A power distribution box and power monitoring system

Abstract

The application discloses a distribution box and a power monitoring system, the distribution box comprises a body mechanism, a heat exchange module, an intelligent regulation mechanism, a power monitoring and load analysis module, a central controller and a communication module, and the body mechanism comprises a distribution box body, a partition plate and electrical elements. By introducing a predictive temperature control model, the system associates heat dissipation control with direct causes of heat generation such as load rate and harmonic components, realizes mode conversion from 'perception-response' to 'prediction-initiative', and combines real-time and dynamic reconstruction of the airflow path by the adjustable flow guide unit, so that the cooling air can be accurately guided to the high-temperature area. The directional and intensified heat dissipation mechanism based on load prediction completely solves the problems of uneven heat dissipation and response lag of the traditional fixed air duct, effectively controls the temperature rise of the core elements, avoids continuous full-speed operation of the fan, and realizes the optimized balance between heat dissipation efficiency and energy consumption.

Description

Technical Field

[0001] This invention belongs to the field of distribution box technology, specifically relating to a distribution box and a power monitoring system. Background Technology

[0002] Distribution boxes are key devices in power systems used for power distribution, control, and protection. They integrate various electrical components such as circuit breakers, contactors, and smart meters. These components generate heat during operation due to load current and contact resistance. Poor heat dissipation will cause the internal temperature of the box to rise continuously, accelerating insulation aging, component performance degradation, and even leading to malfunctions. Furthermore, overloads, short circuits, poor contacts, and leakage in the electrical circuits themselves are major threats to power system safety.

[0003] Currently, common heat dissipation methods for distribution boxes mainly rely on natural convection, simple ventilation holes, or cooling fans with fixed speeds. The heat dissipation path is fixed and cannot be dynamically adjusted according to the actual heat generation of internal components, easily leading to localized overheating. Furthermore, traditional distribution boxes lack online monitoring and early warning capabilities for internal electrical conditions (such as real-time current, voltage, and critical contact temperatures) and component health status. Maintenance relies on periodic manual inspections, which are inefficient and fail to detect potential risks in a timely manner.

[0004] While some existing technologies involve solutions to improve heat dissipation or add monitoring functions, most suffer from the following shortcomings: the heat dissipation system is disconnected from the load status, resulting in a delayed response; the monitoring function is limited, the data is isolated, and it is impossible to form effective predictions and maintenance recommendations; there is a lack of coordination between functional modules, the level of intelligence is limited, and it is difficult to meet the requirements of modern smart grids for equipment observability, controllability, and high reliability.

[0005] Therefore, in order to address the aforementioned technical problems, it is necessary to provide a distribution box and a power monitoring system.

[0006] The information disclosed in this background section is intended only to enhance the understanding of the overall background of the invention and should not be construed as an admission or in any way implying that the information constitutes prior art known to those skilled in the art. Summary of the Invention

[0007] The purpose of this invention is to provide a distribution box and power monitoring system. This solution, through the deep integration of the Internet of Things, big data analysis and advanced thermal management technology, realizes dynamic intelligent control of the heat dissipation capacity of the distribution box, comprehensive real-time monitoring of electrical status, early assessment and prediction of component health, and collaborative optimization among multiple boxes, thereby significantly improving the safety, reliability and intelligent operation and maintenance level of power distribution equipment.

[0008] To achieve the above objectives, a specific embodiment of the present invention provides the following technical solution: A distribution box includes a main body, a heat exchange module, an intelligent control mechanism, a power monitoring and load analysis module, a central controller, and a communication module. The main body includes a distribution box body, a partition plate, and electrical components. The partition plate is fixedly connected to the distribution box body, and the electrical components are mounted on the partition plate. The heat exchange module includes a convection heat exchange unit and a phase change heat exchange unit. The convection heat exchange unit is mounted on the distribution box body, and the phase change heat exchange unit is mounted on the side wall of the heating element of the electrical components. The intelligent control mechanism includes an adjustable flow guiding unit, a backflushing and unblocking unit, and an internal environment sensor group. The adjustable flow guiding unit is mounted on the inner side wall of the distribution box body and is used to guide the airflow entering the box. The backflushing and unblocking unit is used to clean the convection heat exchange unit. The internal environment sensor group... The power monitoring and load analysis module is used to monitor environmental parameters within the distribution box body. It is connected to the power supply circuit of the electrical components and is used to collect electrical parameters and analyze the trends of current harmonic components and load rate changes. The central controller is connected to the intelligent control mechanism and the power monitoring and load analysis module. The central controller has a pre-set predictive temperature control model, used to predict heat generation power based on load rate, harmonic components, and historical temperature rise data. Based on the prediction results and real-time data from the internal environmental sensor group, it generates control commands to adjust the state of the adjustable flow guiding unit and the airflow of the convection heat exchange unit. The central controller is also configured to analyze the electrical parameters and generate an abnormal warning signal when the parameters exceed limits. The communication module is connected to the central controller and is used to send the abnormal warning signal and operating data.

[0009] In one or more embodiments of the present invention, the convection unit includes a pair of air inlets, a filter assembly, an air outlet, a third filter, and a variable-speed cooling fan. The pair of air inlets are opened on the left and right side walls of the distribution box body and are located above the partition plate. The filter assembly includes a first filter and a second filter that are detachably installed in the air inlets from the outside to the inside. The pore size of the first filter is larger than that of the second filter. The air outlet is opened at the center of the top wall of the distribution box body. The third filter is installed in the air outlet. The variable-speed cooling fan is installed on the inner side wall of the top wall of the distribution box body and is located below the air outlet.

[0010] In one or more embodiments of the present invention, the phase change heat dissipation unit includes a plurality of first heat dissipation fins, a phase change chamber, a heat-absorbing phase change material, and a plurality of second heat dissipation fins. The plurality of first heat dissipation fins are fixedly connected to the outer wall of the heat-generating element in the electrical component. A first vertical airflow channel is formed between adjacent first heat dissipation fins. The phase change chamber is detachably connected to the outer wall of the plurality of first heat dissipation fins via a connector. Thermally conductive silicone grease is filled between the first heat dissipation fins and the phase change chamber. The heat-absorbing phase change material is filled inside the phase change chamber. The plurality of second heat dissipation fins are fixedly connected to the outer wall of the phase change chamber. A second vertical airflow channel is formed between adjacent second heat dissipation fins.

[0011] In one or more embodiments of the present invention, the adjustable airflow guiding unit includes a pair of fixed support frames, a pair of rotating shafts, a pair of airflow guiding plates, a plurality of turbulence fins, a pair of micro stepper motors, and an elastic airflow guiding plate. The pair of fixed support frames are fixedly connected to the left and right sides of the partition plate and located below the air inlet. The pair of rotating shafts are respectively rotatably connected to the front and rear side walls of the pair of fixed support frames. The pair of airflow guiding plates are respectively fixedly connected to the side walls of the rotating shafts of the pair of rotating shafts. The plurality of turbulence fins are fixedly connected to the windward side of the pair of airflow guiding plates. The drive output ends of the pair of micro stepper motors are respectively connected to the front ends of the pair of rotating shafts. The elastic airflow guiding plate is fixedly connected in the gap between the fixed support frames and the rotating shafts in a front-to-back arrangement.

[0012] In one or more embodiments of the present invention, the backflushing and unclogging unit includes an unclogging and purging pipe, multiple unclogging nozzles, a telescopic air supply pipe, an air pump, and a drive mechanism. The unclogging and purging pipe is vertically disposed within the electrical distribution box and located on one side of the air inlet. The multiple unclogging nozzles are installed on the side wall of the unclogging and purging pipe facing the air inlet at equal vertical intervals. One end of the telescopic air supply pipe is fixedly connected to the air inlet of the unclogging and purging pipe, and the end of the telescopic air supply pipe away from the unclogging and purging pipe is installed on the air outlet of the air pump. The drive mechanism... The mechanism is used to drive the unblocking and purging pipe to move back and forth; the driving mechanism includes a mounting plate, a sliding groove, a slider, a lead screw, and a motor. The mounting plate is fixedly connected to the inner side wall of the distribution box body and located above the air inlet. The sliding groove is opened in the mounting plate. The slider is slidably connected in the sliding groove, and its lower end extends to the bottom of the mounting plate and is connected to the unblocking and purging pipe. The lead screw is rotatably connected in the sliding groove, and the lead screw is threaded to the slider in a through manner. The driving end of the motor is connected to the front end of the lead screw.

[0013] In one or more embodiments of the present invention, the power monitoring and load analysis module includes a non-invasive current sensor, a voltage sampling circuit, a residual current detector, and a wireless temperature sensor; the wireless temperature sensor is attached to an electrical connection point.

[0014] In one or more embodiments of the present invention, the central controller is further configured to: establish a performance degradation model of electrical components based on long-term collected contact temperature rise curves, equivalent values ​​of contact resistance, and number of actions; calculate a health index, and generate and report preventive replacement recommendations when the index is below a threshold.

[0015] In one or more embodiments of the present invention, the communication module supports point-to-point communication between multiple distribution boxes; the central controller is further configured to: receive load and temperature information of adjacent distribution boxes; and when it predicts that it will enter a full-power heat dissipation mode, initiate a load transient coordination request to the adjacent distribution boxes.

[0016] In one or more embodiments of the present invention, the intelligent control mechanism further includes a filter clogging sensor disposed at the air inlet; the central controller is further configured to: when an abnormal filter pressure difference is detected, increase the speed of the variable speed cooling fan to compensate for the air volume, and send a cleaning reminder.

[0017] A power monitoring system for a distribution box, the monitoring system comprising: The data aggregation unit is used to acquire electrical parameters, ambient temperature parameters, and component status parameters within the distribution box. A predictive temperature control unit is used to predict the heating trend inside the box based on the load rate and harmonic components in the electrical parameters, and generate adaptive heat dissipation control commands. The health assessment unit is used to build a performance degradation model for electrical components based on historical operating data and to calculate the health index. The collaborative management unit is used to coordinate and generate load allocation or heat dissipation strategy optimization suggestions based on the load and thermal status information of each box in a network composed of multiple distribution boxes. The system is connected to the central controller of one or more of the distribution boxes via a communication network. The adaptive heat dissipation control command and optimization suggestions are sent to the corresponding central controller, which controls the adjustable flow guiding unit and the variable speed cooling fan to perform corresponding actions.

[0018] Compared with the prior art, the present invention has the following advantages: 1. This invention introduces a predictive temperature control model, which links heat dissipation control with direct causes of heat generation such as load rate and harmonic components, realizing a shift from a "sensing-response" to a "predictive-active" mode. Combined with the real-time and dynamic reconstruction of the airflow path by the adjustable airflow guide unit, cooling air can be precisely guided to high-temperature areas. This load prediction-based directional enhanced heat dissipation mechanism completely solves the problems of uneven heat dissipation and lag response in traditional fixed air ducts. While ensuring that the temperature rise of core components is effectively controlled, it avoids the continuous full-speed operation of the fan, achieving an optimized balance between heat dissipation efficiency and energy consumption.

[0019] 2. As a passive thermal buffer, the phase change heat exchange unit can absorb a large amount of heat quickly through the latent heat of phase change when the component temperature rises suddenly due to load changes. This effectively smooths out the temperature rise curve, buys a critical time window for the response of the active heat dissipation system, and prevents electrical components from being damaged or tripped due to instantaneous overheating. This significantly improves the reliability and stability of the distribution box under dynamic and impact load conditions.

[0020] 3. The integrated power monitoring and load analysis module enables comprehensive real-time perception of electrical status. Furthermore, by analyzing long-term operating data through health assessment algorithms, it can identify component performance degradation trends in the early stages and generate preventive replacement recommendations. This transforms the operation and maintenance mode from traditional periodic or fault maintenance to condition-based predictive maintenance, greatly reducing the risk of unexpected power outages and optimizing spare parts management and operation and maintenance costs. Attached Figure Description

[0021] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments recorded in the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0022] Figure 1 This is a perspective view of a distribution box according to an embodiment of the present invention; Figure 2 This is a schematic diagram of the interior of a distribution box according to one embodiment of the present invention. Figure 1 ; Figure 3 This is a schematic diagram of the interior of a distribution box according to one embodiment of the present invention. Figure 2 ; Figure 4 This is a cross-sectional view of a distribution box according to an embodiment of the present invention; Figure 5 This is a cross-sectional view of a distribution box according to an embodiment of the present invention; Figure 6 For the present invention Figure 5 Enlarged view of point A in the middle; Figure 7 This is a schematic diagram showing the connection between the phase change box and electrical components in this invention; Figure 8 This is a schematic diagram of the flow guiding structure in this invention; Figure 9 This is a cross-sectional view of the active unit in this invention; Figure 10 This is a schematic diagram of airflow inside the distribution box in this invention.

[0023] Explanation of key figure labels: 1-Main body structure, 11-Distribution box body, 12-Divider plate, 13-Electrical components, 14-Air inlet, 15-First filter, 16-Second filter, 17-Air outlet, 18-Third filter, 19-Variable speed cooling fan, 110-First heat dissipation fin, 111-Phase change box, 112-Heat-absorbing phase change material, 113-Second heat dissipation fin, 2-Intelligent control mechanism, 21-Fixed support frame, 22-Rotating shaft, 23-Guide plate, 24-Break fin, 25-Micro stepper motor, 26-Elastic flow guide plate, 27-Clogging and blowing pipe, 28-Clogging and nozzle, 29-Telescopic air supply pipe, 210-Air pump, 211-Mounting plate, 212-Slide groove, 213-Slider, 214-Lead screw, 215-Motor. Detailed Implementation

[0024] To enable those skilled in the art to better understand the technical solutions in this disclosure, the technical solutions in the embodiments of this disclosure will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this disclosure, and not all embodiments. Based on the embodiments in this disclosure, all other embodiments obtained by those skilled in the art without creative effort should fall within the scope of protection of this disclosure.

[0025] like Figures 1 to 10As shown, a distribution box according to one embodiment of the present invention includes a main body 1, a heat exchange module, an intelligent control mechanism 2, a power monitoring and load analysis module, a central controller, and a communication module. The main body 1 includes a distribution box body 11, a partition plate 12, and electrical components 13. The partition plate 12 is fixedly connected inside the distribution box body 11, and the electrical components 13 are installed on the partition plate 12. The heat exchange module includes a convection heat exchange unit and a phase change heat exchange unit. The convection heat exchange unit is installed on the distribution box body 11, and the phase change heat exchange unit is installed on the side wall of the heating element of the electrical components 13. The intelligent control mechanism 2 includes an adjustable flow guiding unit, a backflushing and unblocking unit, and an internal environment sensor group. The adjustable flow guiding unit is installed on the inner side wall of the distribution box body 11 and is used to guide the airflow entering the box. The backflushing and unblocking unit is used to clean the airflow. The clean convection heat exchange unit has an internal environmental sensor group for monitoring environmental parameters within the distribution box body 11. A power monitoring and load analysis module is connected to the power supply circuit of the electrical components 13 to collect electrical parameters and analyze the current harmonic components and load rate variation trends. A central controller connects the intelligent control mechanism 2 and the power monitoring and load analysis module. The central controller has a pre-set predictive temperature control model to predict heating power based on load rate, harmonic components, and historical temperature rise data. Based on the prediction results and real-time data from the internal environmental sensor group, it generates control commands to adjust the state of the adjustable flow guide unit and the airflow of the convection heat exchange unit. The central controller is also configured to analyze electrical parameters and generate abnormal warning signals when parameters exceed limits. A communication module connects to the central controller to send abnormal warning signals and operating data.

[0026] The working principle of this distribution box is as follows: When the distribution box is working, the power monitoring and load analysis module collects parameters such as the working current and voltage of each electrical circuit in real time, and analyzes the load rate change trend and harmonic components. At the same time, the internal environmental sensor group continuously monitors the temperature, humidity and hot spot distribution in each area of ​​the box. The central controller receives the above data and calls the embedded predictive temperature control model. This model integrates the current load characteristics, the additional heat generated by harmonics, and the historical temperature rise pattern to calculate the predicted heat generation power in the near future. Subsequently, the controller compares and makes decisions with the predicted results and real-time environmental data, generating control signals containing airflow angle commands and airflow commands: on the one hand, it sends the signal to the adjustable airflow unit to drive it to adjust the airflow angle, thereby dynamically changing the airflow path in the box and accurately guiding the cooling air to the predicted or already existing high-temperature area; on the other hand, it controls the convection heat exchange unit to change the total airflow. If any monitored electrical parameter exceeds the safety threshold, the controller immediately generates an abnormal warning signal, which, together with the equipment operating status data, is uploaded to the remote monitoring terminal through the communication module, thus forming a closed-loop intelligent control system integrating real-time monitoring, intelligent prediction, dynamic adjustment and remote early warning. Meanwhile, the phase change heat exchange unit is attached to the heating element as a passive heat buffer to absorb instantaneous high heat.

[0027] like Figures 1 to 6 As shown, the convection unit includes a pair of air inlets 14, a filter assembly, an air outlet 17, a third filter 18, and a variable-speed cooling fan 19. The pair of air inlets 14 are located on the left and right side walls of the distribution box body 11, above the partition plate 12. The filter assembly includes a first filter 15 and a second filter 16, which are detachably installed in the air inlets 14 from the outside to the inside. The pore size of the first filter 15 is larger than that of the second filter 16. The air outlet 17 is located at the center of the top wall of the distribution box body 11. The third filter 18 is installed in the air outlet 17. The variable-speed cooling fan 19 is installed on the inner side wall of the top wall of the distribution box body 11, below the air outlet 17. By setting up symmetrical air inlets 14, a two-stage filter assembly, a top air outlet 17, and a variable-speed cooling fan 19, a highly efficient and controllable forced convection cooling basic path is constructed. The first filter 15 intercepts large particles of debris, and the second filter 16 filters fine dust, ensuring that the air entering the box is clean; the variable speed cooling fan 19 serves as the power core and can steplessly adjust the air volume according to demand; this structure provides a stable and reliable physical air duct for subsequent intelligent airflow control.

[0028] like Figure 4 , Figure 5 and Figure 7As shown, the phase change heat dissipation unit includes multiple first heat dissipation fins 110, a phase change chamber 111, a heat-absorbing phase change material 112, and multiple second heat dissipation fins 113. The multiple first heat dissipation fins 110 are fixedly connected to the outer wall of the heating element in the electrical component 13. A first vertical airflow channel is formed between adjacent first heat dissipation fins 110. The phase change chamber 111 is detachably connected to the outer wall of the multiple first heat dissipation fins 110 via connectors. Thermally conductive silicone grease is filled between the first heat dissipation fins 110 and the phase change chamber 111. The heat-absorbing phase change material 112 is filled inside the phase change chamber 111. The multiple second heat dissipation fins 113 are fixedly connected to the outer wall of the phase change chamber 111. A second vertical airflow channel is formed between adjacent second heat dissipation fins 113. By adding a phase change chamber 111 filled with heat-absorbing phase change material 112 to the side of the first heat dissipation fin 110, and adding a second heat dissipation fin 113 outside the phase change chamber 111, a multi-stage heat storage and heat dissipation system of "component-fin-phase change material-fin-airflow" is constructed. When the electrical component experiences a sudden surge in heat generation, the heat-absorbing phase change material 112 absorbs a large amount of latent heat through melting, directly buffering the temperature rise rate of the component body and preventing thermal shock. At the same time, the inner and outer heat dissipation fins increase the heat exchange area with the air, enabling more efficient dissipation of stored heat after active cooling is activated. Furthermore, the vertical airflow channels formed by the heat dissipation fins guide the flow of cold air, improving the heat dissipation effect of the cold air on the fins.

[0029] like Figure 6 and Figure 8 As shown, the adjustable airflow guiding unit includes a pair of fixed support frames 21, a pair of rotating shafts 22, a pair of airflow guide plates 23, multiple turbulence fins 24, a pair of micro stepper motors 25, and an elastic airflow guide plate 26. The pair of fixed support frames 21 are fixedly connected to the left and right sides of the partition plate 12 and located below the air inlet 14. The pair of rotating shafts 22 are rotatably connected to the front and rear side walls of the pair of fixed support frames 21, respectively. The pair of airflow guide plates 23 are fixedly connected to the side walls of the pair of rotating shafts 22, and multiple turbulence fins 24 are fixedly connected to the windward side of the pair of airflow guide plates 23. The drive output ends of the pair of micro stepper motors 25 are connected to the front ends of the pair of rotating shafts 22, respectively. The elastic airflow guide plate 26 is fixedly connected in the gap between the fixed support frames 21 and the rotating shafts 22 in a front-to-back arrangement. Through the airflow guide plate 23 with turbulence fins 24 driven by the micro stepper motor 25, precise and dynamic control of the airflow direction is achieved. The turbulence fins 24 can disperse laminar flow, enhance airflow turbulence, and improve heat exchange efficiency; the micro stepper motor 25 can precisely control the deflection angle of the guide plate 23, thereby accurately "guiding" or "focusing" the cooling airflow to specific areas or components that need heat dissipation, solving the problem of local overheating caused by uneven heating inside the box.

[0030] like Figure 6 , Figure 8and Figure 9 As shown, the backflushing and unclogging unit includes an unclogging purge pipe 27, multiple unclogging nozzles 28, a telescopic air supply pipe 29, an air pump 210, and a drive mechanism. The unclogging purge pipe 27 is vertically installed inside the distribution box body 11 and located on one side of the air inlet 14. The multiple unclogging nozzles 28 are installed on the side wall of the unclogging purge pipe 27 facing the air inlet 14 at equal vertical intervals. One end of the telescopic air supply pipe 29 is fixedly connected to the air inlet of the unclogging purge pipe 27, and the other end of the telescopic air supply pipe 29 away from the unclogging purge pipe 27 is installed on the air outlet of the air pump 210. The drive mechanism is used to drive the unclogging purge pipe 27 to move back and forth. The drive mechanism includes a mounting plate 211, a slide groove 212, a slider 213, a lead screw 214, and a motor 215. The mounting plate 211 is fixedly connected to the inner wall of the distribution box body 11 and located above the air inlet 14. The slide groove 212 is opened in the mounting plate 211. The slider 213 is slidably connected in the slide groove 212, and its lower end extends to the bottom of the mounting plate 211 and is connected to the cleaning and blowing pipe 27. The lead screw 214 is rotatably connected in the slide groove 212, and the lead screw 214 is threadedly connected to the slider 213 in a through manner. The drive end of the motor 215 is connected to the front end of the lead screw 214. A movable compressed air purging system integrated inside the housing was designed. When dust accumulates inside the filter assembly and affects ventilation, the air pump 210 generates compressed air, which drives the lead screw 214 to rotate via the motor 215. The lead screw 214 then drives the slider 213 to slide back and forth in the slide groove 212, thereby moving the cleaning and purging pipe 27 and the cleaning nozzle 28 back and forth to perform scanning purging on the inner surface of the filter, blowing away the attached dust. This allows for online preliminary cleaning of the filter without opening the housing door or stopping the machine, extending the manual cleaning cycle of the filter and maintaining the efficiency of the heat dissipation system.

[0031] Specifically, the power monitoring and load analysis module includes non-invasive current sensors, voltage sampling circuits, residual current detectors, and wireless temperature sensors; the wireless temperature sensors are attached to electrical connection points. The non-invasive current sensors are easy to install and do not affect circuit insulation, enabling safe current monitoring; the voltage sampling circuit monitors power supply quality; the residual current detector prevents leakage accidents; and the wireless temperature sensor directly monitors the temperature of electrical connection points most prone to overheating. These sensors together constitute a data acquisition network for comprehensive, real-time sensing of the electrical and thermal safety status of the distribution box.

[0032] Preferably, the central controller is also configured to: establish a performance degradation model for electrical components based on long-term collected contact temperature rise curves, equivalent contact resistance values, and number of operations; calculate a health index; and generate and report preventative replacement recommendations when the index falls below a threshold. This empowers the central controller with the ability to perform in-depth data analysis, establishing aging models by tracking component performance parameters over a long period, thus shifting from "fault-based alarms" to "early warnings of performance degradation." The generated "preventative replacement recommendations" enable maintenance to shift from periodic inspections to on-demand predictive maintenance, avoiding unexpected downtime and optimizing spare parts management and maintenance costs.

[0033] Furthermore, the communication module supports point-to-point communication between multiple distribution boxes; the central controller is further configured to: receive load and temperature information from adjacent distribution boxes; and when it predicts that it will enter full-power cooling mode, initiate a load transient coordination request to adjacent distribution boxes. This realizes the evolution of distribution boxes from individual intelligence to group collaboration. Through point-to-point communication, multiple distribution boxes can exchange load and thermal status information; when a box predicts that its cooling capacity will soon be insufficient, it can proactively initiate a coordination request, prompting adjacent boxes to temporarily adjust their operating strategies through peak-shaving and other methods, thereby achieving dynamic balancing and optimization of thermal load at the local power grid level and improving the reliability and resilience of the overall system.

[0034] Specifically, the intelligent control mechanism 2 also includes a filter clogging sensor located at the air inlet 14. The central controller is further configured to: when an abnormal filter pressure difference is detected, increase the speed of the variable-speed cooling fan 19 to compensate for the airflow and send a cleaning reminder. This adds an adaptive reliability assurance layer to the basic heat dissipation control, monitoring ventilation resistance in real time through the filter clogging sensor; when filter clogging is detected, causing a decrease in airflow, the central controller automatically increases the fan speed to compensate for the airflow and temporarily maintain the heat dissipation effect; when cleaning is required, a cleaning reminder is sent to activate the backflushing and unclogging unit to clean the filter components. This ensures that the heat dissipation system can still operate normally during periods of filter performance degradation, providing a buffer time for planned maintenance.

[0035] During operation, the power monitoring and load analysis module acquires real-time circuit current, voltage, harmonics, and key contact temperatures, while the internal environmental sensor group simultaneously monitors the temperature and humidity field inside the enclosure. The central controller integrates this real-time data and invokes a predictive temperature control model. This model, combining the current load rate, harmonic components, and historical temperature rise patterns, proactively predicts the upcoming heat load. Based on this prediction, the controller generates composite control commands: on one hand, the micro stepper motor 25 of the adjustable airflow guiding unit drives the deflection of a specific airflow guide plate 23, whose turbulence fins 24 optimize airflow organization, thereby dynamically and accurately guiding the cooling airflow to the predicted high-temperature area or identified hotspots, achieving "on-demand air delivery"; on the other hand, it adjusts the speed of the variable-speed cooling fan 19 of the convection heat exchange unit to control the total airflow. If a sudden and drastic temperature rise occurs, the heat-absorbing phase change material 112 in the phase change heat exchange unit will melt and absorb latent heat, providing a buffer time for the active cooling system to respond. Meanwhile, the backflushing and unclogging unit can be activated by the controller after the filter clogging sensor alarms. It uses the mobile unclogging and purge pipe 27 to periodically clean the inside of the filter to maintain ventilation efficiency. The controller also continuously runs a health assessment algorithm, providing early warnings of component degradation based on long-term performance data. When the system predicts that its heat dissipation capacity is approaching its limit, it can coordinate load and heat dissipation with adjacent distribution boxes via the communication module to attempt to optimize local heat load distribution. Finally, all operating statuses, warnings, and analysis results are uploaded to a remote platform via the communication module, forming a complete intelligent closed loop from "perception-prediction-execution-optimization-early warning".

[0036] Another embodiment of the present invention provides a power monitoring system for a distribution box, the monitoring system comprising: The data aggregation unit is used to acquire electrical parameters, ambient temperature parameters, and component status parameters within the distribution box. The predictive temperature control unit is used to predict the heating trend inside the box based on the load rate and harmonic components in the electrical parameters, and generate adaptive heat dissipation control commands. The health assessment unit is used to build a performance degradation model for electrical components based on historical operating data and to calculate the health index. The collaborative management unit is used to coordinate and generate load allocation or heat dissipation strategy optimization suggestions based on the load and thermal status information of each box in a network composed of multiple distribution boxes. The system is connected to the central controller of one or more distribution boxes via a communication network. Adaptive heat dissipation control commands and optimization suggestions are sent to the corresponding central controller, which then controls the adjustable flow guiding unit and the variable speed cooling fan 19 to perform corresponding actions.

[0037] As a centralized cloud-based intelligent management hub, this system connects to physical distribution boxes via a communication network, extending, strengthening, and coordinating distributed, local intelligent computing and decision-making capabilities. It receives comprehensive data from the central controllers of each distribution box, utilizes the more powerful computing resources of the cloud, and executes more complex predictive temperature control global optimization algorithms and cross-device health in-depth analysis models. This generates optimized heat dissipation control strategies and maintenance decisions that transcend the perspective of a single distribution box. More importantly, through a collaborative management unit, it comprehensively analyzes the load and thermal status of all distribution boxes in the network, enabling system-level coordination of operation among multiple boxes and achieving regional thermal management and energy consumption optimization. Finally, the system sends the generated high-level instructions and optimization suggestions back to the local controllers of each distribution box, driving specific hardware such as adjustable airflow units and variable-speed cooling fans to execute actions. This completes a closed loop from "individual device self-adaptation" to "group device collaborative optimization," and from "edge computing" to "cloud-edge-device collaboration," significantly improving the intelligent management level, operational economy, and overall reliability of the entire power distribution network.

[0038] It will be apparent to those skilled in the art that this disclosure is not limited to the details of the exemplary embodiments described above, and that this disclosure can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of this disclosure is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within this disclosure. No reference numerals in the claims should be construed as limiting the scope of the claims.

[0039] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A distribution box, characterized in that, include: The main body structure includes a distribution box body, a partition plate, and electrical components. The partition plate is fixedly connected to the distribution box body, and the electrical components are mounted on the partition plate. The heat exchange module includes a convection heat exchange unit and a phase change heat exchange unit. The convection heat exchange unit is installed on the distribution box body, and the phase change heat exchange unit is installed on the side wall of the heating element of the electrical component. The intelligent control mechanism includes an adjustable flow guiding unit, a backflushing and unblocking unit, and an internal environmental sensor group. The adjustable flow guiding unit is installed on the inner wall of the distribution box body and is used to guide the airflow entering the box. The backflushing and unblocking unit is used to clean the convection heat exchange unit. The internal environmental sensor group is used to monitor the environmental parameters inside the distribution box body. The power monitoring and load analysis module is connected to the power supply circuit of the electrical components and is used to collect electrical parameters and analyze the current harmonic components and load rate variation trends. The central controller connects the intelligent control mechanism and the power monitoring and load analysis module. The central controller is pre-installed with a predictive temperature control model, which is used to predict the heating power based on the load rate, harmonic components and historical temperature rise data, and generate control commands based on the prediction results and real-time data of the internal environmental sensor group to adjust the state of the adjustable flow guiding unit and the air volume of the convection heat exchange unit. The central controller is also configured to analyze the electrical parameters and generate an abnormal warning signal when the parameters exceed the limits. The communication module is connected to the central controller and is used to send the abnormal warning signal and operating data.

2. A distribution box according to claim 1, characterized in that, The convection unit includes: A pair of air inlets are provided on the left and right side walls of the distribution box body, and are located above the partition plate. The filter assembly includes a first filter screen and a second filter screen that are detachably installed in the air inlet from the outside to the inside, wherein the pore size of the first filter screen is larger than that of the second filter screen. The air outlet is located at the center of the top wall panel of the distribution box body; The third filter is installed inside the air outlet; A variable-speed cooling fan is installed on the inner side wall of the top panel of the distribution box body, and is located below the air outlet.

3. A distribution box according to claim 2, characterized in that, The phase change heat transfer unit includes: Multiple first heat dissipation fins are fixedly connected to the outer wall of the heat-generating element in the electrical component, and a first vertical airflow channel is formed between adjacent first heat dissipation fins; The phase change box is detachably connected to the outer wall of multiple first heat dissipation fins via connectors, and thermally conductive silicone grease is filled between the first heat dissipation fins and the phase change box. An endothermic phase change material is filled inside the phase change chamber; Multiple second heat dissipation fins are fixedly connected to the outer wall of the phase change box, and a second vertical airflow channel is formed between adjacent second heat dissipation fins.

4. A distribution box according to claim 3, characterized in that, The adjustable flow guiding unit includes: A pair of fixed support frames are fixedly connected to the left and right sides of the partition plate and located below the air inlet; A pair of rotating shafts are respectively rotatably connected to the front and rear side panels of the pair of fixed support frames; A pair of guide vanes are respectively fixedly connected to the side walls of the pair of rotating shafts; Multiple turbulence fins are fixedly connected to the windward side of a pair of guide vanes; A pair of miniature stepper motors, the drive output terminals of which are respectively connected to the front ends of the pair of rotating shafts; The elastic drainage plate is fixedly connected to the gap between the fixed support frame and the rotating shaft in a front-to-back direction arrangement.

5. A distribution box according to claim 4, characterized in that, The backflush unblocking unit includes: The cleaning and purging pipe is installed vertically inside the distribution box and located on one side of the air inlet; Multiple unclogging nozzles are installed at equal vertical intervals on the side wall of the unclogging blowpipe facing the air inlet; A telescopic air supply pipe, one end of which is fixedly connected to the air inlet of the unblocking and purging pipe; An air pump, wherein the end of the telescopic air supply pipe away from the unblocking and purging pipe is installed on the air outlet of the air pump; And a drive mechanism for driving the unblocking and purging pipe to move back and forth, the drive mechanism comprising: The mounting plate is fixedly connected to the inner wall of the distribution box and located above the air inlet. A groove is formed within the mounting plate; The slider is slidably connected in the groove, and its lower end extends to the bottom of the mounting plate and is connected to the unblocking and purging pipe. A lead screw is rotatably connected to the slide groove, and the lead screw is threaded to the slider in a through manner; The motor has its drive end connected to the front end of the lead screw.

6. A distribution box according to claim 1, characterized in that, The power monitoring and load analysis module includes a non-invasive current sensor, a voltage sampling circuit, a residual current detector, and a wireless temperature sensor; the wireless temperature sensor is attached to the electrical connection point.

7. A distribution box according to claim 1, characterized in that, The central controller is also configured to: Based on long-term collected contact temperature rise curves, equivalent values ​​of contact resistance, and number of operations, a performance degradation model for electrical components is established. Calculate the health index and generate and report preventative replacement recommendations when the index falls below a threshold.

8. A distribution box according to claim 1, characterized in that, The communication module supports point-to-point communication between multiple distribution boxes as described in claim 1; The central controller is further configured to: Receive load and temperature information from adjacent distribution boxes; When it predicts that it will enter full-power cooling mode, it initiates a load transient coordination request to the adjacent distribution box.

9. A distribution box according to claim 2, characterized in that, The intelligent control mechanism also includes a filter blockage sensor, which is located at the air inlet. The central controller is further configured to: when an abnormal filter pressure difference is detected, increase the speed of the variable speed cooling fan to compensate for the air volume, and send a cleaning reminder.

10. A power monitoring system for a distribution box, used in a distribution box as described in any one of claims 1-9, characterized in that, The monitoring system includes: The data aggregation unit is used to acquire electrical parameters, ambient temperature parameters, and component status parameters within the distribution box. A predictive temperature control unit is used to predict the heating trend inside the box based on the load rate and harmonic components in the electrical parameters, and generate adaptive heat dissipation control commands. The health assessment unit is used to build a performance degradation model for electrical components based on historical operating data and to calculate the health index. The collaborative management unit is used to coordinate and generate load allocation or heat dissipation strategy optimization suggestions based on the load and thermal status information of each box in a network composed of multiple distribution boxes. The system is connected to the central controller of one or more of the distribution boxes via a communication network. The adaptive heat dissipation control command and optimization suggestions are sent to the corresponding central controller, which controls the adjustable flow guiding unit and the variable speed cooling fan to perform corresponding actions.

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