Intelligent compact box-type substation

Abstract

This application relates to the field of compact substation technology and discloses an intelligent compact prefabricated substation, comprising: a main body of the prefabricated box, the main body of which is composed of lightweight composite material, the composite layered structure material including an outer layer, a middle heat insulation layer and an inner layer; a functional chassis, the functional chassis being fixedly connected to the bottom of the main body of the box, the functional chassis being a sandwich structure with an internal cavity filled with phase change material, the top of which supports the substation structure; and intelligent support columns, a plurality of intelligent support columns being spaced apart below the functional chassis, the upper end of the intelligent support columns being connected to the lower surface of the functional chassis. By adopting a topology optimization structure, reinforcing ribs are set in stress concentration areas and a hollow structure is formed in non-load-bearing areas, the problems of bulky structure and low material utilization rate of traditional prefabricated substations are solved, achieving extreme lightweighting of the box while ensuring the overall structural strength and rigidity.

Description

Technical Field

[0001] This invention relates to the field of compact substation technology, specifically to an intelligent compact prefabricated substation. Background Technology

[0002] Prefabricated substations, as key equipment in power distribution network systems, are widely used in urban power grids, industrial parks, residential communities, and other scenarios. With the acceleration of urbanization and the upgrading of power grids, higher requirements are being placed on the footprint, structural weight, environmental adaptability, and level of intelligence of prefabricated substations.

[0003] The existing prefabricated substations mainly have the following technical problems:

[0004] First, traditional prefabricated substations mostly use ordinary steel plates or concrete structures, with a crude design that lacks systematic stress analysis and material optimization. To ensure structural strength, thick, uniform wall panels are typically used, resulting in a large overall weight of the prefabricated unit. This not only increases the difficulty of transportation and installation but also places higher demands on the foundation's bearing capacity, making it difficult to deploy flexibly in space-constrained urban core areas or the renovation of old residential communities.

[0005] Secondly, the transformers and other electrical equipment inside the prefabricated substation generate a large amount of heat during operation, and the existing heat dissipation methods mainly rely on forced air cooling or natural convection. Forced air cooling requires the configuration of active heat dissipation equipment such as fans, which not only increases energy consumption but also has the problems of high failure rate and high maintenance cost; natural convection heat dissipation is limited by the structure of the enclosure and the ambient temperature, and during the high load period of daytime, local temperature rise is prone to be too fast, which affects the service life and safety of the equipment.

[0006] Third, prefabricated substations are typically installed directly on the foundation, with the supporting structure mostly being rigidly connected. In areas with geological changes or earthquake-prone zones, uneven settlement of the foundation or external vibrations can cause the prefabricated box to tilt or deform. The existing supporting structure cannot adaptively adjust according to the degree of foundation displacement, which can easily lead to damage to the prefabricated box structure or displacement of internal equipment, and in severe cases, cause power outages. Summary of the Invention

[0007] To address the shortcomings of existing technologies, this invention provides an intelligent and compact prefabricated substation, which solves the problems of traditional prefabricated substations being bulky in complex environments, having high heat dissipation and energy consumption, and being unable to adaptively resist geological deformation.

[0008] To achieve the above objectives, the present invention provides the following technical solution: an intelligent compact prefabricated substation, comprising:

[0009] The main body of the box is made of lightweight composite material, and the composite layered structure material includes an outer layer, a middle heat insulation layer and an inner layer.

[0010] A functional chassis is fixedly connected to the bottom of the main body of the box. The functional chassis is a sandwich structure with an internal cavity filled with phase change material, and its top supports a transformer structure.

[0011] Intelligent support columns, multiple intelligent support columns are spaced apart below the functional chassis, and the upper end of the intelligent support columns is connected to the lower surface of the functional chassis.

[0012] Preferably, the main body of the box has a topology-optimized structure, which includes multiple reinforcing ribs and multiple hollow areas distributed on the surface of the main body according to stress analysis. The reinforcing ribs are located in the stress concentration areas of the main body, and the hollow areas are located in the non-load-bearing areas of the main body.

[0013] Preferably, the sandwich structure of the functional chassis is provided with a metal honeycomb skeleton, the phase change material is filled in the pores of the metal honeycomb skeleton, and the lower surface of the functional chassis is provided with multiple heat dissipation fins.

[0014] Preferably, the intelligent support column includes a first connecting member, one end of which is connected to the foundation, and the other end is fixedly connected to a cylinder. The cylinder has an internal accommodating space, and a piston head is slidably connected inside the cylinder. A piston rod is fixedly connected to one side of the outer wall of the piston head, and one end of the piston rod extends out of the cylinder and is fixedly connected to a second connecting member. The second connecting member is connected to the bottom wall of the functional chassis.

[0015] Preferably, the cylinder is filled with magnetorheological fluid, and an excitation coil is provided on the outer peripheral wall of the cylinder. One end of the excitation coil is electrically connected to a sensing unit, which is integrated on one side of the outer wall of the cylinder.

[0016] Preferably, both the first connecting member and the second connecting member are spherical hinge supports. The ball head pin and ball seat of the first connecting member are made of high-strength alloy structural steel, specifically 40Cr or 42CrMo. The ball head and the inner ring of the spherical bearing of the second connecting member are made of stainless steel, specifically 304 stainless steel or 17-4PH precipitation hardening stainless steel.

[0017] Preferably, the sensing unit includes an acceleration sensor disposed at the end of the cylinder.

[0018] Preferably, it also includes an intelligent controller, which is electrically connected to the sensing unit and the excitation coil respectively.

[0019] Preferably, it also includes a tilt sensor disposed on the functional chassis, the tilt sensor being electrically connected to the intelligent controller.

[0020] Preferably, a temperature sensor is also provided inside the internal cavity of the functional chassis, the probe of the temperature sensor is immersed in the phase change material, and an electromagnetic shielding material is also provided on the top of the functional chassis.

[0021] Working Principle: The main body of the enclosure achieves extreme lightweighting while ensuring strength through topology optimization, providing stable support for the bottom functional structure. Heat generated during substation operation is transferred to the functional chassis, where the metal honeycomb skeleton rapidly and evenly distributes the heat to the phase change material. The phase change material absorbs and stores heat through a solid-liquid phase change, suppressing rapid temperature rise. At night or under low load, the heat is slowly released through the heat dissipation fins and the material re-solidifies, achieving passive day-night thermal regulation. When geological changes or external vibrations cause foundation displacement, the sensing unit within the intelligent support column detects the cylinder's acceleration or strain signals in real time and transmits them to the intelligent controller. The intelligent controller determines the degree of deformation based on the signal strength and outputs regulating current to the corresponding excitation coil. By adjusting the apparent viscosity of the magnetorheological fluid by changing the magnetic field strength, the damping and stiffness of the support column are instantly increased to resist deformation. At the same time, the spherical hinge support allows the support column to rotate adaptively in multiple directions to avoid structural damage. Throughout the process, the intelligent controller continuously receives real-time data from the sensing unit, tilt sensor, and temperature sensor. Under normal operating conditions, the excitation coil is kept at a low current to ensure the flexibility of the support column. When the tilt sensor detects that the tilt of the box exceeds the threshold or the temperature sensor detects that the phase change material is close to the complete liquefaction point, the controller dynamically adjusts the excitation current of each support column or triggers the auxiliary heat dissipation device. The electromagnetic shielding material prevents external interference from affecting the accuracy of the sensors, thereby achieving integrated coordination of structural support, thermal management, and intelligent seismic resistance.

[0022] This invention provides an intelligent, compact prefabricated substation. It offers the following advantages:

[0023] 1. This invention solves the problems of bulky structure and low material utilization of traditional box-type substations by using a topology optimization structure combined with lightweight composite layered materials, setting reinforcing ribs in stress concentration areas and forming a hollow structure in non-load-bearing areas. It achieves extreme lightweighting of the box body while ensuring the overall structural strength and rigidity.

[0024] 2. This invention solves the problem of excessively rapid local temperature rise and high heat dissipation energy consumption during the operation of substation structures by setting a metal honeycomb skeleton filled with phase change material in the sandwich structure of the functional chassis and setting heat dissipation fins on the lower surface, utilizing the solid-liquid phase change heat storage and natural heat release at night of the phase change material, and realizing passive day and night thermal regulation without additional energy consumption.

[0025] 3. This invention solves the problem that the box body is difficult to adaptively resist uneven settlement and impact when geological changes or external vibrations by setting up an intelligent support column containing magnetorheological fluid, excitation coil, sensing unit and spherical hinge support, and combining it with the real-time response of intelligent controller to foundation displacement signals in various places and independent current adjustment. It realizes multi-directional adaptive damping adjustment and rapid attitude correction. Attached Figure Description

[0026] Figure 1 This is a perspective view of the compact prefabricated substation in this invention;

[0027] Figure 2 This is a diagram illustrating the compact prefabricated substation of this invention;

[0028] Figure 3 This is an exploded view of the topology optimization structure of the compact prefabricated substation in this invention;

[0029] Figure 4 This is a sectional view of the functional chassis of the compact prefabricated substation in this invention;

[0030] Figure 5 This is an exploded view of the functional chassis of the compact prefabricated substation in this invention;

[0031] Figure 6 This is a schematic diagram of the intelligent support column of the compact prefabricated substation in this invention;

[0032] Figure 7 This is a cross-sectional view of the intelligent support column of the compact box-type substation in this invention;

[0033] Figure 8 This is a diagram showing the intelligent controller connection architecture of the compact prefabricated substation in this invention.

[0034] The components include: 1. Main body of the enclosure; 101. Outer plate; 102. Middle heat insulation layer; 103. Inner plate; 104. Topology optimized structure; 105. Reinforcing rib; 106. Hollowed-out area; 2. Functional chassis; 201. Internal cavity; 202. Phase change material; 203. Metal honeycomb skeleton; 204. Heat dissipation fins; 205. Tilt sensor; 206. Temperature sensor; 207. Electromagnetic shielding material; 3. Intelligent support column; 301. First connecting component; 302. Cylinder; 303. Piston head; 304. Piston rod; 305. Second connecting component; 306. Magnetorheological fluid; 307. Excitation coil; 308. Sensing unit; 4. Transmission structure; 5. Intelligent controller. Detailed Implementation

[0035] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0036] Please see the appendix Figure 1 -Appendix Figure 8 This invention provides an intelligent compact prefabricated substation, comprising:

[0037] The main body of the box is 1, which is made of lightweight composite material. The composite layered structure material includes an outer layer 101, a middle heat insulation layer 102, and an inner layer 103.

[0038] Functional chassis 2 is fixedly connected to the bottom of the main body 1. Functional chassis 2 is a sandwich structure with an internal cavity 201. The internal cavity 201 is filled with phase change material 202, and its top supports the substation structure 4.

[0039] Intelligent support columns 3 are spaced apart below the functional chassis 2, with the upper end of each intelligent support column 3 connected to the lower surface of the functional chassis 2.

[0040] The main body 1 of the box has a topology optimization structure 104. The topology optimization structure 104 includes multiple reinforcing ribs 105 and multiple hollow areas 106 distributed on the surface of the main body 1 according to stress analysis. The reinforcing ribs 105 are located in the stress concentration areas of the main body 1, and the hollow areas 106 are located in the non-load-bearing areas of the main body 1.

[0041] Specifically, the topology optimization structure 104 of the main body 1 is formed through computer-aided design: First, a three-dimensional model of the main body 1 is established in the computer and divided into hundreds of thousands of tiny mesh elements. After setting the material performance parameters of each layer, the actual operating loads such as the self-weight of the substation structure 4, wind pressure, snow accumulation, and seismic force are simulated and applied. With the goal of minimizing structural flexibility and maximizing stiffness, under the premise of meeting the requirements of strength, stiffness, and vibration frequency, the variable density method is used for iterative calculation, and each mesh element is assigned a virtual density value between 0 and 1. In the color cloud map output after the calculation converges, the red high-density area with a density value ≥0.8 represents the high-stress area, which is retained and designed as a reinforcing rib 105, and the blue low-density area represents the high-stress area. Density values ​​≤ 0.2 represent non-load-bearing areas, where material is removed to form hollow areas 106. This determines that reinforcing ribs 105 are mainly distributed at the corners of the enclosure, the interface with the functional chassis 2, and directly above the support points of the transformer structure 4, arranged in a mesh-like skeleton structure along the principal stress lines. Hollow areas 106 are mainly distributed in the central areas of each wall panel and at the edges far from the support points, with the overall hollow area controlled between 30% and 40% of the total wall panel area. Finally, the optimized density cloud map is converted into a manufacturable geometric model, fine-tuned in conjunction with the production process, and the final design is verified for strength, stiffness, and fatigue life, thus forming the final topology-optimized structure 104.

[0042] The functional chassis 2 has a metal honeycomb skeleton 203 inside its sandwich structure, and phase change material 202 is filled in the pores of the metal honeycomb skeleton 203. The lower surface of the functional chassis 2 is provided with multiple heat dissipation fins 204.

[0043] Specifically, when the heat generated by the transformer structure 4 during operation is transferred to the functional chassis 2, the metal honeycomb skeleton 203 acts as a heat-conducting skeleton to quickly and evenly distribute the heat to the entire phase change material 202 area; after absorbing heat, the phase change material 202 undergoes a solid-liquid phase change, storing the heat in the form of latent heat, thereby suppressing the rapid rise in temperature of the functional chassis 2; at night or during low-load periods, when the ambient temperature decreases, the phase change material 202 slowly releases the stored heat to the atmosphere through the heat dissipation fins 204 and re-solidifies, realizing passive day and night heat migration, maintaining stable temperature inside the chamber without additional energy consumption.

[0044] The intelligent support column 3 includes a first connecting member 301. One end of the first connecting member 301 is connected to the foundation, and the other end is fixedly connected to a cylinder 302. The inside of the cylinder 302 forms a receiving space. A piston head 303 is slidably connected inside the cylinder 302. A piston rod 304 is fixedly connected to one side of the outer wall of the piston head 303. One end of the piston rod 304 extends out of the cylinder 302 and is fixedly connected to a second connecting member 305. The second connecting member 305 is connected to the bottom wall of the functional chassis 2.

[0045] The cylinder body 302 is filled with magnetorheological fluid 306. An excitation coil 307 is provided on the outer peripheral wall of the cylinder body 302. One end of the excitation coil 307 is electrically connected to a sensing unit 308, which is integrated on one side of the outer wall of the cylinder body 302.

[0046] Both the first connecting member 301 and the second connecting member 305 are spherical hinge supports. The ball head pin and ball seat of the first connecting member 301 are made of high-strength alloy structural steel, specifically 40Cr or 42CrMo. The ball head and inner ring of the spherical plain bearing of the second connecting member 305 are made of stainless steel, specifically 304 stainless steel or 17-4PH precipitation hardening stainless steel.

[0047] The sensing unit 308 includes an acceleration sensor disposed at the end of the cylinder block 302.

[0048] Specifically, when geological changes or external vibrations cause foundation displacement, the load on the intelligent support column 3 changes, and a relative motion tendency arises between the piston head 303 and the cylinder 302. The sensing unit 308 detects the acceleration or strain signal of the cylinder 302 in real time and transmits it to the intelligent controller 5. The intelligent controller 5 determines the degree of deformation of the area where the support column is located based on the signal strength and outputs an adjustment current to the corresponding excitation coil 307. The magnetic field strength generated by the excitation coil 307 changes the apparent viscosity of the magnetorheological liquid 306, causing it to change from a liquid state to a semi-solid or near-solid state, thereby instantly increasing the damping and stiffness of the support column and resisting further deformation. The spherical hinge support of the first connecting member 301 and the second connecting member 305 allows the support column to rotate adaptively in multiple directions, avoiding structural damage caused by rigid connection.

[0049] It also includes an intelligent controller 5, which is electrically connected to the sensing unit 308 and the excitation coil 307, respectively.

[0050] It also includes a tilt sensor 205 mounted on the functional chassis 2, which is electrically connected to the intelligent controller 5.

[0051] A temperature sensor 206 is also installed in the internal cavity 201 of the functional chassis 2. The probe of the temperature sensor 206 is immersed in the phase change material 202. An electromagnetic shielding material 207 is also provided on the top of the functional chassis 2.

[0052] Specifically, the intelligent controller 5, acting as the control core, continuously receives real-time data from the sensing unit 308, tilt sensor 205, and temperature sensor 206. Under normal operating conditions, the controller only monitors the parameters and maintains the excitation coil 307 in a low-current state to ensure the flexibility of the support column. When the tilt sensor 205 detects that the tilt of the enclosure exceeds the threshold or the sensing unit 308 detects an abnormal impact, the controller dynamically adjusts the excitation current of each support column according to a preset algorithm to achieve rapid correction of the enclosure's attitude. The temperature sensor 206 monitors the temperature of the phase change material 202. When the temperature approaches the complete liquefaction point of the phase change material, the controller can trigger an auxiliary heat dissipation device to enhance heat dissipation. The electromagnetic shielding material 207 is used to prevent external electromagnetic interference from affecting the accurate measurement of the internal sensors.

[0053] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. An intelligent, compact prefabricated substation, characterized in that, include: The main body of the box (1) is made of lightweight composite material, and the composite layered structure material includes an outer layer plate (101), a middle heat insulation layer (102) and an inner layer plate (103). Functional chassis (2), the functional chassis (2) is fixedly connected to the bottom of the box body (1), the functional chassis (2) is a sandwich structure with an internal cavity (201), the internal cavity (201) is filled with phase change material (202), and its top is supported by a transformer structure (4). Intelligent support columns (3) are spaced apart below the functional chassis (2), and the upper end of the intelligent support columns (3) is connected to the lower surface of the functional chassis (2).

2. The intelligent compact prefabricated substation according to claim 1, characterized in that, The main body of the box (1) has a topology optimization structure (104). The topology optimization structure (104) includes multiple reinforcing ribs (105) and multiple hollow areas (106) distributed on the surface of the main body of the box (1) according to stress analysis. The reinforcing ribs (105) are located in the stress concentration area of ​​the main body of the box (1), and the hollow areas (106) are located in the non-load-bearing area of ​​the main body of the box (1).

3. The intelligent compact prefabricated substation according to claim 1, characterized in that, The functional chassis (2) has a metal honeycomb skeleton (203) inside its sandwich structure, and the phase change material (202) is filled in the pores of the metal honeycomb skeleton (203). The lower surface of the functional chassis (2) is provided with a plurality of heat dissipation fins (204).

4. The intelligent compact prefabricated substation according to claim 1, characterized in that, The intelligent support column (3) includes a first connecting member (301), one end of which is connected to the foundation, and the other end is fixedly connected to a cylinder (302). The cylinder (302) forms an accommodating space inside, and a piston head (303) is slidably connected inside the cylinder (302). A piston rod (304) is fixedly connected to one side of the outer wall of the piston head (303). One end of the piston rod (304) extends out of the cylinder (302) and is fixedly connected to a second connecting member (305). The second connecting member (305) is connected to the bottom wall of the functional chassis (2).

5. The intelligent compact prefabricated substation according to claim 4, characterized in that, The cylinder (302) is filled with magnetorheological fluid (306), and an excitation coil (307) is provided on the outer peripheral wall of the cylinder (302). One end of the excitation coil (307) is electrically connected to a sensing unit (308), and the sensing unit (308) is integrated on one side of the outer wall of the cylinder (302).

6. The intelligent compact prefabricated substation according to claim 4, characterized in that, Both the first connecting member (301) and the second connecting member (305) are spherical hinge supports. The ball head pin and ball seat of the first connecting member (301) are made of high-strength alloy structural steel, specifically 40Cr or 42CrMo. The ball head and inner ring of the spherical bearing of the second connecting member (305) are made of stainless steel, specifically 304 stainless steel or 17-4PH precipitation hardening stainless steel.

7. The intelligent compact prefabricated substation according to claim 5, characterized in that, The sensing unit (308) includes an acceleration sensor disposed at the end of the cylinder (302).

8. The intelligent compact prefabricated substation according to claim 5, characterized in that, It also includes an intelligent controller (5), which is electrically connected to the sensing unit (308) and the excitation coil (307) respectively.

9. The intelligent compact prefabricated substation according to claim 8, characterized in that, It also includes a tilt sensor (205) mounted on the functional chassis (2), which is electrically connected to the intelligent controller (5).

10. The intelligent compact prefabricated substation according to claim 1, characterized in that, A temperature sensor (206) is also provided in the internal cavity (201) of the functional chassis (2). The probe of the temperature sensor (206) is immersed in the phase change material (202). An electromagnetic shielding material (207) is also provided on the top of the functional chassis (2).

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