A high-low pressure separation drawer type high pressure tank

Abstract

This application relates to the field of supercapacitor energy storage technology, and in particular to a high-voltage and low-voltage separated drawer-type high-voltage box, specifically including a box body, a high-voltage main circuit power module, and a low-voltage box. The box body is provided with a high-voltage compartment and a low-voltage compartment, with the low-voltage compartment extending along a first direction. The high-voltage main circuit power module is located in the high-voltage compartment. The electrical components of the high-voltage main circuit power module are fixedly connected by fasteners and rigid conductive bars to form a rigid main circuit without plug-in nodes. The low-voltage box is provided with a low-voltage control module. The low-voltage box is removably stored in the low-voltage compartment along the first direction, and a blind-plug connector is provided at the rear end of the low-voltage box. A blind-plug interface is provided on the low-voltage compartment. In the stored position, the blind-plug connector is connected to the blind-plug interface. When the box is pulled out, the blind-plug connector is separated from the blind-plug interface. This high-voltage box has the advantage of enabling rapid maintenance and replacement of the control module while ensuring high reliability of the high-voltage circuit.

Description

Technical Field

[0001] This invention relates to the field of supercapacitor energy storage technology, and in particular to a high-voltage box with separate high and low voltage drawers. Background Technology

[0002] With the continuous growth of global energy demand and the increasing prominence of environmental pollution, the research and application of new energy technologies have received widespread attention. Supercapacitors, as a new type of energy storage device, have demonstrated enormous application potential in power systems, transportation, and new energy fields due to their advantages such as high power density, long cycle life, and rapid charging and discharging.

[0003] In supercapacitor energy storage systems, the high-voltage box, as a key component connecting the supercapacitor bank and energy transmission, undertakes three core tasks: current collection, protection, and control. However, existing high-voltage box designs suffer from the following technical problems: High maintenance costs: In traditional high-voltage boxes, the control unit (CCMU, controller, etc.) and high-voltage power devices are fixedly installed in the same box. When it is necessary to repair or replace the control unit, the entire energy storage system and high-voltage box must be powered off and a large number of connecting cables must be disassembled. The maintenance cycle is long and the labor cost is high.

[0004] High and low voltage interference risk: Although some products adopt a split-chamber design, the control unit still needs to be connected to high-voltage devices through long-distance cables, which poses a risk of electromagnetic interference and affects the accuracy of control signals.

[0005] Publication number CN221380583U discloses a high-voltage control box for a battery pack in an energy storage system, including a shell, a base plate, and a panel. The base plate is designed as a drawer-type assembly / disassembly mechanism, facilitating quick maintenance of the high-voltage control box, thanks to limiting plates on two sets of side plates that allow for easy pulling out and removing. However, during use, low-voltage and high-voltage components are mixed in the same drawer, requiring frequent plugging and unplugging of the high-voltage connector, posing a risk of poor contact and arcing. Furthermore, it is not optimized for the high-frequency charging and discharging characteristics of supercapacitor energy storage systems and lacks physical isolation between high and low voltage levels, resulting in a high risk of electromagnetic interference.

[0006] Although CN223414482U achieves high and low voltage separation, it lacks a drawer-type design, requiring disassembly of the enclosure for maintenance. The three-section enclosure structure is complex, difficult to assemble, and costly, and it has not been optimized for the special needs of supercapacitor energy storage systems.

[0007] Therefore, there is an urgent need for an optimized solution that separates high and low voltage, enabling convenient maintenance while ensuring the reliability of the high-voltage circuit. Summary of the Invention

[0008] The technical problem to be solved by the present invention is to overcome the shortcomings of the prior art and provide a high-voltage box with separate high and low voltage drawers. This high-voltage box has the advantage of enabling rapid maintenance and replacement of the control module while ensuring the high reliability of the high-voltage circuit.

[0009] To achieve the above objectives, the technical solution adopted by the present invention is as follows: A high-voltage box with separate high and low voltage drawers is provided, comprising: a box body, which has a high-voltage compartment and a low-voltage compartment inside, the high-voltage compartment and the low-voltage compartment being spatially separated and electrically isolated by a partition, the low-voltage compartment extending along a first direction; a high-voltage main circuit power module, which is disposed in the high-voltage compartment, the electrical components of the high-voltage main circuit power module being fixedly connected by fasteners and rigid conductive bars to form a rigid main circuit without plug-in nodes; and a low-voltage box, which has a low-voltage control module inside, the low-voltage box being removably stored in the low-voltage compartment along the first direction, and the low-voltage box having a blind-plug connector at its rear end along the first direction, the low-voltage compartment having a blind-plug interface, wherein in the stored position, the blind-plug connector and the blind-plug interface are connected to electrically connect the low-voltage control module and the high-voltage main circuit power module, and when the box is removed, the blind-plug connector and the blind-plug interface are separated.

[0010] To optimize the above plan, the following measures were also taken: As a preferred embodiment, the high-voltage main circuit power module includes a contactor, a high-voltage side fuse, positive and negative power terminals, and charging / discharging maintenance terminals; the positive and negative power terminals are used to connect to the charging and discharging electrodes of the supercapacitor; the external high-voltage bus, the contactor, the high-voltage side fuse, and the positive and negative power terminals are connected in series to form the main circuit, so as to realize the charging and discharging transmission and on / off control of electrical energy between the external high-voltage bus and the supercapacitor; A high-voltage operation panel is provided on one side of the high-voltage chamber. The charging and discharging maintenance terminal is located on the high-voltage operation panel. The charging and discharging maintenance terminal is connected in parallel with the external high-voltage bus and the contactor in a bypass configuration. One end of the terminal is led out to the outside of the high-voltage operation panel, and the other end is connected to the circuit between the contactor and the positive and negative power terminals. The charging and discharging maintenance terminal is used to connect to external testing equipment to directly bypass pre-charge or discharge residual energy of the supercapacitor.

[0011] As a preferred embodiment, the low-voltage box includes a rectangular box frame, the box frame being open on at least two sides along a second direction, the second direction being perpendicular to the first direction and the height direction, each opening having at least two opposing and parallel side mounting edges, the side mounting edges extending along the first direction, the low-voltage control module including at least two main control modules, the main control module including a mounting plate and a PCB circuit board positioned on the mounting plate, the PCB circuit board being disposed on the side of the mounting plate near the inner cavity of the low-voltage box and the two being separated by a first distance; The two sets of main control modules are symmetrically distributed on the side mounting edges on both sides along the second direction. Each set of main control modules includes multiple main control modules. The mounting plate of the main control module is detachably connected to the side mounting edge on the corresponding side, and the multiple mounting plates on each side are spaced apart by a second distance along the first direction.

[0012] As a preferred embodiment, the housing frame is arranged with an open upper side in the height direction, and a top mounting edge is provided inside. The low-voltage control module includes three sets of main control modules, one of which has a mounting plate detachably connected to the top mounting edge.

[0013] As a preferred embodiment, the PCB circuit board and the corresponding mounting plate are arranged opposite to and parallel to each other. The mounting plate is provided with a plurality of positioning posts evenly distributed thereon, and the PCB circuit board and the mounting plate are separated by the positioning posts.

[0014] As one preferred embodiment, the contactor includes a main contact and a low-voltage control coil for driving the main contact to engage. The low-voltage control module outputs a weak current control signal, which is transmitted sequentially to the weak current control coil of the contactor via the blind plug and the blind plug interface in the retracted connection state. This control is achieved by electromagnetically driving the physical on / off of the main contacts, thereby realizing safe isolation control of the high-voltage main circuit power module.

[0015] As one preferred embodiment, the high-voltage main circuit power module includes a Hall sensor, which is embedded and sleeved on the outer periphery of the negative polarity of the conductive busbar. The Hall sensor is used to collect the magnetic field signal around the conductive busbar, convert it into a low-voltage current sampling signal, and transmit it back to the low-voltage control module in the low-voltage box through the blind-plug interface to form a closed-loop monitoring link.

[0016] As one of the preferred methods, the low-voltage control module includes a redundant power supply module, a main control module, an I / O controller, and a terminal block; The redundant power supply module, the main control module, the IO controller, the terminal block, and the blind-plug connector are electrically connected in sequence to form a low-voltage control and communication link.

[0017] As one of the preferred methods, the low-pressure box is provided with a low-pressure operation panel at its front end along the first direction, and the low-pressure operation panel is provided with a pull-out operation part for the user to pull out the low-pressure box.

[0018] As one of the preferred methods, the box frame is arranged with an open upper side in the height direction, and a top mounting edge is provided inside. The low-voltage control module includes two sets of main control modules, which are symmetrically distributed on the side mounting edges on both sides along the second direction. A top cover plate is detachably connected to the top mounting edge.

[0019] Because of the above-described solutions, one or more technical solutions provided in this application embodiment have at least the following technical effects or advantages: In one aspect, this solution adopts a "fixed high voltage, drawer low voltage" structure. The high voltage main circuit uses a rigid connection, avoiding the problems of increased contact resistance and arc erosion caused by long-term high current impact on flexible plug-in nodes, thus ensuring the long-term stable operation of the main circuit. At the same time, through the independent pull-out at the front end of the low voltage box and the blind plug-in docking at the rear end, maintenance personnel can complete the plugging and replacement of the low voltage control module and low voltage box without disassembling the high voltage main circuit and high voltage box, effectively shortening the system downtime for maintenance. The maintenance efficiency is significantly improved compared with the traditional split or overall pull-out design, greatly reducing the system downtime.

[0020] In another aspect, this solution divides the high-voltage box into a high-voltage compartment and a low-voltage compartment, which are spatially and electrically separated. This blocks the interference path of spatial electromagnetic radiation generated by high-voltage and high-current alternation on the low-voltage control signal. The control signal interacts through a blind-plug interface, and with the electromagnetic isolation drive of the contactor, the electrical isolation between the control circuit and the main power circuit is achieved. This design ensures that when maintenance personnel pull out the low-voltage box, the operating area is isolated from the high-voltage live area, improving the safety of daily maintenance operations. Attached Figure Description

[0021] To more clearly illustrate the technical solutions of the embodiments of this application, the accompanying drawings of the embodiments will be briefly described below. Obviously, the drawings described below only involve some embodiments of this application and should not be construed as limiting this application.

[0022] Figure 1 This is a schematic diagram of the overall structure of this embodiment; Figure 2 This is a schematic diagram of the internal structure of this embodiment; Figure 3 This is a schematic diagram of the split structure in this embodiment; Figure 4 This is a schematic diagram of the main control module in this embodiment.

[0023] Figure label: 100. Box body; 101. Box cover; 1. High-voltage chamber; 102. High-voltage copper busbar; 103. Positive and negative power terminals; 104. Contactor; 105. High-voltage side fuse; 107. Charging and discharging maintenance terminals; 108. High-voltage operation panel; 2. Low-voltage box; 201. Box frame; 2011. Side mounting edge; 2012. Top mounting edge; 2013. Top cover; 202. Main control module; 2021. Mounting plate; 2022. PCB circuit board; 2023. Positioning post; 203. IO controller; 204. Redundant power supply module; 205. Low-voltage side fuse; 206. Terminal block; 207. Blind-fit connector; 208. Low-voltage operation panel; 209. Pull-out operation section; 3. Low-pressure chamber; 301. Chamber body; 302. Blind-plug interface; 4. Hall sensor. Detailed Implementation

[0024] To enable those skilled in the art to better understand the technical solutions of this invention, the technical solutions of the embodiments of this invention will be clearly and completely described below with reference to the accompanying drawings, so as to more clearly understand the purpose, features and advantages of this invention. It should be understood that the embodiments shown in the drawings are not intended to limit the scope of this invention, but are only for illustrating the essential spirit of the technical solutions of this invention. Obviously, the described embodiments are only a part of the embodiments of this invention, and not all of them. Based on the embodiments of this invention, all other embodiments obtained by those skilled in the art without creative effort should fall within the scope of protection of this invention.

[0025] Unless the context requires otherwise, throughout the specification and claims, the word “comprising” and its variations, such as “including” and “having”, shall be understood to have an open, inclusive meaning, that is, to be interpreted as “including, but not limited to”.

[0026] Throughout this specification, references to "an embodiment" or "an embodiment" indicate that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. Therefore, the appearance of "in an embodiment" or "an embodiment" in various places throughout the specification does not necessarily refer to the same embodiment. Furthermore, a particular feature, structure, or characteristic may be combined in any manner in one or more embodiments.

[0027] The singular forms “a” and “the” used in this specification and the appended claims include plural references unless otherwise expressly stated herein. It should be noted that the term “or” is generally used to mean “and / or” unless otherwise expressly stated herein.

[0028] In the following description, in order to clearly demonstrate the structure and working method of the present invention, a number of directional terms will be used. However, terms such as "front", "back", "left", "right", "outside", "inside", "outward", "inward", "up", and "down" should be understood as convenient terms and not as limiting terms.

[0029] The implementation details of the embodiments of the present invention will be described in detail below with reference to the accompanying drawings. The following content is only for the convenience of understanding the implementation details and is not necessary for implementing this solution.

[0030] refer to Figures 1 to 4 This embodiment proposes a high-voltage, low-voltage separated drawer-type high-voltage box for supercapacitor energy storage systems. It aims to solve the problems of traditional energy storage high-voltage boxes, which either have fixed and mixed control units and high-voltage power devices or are pulled out as a whole. These issues lead to high maintenance costs and electric shock hazards, requiring power disconnection and disassembly of numerous cables when maintaining the low-voltage control unit. Furthermore, during the overall pulling-out process, the alternating ampere force and thermal stress under the high-frequency, high-transient-current charging and discharging conditions of the supercapacitor can easily cause microscopic contact problems at the insertion and removal nodes, leading to overheating and even arcing risks. While ensuring high reliability of the high-voltage circuit, this design not only enables rapid, online maintenance and replacement of the control unit, significantly reducing maintenance costs, but also effectively reduces electromagnetic interference through the high- and low-voltage physical isolation design, significantly improving the anti-interference capability of the low-voltage control module.

[0031] The following description, in conjunction with the accompanying drawings, details how the technical solution in this embodiment addresses the aforementioned technical problems.

[0032] Combination Figures 1 to 4This embodiment discloses a high-voltage box with separate high and low voltage drawers, comprising a box body 100, a high-voltage main circuit power module, and a low-voltage box 2. The box body 100 contains a high-voltage chamber 1 and a low-voltage chamber 3, which are spatially separated and electrically isolated from each other by a partition, which is the side wall of the low-voltage chamber 3. The low-voltage chamber 3 extends along a first direction. The high-voltage main circuit power module is housed within the high-voltage chamber 1. The electrical components of the high-voltage main circuit power module are fixedly connected by fasteners and rigid conductive bars to form a [structure / structure]. A rigid main circuit without plug-in nodes is provided. The low-voltage box 2 is equipped with a low-voltage control module. The low-voltage box 2 is removably stored in the low-voltage chamber 3 along the first direction. The low-voltage box 2 is provided with a blind-plug connector 207 at the rear end along the first direction. The low-voltage chamber 3 is provided with a blind-plug interface 302. In the stored position, the blind-plug connector 207 and the blind-plug interface 302 are connected to enable the low-voltage control module to be electrically connected to the high-voltage main circuit power module. When it is pulled out, the blind-plug connector 207 and the blind-plug interface 302 are separated.

[0033] Specifically, the upper part of the housing 100 is equipped with a removable cover plate 101 to form a closed outer shell. The interior of the low-pressure chamber 3 is enclosed by independent chamber wall panels 301. These chambers 301 spatially divide the interior of the housing 100 into a high-pressure chamber 1 on the right and a low-pressure chamber 3 on the left, thus achieving a spatially partitioned arrangement of high and low pressure. The first direction is defined as the horizontal sliding and pulling direction parallel to the longitudinal sidewall of the low-pressure chamber 3.

[0034] It should be noted that: Regarding the high and low pressure separation method, in some cases, the high pressure chamber 1 and the low pressure chamber 3 inside the enclosure 100 can be vertically separated, that is, the high pressure chamber 1 is located at the upper part of the enclosure 100 and the low pressure chamber 3 is located at the lower part of the enclosure 100, and the two are physically separated by a horizontal partition. In other cases, the high pressure chamber 1 and the low pressure chamber 3 can be separated front and back, with the high pressure chamber 1 located at the rear of the enclosure 100 against the wall and the low pressure chamber 3 located at the front of the enclosure 100 on the operating side.

[0035] In some cases, the pushing and pulling action of the low-pressure box 2 can be driven by a pneumatic cylinder or an electric push rod to achieve automated entry and exit.

[0036] Regarding the connection method of the high-voltage main circuit, in some cases, the rigid conductive busbar is a high-voltage copper busbar, which can adopt a laminated busbar structure, formed by hot pressing multiple layers of copper foil and insulating film. In other cases, the high-voltage conductive busbar can adopt a hollow copper tube structure, with coolant flowing inside to achieve water cooling. In still other cases, the high-voltage conductor can be made of aluminum alloy profiles, such as 6063-T5 aluminum alloy extrusion molding. In some cases, the high-voltage circuit can use high-temperature superconducting materials (such as YBCO) as conductors, in conjunction with a low-temperature cooling system.

[0037] In addition, high-voltage copper busbars are used here. The low-pressure chamber 3 is a slot-shaped part with an opening at the top and front end. It is fixed inside the high-voltage box by screws. The high-voltage box is divided into high-voltage chamber 1 and low-pressure chamber 3 by the side wall of low-pressure chamber 3. High-pressure chamber 1 is the inner cavity of the high-voltage box other than low-pressure chamber 3.

[0038] In traditional high-voltage control boxes, low-voltage and high-voltage components are mixed during maintenance. Frequent plugging and unplugging of the high-voltage side is unavoidable during extraction, posing a risk of arcing. In this embodiment, the high-voltage compartment 1 and low-voltage compartment 3 inside the high-voltage box are physically isolated by a partition. No connectors are installed on the high-voltage main circuit; a fully rigid connection is used. When the low-voltage control module needs maintenance, the maintenance personnel pull out the low-voltage box 2 in the first direction. The blind-plug connector 207 at the rear of the low-voltage box is smoothly pulled out from the blind-plug interface 302 fixed on the compartment 301, allowing for external maintenance or replacement. The entire process does not require touching the high-voltage components on the right side. It not only achieves physical and electrical isolation between high and low voltage areas, effectively reducing the risk of electromagnetic interference, but also enables automatic docking and disconnection through blind-plug electrical connection ports, eliminating the need for manual intervention to plug and unplug cables. Maintenance personnel can plug, unplug and replace low-voltage modules (including low-voltage control modules and low-voltage boxes) without removing the entire high-voltage box, greatly improving maintenance efficiency by more than 300% compared to traditional split or overall pull-out designs, and significantly reducing system downtime and labor costs.

[0039] In traditional energy storage systems, testing or residual energy discharge necessitates activating the main contactor to run a high-current circuit, which is complex and poses a high-voltage safety hazard. To address this issue, the high-voltage main circuit power module includes a contactor 104, a high-voltage side fuse 105, positive and negative power terminals 103, and charging / discharging maintenance terminals 107. The positive and negative power terminals 103 are used to connect to the charging and discharging electrodes of the supercapacitor. The external high-voltage bus, the contactor 104, the high-voltage side fuse 105, and the positive and negative power terminals 103 are connected in series to form the main circuit, enabling the connection between the external high-voltage bus and the supercapacitor. The charging and discharging transmission and switching control of electrical energy between capacitors are provided. A high-voltage operation panel 108 is provided on one side of the high-voltage chamber. The charging and discharging maintenance terminal 107 is provided on the high-voltage operation panel 108. The charging and discharging maintenance terminal 107 is arranged in parallel bypass with the external high-voltage bus and the contactor 104. One end of the terminal is led out to the outside of the high-voltage operation panel 108, and the other end is connected to the circuit between the contactor 104 and the positive and negative power terminals 103. The charging and discharging maintenance terminal 107 is used to connect to external testing equipment to directly bypass pre-charge or discharge residual electrical energy of the supercapacitor.

[0040] The charge / discharge maintenance terminal 107 forms an independent bypass conductive path outside the main contactor 104. When the main contactor 104 is in the open protection state, external testing equipment connected to the charge / discharge maintenance terminal 107 on the panel is directly connected to the supercapacitor connected to the positive and negative power terminals 103. External equipment can directly bypass pre-charge or discharge residual energy of the supercapacitor through the charge / discharge maintenance terminal 107 without energizing the main circuit, thus improving the safety of testing and maintenance operations. Moreover, the entire process involves zero entry into the enclosure, avoiding the risk of electric shock to operators and enhancing the safety and reliability of the equipment.

[0041] Here, by setting up the charging / discharging maintenance terminal 107, on the one hand, it avoids the risk of surge current in the high-voltage main circuit caused by the supercapacitor being connected to the high-voltage main circuit when it is de-energized, which could result in a sudden surge of high voltage from the power grid or bus. On the other hand, it allows for safe discharge and impedance diagnosis. When the system needs to be shut down for maintenance, the capacitor often contains a deadly high voltage. Before removing the low-voltage box 2 or touching any high-voltage device, maintenance personnel must connect a dummy load through this external terminal for safe venting (discharge) and measure the insulation resistance of the main circuit through this terminal.

[0042] Specifically, the low-voltage box 2 includes a rectangular box frame 201, the box frame 201 being open on at least two sides along a second direction, the second direction being perpendicular to the first direction and the height direction, each opening having at least two opposing and parallel side mounting edges 2011, the side mounting edges 2011 extending along the first direction, the low-voltage control module including at least two sets of main control modules 202, the main control module 202 including a mounting plate 2021 and a PCB circuit board 2 positioned on the mounting plate 2021. 022, the PCB circuit board 2022 is disposed on the side of the mounting plate 2021 near the inner cavity of the low-voltage box 2 and the two are separated by a first distance. Two sets of main control modules 202 are symmetrically distributed on the side mounting edges 2011 on both sides along the second direction. Each set of main control modules 202 includes multiple main control modules 202. The mounting plate 2021 of the main control module 202 is detachably connected to the side mounting edge 2011 on the corresponding side and multiple mounting plates 2021 on each side are separated by a second distance along the first direction.

[0043] In this embodiment, the box frame 201 of the low-voltage box 2 is open on both sides, and multiple main control modules 202 are symmetrically distributed along the side mounting edges 2011 on both sides. A first gap separates the PCB circuit board 2022 from the mounting plate 2021, and multiple mounting plates 2021 on the same side are separated by a second gap along the pull-out direction. The open design on both sides exposes the PCB circuit board 2022 directly. The first gap leaves an airflow gap on the back of the PCB board, and the second gap breaks the continuous circuit boards, facilitating the flow of external cold air from the gaps between the boards. The opposing second gaps create air convection, accelerating the airflow inside the low-voltage box 2. Through the design and coordination of the equal spacing structure of the first and second gaps, the airflow inside the low-voltage box 2 can be significantly improved, enhancing the natural heat dissipation effect.

[0044] Here, multiple mounting plates 2021 on each side are spaced apart by a second spacing along the first direction. Preferably, the multiple mounting plates 2021 are arranged evenly at equal intervals.

[0045] The main control module 202 is fixedly installed on both sides of the low-voltage box 2. When maintenance or replacement is required, it can be quickly removed by pulling out the low-voltage box 2. The modular design facilitates the individual disassembly of the damaged main control module, reducing replacement costs. At the same time, the quantity can be increased or decreased according to needs, flexibly configuring product series with different power levels and different functional combinations.

[0046] Furthermore, as one example, the box frame 201 is arranged with an open upper side in the height direction, and a top mounting edge 2012 is provided inside. The low-voltage control module includes three sets of the main control modules 202, and the mounting plate 2021 of one set of the main control modules 202 is detachably connected to the top mounting edge 2012.

[0047] In this scenario, this embodiment utilizes the top open design of the housing frame 201 to transform the top area, which was originally intended as an outer casing, into an expandable hardware mounting space. Similar to the hardware mounting space corresponding to the side mounting edge, this effectively expands the installation capacity of the main control module without increasing the overall length and width of the high-voltage box. This meets the expansion requirements of high-power energy storage systems for the number of main control modules while maintaining the unchanged external dimensions of the low-voltage box 2, thus reducing the cost of designing the low-voltage box 2 and re-molding.

[0048] Furthermore, as another scenario, the box frame 201 is arranged with an open upper side in the height direction, and a top mounting edge 2012 is provided inside. The low-voltage control module includes two sets of main control modules 202, which are symmetrically distributed on the side mounting edges 2011 on both sides along the second direction. A top cover plate 2013 is detachably connected to the top mounting edge 2012.

[0049] When it is not necessary to expand the number of main control modules 202, for example in this embodiment, two sets of main control modules 202 are used, respectively located on both sides of the low-voltage box 2 along the second direction. Each set of main control modules 202 includes two main control modules 202, which are mounted on the side mounting edge 2012 in the corresponding side opening. The mounting plate 2021 in the main control module 202 forms the side wall of the low-voltage box 2. The two main control modules 202 are arranged at intervals along the first direction. The top layer of the component on the PCB circuit board faces the inside of the box. At this time, the top opening area does not need to be expanded with main control modules 202, and can be covered by the top cover plate 2013 to prevent dust and foreign objects from falling into the low-voltage box 2. The top cover plate 2013 and the third set of main control modules 202 share the same top mounting edge 2012 interface, realizing seamless switching between high and low configuration schemes. During production, only a standard basic frame 201 needs to be prepared. Depending on the different order requirements, the mounting cover or the mounting plate 2021 of the third main control module can be selected, which greatly improves the standardization of production capabilities and the convenience of supply chain management.

[0050] Specifically, such as Figure 4 As shown, the PCB circuit board 2022 and the corresponding mounting plate 2021 are arranged opposite to and parallel to each other. The mounting plate 2021 is provided with a plurality of positioning posts 2023 evenly distributed on it. The PCB circuit board 2022 and the mounting plate 2021 are separated by the positioning posts 2023.

[0051] Specifically, the PCB circuit board 2022 is a rectangular circuit board with a positioning post 2023 at each of its four corners. The PCB circuit board 2022 has positioning holes, and the PCB circuit board 2022 is fixed by screws passing through the positioning holes and corresponding to the positioning posts 2023.

[0052] Specifically, the contactor 104 includes a main contact and a low-voltage control coil for driving the main contact to close. The low-voltage control signal output by the low-voltage control module is transmitted sequentially to the low-voltage control coil of the contactor 104 via the blind plug 207 and the blind plug interface 302 in the retracted connection state, so as to control the physical on / off of the main contact through electromagnetic drive, thereby realizing the safe isolation control of the high-voltage main circuit power module.

[0053] In traditional methods, the control unit needs to be connected to high-voltage devices across regions via long-distance cables, posing risks of leakage and electromagnetic interference. In this embodiment, the low-voltage DC signal is transmitted to the contactor coil only through the blind-plug interface 302. The electromagnetic attraction inside the contactor 104 drives the main contacts on the high-voltage side to operate. High-voltage and low-voltage signals are physically and electrically isolated through the contactor 104 itself. This avoids electromagnetic interference between high and low-voltage signals, significantly reducing the risk of electric shock to operators. The contactor's characteristics ensure reliable opening and closing operations without arc reignition.

[0054] Specifically, the high-voltage main circuit power module includes a Hall sensor 106, which is embedded and sleeved on the outer periphery of the negative polarity conductive busbar. The Hall sensor 106 is used to collect the magnetic field signal around the conductive busbar, convert it into a low-voltage current sampling signal, and transmit it back to the low-voltage control module in the low-voltage box 2 through the blind insertion interface 302 to form a closed-loop monitoring link.

[0055] Traditional current monitoring methods for series shunts require disconnecting the high-voltage copper busbar, which not only disrupts the rigid connection but also generates unnecessary contact heat. In this embodiment, as... Figure 2 , Figure 3 As shown, the high-voltage copper busbar 102 passes directly through the center hole of the Hall sensor 4 without needing to disconnect the busbar. The Hall sensor 4 collects the magnetic field generated by the large current in the air and converts it into a weak electrical signal, which is then transmitted back to the low-voltage box 2 via the blind-plug interface. This achieves non-contact real-time current monitoring and signal output, ensuring a fully rigid connection of the high-voltage main circuit without plugging or unplugging nodes, and fundamentally guaranteeing the long-term operational stability of the supercapacitor under charging and discharging conditions. Specifically, the low-voltage control module includes a redundant power supply module 204, a main control module 202, an I / O controller 203, and a terminal block 206. The redundant power supply module 204, the main control module 202, the I / O controller 203, the low-voltage side fuse 205, the terminal block 206, and the blind-fit connector 207 are electrically connected in sequence to form a low-voltage control and communication link. The electrical signal from the Hall sensor 4 is transmitted back to the main control module 202 through the blind-fit interface. In this way, the main control module 202 can monitor the changes in the current on the high-voltage main circuit at any time.

[0056] Here, the main control module 202 is fixedly installed on both sides of the low-voltage box 2. When maintenance or replacement is required, it can be quickly removed by pulling out the low-voltage box 2. The main control module 202 and the IO controller 203 form the main control and communication unit, realizing system status monitoring, logic control, and communication interaction functions. The redundant power supply module 204 provides multiple DC power supplies, supporting redundant power supply. The low-voltage side fuse 205 enables rapid disconnection in case of overcurrent or short circuit. The terminal block 206 serves as the physical interface hub for external signal input / output, integrating signal channels.

[0057] Specifically, the low-pressure box 2 is provided with a low-pressure operation panel 208 at its front end along the first direction. The low-pressure operation panel 208 is provided with a pull-out operation part for the user to pull out the low-pressure box 2.

[0058] In this embodiment, a design featuring a stacked copper busbar layout, compact device arrangement, and rail-mounted sliding installation is adopted. While ensuring electrical clearance (≥15 mm), the overall volume is reduced by about 30% and the weight is reduced by about 25% compared to the traditional split design, making it particularly suitable for space-constrained application scenarios.

[0059] In this embodiment, the circuits of each cluster in the high-voltage box are clearly arranged, and the number of circuits can be increased or decreased according to the number of clusters. This design facilitates mass production, quality control and inventory management, and supports flexible configuration of product series with different power levels and different functional combinations according to needs, shortening the delivery cycle by more than 50%.

[0060] Specifically, the positive and negative power terminals 103 of the high-voltage and low-voltage separated drawer-type high-voltage box are electrically connected to the energy storage capacitor cluster to realize the charging and discharging control and high and low voltage isolation of the supercapacitor energy storage system.

[0061] In supercapacitor high-voltage boxes employing fully rigid main circuits, high-current pulse discharges generate strong electrodynamic impacts, which, over long-term operation, can easily lead to mechanical loosening of the high-voltage rigid support structures (such as insulator fastening bolts). Since external converters typically exhibit constant power control characteristics, when localized mechanical loosening causes an increase in contact resistance, the current in the high-voltage main circuit does not decrease significantly. Therefore, how to safely and cost-effectively achieve early warning of microscopic mechanical loosening within the high-voltage main circuit without adding any high-voltage side sensors (such as vibration sensors or high-voltage temperature probes) to prevent thermal runaway and electrical fires caused by abnormally increased local contact resistance has become another urgent problem to be solved.

[0062] Accordingly, in this embodiment, the main control module has a built-in microprocessor unit or MCU main control chip. Based on the above-mentioned high and low voltage separated drawer-type high voltage box, a circuit fault detection method is also proposed, which specifically includes the following steps: Impedance calculation steps: During the high-current charging and discharging cycle of the supercapacitor, the transient drive voltage of the control coil circuit of the contactor 104 is synchronously acquired. and transient drive current The dynamic contact resistance of the blind-fit connector at the interface is calculated and obtained in real time. Specifically, the resistance of the low-voltage control module output to the contactor coil is calculated in real time according to Ohm's law. : ; Range extraction step: Extract the maximum and minimum values ​​of the dynamic contact resistance during the high current charge and discharge cycle, and calculate the difference between the maximum and minimum values ​​to obtain the fluctuation range of the dynamic contact resistance; Specifically, when a supercapacitor undergoes a large current discharge, the maximum value of the blind insertion resistance is recorded within a few seconds of this discharge process. and minimum value Calculate the maximum amplitude of the resistance fluctuation during this period, that is, the amplitude of the dynamic contact resistance fluctuation. : ; Normalization process: Obtain the high voltage peak current of the high voltage main circuit within the same high current charging and discharging cycle, divide the fluctuation amplitude of the dynamic contact resistance by the square of the high voltage peak current, and obtain the loosening coefficient used to characterize the structural damping characteristics. Based on the relationship between Ampere's force and current, the larger the discharge current, the greater the electromagnetic force (Ampere's force), and the more violent the copper busbar vibration. The electromagnetic force is proportional to the square of the current. Record the peak value of the maximum high-voltage current during this discharge. Divide the resistance fluctuation by the square of the current to obtain the looseness coefficient. : ; It should be noted that inside the high-voltage box, the two parallel high-voltage copper busbars generate an electrodynamic force (Ampere force / Lorentz force) when a large current flows through them. According to the laws of electromagnetism, this force F is proportional to the square of the current I, i.e. With the mechanical structure tightened, the copper busbar transmits minute vibrations and displacements to the blind-plug connector, resulting in resistive frictional vibrations. In other words, under normal circumstances, In other words, as long as the fasteners on the high-voltage main circuit are not loose, regardless of whether the supercapacitor discharge current is 500A or 2000A, / Both should be a constant, i.e., the loosening coefficient, and when / When the resistance increases, the fluctuation range at the blind-fit connector increases, which means that there may be mechanical loosening.

[0063] Early warning determination step: Compare the loosening coefficient with a preset reference system; if the loosening coefficient is greater than the reference coefficient, it is determined that the physical support structure of the fully rigid main circuit has become mechanically loose, and a corresponding early warning signal is output.

[0064] The preset reference coefficient is a constant obtained by the drawer-type high-voltage box through self-learning calibration by performing the impedance calculation step, range extraction step, and normalization processing step under the factory-sealed structural condition.

[0065] Specifically, the system undergoes several tests before the equipment leaves the factory (with all bolts tightened) to determine a baseline coefficient. In future operation, the system will calculate the value every time it discharges. : if This indicates that the vibration amplitude is within the normal range and the structure is secure.

[0066] if This indicates that under the same current impact, the resistance fluctuation is abnormally amplified, indicating that the rigid structure inside the high-pressure chamber 1 has become loose.

[0067] This fault detection method cleverly utilizes the change in dynamic contact resistance at the low-pressure blind connector in high-pressure chamber 1 to effectively capture abnormal high-frequency vibrations caused by a decrease in system mechanical damping due to loosening of fasteners such as high-pressure side bolts. Furthermore, all calculation parameters used in this method are derived from measurable electrical signals from the high-pressure chamber itself, without introducing additional high-pressure vibration sensors susceptible to strong electromagnetic interference, or expensive fiber optic or infrared temperature probes. Specifically, the transient drive voltage and transient drive current characterizing the vibration response are directly obtained from the drive circuit of the low-pressure control module within low-pressure chamber 3; the high-pressure peak current characterizing the excitation source is directly reused from the existing non-contact through-core Hall sensor 4 within high-pressure chamber 1. This method not only prevents danger in advance when the macroscopic current in the high-pressure main circuit is not abnormal and the local area is still in the early stages of microscopic heating, but also keeps costs under control.

[0068] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or basic characteristics. Therefore, the embodiments should be considered illustrative and non-limiting in all respects. The scope of the invention is defined by the appended claims rather than the foregoing description. Therefore, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention, and no reference numerals in the claims should be construed as limiting the scope of the claims.

[0069] 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 high-low pressure separation drawer-type high-pressure tank characterized by, include: The enclosure (100) is provided with a high-pressure chamber (1) and a low-pressure chamber (3) inside. The high-pressure chamber (1) and the low-pressure chamber (3) are spatially separated and electrically isolated by a partition. The low-pressure chamber (3) extends along a first direction. The high-voltage main circuit power module is installed in the high-voltage chamber (1). The electrical components of the high-voltage main circuit power module are fixedly connected by fasteners and rigid conductive busbars to form a rigid main circuit without plug-in nodes. The low-pressure box (2) is equipped with a low-pressure control module. The low-pressure box (2) is removably stored in the low-pressure chamber (3) along the first direction. The low-pressure box (2) is equipped with a blind-plug connector (207) at the rear end along the first direction. The low-pressure chamber (3) is equipped with a blind-plug interface (302). In the storage position, the blind-plug connector (207) and the blind-plug interface (302) are connected to make the low-pressure control module electrically connected to the high-voltage main circuit power module. When it is pulled out, the blind-plug connector (207) and the blind-plug interface (302) are separated.

2. The high- and low-pressure separated drawer-type high-pressure box according to claim 1, characterized in that: The high-voltage main circuit power module includes a contactor (104), a high-voltage side fuse (105), positive and negative power terminals (103), and a charging and discharging maintenance terminal (107). The positive and negative power terminals (103) are used to connect to the charging and discharging electrodes of the supercapacitor; The external high-voltage bus, the contactor (104), the high-voltage side fuse (105), and the positive and negative power terminals (103) are connected in series to form a main circuit, so as to realize the charging and discharging transmission and switching control of electrical energy between the external high-voltage bus and the supercapacitor. A high-voltage operation panel (108) is provided on one side of the high-voltage chamber. The charging and discharging maintenance terminal (107) is located on the high-voltage operation panel (108). The charging and discharging maintenance terminal (107) is connected in parallel with the external high-voltage bus and the contactor (104) in a bypass configuration. One end of the terminal is led out to the outside of the high-voltage operation panel (108), and the other end is connected to the circuit between the contactor (104) and the positive and negative power terminals (103). The charging and discharging maintenance terminal (107) is used to connect to external testing equipment to directly bypass pre-charge or discharge residual energy of the supercapacitor.

3. The high- and low-pressure separated drawer-type high-pressure box according to claim 1, characterized in that: The low-voltage box (2) includes a rectangular box frame (201). The box frame (201) is open on at least two sides along a second direction. The second direction is perpendicular to the first direction and the height direction. Each opening is provided with at least two opposite and parallel side mounting edges (2011). The side mounting edges (2011) extend along the first direction. The low-voltage control module includes at least two sets of main control modules (202). The main control module (202) includes a mounting plate (2021) and a PCB circuit board (2022) positioned on the mounting plate (2021). The PCB circuit board (2022) is located on the side of the mounting plate (2021) close to the inner cavity of the low-voltage box (2) and the two are separated by a first distance. Two sets of main control modules (202) are symmetrically distributed on the side mounting edges (2011) on both sides along the second direction. Each set of main control modules (202) includes multiple main control modules (202). The mounting plate (2021) of the main control module (202) is detachably connected to the side mounting edge (2011) on the corresponding side, and multiple mounting plates (2021) on each side are spaced apart by a second distance along the first direction.

4. The high- and low-pressure separated drawer-type high-pressure box according to claim 3, characterized in that: The box frame (201) is arranged with an open upper side in the height direction, and a top mounting edge (2012) is provided inside. The low-voltage control module includes three sets of main control modules (202), and the mounting plate (2021) of one set of main control modules (202) is detachably connected to the top mounting edge (2012).

5. The high- and low-pressure separated drawer-type high-pressure box according to claim 3 or 4, characterized in that: The PCB circuit board (2022) is arranged opposite to and parallel to the corresponding mounting plate (2021). The mounting plate (2021) is provided with a plurality of positioning posts (2023) evenly distributed. The PCB circuit board (2022) and the mounting plate (2021) are separated by the positioning posts (2023).

6. The high- and low-pressure separated drawer-type high-pressure box according to claim 2, characterized in that: The contactor (104) includes a main contact and a low-voltage control coil for driving the main contact to engage. The low-voltage control module outputs a weak current control signal, which is transmitted sequentially through the blind plug (207) and the blind plug interface (302) in the retracted connection state to the weak current control coil of the contactor (104) so ​​as to control the physical on / off of the main contacts by electromagnetic drive, thereby realizing the safe isolation control of the high-voltage main circuit power module.

7. The high- and low-pressure separated drawer-type high-pressure box according to claim 1, characterized in that: The high-voltage main circuit power module includes a Hall sensor (106), which is embedded and sleeved on the outer periphery of the negative polarity of the conductive busbar. It is used to collect the magnetic field signal around the conductive busbar and convert it into a low-voltage current sampling signal. The signal is then transmitted back to the low-voltage control module in the low-voltage box (2) through the blind insertion interface (302) to form a closed-loop monitoring link.

8. The high- and low-pressure separated drawer-type high-pressure box according to claim 1, characterized in that: The low-voltage control module includes a redundant power supply module (204), a main control module (202), an IO controller (203), and a terminal block (206). The redundant power supply module (204), the main control module (202), the IO controller (203), the terminal block (206), and the blind plug (207) are electrically connected in sequence to form a low-voltage control and communication link.

9. The high- and low-pressure separated drawer-type high-pressure box according to claim 1, characterized in that: The low-pressure box (2) has a low-pressure operation panel (208) at its front end along the first direction. The low-pressure operation panel (208) has a pull-out operation part for the user to pull out the low-pressure box (2).

10. The high- and low-pressure separated drawer-type high-pressure box according to claim 4, characterized in that: The box frame (201) is arranged with an open upper side in the height direction, and a top mounting edge (2012) is provided inside. The low-voltage control module includes two sets of main control modules (202). The two sets of main control modules (202) are symmetrically distributed on the side mounting edges (2011) on both sides along the second direction. The top mounting edge (2012) is detachably connected to the top cover plate (2013).

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