the second partition 9, and the exhaust fan 10 is disposed inside the annular cover 903. This allows the exhaust fan 10 to form a more concentrated and powerful airflow at the annular cover 903, quickly expelling the hot air inside the housing 1. Moreover, the exhaust fan 10 being located inside the annular cover 903 can also prevent interference with other components.

[0101] Example 2

[0102] This embodiment discloses another backup power system, which differs from Embodiment 1 in that the independent exhaust structure for housing the silencer assembly 8 is different from that in Embodiment 1. For example... Figure 6 , Figure 7 As shown, in this embodiment, the independent exhaust structure includes a second heat dissipation shroud 11, a silencer assembly 8 located inside the second heat dissipation shroud 11, and a second air guide shroud 5, a first air guide shroud 4, and a second heat dissipation shroud 11 connected in sequence. The exhaust port of the second heat dissipation shroud 11 faces and is close to the first exhaust port 102 of the housing 1.

[0103] In some specific embodiments, an exhaust hood 12 with an opening 161 on one side is also provided. One side of the opening 161 of the exhaust hood 12 is close to or abuts against the first exhaust port 102 of the housing 1. The other side of the exhaust hood 12 is connected to the second heat dissipation hood 11. The exhaust pipe 803 of the muffler assembly 8 extends into the exhaust hood 12. The exhaust pipe 803 is provided with several exhaust ports.

[0104] Example 3

[0105] This embodiment discloses another backup power system. Unlike Embodiment 1 or Embodiment 2, the dedicated heat dissipation structure for housing the inverter 6 is different. In this embodiment, the dedicated heat dissipation structure includes a first heat dissipation shroud 13 disposed on the top or side of the housing 1, such as... Figure 8-11As shown, a first heat sink shroud 13 is arranged at the top inside the housing 1. The inverter 6 is installed inside the first heat sink shroud 13. The first heat sink shroud 13 has a second air inlet 131 and a second air outlet 132 arranged opposite to each other. A cooling fan 14 is provided at both the second air inlet 131 and the second air outlet 132. A third air guide shroud 15 is also provided at the second air inlet 131 and the second air outlet 132. One side of the third air guide shroud 15 is adjacent to the second air inlet 131 or the second air outlet 132, and one side of the third air guide shroud 15 extends to a side plate on one side of the housing 1. A third air inlet 108 communicating with the third air guide shroud 15 is provided on the side plate on one side of the housing 1. In some other embodiments, the second air inlet 131 and the second air outlet 132 are also adjacent or otherwise arranged, and a cooling fan 14 may also be provided at the second air inlet 131 or the second air outlet 132.

[0106] Example 4

[0107] like Figure 12 , Figure 13 As shown, this embodiment discloses another backup power system. Unlike embodiment 1, the engine 2 is located near the first air inlet 101, the engine 3 has a cooling fan on its air intake side, and the generator 3 is located near the first exhaust outlet 102, with an exhaust fan 10 mounted on it. Furthermore, the independent exhaust structure for housing the muffler assembly 8 differs from that in embodiment 1. In this embodiment, the independent exhaust structure includes a component located inside the housing 1 at the top, above the generator 3 (e.g., ...). Figure 12 ), or set inside the housing 1 on one side parallel to the generator 3 (e.g. Figure 13 The third heat dissipation cover 16 is located inside the third heat dissipation cover 16, and the third heat dissipation cover 16 has an opening 161 on one side facing the first exhaust port 102 of the box 1.

[0108] Example 5

[0109] like Figure 14-15 As shown, this embodiment discloses another backup power system. Unlike embodiment 1, the engine 2 is located near the first air inlet 101, the engine 3 is equipped with a cooling fan on the side of the cooling air intake, the generator 3 is located near the first air outlet 102, the generator 3 is equipped with an exhaust fan 10, the first air guide shroud 4 and the second air guide shroud 5 are separated and independent, the second air guide shroud 5 is equipped with a second air inlet 131 on the side away from the engine 2, the generator 3 is equipped with an intake fan 17 near the second air inlet 131, the second air guide shroud 5 is equipped with a second air outlet 132 on the side of the second air guide shroud 5 near the engine 2, and the second air inlet 131 extends to the side or bottom of the housing 1 through the air intake pipe 18.

[0110] like Figure 16As shown, when the second air inlet 131 extends to the bottom of the box 1 through the air inlet pipe 18, a shield 19 with an open side 161 is provided at the bottom of the box 1. The two ends of the shield 19 are connected to the bottom of the box 1, and a cooling air inlet gap 20 is formed between the two sides of the shield 19 and the bottom of the box 1.

[0111] like Figure 15 As shown, in some specific embodiments, the bottom of the housing 1 is also provided with a fourth air inlet 21 facing the inverter 6. The cooling air from the fourth air inlet 21 also enters the housing 1 through the air inlet gap 20 and blows towards the inverter 6. The cooling air that enters the housing 1 through the first air inlet 101 has to go through multiple changes of direction before entering the inverter cooling air duct 703 between the inverter 6 and the first partition 7. The air intake and the heat dissipation efficiency of the inverter 6 may be insufficient. By adding the fourth air inlet 21, the air intake can be further increased and the heat dissipation efficiency and heat dissipation effect of the inverter 6 can be improved.

[0112] The above embodiments are merely preferred embodiments of the present invention and should not be construed as limiting the scope of protection of the present invention. Any non-substantial changes and substitutions made by those skilled in the art based on the present invention shall fall within the scope of protection claimed by the present invention.

Claims

1. A backup power system, comprising a housing, wherein a first air inlet is provided on one side of the housing and a first air outlet is provided on the other side, characterized in that, The backup power system uses a permanent magnet generator set with a metal casing. It also includes an automatic load management subsystem, an engine and generator, an AC-DC-AC inverter circuit system controller and a muffler assembly, all housed inside the casing. The automatic load management subsystem is connected to the ATS module system. The engine and generator are connected by a drive. The engine is encased in a first air guide shroud. A cooling fan is provided on the cooling air intake side of the engine and / or generator. The generator is encased in a second air guide shroud. The first air guide shroud and the second air guide shroud are either connected or separate and independent. The enclosure is equipped with a dedicated heat dissipation structure for housing the AC-DC-AC inverter circuit system controller. The muffler assembly is used to reduce the noise of the exhaust gas from the engine, and the housing is provided with an independent exhaust structure for accommodating the muffler assembly.

2. The backup power system according to claim 1, characterized in that: The dedicated heat dissipation structure includes a first partition plate disposed inside the housing near the first air inlet. The first partition plate and the first air inlet side of the housing form an air intake cavity. The first partition plate is provided with a first ventilation opening. The AC-DC-AC inverter circuit system controller is located inside the air intake cavity.

3. The backup power system according to claim 2, characterized in that: The AC-DC-AC inverter circuit system controller is installed on the first partition, and an inverter cooling air duct is formed between the AC-DC-AC inverter circuit system controller and the first partition. One side of the inverter cooling air duct is connected to the first ventilation port, and the other side is connected to the first air inlet on the housing.

4. The backup power system according to claim 1, characterized in that: The dedicated heat dissipation structure includes a first heat dissipation shroud disposed on the top or side of the housing, the AC-DC-AC inverter circuit system controller being installed in the first heat dissipation shroud, the first heat dissipation shroud being provided with a second air inlet and a second air outlet, and a cooling fan being provided at the second air inlet and / or the second air outlet.

5. The backup power supply system of claim 1, wherein: The independent exhaust structure is arranged near the first exhaust port of the box. The independent exhaust structure includes a second partition installed in the box near the first exhaust port. The second partition and the first exhaust port on the box form an exhaust chamber. The second partition is provided with a second vent. The silencer assembly is located in the exhaust chamber.

6. The backup power supply system of claim 5, wherein: The muffler assembly includes a first muffler, a second muffler, and an exhaust pipe connected in sequence, with several exhaust ports on the exhaust pipe.

7. The backup power system according to claim 5 or 6, characterized in that: The generator is equipped with an exhaust fan, which is arranged opposite to the second vent.

8. The backup power supply system of claim 1, wherein: The independent exhaust structure is arranged near the first exhaust port of the housing. The independent exhaust structure includes a second heat dissipation hood, and a silencer assembly is located inside the second hood. The second air guide hood, the first air guide hood, and the second heat dissipation hood are connected in sequence. The exhaust port of the second heat dissipation hood faces and is close to the first exhaust port of the housing.

9. The backup power supply system of claim 8, wherein: It is also equipped with an exhaust hood with one side open. The open side of the exhaust hood is close to or abuts the first exhaust port of the box. The other side of the exhaust hood is connected to the second heat dissipation hood. The exhaust pipe of the muffler assembly extends into the exhaust hood. The exhaust pipe is provided with several exhaust ports.

10. The backup power supply system of claim 1, wherein: The independent exhaust structure is arranged near the first exhaust port of the housing. The independent exhaust structure includes a third heat dissipation shroud located at the top of the housing above the generator, or located on one side of the housing alongside the generator. The silencer assembly is located inside the third heat dissipation shroud.

11. The backup power supply system of claim 1, wherein: The side panel of the first air inlet and / or the first air outlet of the enclosure includes a first protective plate and a second protective plate. The first protective plate and the second protective plate are provided with a number of air holes, and the air holes between the second protective plate and the first protective plate are staggered.

12. The backup power supply system of claim 11, wherein: A protective net is also provided between the first protective plate and the second protective plate.

13. The backup power supply system of claim 1, wherein: The first air guide shroud and the second air guide shroud are separate and independent. The second air guide shroud has a second air inlet on the side away from the engine. An intake fan is provided on the generator near the second air inlet. The second air guide shroud has a second exhaust vent on the side near the engine. The second air inlet extends to the side or bottom of the housing through an air intake duct.

14. The backup power system according to claim 13, characterized in that: When the second air inlet extends to the bottom of the box through the air inlet pipe, a shield with one open side is provided at the bottom of the box. The two ends of the shield are connected to the bottom of the box, and a cooling air intake gap is formed between the two sides of the shield and the bottom of the box.

15. The backup power system according to any one of claims 1-14, characterized in that: The backup power system is a household backup power system.

16. The backup power system according to claim 1, characterized in that: The automatic load management subsystem collects the current of each output channel at different levels and calculates the total generator power Pn. The output channels at different levels include uncontrolled channels and multiple controlled channels at different levels. Based on the overload status and duration of the total generator power Pn, the system sequentially closes each controlled channel in ascending order of its level until the total generator power Pn < 90%. When the margin of the total generator power Pn is sufficient, the system can automatically reopen each controlled channel that was closed due to overload.

17. The backup power supply system of claim 16, wherein: The automatic load management subsystem is also used to automatically shut down the corresponding controlled channel when the single current of the controlled channel at different levels exceeds its respective set current threshold and duration, and to restore it within a set time after removing the corresponding load. When a short circuit is detected in any controlled channel, the controlled channel is shut down and restored within a set time after removing the corresponding load.

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