A double cold source energy-saving cabinet system based on recycling cooling water waste heat utilization

Abstract

The application discloses a double-cold-source energy-saving cabinet system based on recycling of cooling water residual heat, and relates to the field of industrial cabinet heat management. The system comprises a target identification module, a waterway reconstruction module, an impedance transfer module and a system recovery module. The target identification module screens out a target heat exchange area with fouling, deflection and self-locking according to fluid and thermodynamic data; the waterway reconstruction module reconstructs the target heat exchange area and a flow guide heat exchange area into a directional series state, and forces circulating water to flow through the target heat exchange area by a series booster pump; the impedance transfer module triggers mechanical deformation of a differential pressure response type flow equalization component by using initial flow difference of channels, and directionally transfers hydraulic pressure head to peel off internal deposits; and the system recovery module recovers parallel operation after judging that the self-locking is removed, and performs step-by-step distribution of total available residual heat according to real-time heat load at the cabinet end; online diagnosis and automatic removal of hidden local fouling of the heat exchanger are realized, and the heat stability of accurate matching of the cabinet cold quantity and continuous operation of the system is ensured.

Description

Technical Field

[0001] This invention relates to the field of industrial cabinet thermal management, specifically to a dual-cold-source energy-saving cabinet system based on the utilization of residual cooling water. Background Technology

[0002] The hot strip rolling production line is equipped with a large-capacity main drive frequency converter cabinet. The cabinet integrates high-heat-generating semiconductor devices such as rectifier modules and inverter modules, as well as dispersed heat-generating components like reactors and capacitors. To address the heat dissipation requirements of different components, the industry typically employs a dual-channel cooling architecture combining liquid-cooled plates and enclosed air ducts within the cabinet. The hot strip rolling mill has a large-scale circulating cooling water system, and the treated circulating water retains considerable cooling capacity. Current solutions often use the circulating cooling water as the primary cold source, indirectly exchanging heat with the secondary clean coolant through parallel plate heat exchanger components in the cabinet. When the residual cooling of the circulating water is insufficient, auxiliary chilled water is connected as a secondary cold source, forming a dual-cold-source cooling system.

[0003] The harsh operating conditions of hot continuous rolling inevitably result in the presence of micron-sized iron oxide particles and oily suspended solids in the circulating cooling water. To alleviate heat exchanger clogging, conventional maintenance typically relies on adding high-precision filtration equipment at the pipeline upstream or performing periodic shutdowns for manual cleaning. However, excessively high-precision filtration can cause hydraulic pressure drops that the system cannot withstand, while periodic shutdowns contradict the rigid requirements of continuous production. In actual long-term operation, within the multiple parallel narrow-gap flow channels inside the plate heat exchanger, a few channels with initially low flow rates readily capture escaping particulate contaminants, causing a sharp increase in local hydraulic resistance. This leads to circulating water that should flow through these channels bypassing to other cleaner channels with lower resistance. Increased channel resistance is accompanied by a sharp decrease in internal flow velocity, significantly reducing the hydrodynamic shearing effect of the fluid on the channel walls. Deposits become difficult to detach, local contamination intensifies, and a self-locking state of fouling and flow deviation develops. Existing dual-cold-source systems generally rely on monitoring the total inlet water temperature and total flow rate of the circulating water to assess the cooling capacity of the first cold source. When blockage and flow deviation self-locking occur, even if the total macroscopic flow rate remains within a reasonable range according to sensor readings, the flow channel where self-locking occurs has actually lost its effective heat exchange capacity. This monitoring blind spot makes it easy for the control end to overestimate the actual residual cooling capacity of the first cold source, resulting in a serious mismatch between the cooling capacity allocated to the liquid cooling branch and the air cooling branch and the actual heat load. This forces the second cold source to frequently and ineffectively intervene, ultimately leading to a decrease in the residual cooling utilization rate of the cooling system and the risk of local thermal runaway in the cabinet. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this invention proposes a dual-cold-source energy-saving cabinet system based on the utilization of residual cooling water. This system solves the problem of unbalanced cooling capacity distribution and localized thermal runaway in the cabinet caused by the inability to identify and release localized blockages and flow deviations in the heat exchanger due to blind spots in macroscopic monitoring.

[0005] To achieve the above objectives, the present invention provides the following technical solution: a dual-cold-source energy-saving cabinet system based on the utilization of waste cooling water, comprising: The target identification module is used to collect basic fluid and thermodynamic data of the heat exchange zone that is cooled by the first cold source and operates in parallel. The heat exchange zone is equipped with a channel group including a clean channel group and a high resistance channel group, as well as a differential pressure response flow equalization component. Based on the basic fluid and thermodynamic data, the module filters out the target heat exchange zone with increased resistance and heat transfer decay, which is blocked and deflected and self-locked, and the normally operating flow guiding heat exchange zone. The water circuit reconfiguration module is used to reconfigure the target heat exchange zone and the guide heat exchange zone into a directional series state, introduce a second cold source to maintain the stable liquid supply temperature of the cooling branch including the liquid cooling branch and the air cooling branch, and force the circulating water flowing through the guide heat exchange zone to flow through the target heat exchange zone and reach the unlock flow rate through the series booster pump. The impedance transfer module is used to trigger the mechanical deformation of the differential pressure response flow equalization component in the target heat exchange zone after the unlocking flow rate is reached, by utilizing the initial flow difference of the channel group inside the target heat exchange zone to directionally transfer the hydraulic head to the high resistance channel group containing sediments in order to remove the sediments, and to collect the actual pressure difference and actual volume flow rate of the primary side of the target heat exchange zone. The system recovery module is used to determine the release of the self-locking mechanism for the primary side of the heat exchange zone after the actual pressure difference and actual volumetric flow rate of the primary side are determined based on the target heat exchange zone. It then restores the parallel operation status of the primary side of the heat exchange zone and performs dual-source cascade distribution based on the current available total residual cooling capacity of the first cold source and the real-time heat load at the cabinet end.

[0006] Compared with existing technologies, it has the following advantages: This solution proposes a dual-cold-source energy-saving cabinet system based on the utilization of waste cooling water from circulating cooling water. It overcomes the limitations of traditional cabinet cooling solutions that rely solely on macroscopic monitoring of the total inlet water temperature and total pipe flow rate. This effectively solves the problems of unbalanced cooling capacity distribution and hidden thermal runaway caused by localized blockage and flow deviation in the heat exchanger's flow channels. Without altering the front-end filtration accuracy in the industrial environment or interrupting continuous production, the system extracts the actual pressure difference on the primary side of the heat exchange zone and the actual cooling capacity transferred to the secondary side of the cabinet. This data is then converted into relative hydraulic resistance and relative heat transfer capacity. Using thermal decoupling calculations, the system accurately pinpoints the target heat exchange zone experiencing microscopic failure among multiple parallel-operating heat exchangers. Once the blocked target is located, the system coordinates the switching valves in the pipeline to perform topology reconfiguration, changing the normally operating guide heat exchange zone and the target heat exchange zone from parallel to directional series connection. Simultaneously, the series booster pump is activated, forcing all circulating water flowing out of the guide heat exchange zone to flow through the blocked area, thus establishing a solid hydrodynamic foundation for subsequently breaking through fluid stagnation dead zones.

[0007] After establishing a directional series water path and reaching the unlocked flow rate, the system utilizes the inherent initial flow difference within the flow channel to trigger the mechanical linkage of the internal flow equalization components, fundamentally preventing the vicious cycle of escalating particle deposition. The circulating water entering the inlet distribution chamber preferentially pushes and displaces the elastic tongues at the clean channel group with lower resistance, reducing the effective flow area of ​​the clean channel and increasing local additional resistance, forcing the hydraulic head to directionally shift towards the high-resistance channel group where sediment is attached. Driven by the increased pressure head, the high-resistance channel group gains a velocity increment, directly using fluid shear force to detach particle sediments from the channel walls and capture them in the end-capture chamber. After confirming the internal channels are clear based on the hydraulic resistance coefficient, the system cancels the series water path and restores the parallel cooling state for the entire area. Based on the real-time calculated actual heat load of the cabinet's liquid cooling and air cooling, the system performs tiered cooling capacity distribution to the total available residual cooling capacity of the first cold source in the order of liquid cooling followed by air cooling. The above mechanism achieves a close match between the cold source supply side and the actual load of each heat-generating component in the cabinet, eliminates the hidden danger of frequent and ineffective start-stop of the second cold source, and greatly improves the comprehensive utilization rate of the residual cooling water and the thermal stability of the high-power electrical cabinet during continuous operation. Attached Figure Description

[0008] Figure 1 This is a schematic diagram of the system framework of the present invention.

[0009] Figure 2 This is a schematic diagram of the system execution flow of the present invention. Detailed Implementation

[0010] 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.

[0011] Please see Figures 1 to 2 This application provides a dual-cold-source energy-saving cabinet system based on the utilization of waste cooling water, including a target identification module, a water path reconstruction module, an impedance transfer module and a system recovery module; Among them, when the cabinet cooling system is in a normal cooling state with multiple heat exchange zones connected in parallel, the target recognition module collects the basic fluid and thermodynamic data of each heat exchange zone currently in operation in real time, and calculates the actual pressure difference on the primary side of each heat exchange zone and the actual amount of cooling transferred to the secondary side of the cabinet based on this data.

[0012] During data acquisition, the controller receives real-time data from the sensor array, including primary side supply and return water pressures, primary and secondary side volumetric flow rates, primary side supply and return water temperatures, and secondary side supply and return liquid temperatures for each heat exchange zone. For the baseline fluid pressure, the controller subtracts the primary side supply and return water pressures to obtain the actual primary side pressure difference for the corresponding heat exchange zone. For the heat transfer status, the controller multiplies the difference between the secondary side return and supply liquid temperatures by the secondary side volumetric flow rate and the pre-stored density and specific heat capacity of the secondary side clean coolant to determine the actual cooling capacity transferred in that heat exchange zone. By combining the actual temperature difference before and after fluid entry and exit with the volumetric flow rate and medium properties, the controller characterizes the actual heat power removed from the inverter cabinet by the heat exchange zone, providing fundamental data for subsequent data processing.

[0013] As a supplement to the basic concept, the primary side is the side flowing through the hot continuous rolling cooling water, and the secondary side is the side flowing through the clean coolant inside the cabinet. The heat exchange zone mentioned in this article refers to multiple plate bundle heat exchange units that are located in the same cabinet water circuit equipment compartment and are currently operating in parallel, and can be independently detected and have their water circuits switched.

[0014] Based on the primary side volumetric flow rate and the corresponding fluid temperature, the target identification module retrieves the cleaning baseline value under the corresponding operating conditions through a lookup table interpolation algorithm, and then converts the dimensional actual measurement quantity into a dimensionless relative characteristic quantity through proportional calculation.

[0015] To achieve dimensionless conversion of hydraulic characteristics, the controller first retrieves the clean reference pressure difference corresponding to the current operating condition from a pre-entered clean hydraulic reference table, and divides the currently measured primary side actual pressure difference by this clean reference pressure difference to obtain the relative hydraulic resistance. This calculation eliminates pressure difference fluctuations caused by normal flow regulation, reflecting whether the pipeline is currently physically constrained. For thermodynamic characteristics, the controller calculates the average temperature of the primary side supply and return water and the average temperature of the secondary side supply and return liquid, and takes the absolute value of the difference between the two to obtain the average heat transfer driving temperature difference. Using the absolute value of the temperature difference instead of the conventional logarithmic average temperature difference avoids mathematical divergence faults when the temperature differences at the system ends are close. Further, the controller divides the actual transferred cooling capacity by this average heat transfer driving temperature difference to obtain the effective heat transfer characterization quantity. Finally, the controller retrieves the clean effective heat transfer reference corresponding to the current operating condition from the clean heat transfer reference table, and divides the aforementioned effective heat transfer characterization quantity by this clean effective heat transfer reference to obtain the relative heat transfer capacity. This calculation logic quantitatively evaluates the degree of decay of heat transfer efficiency in the heat exchange zone.

[0016] Furthermore, the aforementioned clean baseline pressure difference is pre-calibrated and generated by establishing a feature matrix with primary-side volumetric flow rate and fluid temperature as dual independent coordinate axes before the cabinet and cooling water system are connected for operation, while the heat exchange components are in a clean state. The controller employs a bilinear interpolation algorithm when retrieving the clean baseline pressure difference. For a clean and effective heat transfer baseline, its calibration generation process includes establishing a multi-dimensional spatial feature matrix with primary and secondary-side volumetric flow rates and inlet temperatures on both sides as coordinates, and employing a multi-dimensional spatial interpolation algorithm during retrieval to eliminate numerical jumps outside the calibration grid nodes.

[0017] After feature extraction is completed, the target recognition module performs threshold verification on the dimensionless feature quantities of each heat exchange zone, thereby delineating a candidate set of suspected fouling, flow deviation and self-locking.

[0018] During the specific verification process, the controller determines whether the relative hydraulic resistance of the heat exchange zone is greater than the sum of one and the hydraulic judgment error tolerance, and simultaneously determines whether the relative heat transfer capacity of the heat exchange zone is less than the difference between one and the heat transfer judgment error tolerance. When the increase in channel resistance in the fluid dynamics dimension and the internal heat transfer decay in the thermodynamics dimension occur simultaneously and meet the aforementioned dual judgment conditions, the controller determines that the corresponding heat exchange zone has entered a fouling and flow deviation self-locking state and includes it in the candidate set. This judgment logic eliminates measurement interference caused by noise from a single sensor or air bubbles mixed in the pipeline. If no heat exchange zone meeting the conditions is found after traversal, the cabinet system continues to maintain parallel operation of all zones.

[0019] In this step, the methods for obtaining the hydraulic judgment error tolerance and the heat transfer judgment error tolerance include: during the initial window period when the system is running at full load without any abnormalities, extracting real-time samples of relative hydraulic resistance and relative heat transfer capacity and calculating three times the standard deviation of normal fluctuations; then comparing the calculated three times the standard deviation with the expanded measurement uncertainty of the system's configured sensors, and taking the larger value of the two as the corresponding tolerance assignment.

[0020] After determining the candidate set, the target identification module performs quantitative decoupling and sorting of the heat exchange zones within the candidate set to identify the target heat exchange zone with the most severe fault, and selects the flow-guiding heat exchange zone with the least fluid resistance from the normal heat exchange zone.

[0021] For heat exchange zones within the candidate set, the thermal decoupling amount is calculated by dividing the relative hydraulic resistance by the relative heat transfer capacity. When particle deposition occurs in the flow channel, the increased resistance leads to a larger relative hydraulic resistance (the numerator), while the obstructed effective heat exchange area reduces the relative heat transfer capacity (the denominator), resulting in a non-linear amplification of the thermal decoupling amount. The controller extracts the heat exchange zone with the largest thermal decoupling amount from the candidate set and establishes it as the target heat exchange zone. Simultaneously, among the normal heat exchange zones not included in the candidate set, the controller iterates through and selects the heat exchange zone with the relative hydraulic resistance closest to one, establishing it as the guiding heat exchange zone. This sorting logic provides a clear execution target anchor point for subsequent water-directed flushing and reconfiguration.

[0022] To prevent the system from falling into evaluation deadlock, if two or more heat exchange zones in the candidate set have completely equal calculated thermal resistance and decoupling values, the heat exchange zone with the greater relative hydraulic resistance is selected as the target heat exchange zone. Similarly, if multiple normal heat exchange zones have completely equal relative hydraulic resistance, the heat exchange zone with the greater relative heat transfer capacity is preferred as the guiding heat exchange zone. If there is no normal guiding heat exchange zone in the water system, subsequent topology reconfiguration actions are blocked, the backup dual cold source is maintained, and a manual maintenance alarm is triggered.

[0023] After completing quantitative diagnosis and sorting, the target identification module outputs the heat exchange zone identity anchor point and the preset cooling capacity benchmark to the downstream actuator.

[0024] The module outputs the established target heat exchange zone and guide heat exchange zone codes to guide downstream action units in addressing the corresponding heat exchange zone switching valves and series connection valves. Simultaneously, the module extracts the actual transferred cooling capacity of the target heat exchange zone at the determination moment, establishing it as the initial energy reference value for initiating pre-cooling with the second cold source during subsequent smooth switching, and locking the current liquid supply temperature of the liquid-cooled branch and the liquid supply temperature of the air-cooled branch. The transmission of energy and temperature state snapshots lays the data foundation for the smooth thermal takeover of the system.

[0025] Among them, after receiving the target heat exchange zone and the guide heat exchange zone code established by the target identification module, the water circuit reconstruction module performs pipeline topology state switching, reconstructs the aforementioned heat exchange zone from parallel state to directional series state, and simultaneously introduces a second cold source for thermal connection to maintain the stable supply temperature of the cooling branch in the frequency converter cabinet.

[0026] In the preparation phase before the water circuit topology switch, the secondary cleaned coolant after heat exchange from the first cold source forms a medium-temperature supply, and the secondary cleaned coolant after cooling from the second cold source forms a low-temperature supply. The controller starts the second cold source and assigns its initial supplementary cooling capacity to the actual cooling capacity transferred to the target heat exchange area as transmitted by the target identification module. After startup, the controller monitors the supply temperatures of the liquid-cooled branch and the air-cooled branch respectively. The two inlets of the three-way mixing valves of the liquid-cooled branch and the air-cooled branch are connected to the medium-temperature supply pipe and the low-temperature supply pipe, respectively, and the outlets are connected to the corresponding cooling branches. The controller controls the aforementioned two three-way mixing valves to adjust the mixing ratio of the medium-temperature and low-temperature supply, keeping the liquid-cooled branch supply temperature at the target control temperature, while simultaneously keeping the air-cooled branch supply temperature at the corresponding target control temperature. When the supply temperatures of both cooling branches are within the allowable control range, the controller grants the primary side valve switching permission. This operation compensates for the temporary reduction in cold source heat transfer in the target heat exchange area during the water circuit switch, ensuring that the inverter cabinet continuously receives effective cooling capacity.

[0027] During the water circuit switching execution phase, the controller opens the series connection valve between the primary side outlet of the guiding heat exchange zone and the primary side inlet of the target heat exchange zone. Upon receiving a position feedback signal indicating the series connection valve is fully open, the controller starts the series booster pump at low speed to establish a forward flow from the outlet of the guiding heat exchange zone to the inlet of the target heat exchange zone. Subsequently, the controller closes the parallel inlet valve between the target heat exchange zone and the first cold source supply water header, and also closes the parallel outlet valve between the guiding heat exchange zone and the first cold source return water header to block the bypass of direct return water from the guiding heat exchange zone, while maintaining the parallel outlet valve between the target heat exchange zone and the first cold source return water header in the open state. After completing the aforementioned valve actions, the circulating water from the first cold source supply water header flows sequentially through the guiding heat exchange zone and the target heat exchange zone before returning to the first cold source return water header. The circulating water flowing through the guiding heat exchange zone is forced to continue flowing through the target heat exchange zone, eliminating the external bypass path of the circulating water bypassing the high-resistance target heat exchange zone.

[0028] With the aforementioned series path established, the controller increases the speed of the series booster pump via a variable frequency drive unit, bringing the primary-side flow rate of the target heat exchange zone to the unlocked flow rate. The series booster pump employs a flow closed-loop control strategy, adjusting its speed in real time based on the detected primary-side flow rate of the target heat exchange zone. During the flow rate increase, the controller simultaneously monitors the primary-side pressure difference between the target heat exchange zone and the guiding heat exchange zone, as well as the flow rate in the series connecting pipe.

[0029] It should be added that the target control temperature of the aforementioned liquid-cooled branch is determined by the highest allowable inlet temperature of the power devices, while the target control temperature of the air-cooled branch is determined by the target supply air temperature inside the cabinet. To ensure the safe operation of the cabinet, both of the aforementioned target control temperatures must be higher than the sum of the dew point temperature of the air inside the cabinet and the anti-condensation safety temperature difference. The anti-condensation safety temperature difference is obtained based on the error of the temperature and humidity sensors, the differences in temperature and humidity distribution inside the cabinet, and the temperature difference on the surface of the pipes, and its value range is set to two Kelvin to four Kelvin.

[0030] In one specific embodiment, the aforementioned unlocking flow rate is the target total flow rate that, after the target heat exchange zone enters a series connection state, enables the differential pressure-responsive flow equalization component to generate an effective opening difference and redistribute the flow between the low-resistance channel group and the high-resistance channel group. The unlocking flow rate is obtained by simulating an increase in channel group resistance using a detachable throttling plate during equipment commissioning and progressively increasing the speed of the series booster pump. The lowest total flow rate in the heat exchange zone when the flow rate of the high-resistance simulated channel group begins to continuously increase and the total pressure difference in the heat exchange zone does not exceed the allowable operating pressure difference is determined as the unlocking flow rate for the corresponding model heat exchange zone.

[0031] The logic for limiting abnormal operating conditions and equipment safety is as follows: the series booster pump must not be started in the dead zone state where the outlet valve of the downstream target heat exchange zone is closed. The output speed of the series booster pump is subject to multiple boundary restrictions, specifically including that the primary side pressure difference of the target heat exchange zone and the primary side pressure difference of the guide heat exchange zone must not exceed their respective allowable operating pressure difference limits, and the flow rate of the series connection pipe must not exceed the allowable flow rate limits of the pipeline and the particle collection chamber. If the flow rate of the target heat exchange zone still does not reach the unlocking flow rate after the series booster pump reaches the maximum allowable speed, the controller terminates the automatic unlocking program, restores the original parallel water circuit, and issues a manual cleaning prompt signal to prevent equipment overpressure and overload.

[0032] Among them, after the water circuit reconstruction module completes the establishment of the directional series water circuit and reaches the unlocking flow rate, the impedance transfer module uses the initial flow difference of the channel group inside the heat exchange zone to trigger the differential pressure response flow equalization component to undergo mechanical deformation, and directionally transfers the primary side hydraulic head from the clean channel group to the high resistance channel group, thereby stripping off and retaining the sediments attached to the channel surface.

[0033] In the automatic impedance transfer stage, after the circulating water enters the primary inlet distribution chamber of the target heat exchange zone, it flows to each channel group. For clean channel groups where there is no severe internal deposition, the initial hydraulic resistance is small, and the initial flow rate allocated is large. This larger flow rate exerts a significant pushing force on the free end of the elastic tongue corresponding to the channel group inlet, overcoming the restoring force of the elastic support and forcing the elastic tongue to bend and displace towards the channel group inlet. This displacement reduces the effective flow area at the inlet of the clean channel group, thereby increasing the additional resistance at the inlet of the clean channel group. For high-resistance channel groups with internal particle deposition, the initial flow rate is small, and the pushing force on the corresponding elastic tongue is weak. The elastic tongue maintains a large inlet opening, with little or no increase in additional resistance.

[0034] During the hydraulic head transfer and fluid stripping process, as the inlet resistance of the clean channel group increases, the fluid in the target heat exchange zone inlet distribution chamber forces more flow and corresponding dynamic head to transfer to the high-resistance channel group. Driven by the increased hydraulic head, the high-resistance channel group gains a flow increment, and the increased internal velocity enhances the wall shearing effect. This enhanced shearing force hydrodynamically strips iron oxide particles, metal oxide flocs, or oily particles adhering to the channel surface. The deposits detached from the channel walls flow out of the target heat exchange zone with the circulating water and enter the particle collection chamber located at the primary side outlet. The circulating water containing particles enters the expanded-diameter cavity of the particle collection chamber, where the velocity decreases. A removable filter basket within the cavity traps the aforementioned detached material, preventing contaminants from entering the first cold source return water header and causing cross-contamination.

[0035] In the dynamic monitoring phase, the controller continuously monitors changes in the hydraulic state of the target heat exchange zone. During impedance transfer, the sensor array collects the current actual primary-side pressure difference and actual primary-side volumetric flow rate of the target heat exchange zone at millisecond sampling periods, preferably between ten and one hundred milliseconds. These real-time dynamic hydraulic data serve as indicators of the degree of fluid impedance transfer, providing data input for the subsequent system determination of the heat exchange zone's self-locking release status.

[0036] It should be added that the aforementioned differential pressure response flow equalization component does not require an external electronic actuator and operates independently based on fluid dynamics feedback. The periphery of the distribution plate is sealed to the inner wall of the inlet distribution chamber, ensuring that all circulating water enters the downstream plate flow channel through the channel group inlet. Each channel group contains four to eight adjacent plate flow channels. The elastic tongue is fixed to the distribution plate using a cantilever structure, with its fixed end located upstream of the channel group inlet and its free end facing downstream of the channel group inlet. The aforementioned elastic support is formed by the cantilever root of the elastic tongue body made of elastic composite material, providing deformation recovery force through the structural stiffness of the material itself. To prevent high-frequency fatigue fracture or unstable oscillation caused by water flow impact, the flow equalization component is equipped with a damping part to reduce mechanical vibration. This damping part uses a polymer damping coating attached to the backwater side of the elastic tongue or a corrosion-resistant damping gasket set at the root of the cantilever structure.

[0037] To ensure equipment safety under extreme water flow impact or full-load, high-flow conditions, the flow equalization component incorporates a mechanical limiting block to restrict the maximum closing displacement of the elastic tongue. This mechanical limiting block ensures that even when the elastic tongue reaches its maximum displacement position, a minimum flow clearance remains between it and the channel inlet. The lower limit of this minimum flow clearance is set as the sum of the upper limit of the equivalent particle size in the first cold source and an additional clearance margin. The aforementioned upper limit of the equivalent particle size is defined by the particle size distribution reaching 95% obtained from particle size analysis of the first cold source water sample. The additional clearance margin is determined by a combination of tongue manufacturing tolerances, assembly tolerances, and thermal deformation at operating temperature. This structural boundary constraint eliminates the safety hazards of the elastic tongue being jammed by large foreign objects or the channel inlet being completely blocked.

[0038] Among them, during the continuous hydrodynamic stripping action of the impedance transfer module, the system recovery module evaluates the hydraulic self-recovery status of the target heat exchange zone in real time, and restores the cabinet water circuit topology to the parallel operation state of the entire area after confirming that the channel self-locking is released, thereby re-establishing the dual cold source air-liquid graded cooling closed loop.

[0039] While the impedance transfer module continuously strips away sediment, the controller simultaneously acquires the current actual primary side pressure difference and actual primary side volumetric flow rate of the target heat exchange zone. The controller then divides the aforementioned actual primary side pressure difference by the square of the actual primary side volumetric flow rate to obtain the hydraulic resistance coefficient of the target heat exchange zone's primary side. Simultaneously, the controller extracts the actual primary side pressure difference and actual primary side volumetric flow rate of each normally operating heat exchange zone currently in parallel, and uses the same division operation to obtain the hydraulic resistance coefficient of each normally operating heat exchange zone's primary side. An upper limit boundary is defined by adding a safety margin to the maximum value of the hydraulic resistance coefficient of each currently operating normally operating heat exchange zone. The controller then determines whether the hydraulic resistance coefficient of the target heat exchange zone's primary side has decreased below this upper limit boundary. When this condition is met, the controller determines that the sediment in the internal channels of the target heat exchange zone has been cleared, and the pipeline's self-locking state is released.

[0040] During the water circuit topology restoration phase, the controller first shuts down the series booster pump, then closes the series connection valve between the primary side inlet of the target heat exchange zone and the primary side outlet of the guide heat exchange zone. After confirming that the series path is completely cut off, the controller reopens the parallel inlet valve between the target heat exchange zone and the first cold source supply water header, as well as the parallel outlet valve between the guide heat exchange zone and the first cold source return water header. This series of valve and pump actions causes the target heat exchange zone and the guide heat exchange zone to exit the directional series state, restoring the initial operating topology where the primary sides of each heat exchange zone are connected in parallel.

[0041] In the cooling demand conversion stage, the controller summarizes the actual cooling capacity transferred in each heat exchange zone and adds up the aforementioned cooling capacity values ​​to obtain the total available residual cooling capacity of the first cold source. Regarding the heat load at the rack end, the real-time heat load at the rack end is composed of the sum of the real-time heat loads of each branch within the rack. Specifically, the controller multiplies the difference between the return liquid temperature and the supply liquid temperature of the liquid-cooled branch by the secondary-side flow rate of the liquid-cooled branch and the pre-stored density and specific heat capacity of the secondary-side clean coolant to obtain the real-time heat load of the liquid-cooled branch. Using the same calculation logic, the controller multiplies the difference between the return liquid temperature and the supply liquid temperature of the air-cooled branch by the secondary-side flow rate of the air-cooled branch and the aforementioned pre-stored density and specific heat capacity of the secondary-side clean coolant to obtain the real-time heat load of the air-cooled branch.

[0042] In the dual-cold-source cascade distribution stage, the controller compares the secondary-side liquid supply temperature, uniformly formed after heat exchange of the first cold source, with the temperature tolerance limits of each branch of the cabinet. If the aforementioned secondary-side liquid supply temperature is not higher than the maximum peak liquid supply temperature allowed by the liquid cooling plate, the controller prioritizes allocating the total available residual cooling capacity of the first cold source to the liquid cooling branch. In the assignment calculation logic, if the total available residual cooling capacity of the first cold source is greater than the real-time heat load of the liquid cooling branch, then the actual cooling capacity allocated by the first cold source to the liquid cooling branch is equal to the real-time heat load; if the available total residual cooling capacity is insufficient, then all available total residual cooling capacity is assigned to the liquid cooling branch. If the aforementioned secondary-side liquid supply temperature is simultaneously not higher than the maximum peak liquid supply temperature allowed by the air-cooled heat exchanger, the controller continues to allocate the remaining total residual cooling capacity after allocation to the air-cooled branch, and the actual allocated cooling capacity of the air-cooled branch is determined using the same comparison and assignment logic as described above.

[0043] In the cold source differential compensation stage, the controller calculates the difference between the real-time heat load of the liquid-cooled branch and the actual cooling capacity allocated to the liquid-cooled branch by the first cold source, as well as the difference between the real-time heat load of the air-cooled branch and the actual cooling capacity allocated to the air-cooled branch by the first cold source. Since the actual heat load may be less than the allocated cooling capacity, the controller only extracts the positive value of the two differences and sums them to obtain the total cooling capacity that the second cold source needs to supplement. Based on this instruction, the controller adjusts the output power of the second cold source and the opening of the three-way mixing valves of each branch to complete the system energy closed loop.

[0044] The abnormal handling logic for equipment protection and cleaning failures is as follows: if the target heat exchange zone operates continuously in a directional series state for more than the preset flushing timeout threshold, and the primary side hydraulic resistance coefficient of the target heat exchange zone has not yet decreased below the aforementioned upper limit boundary, the controller determines that irreversible hard solidification and fouling has occurred inside the heat exchange zone. The aforementioned flushing timeout threshold is set comprehensively based on the maximum allowable continuous series pressure bearing time of the target heat exchange zone and the maximum time margin for the inverter cabinet to withstand thermal imbalance. At this time, the controller forcibly disconnects the primary side water circuit connection of the target heat exchange zone, triggers a severe fault shutdown alarm through the host computer, and schedules the second cold source to operate at full load to take over the entire heat load of the cabinet, preventing the heat exchanger plates from being continuously damaged by pressure due to ineffective hydraulic flushing.

[0045] The above embodiments are only used to illustrate the technical methods of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical methods of the present invention without departing from the spirit and scope of the technical methods of the present invention.

Claims

1. A dual-cold-source energy-saving cabinet system based on the utilization of waste cooling water, characterized in that, include: The target identification module is used to collect basic fluid and thermodynamic data of the heat exchange zone that is cooled by the first cold source and operates in parallel. The heat exchange zone is equipped with a channel group including a clean channel group and a high resistance channel group, as well as a differential pressure response flow equalization component. Based on the basic fluid and thermodynamic data, the module filters out the target heat exchange zone with increased resistance and heat transfer decay, which is blocked and deflected and self-locked, and the normally operating flow guiding heat exchange zone. The water circuit reconfiguration module is used to reconfigure the target heat exchange zone and the guide heat exchange zone into a directional series state, introduce a second cold source to maintain the stable liquid supply temperature of the cooling branch including the liquid cooling branch and the air cooling branch, and force the circulating water flowing through the guide heat exchange zone to flow through the target heat exchange zone and reach the unlock flow rate through the series booster pump. The impedance transfer module is used to trigger the mechanical deformation of the differential pressure response flow equalization component in the target heat exchange zone after the unlocking flow rate is reached, by utilizing the initial flow difference of the channel group inside the target heat exchange zone to directionally transfer the hydraulic head to the high resistance channel group containing sediments in order to remove the sediments, and to collect the actual pressure difference and actual volume flow rate of the primary side of the target heat exchange zone. The system recovery module is used to determine the release of the self-locking mechanism for the primary side of the heat exchange zone after the actual pressure difference and actual volumetric flow rate of the primary side are determined based on the target heat exchange zone. It then restores the parallel operation status of the primary side of the heat exchange zone and performs dual-source cascade distribution based on the current available total residual cooling capacity of the first cold source and the real-time heat load at the cabinet end.

2. The dual-cold-source energy-saving cabinet system based on the utilization of waste cooling water according to claim 1, characterized in that, The data transformation and verification operations performed by the target recognition module include: Based on the actual volumetric flow rate and corresponding fluid temperature on the primary side, the clean reference pressure difference and the clean effective heat transfer reference are retrieved. The actual pressure difference on the primary side is divided by the clean reference pressure difference to obtain the relative hydraulic resistance. The actual transferred cold capacity is divided by the average heat transfer drive temperature difference to obtain the effective heat transfer characterization quantity. The effective heat transfer characterization quantity is divided by the clean effective heat transfer reference to obtain the relative heat transfer capacity. When the relative hydraulic resistance is greater than the sum of the hydraulic judgment error tolerance and the relative heat transfer capacity is less than the difference between the heat transfer judgment error tolerance and the relative hydraulic resistance, the heat exchange zone is included in the candidate set.

3. The dual-cold-source energy-saving cabinet system based on the utilization of waste cooling water according to claim 2, characterized in that, The quantitative decoupling and sorting operations performed by the target recognition module include: The heat resistance decoupling amount is obtained by dividing the relative hydraulic resistance of the heat exchange zone in the candidate set by the relative heat transfer capacity of the heat exchange zone in the candidate set. The heat exchange zone with the largest thermal resistance decoupling value in the candidate set is selected as the target heat exchange zone. If there are heat exchange zones with equal thermal resistance decoupling values ​​in the candidate set, the heat exchange zone with the larger relative hydraulic resistance value is selected as the target heat exchange zone. In the normal heat exchange zone not included in the candidate set, the heat exchange zone with the closest relative hydraulic resistance to one is selected as the guiding heat exchange zone. If there are heat exchange zones with equal relative hydraulic resistance values ​​in the normal heat exchange zone not included in the candidate set, the heat exchange zone with the larger relative heat transfer capacity value is selected as the guiding heat exchange zone.

4. The dual-cold-source energy-saving cabinet system based on the utilization of waste cooling water according to claim 1, characterized in that, The water circuit reconfiguration module performs water circuit and temperature control operations, including: The three-way mixing valves of the liquid cooling branch and the air cooling branch are controlled to adjust the mixing ratio of medium-temperature and low-temperature liquid supply, so that the liquid supply temperature of the liquid cooling branch is maintained at the target control temperature of the liquid cooling branch, and the liquid supply temperature of the air cooling branch is maintained at the target control temperature of the air cooling branch. The medium-temperature liquid supply is the secondary clean coolant after heat exchange from the first cold source, and the low-temperature liquid supply is the secondary clean coolant after cooling from the second cold source. Open the series connection valve between the primary side outlet of the diversion heat exchange zone and the primary side inlet of the target heat exchange zone, close the parallel inlet valve between the target heat exchange zone and the first cold source water supply header, close the parallel outlet valve between the diversion heat exchange zone and the first cold source water return header, and keep the parallel outlet valve between the target heat exchange zone and the first cold source water return header in the open state.

5. A dual-cold-source energy-saving cabinet system based on the utilization of waste cooling water according to claim 4, characterized in that, The dynamic boundary safety configuration of the waterway reconfiguration module includes: The unlocked flow configuration is to enable the differential pressure response flow equalization component to generate an effective opening difference and to redistribute the clean channel group and the high resistance channel group into a target total flow after the target heat exchange zone enters the series state; The output speed of the series booster pump is subject to multiple boundary restrictions, including that the primary side pressure difference of the target heat exchange zone and the primary side pressure difference of the guide heat exchange zone do not exceed the upper limit of the allowable working pressure difference, and the flow rate of the series connection pipe does not exceed the upper limit of the allowable flow rate of the pipeline. The series booster pump must not be started or operated in the dead zone state where the outlet valve of the downstream target heat exchange zone is closed. When the series booster pump reaches the maximum allowable speed and the flow rate of the target heat exchange zone does not reach the unlocking flow rate, the automatic unlocking procedure will be terminated, the original parallel water circuit will be restored, and a manual cleaning prompt signal will be issued.

6. The dual-cold-source energy-saving cabinet system based on the utilization of waste cooling water according to claim 1, characterized in that, The internal structure of the differential pressure response flow equalization component includes: Distribution plate, elastic tongue, elastic support, damping part and mechanical limit block; The periphery of the distribution plate is sealed to the inner wall of the primary side inlet distribution cavity of the target heat exchange zone; The elastic tongue is fixed to the distribution plate using a cantilever structure. The fixed end of the elastic tongue is located upstream of the channel group inlet, and the free end of the elastic tongue faces downstream of the channel group inlet. The elastic support is formed by the cantilever root of the elastic tongue body, and the elastic support provides deformation recovery force by relying on the structural stiffness of the material itself. Damping components are used to reduce mechanical vibration; The mechanical limit block restricts the maximum closing displacement of the elastic tongue, ensuring that a minimum flow gap is maintained between the elastic tongue and the channel inlet when the elastic tongue reaches the maximum displacement position. The lower limit of the minimum flow gap is set as the sum of the upper limit of the equivalent particle size of the particles in the first cold source and the additional gap margin.

7. A dual-cold-source energy-saving cabinet system based on the utilization of waste cooling water according to claim 6, characterized in that, The sediment stripping and retention operations performed by the impedance transfer module include: The initial flow rate allocated to the clean channel group inside the target heat exchange zone is used to push the free end of the elastic tongue to overcome the restoring force of the elastic support, forcing the elastic tongue to bend and displace towards the inlet of the channel group to reduce the effective flow area, increase the additional resistance at the inlet of the clean channel group, and transfer the hydraulic head to the high resistance channel group. The high-resistance channel group gains an increase in flow rate driven by the new hydraulic head. The increased flow velocity inside the high-resistance channel group promotes the shearing effect on the wall, and the hydrodynamic stripping effect generated by the shearing force of the water flow causes the sediment to fall off the channel surface. The detached sediment flows out of the target heat exchange zone with the circulating water and enters the particle collection chamber located at the primary side outlet of the target heat exchange zone. The circulating water containing particles enters the particle collection chamber and its flow velocity decreases after entering the expanded cavity. The detached sediment is intercepted by the removable filter basket inside the particle collection chamber.

8. A dual-cold-source energy-saving cabinet system based on the utilization of waste cooling water according to claim 1, characterized in that, The self-recovery determination operation performed by the system recovery module includes: The hydraulic resistance coefficient of the primary side of the target heat exchange zone is obtained by dividing the actual pressure difference on the primary side of the target heat exchange zone by the square of the actual volumetric flow rate on the primary side of the target heat exchange zone. Divide the actual pressure difference on the primary side of each heat exchange zone during normal operation by the square of the actual volumetric flow rate on the primary side of each heat exchange zone during normal operation to obtain the hydraulic resistance coefficient on the primary side of each heat exchange zone during normal operation. The upper limit boundary is defined as the sum of the maximum value of the primary side hydraulic resistance coefficient of each heat exchange zone under normal operation and the safety margin. When the primary side hydraulic resistance coefficient of the target heat exchange zone drops below the upper limit boundary, the fouling and deflection self-locking is determined to be released.

9. A dual-cold-source energy-saving cabinet system based on the utilization of waste cooling water according to claim 1, characterized in that, The dual-cold source cascade allocation operation performed by the system recovery module includes: The real-time heat load at the rack end is divided into the real-time heat load of the liquid cooling branch and the real-time heat load of the air cooling branch. Compare the secondary side liquid supply temperature formed uniformly after the first cold source heat exchange with the maximum peak liquid supply temperature allowed by the liquid cooling plate and the maximum peak liquid supply temperature allowed by the air-cooled heat exchanger, and perform cascaded cold capacity distribution. When the secondary side liquid supply temperature formed uniformly after the heat exchange of the first cold source is not higher than the maximum peak liquid supply temperature allowed by the liquid cooling plate, the current available total residual cooling capacity of the first cold source is preferentially allocated to the liquid cooling branch. When the secondary side liquid supply temperature formed uniformly after the first cold source heat exchange is not higher than the maximum peak liquid supply temperature allowed by the air-cooled heat exchanger, the remaining total residual cooling capacity after being allocated to the liquid cooling branch will continue to be allocated to the air-cooled branch. Calculate the difference between the real-time heat load of the liquid cooling branch and the actual cooling capacity allocated to the liquid cooling branch by the first cold source, and the difference between the real-time heat load of the air cooling branch and the actual cooling capacity allocated to the air cooling branch by the first cold source. Extract the positive values ​​from the calculated differences and sum them to obtain the total cooling capacity that the second cold source needs to supplement.

10. A dual-cold-source energy-saving cabinet system based on the utilization of waste cooling water according to claim 8, characterized in that, The anomaly protection operations configured in the system recovery module include: If the continuous operating time of the target heat exchange zone in the directional series state exceeds the flushing timeout threshold, and the hydraulic resistance coefficient of the primary side of the target heat exchange zone does not drop below the upper limit boundary, it is determined that irreversible hard solidification and fouling has occurred, the primary side water circuit connection of the target heat exchange zone is forcibly cut off, a severe fault shutdown alarm is triggered through the host computer, and the second cold source is scheduled to run at full load to take over all the heat load of the cabinet. The flushing timeout threshold is set based on the maximum allowable continuous series pressure bearing time of the target heat exchange zone and the maximum time margin for the inverter cabinet to withstand thermal imbalance.

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