Energy storage converter and energy storage system

Abstract

This invention discloses an energy storage converter and energy storage system, relating to the field of energy storage system technology. The energy storage converter includes: a housing; a power conversion unit disposed within the housing for bidirectional conversion between DC and AC; a DC-side power distribution unit disposed within the housing and electrically connected to the power conversion unit for DC-side on / off control and overcurrent protection; and a liquid-cooled plate disposed within the housing. The power conversion unit includes a main power consumption component, which is centrally disposed on the liquid-cooled plate and thermally connected to it, with the liquid-cooled plate providing liquid cooling for the main power consumption component. The energy storage converter also includes a secondary power consumption component, disposed within the housing on the opposite side of the liquid-cooled plate to form thermal isolation between it and the main power consumption component. This energy storage converter integrates the functions of a high-voltage box while isolating the heat generated by the main power consumption component from the thermal interference of the secondary power consumption component, thereby improving the overall reliability and safety of the energy storage system.

Description

Technical Field

[0001] This invention relates to the field of energy storage system technology, and more specifically, to an energy storage converter and an energy storage system. Background Technology

[0002] The power conversion system (PCS) is the core component of an energy storage system, used to achieve bidirectional conversion between battery DC power and grid AC power. Traditional energy storage systems typically arrange the PCS and the DC high-voltage box as two separate devices, connected by cables. This discrete design occupies significant installation space, increases system cost and wiring complexity, and is severely out of step with the compact, high-density installation requirements of energy storage systems.

[0003] To reduce the size of energy storage systems and improve integration, some companies directly integrate the components of the high-voltage box into the energy storage converter. However, this approach has several drawbacks. First, it increases the size of the energy storage converter, affecting the overall integration layout of the energy storage system. Second, integrating the heat-generating components from the high-voltage box leads to a more concentrated internal heat source. This, combined with the main power consumption components in the energy storage converter (such as IGBT modules and inverter inductors), generates a significant amount of heat during operation. Secondary power consumption components, such as control boards and detection boards, are highly sensitive to temperature. Excessive operating temperatures can severely impact their reliability and lifespan, posing a risk of thermal runaway to the entire energy storage converter and ultimately reducing the overall reliability and safety of the system.

[0004] Therefore, how to integrate high-voltage box devices into energy storage converters and isolate the thermal interference of heat generated by the main power consumption components to the secondary power consumption components is a problem that urgently needs to be solved by those skilled in the art. Summary of the Invention

[0005] In view of this, the purpose of the present invention is to provide an energy storage converter and an energy storage system. The energy storage converter integrates the function of a high-voltage box and can isolate the heat generated by the main power consumption component from the thermal interference of the secondary power consumption component, thereby improving the overall reliability and safety of the energy storage system.

[0006] To achieve the above objectives, the present invention provides the following technical solution:

[0007] An energy storage converter includes:

[0008] case;

[0009] A power conversion unit, located inside the housing, is used to achieve bidirectional conversion between DC and AC.

[0010] A DC-side power distribution unit is located inside the housing and is electrically connected to the power conversion unit. It is used to realize DC-side on / off control and overcurrent protection.

[0011] A liquid cooling plate is disposed inside the housing;

[0012] The power conversion unit includes a main power consumption component, which is centrally located on the liquid cooling plate and thermally connected to the liquid cooling plate. The liquid cooling plate is used to perform liquid cooling heat dissipation on the main power consumption component.

[0013] The energy storage converter also includes a secondary power consumption component, the power consumption of which is less than that of the primary power consumption component. The secondary power consumption component is located inside the housing on the opposite side from the liquid cooling plate to form thermal isolation with the primary power consumption component.

[0014] Preferably, the main power consumption component includes a group of IGBT modules and a group of inverter inductor modules arranged at intervals along the length of the liquid cooling plate.

[0015] Preferably, the liquid cooling plate is divided into a first plate section and a second plate section along its length direction, and the first plate section is provided with an inlet port and an outlet port for connecting to the liquid supply system;

[0016] The first plate has a main liquid inlet channel connected to the liquid inlet port, a main liquid outlet channel connected to the liquid outlet port, and multiple parallel branch channels branching off from the main liquid inlet channel. The liquid cooling plate area corresponding to each branch channel is used to set the IGBT module.

[0017] The second plate has an inductor cooling channel. The ends of all the branch channels converge and connect to one end of the inductor cooling channel. The other end of the inductor cooling channel connects to the main liquid outlet channel. The liquid cooling plate area corresponding to the inductor cooling channel is used to set up multiple inverter inductor modules.

[0018] Preferably, each of the branch channels extends in a bent shape, and its interior is provided with multiple sets of turbulence-disrupting parts along the extension direction, with multiple turbulence-disrupting parts in each set arranged in an array.

[0019] Preferably, the surface of the liquid cooling plate area corresponding to each branch flow channel is provided with a heat-conducting medium to conduct the heat generated by the IGBT module located in the area to the liquid cooling plate.

[0020] Preferably, the inductive cooling channel includes multiple independent and parallel inductive branch channels, each of which is connected between the end convergence point of all the branch channels and the main liquid outlet channel.

[0021] Preferably, the space between the inverter inductor module and the liquid cooling plate is filled with thermally conductive potting compound to form an integrated potting structure.

[0022] Preferably, the secondary power consumption component includes a first power consumption component and a second power consumption component, the power consumption of the second power consumption component is greater than that of the first power consumption component, the first power consumption component and the second power consumption component are arranged sequentially along the width direction of the housing, and the first power consumption component is closer to the liquid cooling plate than the second power consumption component.

[0023] Preferably, the first power consumption component includes an AC filter board, a control board, a detection board, and a voltage detection board. The AC filter board is located on a base plate inside the housing. A detection board mounting bracket is provided on the side of the AC filter board facing away from the base plate. The control board, detection board, and voltage detection board are located on the detection board mounting bracket, forming a stacked layout.

[0024] Preferably, the second power consumption component includes an AC EMC common-mode inductor, and the AC EMC common-mode inductor and the AC Hall sensor component are pre-assembled into an integrated module.

[0025] Preferably, the power conversion unit includes a power board, which is mounted on a group of IGBT modules; the DC-side power distribution unit includes a pre-charge resistor, which is mounted on the side of the power board away from the group of IGBT modules via a pre-charge resistor mounting bracket, forming a stacked layout.

[0026] Preferably, the liquid cooling plate is disposed adjacent to the first side plate in the width direction of the housing and extends from the front panel in the length direction of the housing to the opposite back panel, and a group of IGBT modules is closer to the front panel than a group of inverter inductor modules;

[0027] Along the width direction of the housing, the remaining components of the DC-side power distribution unit, except for the pre-charge resistor, are arranged on the side of the power board away from the first side plate, and the remaining components and the power board are both located on the side of the housing closer to the panel.

[0028] The first power consumption component and the second power consumption component are both located on the side of the housing near the back plate, and are arranged sequentially along the width direction of the housing.

[0029] Preferably, the housing is further provided with at least two cooling fans, at least one of which is located between the DC-side power distribution unit and the second power consumption component, and at least one of which is located between the second power consumption component and the first power consumption component, so as to form a wind-cooled circulation for heat dissipation.

[0030] Preferably, it also includes a control unit, which is used to adjust the flow rate or velocity of the coolant in the liquid cooling plate according to the temperature of the main power consumption component;

[0031] When the temperature exceeds the first threshold, the flow rate and velocity of the coolant are increased to the rated value; when the temperature exceeds the second threshold, they are increased to the excess value; when the temperature exceeds the third threshold, derating protection is triggered.

[0032] An energy storage system comprising the energy storage converter described in any one of the above claims.

[0033] The energy storage converter provided by this invention centrally houses the main power consumption components (such as IGBT modules and inverter inductor modules) in the power conversion unit on a liquid cooling plate for liquid cooling. This achieves efficient utilization of the internal space, making the energy storage converter structure more compact, facilitating installation and deployment in limited spaces, and increasing power density. Furthermore, the liquid cooling plate directly cools the main power consumption components, resulting in a short heat dissipation path and low thermal resistance, quickly removing the large amount of heat generated by the main power consumption components and effectively suppressing their temperature rise. Simultaneously, secondary power consumption components (such as control boards and detection boards) are located on the opposite side of the liquid cooling plate within the housing, allowing for partitioned placement of the main and secondary power consumption components within the housing. This further reduces the possibility of heat dissipation from the main power consumption components to the areas where the secondary power consumption components are located. The secondary power consumption components do not need to withstand the thermal radiation from the main power consumption components, effectively avoiding mutual thermal interference, reducing the risk of thermal runaway, ensuring the safe and reliable operation of the secondary power consumption components, and ultimately improving the overall reliability and safety of the system. Attached Figure Description

[0034] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the provided drawings without creative effort.

[0035] Figure 1 This is a schematic diagram of the structure of an energy storage converter provided by the present invention;

[0036] Figure 2 for Figure 1 The diagram shows the structure of the panel shown.

[0037] Figure 3 for Figure 1 Schematic diagram of the internal structure after removing the cover plate. Figure 1 ;

[0038] Figure 4 for Figure 3 The diagram shows the internal structure after removing the thermally conductive potting compound, control board, detection board, voltage detection board, and pre-charge resistor mounting bracket.

[0039] Figure 5 for Figure 1 Schematic diagram of the internal structure after removing the cover plate. Figure 2 ;

[0040] Figure 6 for Figure 5 The diagram shows the internal structure of the structure after removing the shell body (i.e., the four side panels).

[0041] Figure 7 for Figure 5 The diagram shows the internal structure from another perspective after removing the shell body (i.e., the four side panels).

[0042] Figure 8 An exploded view of the liquid cooling plate and the main power consumption component thereon provided by the present invention;

[0043] Figure 9 An exploded view of the IGBT module and the heat-conducting medium below it provided by the present invention;

[0044] Figure 10 A front view of the liquid cooling plate provided by the present invention;

[0045] Figure 11 for Figure 10 Sectional view at point AA;

[0046] Figure 12 A schematic diagram of an integrated module formed by an AC EMC common-mode inductor and an AC Hall sensor assembly provided by the present invention;

[0047] Figure 13 for Figure 12 An exploded view of the AC Hall sensor assembly shown.

[0048] Figure label:

[0049] 1. Housing; 11. Housing body; 111. Panel; 12. Housing cover; 13. Sealing strip;

[0050] 2. Power conversion unit; 21. Main power consumption component; 211. IGBT module; 212. Inverter inductor module; 22. Power board; 23. Thermally conductive potting compound;

[0051] 3. DC side power distribution unit; 31. DC circuit breaker; 32. DC contactor; 33. Fuse; 34. Precharge resistor; 35. DC common mode inductor; 36. DC Hall sensor;

[0052] 4. Secondary power consumption component; 41. Primary power consumption component; 411. AC filter board; 412. Control board; 413. Detection board; 414. Voltage detection board; 42. Secondary power consumption component; 421. AC EMC common mode inductor; 422. AC Hall sensor assembly; 4221. AC Hall sensor; 4222. Upper sheet metal; 4223. Lower sheet metal; 43. Isolation power supply board;

[0053] 5. Liquid cooling plate; 51. Liquid inlet port; 52. Liquid outlet port; 53. Main liquid inlet channel; 54. Main liquid outlet channel; 55. Branch channel; 56. Inductor cooling channel; 561. Inductor branch channel; 562. Inductor main channel; 57. Turbulence section; 58. Heat transfer medium; 59. Converging channel; 510. Liquid inlet connector; 511. Liquid outlet connector;

[0054] 6. Cooling fan; 7. Grounding point; 8. Handle; 9. Communication connector; 10. Indicator light; 14. DC side power connector; 15. AC side power connector; 16. DC circuit breaker manual operation; 17. Network port; 18. Precharge resistor mounting bracket; 19. Detection board mounting bracket; 20. Copper busbar; 21. Power switch button; 22. Power supply interface. Detailed Implementation

[0055] 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.

[0056] The core of this invention is to provide an energy storage converter and an energy storage system. This energy storage converter integrates the function of a high-voltage box and can isolate the heat generated by the main power consumption component from the thermal interference of the secondary power consumption component, thereby improving the overall reliability and safety of the energy storage system.

[0057] It should be noted that in this embodiment, the orientation or positional relationship indicated by "up", "down", "front", "back", "left", "right", etc. is based on the orientation or positional relationship shown in the accompanying drawings. It is only for the convenience of describing this application and simplifying the description, and is not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, it should not be construed as a limitation on this application.

[0058] Please refer to Figure 1 , Figure 3 , Figure 5 , Figure 6 and Figure 7The energy storage converter provided in this embodiment includes a housing 1, a power conversion unit 2, a DC-side power distribution unit 3, a liquid cooling plate 5, and a secondary power consumption component 4.

[0059] The housing 1 is used to house and protect the internal components. In an optional embodiment, the housing 1 includes a housing body 11 and a cover 12. The housing body 11 is a rectangular box with an opening on one side, and a sealing strip 13 is provided at the opening. The cover 12 is detachably fitted onto the opening of the housing body 11 by fasteners (such as screws) and compresses the sealing strip 13 to seal the opening, making the housing 1 a sealed structure. This arrangement not only facilitates the disassembly and assembly of the components inside the housing 1 for subsequent maintenance, but also prevents external impurities and moisture from entering the housing 1, thus protecting the components.

[0060] The power conversion unit 2 is located inside the housing 1 and is used to realize bidirectional conversion between DC and AC power. That is, it can both invert the DC power from the battery side into AC power to feed into the grid or supply the load, and rectify the AC power from the grid into DC power to charge the battery. The DC side power distribution unit 3 is also located inside the housing 1 and is electrically connected to the DC input terminal of the power conversion unit 2. It is used to realize DC side on / off control and overcurrent protection, such as timely disconnection of the DC circuit in the event of short circuit, overload or other faults to ensure system safety.

[0061] It should be noted that this application categorizes components into three levels based on power consumption: Primary power consumption component 21 is a high-power component, such as IGBT module 211 and inverter inductor module 212, which generates a large amount of heat during operation and requires liquid cooling; secondary power consumption component 42 is a medium-power component, such as AC EMC common-mode inductor 421, which generates considerable heat but does not require liquid cooling; primary power consumption component 41 is a low-power component, such as control board 412 and detection board 413, which generates very little heat and is sensitive to temperature. The power consumption relationship is: power consumption of primary power consumption component 21 > power consumption of secondary power consumption component 42 > power consumption of primary power consumption component 41. Primary power consumption component 41 and secondary power consumption component 42 are collectively referred to as secondary power consumption component 4.

[0062] The liquid cooling plate 5 is disposed inside the housing 1. The power conversion unit 2 includes a main power consumption component 21, which is disposed on the liquid cooling plate 5 and is thermally connected to the liquid cooling plate 5.

[0063] In one specific embodiment, the main power consumption component 21 includes an IGBT module 211 and an inverter inductor module 212. The IGBT module 211, short for Insulated Gate Bipolar Transistor, is the core switching device for DC-AC conversion. During operation, it experiences high switching and conduction losses, resulting in concentrated heat generation. The inverter inductor module 212 is used for filtering and energy exchange, also generating significant heat. Both are in close contact with the liquid cooling plate 5, which contains a circulating coolant. The circulating coolant carries away the large amount of heat generated by the main power consumption component 21 (i.e., the IGBT module 211 and the inverter inductor module 212) during operation, achieving liquid cooling for the main power consumption component 21.

[0064] Furthermore, it should be noted that the DC-side power distribution unit 3 includes components such as a DC common-mode inductor 35, a DC circuit breaker 31, a DC contactor 32, a fuse 33, and a pre-charge resistor 34. A panel 111 is typically provided on one side of the housing 1 along its length (e.g., the front side). The panel 111 has a DC-side power connector 14. The DC current introduced by the DC-side power connector 14 passes sequentially through the DC common-mode inductor 35, the DC circuit breaker 31, the fuse 33, and the DC contactor 32 before entering the power board 22 of the power conversion unit 2. Power conversion is then completed via the IGBT module 211 and the inverter inductor module 212. The DC circuit breaker 31 is used for manual or automatic disconnection of the main circuit, the DC contactor 32 is used for remote control of on / off switching, the fuse 33 provides overcurrent backup protection, and the pre-charge resistor 34 limits the inrush current during startup. The specific connection methods of these components are conventional techniques in the field and will not be described in detail here.

[0065] The energy storage converter also includes a secondary power consumption component 4, which is located inside the housing 1 on the opposite side from the liquid cooling plate 5. Since the primary power consumption component 21 is concentrated on the liquid cooling plate 5, while the secondary power consumption component 4 is located away from the liquid cooling plate 5, the two are effectively partitioned within the housing space. The heat generated by the primary power consumption component 21 is mainly carried away by the liquid cooling plate 5, with very little diffusion to the area where the secondary power consumption component 4 is located, thus achieving thermal isolation.

[0066] In one specific embodiment, the secondary power consumption component 4 includes a control board 412, a detection board 413, a voltage detection board 414, an AC filter board 411, an AC EMC common-mode inductor 421, and an isolation power supply board 43, etc. These components generate far less heat than the main power consumption component 21 (i.e., the IGBT module 211 and the inverter inductor module 212) during operation and are more sensitive to temperature. Placing them on the side away from the main power consumption component 21 helps to ensure their operational reliability and lifespan.

[0067] In the above structure, the main power consumption component 21 in the power conversion unit 2 is centrally located on the liquid cooling plate 5 and subjected to liquid cooling. On the one hand, the centralized arrangement of the main power consumption component 21 makes efficient use of the internal space of the housing 1, the overall structure is more compact, it is easy to install and deploy in a limited space, and the power density is improved; on the other hand, the main power consumption component 21 is directly attached to the liquid cooling plate 5, the heat dissipation path is short and the thermal resistance is small, which can quickly remove the large amount of heat generated by the IGBT module 211, the inverter inductor module 212, etc., effectively suppress their temperature rise, and avoid power derating or device damage caused by overheating.

[0068] Meanwhile, the secondary power consumption component 4 is located on the opposite side of the liquid cooling plate 5 inside the housing 1, allowing the primary power consumption component 21 and the secondary power consumption component 4 to be partitioned within the housing 1. The heat generated by the primary power consumption component 21 is promptly carried away by the liquid cooling plate 5, with minimal diffusion to the area where the secondary power consumption component 4 is located. The secondary power consumption component 4 does not need to withstand the heat radiation from the primary power consumption component 21, thereby effectively avoiding mutual heat interference, reducing the risk of thermal runaway, and ensuring that temperature-sensitive devices such as the control board 412, detection board 413, voltage detection board 414, AC filter board 411, AC EMC common mode inductor 421, and isolation power supply board 43 can operate safely in a more stable thermal environment, thereby improving the overall reliability and safety of the system.

[0069] In summary, the energy storage converter of the present invention integrates DC-side on / off control and overcurrent protection, and centrally cools the main power consumption component 21 through the liquid cooling plate 5, and arranges the secondary power consumption component 4 on the opposite side, thereby achieving efficient heat dissipation and compact layout.

[0070] Based on the above embodiments, considering the specific configuration of the main power consumption component 21, as a preferred option, please refer to... Figure 7 and Figure 8 The main power consumption component 21 includes a set of IGBT modules 211 and a set of inverter inductor modules 212. The IGBT modules 211 are used for DC-AC power conversion, while the inverter inductor modules 212 are used for filtering and energy exchange. The IGBT modules 211 and the inverter inductor modules 212 are arranged at intervals along the length of the liquid cooling plate 5; that is, the IGBT modules 211 are concentrated on one side of the liquid cooling plate 5, and the inverter inductor modules 212 are concentrated on the other side, achieving partitioned heat dissipation on the liquid cooling plate 5.

[0071] It should be noted that the IGBT module 211 generates concentrated heat and has high requirements for temperature uniformity, while the inverter inductor module 212 generates a large amount of heat but has relatively lower requirements for temperature uniformity. The partitioned heat dissipation of the two modules on the liquid cooling plate 5 allows for differentiated cooling of different areas, while also facilitating independent installation and maintenance of each module and preventing heat interference between modules. Furthermore, this partitioned arrangement of the cooling areas for the two different power devices along the length of the liquid cooling plate 5 results in a compact overall structure, saving internal space and facilitating overall assembly and piping connections within the energy storage converter.

[0072] Based on the above embodiments, and considering the specific arrangement of the internal flow channel structure of the liquid cooling plate 5, as a preferred option, please refer to... Figure 8 , Figure 10 and Figure 11 The liquid cooling plate 5 is divided into a first plate section and a second plate section along its length. The first plate section is one side of the liquid cooling plate 5 along its length, and its plate wall has an inlet port 51 and an outlet port 52 for connecting to an external liquid supply system (such as a water pump, coolant tank, etc.). The first plate section has a main inlet flow channel 53, a main outlet flow channel 54, and multiple parallel branch flow channels 55. The main inlet flow channel 53 is connected to the inlet port 51, and the main outlet flow channel 54 is connected to the outlet port 52. The main inlet flow channel 53 branches into multiple parallel branch flow channels 55, and each branch flow channel 55 extends in a bent shape (such as a serpentine bend or a U-shape) to increase the heat exchange area between the coolant and the liquid cooling plate 5. Each branch flow channel 55 corresponds to a liquid cooling plate 5 area for setting up an IGBT module 211. That is, multiple IGBT modules 211 are installed directly above each branch flow channel 55, so that the coolant can directly carry away the heat generated by the IGBT module 211 when it flows through the branch flow channel 55.

[0073] The second plate section is the other side along the length of the liquid-cooled plate 5, and an inductor cooling channel 56 is formed inside it. The ends of all the branch channels 55 converge and connect to one end of the inductor cooling channel 56, and the other end of the inductor cooling channel 56 connects to the main outlet channel 54. The area of ​​the liquid-cooled plate 5 corresponding to the inductor cooling channel 56 is used to house multiple inverter inductor modules 212. After the coolant flows through each branch channel 55 to cool the IGBT module 211, it converges into the inductor cooling channel 56 to continue cooling the inverter inductor module 212, and finally flows back to the liquid supply system through the main outlet channel 54 and the outlet port 52.

[0074] In the aforementioned flow channel structure, the coolant first flows through the IGBT module 211 area and then through the inverter inductor module 212 area, forming a series cooling path. This ensures priority cooling of the IGBT module 211, which has concentrated heat generation and high temperature uniformity requirements, while also fully utilizing the remaining heat absorption capacity of the coolant to cool the inverter inductor module 212, thereby improving overall heat dissipation efficiency. Simultaneously, multiple parallel branch flow channels 55 ensure that the cooling conditions of each IGBT module 211 are essentially the same, guaranteeing temperature uniformity for each IGBT module 211. It should also be noted that this flow channel layout eliminates the need for separate inlet and outlet ports for the inverter inductor module 212, reducing the complexity and cost of external piping connections to the liquid cooling plate 5, and making the internal structure of the liquid cooling plate 5 compact, facilitating integrated arrangement within the limited space of the energy storage converter.

[0075] Based on the above embodiments, to enhance the heat dissipation and efficiency of the IGBT module 211, as a preferred embodiment, please refer to... Figure 11 Each branch flow channel 55 extends in a bent shape. In one specific embodiment, each branch flow channel 55 has multiple U-shaped bends, with adjacent U-shaped bends facing opposite directions and sharing a common side connection to extend the flow path of the coolant below the IGBT module 211 and increase the heat exchange area. Simultaneously, each branch flow channel 55 has multiple sets of turbulence-disrupting sections 57 arranged along its extension direction. The multiple turbulence-disrupting sections 57 in each set are arranged in an array. These turbulence-disrupting sections 57 disrupt the laminar flow of the coolant, causing turbulence and thereby enhancing the convective heat transfer efficiency between the coolant and the flow channel wall.

[0076] By combining the serpentine flow channel with the turbulence section 57, the coolant has a longer flow path and more intense turbulence when flowing through the IGBT module 211 area, which can more fully absorb the heat generated by the IGBT module 211 and significantly improve the heat dissipation effect and efficiency of the IGBT module 211.

[0077] Regarding the specific structure of the turbulence section 57, the turbulence section 57 may adopt at least one of heat dissipation fins, needle-shaped turbulence columns, or turbulence protrusions.

[0078] Among these components, heat dissipation fins are typically thin-plate structures with a large heat exchange surface area. Needle-shaped turbulence columns are cylindrical or prismatic protrusions that generate eddy currents during coolant flow. Turbulence bosses are raised structures that also enhance heat exchange by turbulent fluid flow. All of these turbulence components effectively turbulent the coolant and enhance heat exchange. One type can be selected based on actual heat dissipation requirements and processing conditions, or multiple types can be combined within the same flow channel to achieve optimal heat exchange performance.

[0079] Based on the above embodiments, to further enhance the heat dissipation effect and efficiency of the IGBT module 211, as a preferred embodiment, please refer to... Figure 9 Each branch flow channel 55 has a heat-conducting medium 58 disposed on the surface of the liquid cooling plate 5 area. The heat-conducting medium 58 is located between the liquid cooling plate 5 and the IGBT module 211 disposed in that area, and is used to conduct the heat generated by the IGBT module 211 during operation to the liquid cooling plate 5. The heat-conducting medium 58 can effectively fill the gap between the IGBT module 211 and the liquid cooling plate 5, so that the heat generated by the IGBT module 211 can be transferred to the liquid cooling plate 5 more efficiently and then carried away by the coolant, thereby further enhancing the heat dissipation effect and efficiency of the IGBT module 211.

[0080] Regarding the specific material of the thermal conductive medium 58, the thermal conductive medium 58 can be at least one of graphene thermal conductive pads, thermal conductive gels, or thermal conductive greases.

[0081] Among them, graphene thermal pads have the advantages of high thermal conductivity, good flexibility, and easy installation (simply stick them on), enabling efficient and stable heat conduction. Thermal conductive gel has good flowability and filling properties, and can adapt to different gap thicknesses. Thermal conductive silicone grease has low cost and wide application. All of the above materials can effectively reduce contact thermal resistance, ensuring that the heat from the IGBT module 211 is quickly conducted to the liquid cooling plate 5, improving the heat dissipation effect. One of the materials can be selected according to the actual application requirements, or a combination of materials can be used.

[0082] Based on the above embodiments, to enhance the heat dissipation and efficiency of the inverter inductor module 212, as a preferred embodiment, please refer to... Figure 11 The inductor cooling channel 56 includes multiple independent and parallel inductor branch channels 561. One end of each inductor branch channel 561 is connected to the converging point (i.e., the converging channel 59) of all the branch channels 55, and the other end is connected to the main liquid outlet channel 54. The liquid cooling plate 5 area corresponding to all the inductor branch channels 561 is used to house multiple inverter inductor modules 212.

[0083] It should be noted that while the inverter inductor module 212 has relatively low requirements for temperature uniformity, it generates a large amount of heat. Therefore, multiple independent and parallel inductor branch channels 561 are used. The coolant flows from the branch channels 55 into the converging channel 59, and then simultaneously into each inductor branch channel 561. Each branch channel flows through the corresponding liquid cooling plate 5 area of ​​the inverter inductor module 212, and then flows into the main outlet channel 54. Because the multiple inductor branch channels 561 are independent and parallel, the coolant can pass through the corresponding area of ​​the inverter inductor module 212 at a relatively high flow rate and velocity, quickly carrying away the heat generated by the inductor and preventing heat accumulation near the inductor. This ensures the stable operation of the inverter inductor module 212 and surrounding electrical components.

[0084] Based on the above embodiments, and considering the specific arrangement of the multiple inductor branch channels 561 included in the inductor cooling channel 56 on the second plate, as a further preferred embodiment, please refer to... Figure 11 All inductor branch channels 561 extend along the length of the liquid cooling plate 5 and are arranged in two groups. The inductor cooling channel 56 also includes an inductor main channel 562, which is located at the edge of the second plate portion away from the first plate portion (i.e., at the second side edge along the length of the liquid cooling plate 5). One group of inductor branch channels 561 connects the converging end of the branch channels 55 (i.e., the converging channel 59) with one port of the inductor main channel 562, and the other group of inductor branch channels 561 connects the other port of the inductor main channel 562 with the main outlet channel 54.

[0085] In this way, the coolant first enters the first group of inductor branch channels 561 from the confluence channel 59, then flows into the main inductor channel 562, and after being split by the second group of inductor branch channels 561, it flows into the main outlet channel 54, forming a U-shaped flow path. This U-shaped flow path increases the flow path of the coolant within the second plate of the liquid cooling plate 5, allowing for more thorough heat exchange between the coolant and the wall of the liquid cooling plate 5 (and consequently with the inverter inductor module 212). This facilitates the rapid removal of heat generated by the inverter inductor module 212, further improving its heat dissipation efficiency. Furthermore, the multiple inductor branch channels 561 are arranged at intervals along the length of the liquid cooling plate 5 and divided into two groups, avoiding intersections or detours. This helps to fully utilize the internal space of the second plate of the liquid cooling plate 5, allowing for the arrangement of more or longer inductor branch channels 561 within the limited plate space. This increases the cooling coverage area of ​​multiple inverter inductor modules 212, further improving their heat dissipation efficiency.

[0086] Furthermore, all inverter inductor modules 212 are spaced apart along the length of the liquid cooling plate 5 in the second plate portion of the liquid cooling plate 5 (i.e., the liquid cooling plate 5 area corresponding to the inductor cooling channel 56 formed by all inductor branch channels 561 and inductor main channels 562). This arrangement can well adapt to the long and narrow liquid cooling plate 5, thereby greatly saving the installation space inside the energy storage converter and contributing to the compact structure of the whole machine.

[0087] Based on the above embodiments, as a further preferred option, please refer to... Figure 8All gaps between the inverter inductor modules 212 and the liquid cooling plate 5 are filled with thermally conductive potting compound 23, which cures the inverter inductor modules 212, thermally conductive potting compound 23, and liquid cooling plate 5 to form an integrated potting structure. The thermally conductive potting compound 23 can be a two-component thermally conductive curing adhesive, which is formed by mixing component A (resin) and component B (curing agent) in a certain proportion and then undergoing a cross-linking reaction to form a solid filling layer with good thermal conductivity, adhesion, and insulation, which can fully fill complex gaps and bond firmly.

[0088] Because the potting compound can fully fill all the gaps between the inverter inductor module 212 and the liquid cooling plate 5, eliminating air gaps and significantly reducing contact thermal resistance, the heat generated by the inverter inductor module 212 can be more efficiently conducted to the liquid cooling plate 5 and carried away by the coolant, thereby improving the overall heat dissipation efficiency. Furthermore, multiple inverter inductor modules 212 and the liquid cooling plate 5 are integrally cured with thermally conductive potting compound 23, achieving integrated heat dissipation and making the heat dissipation effect more uniform. At the same time, the thermally conductive potting compound 23 provides a sealing and protective function for the inductor modules, preventing dust and moisture intrusion and improving the long-term operational reliability of the energy storage converter under complex operating conditions.

[0089] Based on the above embodiments, and considering the internal structure and layout of the secondary power consumption component 4, as a preferred option, please refer to... Figure 3 The secondary power consumption component 4 includes a primary power consumption component 41 and a secondary power consumption component 42. Along the width direction of the housing 1 (i.e., from the side where the liquid cooling plate 5 is located to the opposite side), the primary power consumption component 41 and the secondary power consumption component 42 are arranged sequentially, with the primary power consumption component 41 being closer to the liquid cooling plate 5 than the secondary power consumption component 42. In other words, the secondary power consumption component 42 is relatively far away from the primary power consumption component 21 on the liquid cooling plate 5, while the primary power consumption component 41 is located between the two.

[0090] Since the secondary power consumption component 42 (such as the AC EMC common mode inductor 421) generates a significant amount of heat during operation and is prone to overheating, making it highly sensitive to temperature, placing it away from the main power consumption component 21 effectively prevents the heat generated by the main power consumption component 21 from causing additional heat accumulation on the secondary power consumption component 42, thus preventing the secondary power consumption component 42 from overheating. Meanwhile, the primary power consumption component 41 (such as the control board 412, detection board 413, etc.) generates very little heat and can be placed relatively close to the liquid cooling plate 5. This layout enables differentiated thermal management of devices with different heat-generating characteristics, optimizes the overall thermal environment within the housing, and helps improve the long-term operational reliability of the system.

[0091] Based on the above embodiments, and considering the specific structure and installation method of the first power consumption component 41, as a preferred option, please refer to... Figure 3 , Figure 4 , Figure 5 and Figure 6 The first power consumption component 41 includes an AC filter board 411, a control board 412, a detection board 413, and a voltage detection board 414. The AC filter board 411 is disposed on the bottom plate inside the housing 1. A detection board mounting bracket 19 is fixedly provided on the side of the AC filter board 411 facing away from the bottom plate (i.e., above). The control board 412, the detection board 413, and the voltage detection board 414 are all mounted on the detection board mounting bracket 19, thereby forming a stacked layout above the AC filter board 411.

[0092] This stacked layout, where the AC filter board 411, control board 412, detection board 413, and voltage detection board 414 are stacked vertically, fully utilizes the internal height space of the housing 1, resulting in a compact overall structure. Simultaneously, the stacked layout shortens electrical connections between boards, simplifies wiring, and facilitates production assembly and subsequent maintenance.

[0093] Based on the above embodiments, and considering the specific structure and installation method of the second power consumption component 42, as a preferred option, please refer to... Figure 3 The second power consumption component 42 includes an AC EMC common-mode inductor 421. The AC EMC common-mode inductor 421, also known as an AC electromagnetic compatibility common-mode inductor, is used to suppress common-mode interference on the AC side of the energy storage converter and improve grid-connected power quality. In this embodiment, the AC EMC common-mode inductor 421 and the AC Hall sensor component 422 are pre-assembled into an integrated module. Specifically, as shown... Figure 12 and Figure 13 As shown, the AC Hall sensor assembly 422 includes an AC Hall sensor 4221, an upper sheet metal 4222, and a lower sheet metal 4223. Multiple AC Hall sensors 4221 are disposed between the upper sheet metal 4222 and the lower sheet metal 4223. The lower sheet metal 4223 is fixedly mounted on the AC EMC common-mode inductor 421, forming an integrated module. This integrated module is mounted on the base plate inside the housing 1 and is located on the side of the first power consumption assembly 41 opposite to the liquid cooling plate 5.

[0094] The AC EMC common mode inductor 421 and the AC Hall sensor assembly 422 are pre-assembled into an integrated module, which reduces the number of assembly steps and fasteners during the assembly process, simplifies the wiring inside the housing 1, improves assembly efficiency, and also facilitates subsequent maintenance and replacement.

[0095] Based on the above embodiments, and considering the mounting method of the power board 22 and the pre-charge resistor 34, as a preferred option, please refer to... Figure 3 , Figure 4 , Figure 5 , Figure 6 and Figure 7The power conversion unit 2 includes a power board 22, which is mounted on a group of IGBT modules 211. Specifically, the power board 22 is directly mounted on top of the IGBT modules 211, forming an electrical connection. The DC-side power distribution unit 3 includes a pre-charging resistor 34, which is mounted on the side of the power board 22 away from the group of IGBT modules 211 (i.e., above the power board 22) via a pre-charging resistor mounting bracket 18. Thus, the pre-charging resistor 34, the pre-charging resistor mounting bracket 18, the power board 22, and the IGBT modules 211 are stacked vertically in sequence, forming a layered layout. The pre-charging resistor 34 no longer occupies additional horizontal mounting area, but utilizes the vertical space above the power board 22, thereby effectively saving horizontal space inside the housing 1 and making the overall structure more compact.

[0096] In summary, by stacking the AC filter board 411, control board 412, detection board 413, and voltage detection board 414 on top of each other via the detection board mounting bracket 19, stacking the pre-charge resistor 34 on top of the power board 22 via the pre-charge resistor mounting bracket 18, and pre-assembling the AC EMC common-mode inductor 421 and the AC Hall sensor assembly 422 into a single module, multiple components that would otherwise need to be distributed horizontally can now be arranged in a modular, stacked manner, greatly improving the space utilization within the housing 1. With this layout, the overall height of the energy storage converter can be controlled within 140mm, and the thickness is significantly reduced. Simultaneously, the stacked layout and modular pre-assembly simplify the assembly process, making assembly and maintenance more convenient. Furthermore, the compact layout shortens the electrical connection paths between components, reducing line losses. Combined with the centralized heat dissipation of the liquid cooling plate 5 and the air-cooled circulation of the cooling fan 6 within the housing 1, the overall heat dissipation effect of the energy storage converter can be further improved.

[0097] Based on the above embodiments, considering the overall layout of each region inside the housing 1, as a preferred option, please refer to... Figure 7 The liquid cooling plate 5 is disposed adjacent to the first side plate (e.g., the left side plate) in the width direction of the housing 1, and extends from the front panel 111 in the length direction of the housing 1 to the opposite back panel, that is, the length of the liquid cooling plate 5 is substantially the same as the length of the housing 1, and runs through the entire front-rear direction of the housing 1. On the liquid cooling plate 5, a set of IGBT modules 211 is closer to the front panel 111 than a set of inverter inductor modules 212. That is, the IGBT modules 211 are located in the front region of the liquid cooling plate 5 (close to the front panel 111), and the inverter inductor modules 212 are located in the rear region of the liquid cooling plate 5 (close to the back panel).

[0098] Please refer to Figure 3Along the width direction of housing 1, the remaining components of the DC-side power distribution unit 3, except for the pre-charging resistor 34 (including the DC circuit breaker 31, DC contactor 32, fuse 33, DC common-mode inductor 35, and DC Hall sensor 36), are arranged on the side of power board 22 away from the first side plate (i.e., the right side of power board 22), and these remaining components and power board 22 are all located on the side of housing 1 near panel 111 (i.e., the front area). In other words, at the front of housing 1, power board 22 and the aforementioned DC-side protection components are arranged side by side along the width direction.

[0099] In this way, the power board 22 can be connected to the DC contactor 32 in the DC-side power distribution unit 3, which is also located at the front, via a copper busbar 20, shortening the electrical path, i.e., shortening the length of the copper busbar 20, and reducing costs. The DC-side power distribution unit 3 is close to the panel 111, which facilitates direct wiring with the DC-side power connector 14 on the panel 111, reducing cable loss and wiring complexity. At the same time, the first plate part of the liquid cooling plate 5 (corresponding to the IGBT module area) is close to the panel 111, and the liquid inlet port 51 and liquid outlet port 52 provided on it can be conveniently connected to the external liquid supply system through the perforations on the panel 111 via the liquid inlet connector 510 and liquid outlet connector 511, respectively, avoiding pipe detours.

[0100] In addition, please refer to Figure 3 The first power consumption component 41 (including AC filter board 411, control board 412, detection board 413, voltage detection board 414) and the second power consumption component 42 (including an integrated module formed by AC EMC common mode inductor 421 and AC Hall sensor component 422) are both located on the side of the housing 1 near the back plate (i.e., the rear area) and are arranged sequentially along the width direction of the housing 1. That is, the first power consumption component 41 is closer to the liquid cooling plate 5 than the second power consumption component 42, and the two are distributed sequentially from the side closer to the liquid cooling plate to the opposite side.

[0101] Since the first power consumption component 41 and the second power consumption component 42 are arranged sequentially along the width direction of the housing 1 and are spread out in the horizontal direction, the space above each component is unobstructed, which is conducive to the smooth flow of air in the rear area of ​​the housing 1, preventing local heat accumulation. This makes full use of the width direction space of the housing 1, making the rear area structure simple and heat dissipation smooth, further improving the integration and heat dissipation efficiency of the whole machine.

[0102] Based on the above embodiments, to significantly improve the overall heat dissipation efficiency of the system, as a preferred option, please refer to... Figure 3 and Figure 6The housing 1 contains at least two cooling fans 6. At least one cooling fan 6 is located between the DC-side power distribution unit 3 and the secondary power consumption component 42, with its intake side facing the DC-side power distribution unit 3 and its exhaust side facing the secondary power consumption component 42 (i.e., the integrated module formed by the AC EMC common-mode inductor 421 and the AC Hall sensor component 422). At least one cooling fan 6 is located between the secondary power consumption component 42 and the primary power consumption component 41, with its intake side facing the secondary power consumption component 42 and its exhaust side facing the primary power consumption component 41 (including the AC filter board 411, control board 412, detection board 413, and voltage detection board 414).

[0103] During operation, the front-mounted cooling fan 6 draws out hot air from around the DC-side power distribution unit 3 and blows it towards the secondary power consumption component 42, preventing heat accumulation at the front and simultaneously carrying away heat from the secondary power consumption component 42 with the airflow. The rear-mounted cooling fan 6 then draws out hot air from around the secondary power consumption component 42 and blows it towards the primary power consumption component 41, ultimately dissipating or dispersing heat from the area of ​​the primary power consumption component 41. In this way, a front-to-back air-cooling circulation path is formed inside the housing 1, from the DC-side power distribution unit to the secondary power consumption component and then back to the primary power consumption component, effectively preventing localized heat accumulation and improving overall heat dissipation efficiency.

[0104] In one alternative embodiment, please refer to Figure 3 and Figure 5 An isolation power supply board 43 is also provided on the side (i.e., the rear side) facing the back panel of the integrated module formed by the pre-assembled AC EMC common mode inductor 421 and AC Hall sensor assembly 422. The isolation power supply board 43 is used to supply power to components such as the control board 412, detection board 413, and voltage detection board 414. By placing the isolation power supply board 43 on the rear side of the integrated module, that is, near the end of the back panel, away from the main power consumption components 21 (IGBT module 211, inverter inductor module 212) and DC side power distribution unit 3 at the front, the impact of electromagnetic interference on the high-voltage side on the isolation power supply board 43 is reduced, which is conducive to the output of stable and safe power. In addition, the proximity of the isolation power supply board 43 to the main power consumption components 41 (control board 412, detection board 413, voltage detection board 414) at the rear can also shorten the length of the power supply harness.

[0105] Based on the above embodiments, the main electrical connections within the energy storage converter are further explained. Please refer to... Figure 2 , Figure 3 , Figure 6 and Figure 7The panel 111 is provided with a DC-side power connector 14 and an AC-side power connector 15; the DC-side power distribution unit 3 includes a DC circuit breaker 31, a DC contactor 32, a fuse 33, a DC common-mode inductor 35, and a DC Hall sensor 36; the DC-side power connector 14, the DC common-mode inductor 35, the DC circuit breaker 31, the fuse 33, the DC contactor 32, the power board 22, the IGBT module 211, the inverter inductor module 212, the AC filter board 411, the AC EMC common-mode inductor 421, and the AC Hall sensor assembly 422 are sequentially electrically connected to the AC-side power connector 15; the pre-charge resistor 34 is connected in parallel with the DC contactor 32.

[0106] Specifically, panel 111 is provided with DC-side power connector 14 and AC-side power connector 15. DC-side power connector 14 is used to connect to an external battery pack (positive terminal BAT+, negative terminal BAT-), and AC-side power connector 15 is used to connect to the power grid or load (three-phase AC L1, L2, L3 and N line).

[0107] The DC-side power distribution unit 3 includes a DC common-mode inductor 35, a DC circuit breaker 31, a fuse 33, a DC contactor 32, and a DC Hall sensor 36. The electrical connections between these components are as follows:

[0108] The positive and negative terminals of the DC-side power connector 14 are connected to the input side of the DC common-mode inductor 35 via copper busbars or wires, respectively. The output side of the DC common-mode inductor 35 is connected to the input side of the DC circuit breaker 31 via copper busbar 20. The output side of the DC circuit breaker 31 is connected to the input side of the fuse 33 (one positive and one negative) via copper busbar 20. The output side of the fuse 33 is connected to the input side of the DC contactor 32 (one positive and one negative) via copper busbar 20. The output side of the DC contactor 32 is connected to the DC input terminal of the power board 22 via copper busbar 20. The pre-charge resistor 34 is connected in parallel with the positive DC contactor 32, that is, one end of the pre-charge resistor 34 is connected to the input terminal of the positive DC contactor 32, and the other end is connected to the output terminal of the positive DC contactor 32. A pre-charge contactor is connected in series in the pre-charge circuit to limit the inrush current during startup.

[0109] The drive output terminal of power board 22 is connected to IGBT module 211. The AC output terminal of IGBT module 211 is connected to the input terminal of inverter inductor module 212 via a wire. The output terminal of inverter inductor module 212 is connected to the input terminal of AC filter board 411 via copper busbar 20. The output terminal of AC filter board 411 is connected to the input terminal of AC EMC common mode inductor 421 via copper busbar 20. The output terminal of AC EMC common mode inductor 421 is connected to the input terminal of AC Hall sensor assembly 422 via a wire. The output terminal of AC Hall sensor assembly 422 is connected to AC side power connector 15 via a wire.

[0110] A DC Hall sensor 36 is located on the positive or negative circuit between the DC-side power connector 14 and the DC common-mode inductor 35, and is used to sample DC current signals and feed them back to the control board 412. An AC Hall sensor assembly 422 is used to sample three-phase AC current signals and feed them back to the control board 412. The control board 412 controls the power board 22 to drive the IGBT module 211 to work based on the collected voltage and current signals, realizing bidirectional conversion between DC and AC.

[0111] In addition, panel 111 also includes a grounding point 7, a handle 8, a communication connector 9, indicator lights 10, a DC circuit breaker manual control 16, and a network port 17. Grounding point 7 is located on one side of panel 111 (e.g., the left side) and is used to connect to an external protective grounding wire, ensuring that the potential of the casing 1 of the energy storage converter is equipotential with the earth in the event of leakage or fault, thus ensuring operator safety. Handles 8 are symmetrically located on the left and right sides of panel 111 for easy handling and installation of the entire energy storage converter. Communication connector 9 is used to connect external communication cables, enabling data exchange and remote monitoring between the energy storage converter and the battery management system (BMS), energy management system (EMS), or a host computer. It can be located at the bottom of the central area of ​​panel 111. Indicator lights 10 are located above or near communication connector 9 and typically include power, operation, and fault indicators, used to visually display the operating status of the energy storage converter. The manual control panel 16 for the DC circuit breaker is located on the panel 111 near the DC-side power connector 14 (e.g., on the right side adjacent to the DC-side power connector 14). It is linked to the DC circuit breaker 31 inside the housing 1 and is used to manually disconnect the DC main circuit, facilitating the disconnection of battery-side power during maintenance or emergencies. The network port 17 is located on the right side of the manual control panel 16 for the DC circuit breaker and typically includes multiple (e.g., six in two rows) interfaces for connecting to commissioning equipment or a host computer to enable parameter configuration and real-time monitoring of data.

[0112] In addition, the panel 111 is equipped with a power switch button 21 and a power supply interface 22. The power switch button 21 is used to control the switching on and off of the auxiliary power supply of the energy storage converter. When pressed, it can supply power to low-power components such as the control board 412 and the detection board 413. The power supply interface 22 is a 220V AC input interface, used to connect to external mains power to supply power to internal auxiliary electrical equipment such as the power module and the cooling fan 6.

[0113] In one alternative embodiment, please refer to Figure 2The DC-side power connector 14, DC circuit breaker manual control 16, network port 17, and AC-side power connector 15 are arranged sequentially along the width of panel 111 (from left to right), and are located on the side where most of the components of the DC-side power distribution unit 3 (i.e., all components except the pre-charge resistor 34) are located, to maintain consistency with the arrangement order of the main circuit components inside housing 1. Most of the components of the DC-side power distribution unit 3 inside housing 1 are located in the front right area, with the corresponding DC input interface (DC-side power connector 14) and manual control (DC circuit breaker manual control 16) positioned slightly to the right; network port 17 is further to the right; and the AC output interface (AC-side power connector 15) is located on the far right, close to the rear inverter inductor module 212 and AC filter components. In this way, DC input, communication, and AC output are clearly partitioned on the panel, without interfering with each other.

[0114] Based on the above embodiments, and considering the dynamic control method of the coolant in the energy storage converter, as a preferred embodiment, the energy storage converter also includes a control unit (which can be integrated into the control board 412). The control unit is electrically connected to the liquid supply system of the liquid cooling plate 5 (such as an electronic water pump or adjustable valve) and can acquire the temperature information of the main power consumption component 21 (including the IGBT module 211 and the inverter inductor module 212) in real time, for example, by acquiring the temperature information through a temperature sensor located on the surface of the IGBT module 211. Because the IGBT module 211 generates more concentrated heat and is more sensitive to temperature changes, using it as the main monitoring point can more timely and accurately reflect the thermal state of the main power consumption component 21, thereby providing a more effective basis for cooling regulation.

[0115] When the temperature of the main power consumption component 21 exceeds the first threshold (e.g., 50℃~55℃), the control unit controls the liquid supply system to increase the flow rate and velocity of the coolant to the rated value, so that the liquid cooling plate 5 enters the normal heat dissipation working state. When the temperature continues to rise and exceeds the second threshold (e.g., 65℃), the control unit controls the liquid supply system to further increase the flow rate and velocity of the coolant to the excess value (e.g., 1.1 times the rated value) to enhance heat dissipation capacity and suppress temperature rise. When the temperature exceeds the third threshold (e.g., 75℃), the control unit triggers derating protection, that is, actively reduces the output power of the energy storage converter to reduce the heat generated by the main power consumption component 21 itself, and resumes normal operation after the temperature drops back to a safe range (e.g., 50℃~55℃).

[0116] Through the above-mentioned intelligent adjustment, the coolant flow rate and velocity can be automatically and quickly adjusted according to the real-time temperature changes of the main power consumption component 21, effectively maintaining the temperature stability of the energy storage converter and preventing thermal runaway.

[0117] The present invention also provides an energy storage system, including the energy storage converter disclosed in the above embodiments. Thus, the energy storage converter, based on integrated DC-side on / off control and overcurrent protection, centrally cools the main power consumption component 21 via a liquid cooling plate 5, and arranges the secondary power consumption component 4 on the opposite side, thereby effectively avoiding mutual heat interference, reducing the risk of thermal runaway, ensuring the safe and reliable operation of the secondary power consumption component, and thus improving the overall reliability and safety of the system.

[0118] It should be noted that in this specification, relational terms such as first and second are used only to distinguish one entity from several other entities, and do not necessarily require or imply any such actual relationship or order between these entities.

[0119] The various embodiments in this specification are described in a progressive manner, with each embodiment focusing on the differences from other embodiments. The same or similar parts between the various embodiments can be referred to each other.

[0120] The energy storage converter and energy storage system provided by this invention have been described in detail above. Specific examples have been used to illustrate the principles and implementation methods of this invention. The descriptions of the embodiments above are only for the purpose of helping to understand the method and core ideas of this invention. It should be noted that those skilled in the art can make several improvements and modifications to this invention without departing from the principles of this invention, and these improvements and modifications also fall within the protection scope of the claims of this invention.

Claims

1. An energy storage converter, characterized in that, include: Shell (1); A power conversion unit (2) is located inside the housing (1) and is used to realize bidirectional conversion between DC and AC. The DC side power distribution unit (3) is located inside the housing (1) and is electrically connected to the power conversion unit (2) to realize the DC side on / off control and overcurrent protection; A liquid cooling plate (5) is disposed inside the housing (1); The power conversion unit (2) includes a main power consumption component (21), which is centrally located on the liquid cooling plate (5) and thermally connected to the liquid cooling plate (5). The liquid cooling plate (5) is used to perform liquid cooling heat dissipation on the main power consumption component (21). The energy storage converter also includes a secondary power consumption component (4), the power consumption of which is less than that of the primary power consumption component (21). The secondary power consumption component (4) is located inside the housing (1) on the opposite side of the liquid cooling plate (5) to form thermal isolation with the primary power consumption component (21).

2. The energy storage converter according to claim 1, characterized in that, The main power consumption component (21) includes a set of IGBT modules (211) and a set of inverter inductor modules (212) arranged at intervals along the length of the liquid cooling plate (5).

3. The energy storage converter according to claim 2, characterized in that, The liquid cooling plate (5) is divided into a first plate section and a second plate section along its length direction. The first plate section is provided with an inlet port (51) and an outlet port (52) for connecting the liquid supply system. The first plate has a main liquid inlet channel (53) connected to the liquid inlet port (51), a main liquid outlet channel (54) connected to the liquid outlet port (52), and multiple parallel branch channels (55) branched from the main liquid inlet channel (53). The liquid cooling plate (5) area corresponding to each branch channel (55) is used to set the IGBT module (211). The second plate has an inductor cooling channel (56) inside. The ends of all the branch channels (55) converge and connect to one end of the inductor cooling channel (56). The other end of the inductor cooling channel (56) connects to the main liquid outlet channel (54). The liquid cooling plate (5) area corresponding to the inductor cooling channel (56) is used to set up multiple inverter inductor modules (212).

4. The energy storage converter according to claim 3, characterized in that, Each of the branch channels (55) extends in a bent shape and has multiple sets of turbulence sections (57) arranged in an array along the extension direction.

5. The energy storage converter according to claim 3, characterized in that, Each branch flow channel (55) has a heat-conducting medium (58) on its surface in the area of ​​the liquid cooling plate (5) to conduct the heat generated by the IGBT module (211) in the area to the liquid cooling plate (5).

6. The energy storage converter according to claim 3, characterized in that, The inductive cooling channel (56) includes multiple independent and parallel inductive branch channels (561), each of which is connected between the end convergence point of all the branch channels (55) and the main liquid outlet channel (54).

7. The energy storage converter according to claim 2, characterized in that, The inverter inductor module (212) and the liquid cooling plate (5) are filled with thermally conductive potting compound (23) to form an integrated potting structure.

8. The energy storage converter according to claim 2, characterized in that, The secondary power consumption component (4) includes a first power consumption component (41) and a second power consumption component (42). The power consumption of the second power consumption component (42) is greater than that of the first power consumption component (41). The first power consumption component (41) and the second power consumption component (42) are arranged sequentially along the width direction of the housing (1), and the first power consumption component (41) is closer to the liquid cooling plate (5) than the second power consumption component (42).

9. The energy storage converter according to claim 8, characterized in that, The first power consumption component (41) includes an AC filter board (411), a control board (412), a detection board (413), and a voltage detection board (414). The AC filter board (411) is located on the bottom plate inside the housing (1). A detection board mounting bracket is provided on the side of the AC filter board (411) facing away from the bottom plate. The control board (412), the detection board (413), and the voltage detection board (414) are located on the detection board mounting bracket, forming a stacked layout.

10. The energy storage converter according to claim 8, characterized in that, The second power consumption component (42) includes an AC EMC common mode inductor (421), which is pre-assembled with the AC Hall sensor component (422) into an integrated module.

11. The energy storage converter according to claim 8, characterized in that, The power conversion unit (2) includes a power board (22), which is mounted on a set of IGBT modules (211); the DC side power distribution unit (3) includes a pre-charge resistor (34), which is mounted on the side of the power board (22) away from the set of IGBT modules (211) via a pre-charge resistor mounting bracket, forming a stacked layout.

12. The energy storage converter according to claim 11, characterized in that, The liquid cooling plate (5) is disposed adjacent to the first side plate in the width direction of the housing (1) and extends from the panel (111) in the length direction of the housing (1) to the opposite back plate, and a set of IGBT modules (211) is closer to the panel (111) than a set of inverter inductor modules (212). Along the width direction of the housing (1), the remaining components of the DC side power distribution unit (3), except for the pre-charge resistor (34), are arranged on the side of the power board (22) away from the first side plate, and the remaining components and the power board (22) are both located on the side of the housing (1) close to the panel (111). The first power consumption component (41) and the second power consumption component (42) are both located on the side of the housing (1) near the back plate and are arranged sequentially along the width direction of the housing (1).

13. The energy storage converter according to claim 12, characterized in that, The housing (1) is also provided with at least two cooling fans (6), at least one of the cooling fans (6) is located between the DC side power distribution unit (3) and the second power consumption component (42), and at least one of the cooling fans (6) is located between the second power consumption component (42) and the first power consumption component (41) to form a wind-cooled circulation heat dissipation.

14. The energy storage converter according to any one of claims 1 to 13, characterized in that, It also includes a control unit, which is used to adjust the flow rate or velocity of the coolant in the liquid cooling plate (5) according to the temperature of the main power consumption component (21); When the temperature exceeds the first threshold, the flow rate and velocity of the coolant are increased to the rated value; when the temperature exceeds the second threshold, they are increased to the excess value; when the temperature exceeds the third threshold, derating protection is triggered.

15. An energy storage system, characterized in that, Includes the energy storage converter as described in any one of claims 1 to 14.

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