Intelligent temperature control condensation-proof cooling module

Abstract

The application provides a cooling module with intelligent temperature control and condensation prevention, which comprises a closed circulation cooling loop, an inner circulation loop comprising a cooled object interface, a main circulation pump, an inner water side of a plate heat exchanger and a main filter connected in sequence to form a circulation loop, and a water storage tank connected in series in the inner circulation loop; an outer circulation loop comprising an outer water inlet and an outer water outlet, and an outer water filter arranged between the outer water inlet and an outer water side of the plate heat exchanger; and an intelligent temperature control system comprising a temperature sensor, a temperature and humidity sensor and an electric flow regulating valve; the intelligent temperature control system controls the heating rod and the electric flow regulating valve to act according to the detection signals of the temperature sensor and the temperature and humidity sensor. The technical scheme of the application can simultaneously solve the technical problems of insufficient cooling efficiency, high risk of condensation, insufficient temperature control precision, poor compactness of structure, weak anti-electromagnetic interference ability, imperfect impurity filtration and insufficient pipeline process and sealing performance in the cooling system of the existing high-power frequency conversion control device.

Description

Technical Field

[0001] This invention belongs to the field of power electronic equipment cooling technology, and specifically relates to an intelligent temperature-controlled anti-condensation cooling module. Background Technology

[0002] Currently, the cooling systems of high-power frequency converter control cabinets mainly adopt air cooling or conventional water cooling: Air cooling systems: These use forced convection cooling via fans, have a simple structure but low heat exchange efficiency, and cannot meet the cooling requirements of high-power scenarios with a total loss of approximately 10kW. They are also significantly affected by ambient temperature, and are prone to overheating in high-temperature or high-humidity environments. Conventional water cooling systems: These often use a simple circulating pump + heat exchanger structure, with some products using shell-and-tube heat exchangers (low heat exchange efficiency and large size). They lack anti-condensation design and do not have high-efficiency filtration devices to address impurities in seawater cooling sources; their electromagnetic interference resistance is weak, making it difficult to meet the stable operation requirements of strong electromagnetic environments such as military or marine applications (e.g., not complying with the GJB151B-2013 electromagnetic compatibility standard); the piping system uses ordinary welding processes, resulting in insufficient pressure resistance and cleanliness (it has not undergone multiple cleaning and passivation processes and an 8-hour pressure test).

[0003] The cooling devices of existing high-power frequency converter control systems suffer from the following core technological bottlenecks: 1) Insufficient cooling efficiency: Shell-and-tube heat exchangers have low heat exchange efficiency and cannot quickly remove the total losses of 10kW (including power unit, filter, and reactor losses), which can easily lead to excessive cooling water temperature and affect the stable operation of the main equipment.

[0004] 2) High risk of condensation: In traditional water-cooled systems, the surface temperature of the cold plate is easily lower than the air dew point temperature under low temperature or high humidity conditions, leading to water vapor condensation and causing short circuit failures in the devices. For example, when the cold plate temperature is below 20°C and the ambient humidity exceeds 93%, condensation is likely to form on the surface of the inverter's IGBT power module.

[0005] 3) Insufficient temperature control accuracy: Conventional cooling systems rely on a single mechanical thermostat to regulate flow, which cannot adjust cooling power in real time according to dynamic changes in load. For example, engine cooling systems achieve temperature control by switching between large and small circulation loops, but the response speed is slow and cannot meet the rapidly changing heat load requirements of the frequency converter.

[0006] 4) Poor structural compactness: Traditional water-cooled units adopt a split design, such as rectifier modules and inverter modules with independent water-cooling plates, resulting in a large size. For example, although the water-cooled unit of a certain modular high-voltage frequency converter adopts a vertical arrangement, it still requires multiple water-cooling plates, which limits economy and maintainability.

[0007] 5) Weak electromagnetic interference resistance: High-power power electronic environments are subject to strong electromagnetic interference. Existing systems lack targeted EMC measures in their power supply, data acquisition, and control circuits, making them prone to control failures or distorted instrument data.

[0008] Therefore, how to provide an intelligent temperature-controlled and anti-condensation cooling module that can simultaneously solve the technical problems existing in the cooling systems of high-power frequency converter control devices, such as insufficient cooling efficiency, high risk of condensation, insufficient temperature control accuracy, poor structural compactness, weak anti-electromagnetic interference capability, imperfect impurity filtration, and insufficient pipeline technology and sealing, has become an urgent technical problem to be solved. Summary of the Invention

[0009] This invention provides an intelligent temperature-controlled anti-condensation cooling module that can simultaneously solve the technical problems existing in the cooling systems of high-power frequency converter control devices, such as insufficient cooling efficiency, high risk of condensation, insufficient temperature control accuracy, poor structural compactness, weak anti-electromagnetic interference capability, imperfect impurity filtration, and insufficient pipeline technology and sealing.

[0010] In one embodiment of the present invention, a smart temperature-controlled anti-condensation cooling module is provided, comprising: A closed-loop cooling circuit, comprising an inner loop and an outer loop; The internal circulation loop includes the cooled object interface, the main circulation pump, the inner water side of the plate heat exchanger, and the main filter, which are connected in sequence through pipelines to form the circulation loop. A water storage tank is also connected in series in the internal circulation loop, and an immersion heating rod is provided in the water storage tank. The external circulation loop includes an external water inlet and an external water return outlet connected to the external water side of the plate heat exchanger via a pipeline, and an external water filter is provided between the external water inlet and the external water side of the plate heat exchanger. The intelligent temperature control system includes a temperature sensor installed on the inner circulation loop, a temperature and humidity sensor installed in the module cavity, and an electric flow regulating valve connected in series between the inlet pipe and the return pipe of the outer circulation loop. The heating rod and the electric flow regulating valve are electrically connected to the intelligent temperature control system, and the intelligent temperature control system controls the operation of the heating rod and the electric flow regulating valve according to the detection signals of the temperature sensor and the temperature and humidity sensor. The electric flow regulating valve is an electric ball valve, and its valve body is made of PPH.

[0011] Furthermore, the filtration accuracy of both the external water filter and the main filter is 60μm, the filter element material of the external water filter is PVDF, and the filter element material of the main filter is stainless steel.

[0012] Furthermore, the water storage tank is equipped with a level switch, which is electrically connected to the control circuit of the main circulation pump and the heating rod, and is used to cut off the power supply to the main circulation pump and the heating rod when the liquid level is lower than a preset value.

[0013] Furthermore, the temperature sensor includes a first temperature transmitter disposed on the inlet side of the internal circulation loop and a second temperature transmitter disposed on the return side of the internal circulation loop; the internal circulation loop is also provided with a first pressure transmitter and a second pressure transmitter, the first pressure transmitter being disposed on the inlet side of the internal circulation loop and the second pressure transmitter being disposed on the return side of the internal circulation loop; the first temperature transmitter and the second temperature transmitter have a range of -50℃ to 80℃, an accuracy of ±0.5%, and output a 4 to 20mA signal; the first pressure transmitter and the second pressure transmitter have a range of 0 to 10 Bar, an accuracy of ±0.5%, and output a 4 to 20mA signal.

[0014] Furthermore, it also includes a sampling control board, which is equipped with a PT100 temperature signal acquisition circuit, a 4-20mA pressure signal acquisition circuit, a digital input interface, a digital output interface, and a 4-20mA analog signal output interface; the temperature sensor is connected to the sampling control board through the PT100 temperature signal acquisition circuit, the pressure sensor is connected to the sampling control board through the 4-20mA pressure signal acquisition circuit, and the electric flow regulating valve is connected to the sampling control board through the 4-20mA analog signal output interface.

[0015] Furthermore, the plate heat exchanger is a corrugated plate heat exchanger with a cooling capacity of 11kW; the main circulating pump is a horizontal centrifugal pump with a circulation flow rate of 1.5m³ / h, a head of 38m, a pump body material of 304 stainless steel, and a motor insulation class of F.

[0016] Furthermore, the piping system of the cooling module adopts 316 stainless steel pipes or PPH pipes, the pipe connections adopt an automatic argon arc welding structure, the welds are polished, the pipes and containers are pressure tested respectively, the pipe test pressure is 0.8 MPa to 1.0 MPa, the container test pressure is 1.5 times the working pressure, and the nominal diameter of the main circuit is DN25.

[0017] Furthermore, the cooling module also includes an electromagnetic interference suppression structure, which includes: An LC filter is installed at the power input terminal. The LC filter consists of a 10μF capacitor and a 100mH inductor and is used to attenuate electromagnetic interference in the 10kHz to 100MHz frequency band. The double-shielded cable installed on the control signal line has an outer layer grounded and an inner layer for differential transmission, with a shielding effectiveness greater than 60dB. The system also features a multi-point grounding system, with the cabinet connected to the grounding busbar via a 4mm² copper braided strip. The connection impedance between the cabinet and the grounding busbar is less than 0.1Ω.

[0018] Furthermore, it also includes a module housing with external dimensions of 620mm×300mm×580mm. The bottom of the module housing is equipped with a slide rail, and the back is equipped with a positioning pin.

[0019] Furthermore, the intelligent temperature control system is configured as follows: When the temperature sensor detects that the internal circulating water temperature is below 20°C, it controls the electric ball valve to close slightly to reduce the flow rate of external water into the plate heat exchanger and controls the heating rod to start heating. When the temperature and humidity sensor detects that the ambient humidity is greater than 95% or the ambient temperature is lower than 5°C, the heating rod is triggered to work. When the temperature sensor detects that the internal circulation return water temperature is greater than 45°C, it controls the electric ball valve to increase the opening degree to increase the external water flow.

[0020] The beneficial effects of this invention are as follows: As can be seen from the above scheme, the embodiments of the present invention provide an intelligent temperature-controlled anti-condensation cooling module, including a closed-loop cooling circuit, which includes an inner circulation circuit and an outer circulation circuit; the inner circulation circuit includes the interface of the object to be cooled, a main circulation pump, the inner water side of a plate heat exchanger, and a main filter connected in sequence through pipes to form the circulation circuit, and a water storage tank is connected in series in the inner circulation circuit; the outer circulation circuit includes an external water inlet and an external water return outlet connected to the external water side of the plate heat exchanger through pipes, and an external water filter is provided between the external water inlet and the external water side of the plate heat exchanger; the intelligent temperature control system includes a temperature sensor installed on the inner circulation circuit, a temperature and humidity sensor installed in the module cavity, and an electric flow regulating valve connected in series between the inlet pipe and the return pipe of the outer circulation circuit; the intelligent temperature control system controls the operation of the heating rod and the electric flow regulating valve according to the detection signals of the temperature sensor and the temperature and humidity sensor. The technical solution of this invention can simultaneously solve the technical problems existing in the cooling system of existing high-power frequency converter control devices, such as insufficient cooling efficiency, high risk of condensation, insufficient temperature control accuracy, poor structural compactness, weak anti-electromagnetic interference capability, imperfect impurity filtration, and insufficient pipeline process and sealing. Attached Figure Description

[0021] Figure 1 This is a flowchart illustrating the operation of an intelligent temperature-controlled anti-condensation cooling module according to the present invention. Figure 2This is a schematic diagram of the composition of an intelligent temperature-controlled anti-condensation cooling module according to the present invention; Figure 3 This is a functional diagram of the water-cooled control board of an intelligent temperature-controlled anti-condensation cooling module according to the present invention; In the diagram, W1 is the external water return port, W2 is the external water inlet, TT1 is the load return water temperature transmitter, PT1 is the load return water pressure transmitter, TT2 is the load inlet water temperature transmitter, PT2 is the load inlet water pressure transmitter, M1 is the electric ball valve, C1 is the water storage tank, H1 is the heating rod, LT1 is the level switch, Z1 is the filter, Z2 is the filter, T is the plate heat exchanger, M2 is the main circulation pump, W3 is the load inlet, and W4 is the load return port. 1. External water inlet: Seawater supply connection port; 2. External water return port: Seawater return connection port; 3. Load return port: Load → water turbine connection port; 4. Load return water temperature transmitter: Detects the load return water temperature; 5. Plate heat exchanger: Allows heat exchange between the load and the cold source seawater, achieving heat dissipation; 6. Heating rod: Forces a temperature increase for the circulating cooling medium, preventing condensation in the water circulation system; 7. Load return water pressure transmitter: Detects the load return water pressure; 8. Water storage tank: Increases the water intake of the main circulation pump, ensuring stable pump operation; 9. Level switch: Detects the water level in the storage tank, protecting the main pump and heating rod for safe operation; 10. Electric ball valve: Regulates the water intake of the plate heat exchanger, preventing condensation in the water circulation system; 11. Load inlet water temperature transmitter... 12 is a filter: it detects the load inlet water temperature; 13 is a load inlet water pressure transmitter: it detects the load inlet water pressure; 14 is an overflow port: when the water level in the storage tank exceeds a certain height, it automatically discharges excess water to prevent the storage tank from overflowing and damaging it; this port can also be used as a liquid filling port; 15 is a drain port: it discharges accumulated liquid in the system and empties the test coolant; 16 is the main circulation pump: it provides power for the system water circulation; 17 is the load inlet water: the connection port between the water turbine and the load; 18 is an external water filter: it prevents small particles in the cold source water (seawater) from flowing through the plate heat exchanger (PVDF external water filter); 19 is a mechanical level gauge. J1 is a single power supply interface, providing an external DC15V power supply; J2 is an eight-channel quantitative input interface, acquiring switch quantity information; J3 is a four-channel digital output interface, providing passive contact output; J4 is a two-channel 4-20mA signal output, driving electric ball valves; J5 is a four-channel 4-20mA signal acquisition circuit, acquiring pressure sensor signals; J6 is a four-channel PT100 temperature signal acquisition circuit, acquiring temperature sensor signals. Detailed Implementation

[0022] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of the embodiments of this invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this invention. Based on the embodiments of this invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this invention.

[0023] like Figure 1 and Figure 2 As shown, Figure 1 This is a flowchart illustrating the operation of an intelligent temperature-controlled anti-condensation cooling module according to the present invention. Figure 2 This is a schematic diagram of the composition of an intelligent temperature-controlled anti-condensation cooling module according to the present invention.

[0024] In the diagram, the external circulation is as follows: seawater → external water inlet → external water filter → plate heat exchanger → external water outlet. The internal circulation is as follows: object being cooled → main water inlet → main circulation pump → plate heat exchanger → main filter → main water outlet → object being cooled.

[0025] In this embodiment of the invention, a smart temperature-controlled anti-condensation cooling module includes: A closed-loop cooling circuit, comprising an inner loop and an outer loop; The internal circulation loop includes the cooled object interface, the main circulation pump, the inner water side of the plate heat exchanger, and the main filter, which are connected in sequence through pipelines to form the circulation loop. A water storage tank is also connected in series in the internal circulation loop, and an immersion heating rod is provided in the water storage tank. The external circulation loop includes an external water inlet and an external water return outlet connected to the external water side of the plate heat exchanger via a pipeline, and an external water filter is provided between the external water inlet and the external water side of the plate heat exchanger. The intelligent temperature control system includes a temperature sensor installed on the inner circulation loop, a temperature and humidity sensor installed in the module cavity, and an electric flow regulating valve connected in series between the inlet pipe and the return pipe of the outer circulation loop. The heating rod and the electric flow regulating valve are electrically connected to the intelligent temperature control system, and the intelligent temperature control system controls the operation of the heating rod and the electric flow regulating valve according to the detection signals of the temperature sensor and the temperature and humidity sensor. The electric flow regulating valve is an electric ball valve, and its valve body is made of PPH.

[0026] In this embodiment of the invention, a smart temperature-controlled anti-condensation cooling module employs a closed-loop water cooling system, including a closed-loop cooling circuit and a smart temperature control system. The closed-loop cooling circuit comprises an inner circulation circuit and an outer circulation circuit, forming a dual-circulation structure. The dual-circulation structure achieves isolation between the inner and outer circulations through a plate heat exchanger, effectively preventing impurities in the outer circulation cold source (seawater) from contaminating the inner circulation working fluid and extending the equipment's service life. Compared to the dual-circulation scheme in prior art document 2, this invention incorporates a submersible heating rod (10L capacity, 1kW power) within the water storage tank, achieving a dual-synergistic anti-condensation mechanism of active heating and electric ball valve regulation of the external water flow. Prior art document 2 relies solely on regulating the external circulation flow to control temperature, resulting in insufficient anti-condensation capability in extreme low-temperature and high-humidity environments. In contrast, the heating rod of this invention can actively intervene to raise the temperature when the ambient temperature is below 5℃ or the humidity is above 95%, working in conjunction with the electric ball valve to achieve a wider temperature range and more reliable anti-condensation control. Furthermore, the electric ball valve body is made of PPH material, which has better corrosion resistance and chemical stability compared to conventional metal valve bodies, making it particularly suitable for seawater cold source environments.

[0027] In one embodiment of the present invention, both the external water filter and the main filter have a filtration accuracy of 60 μm. The filter element material of the external water filter is PVDF, and the filter element material of the main filter is stainless steel. The external water filter is used to intercept tiny particulate impurities in seawater (filtration accuracy 60 μm) to prevent them from entering the plate heat exchanger and causing channel blockage. The main filter is used to intercept rigid particles (filtration accuracy 60 μm) that may be washed away from the internal circulating cooling medium to prevent them from entering precision components such as power units.

[0028] In one embodiment of the present invention, a level switch is provided in the water storage tank. The level switch is electrically connected to the control circuit of the main circulation pump and the heating rod, and is used to cut off the power supply to the main circulation pump and the heating rod when the liquid level is lower than a preset value. This invention effectively prevents the main circulation pump from running dry and being damaged, and the heating rod from burning out, thus improving the operational safety of the system.

[0029] In one embodiment of the present invention, the temperature sensor includes a first temperature transmitter disposed on the inlet side of the internal circulation loop and a second temperature transmitter disposed on the return side of the internal circulation loop; the internal circulation loop is also provided with a first pressure transmitter and a second pressure transmitter, the first pressure transmitter being disposed on the inlet side of the internal circulation loop and the second pressure transmitter being disposed on the return side of the internal circulation loop; the first temperature transmitter and the second temperature transmitter have a range of -50℃ to 80℃, an accuracy of ±0.5%, and output a 4 to 20mA signal; the first pressure transmitter and the second pressure transmitter have a range of 0 to 10 Bar, an accuracy of ±0.5%, and output a 4 to 20mA signal.

[0030] The system employs a multi-point sensor layout, enabling comprehensive real-time monitoring of the inlet / outlet water temperature and pressure in the internal circulation loop. This provides a richer data foundation for precise temperature control, allowing for comprehensive perception and accurate control of the system's operating status.

[0031] In another embodiment of the present invention, the cooling module further includes a sampling control board, which is provided with a PT100 temperature signal acquisition circuit, a 4-20mA pressure signal acquisition circuit, a digital input interface, a digital output interface, and a 4-20mA analog signal output interface; the temperature sensor is connected to the sampling control board through the PT100 temperature signal acquisition circuit, the pressure sensor is connected to the sampling control board through the 4-20mA pressure signal acquisition circuit, and the electric flow regulating valve is connected to the sampling control board through the 4-20mA analog signal output interface.

[0032] The sampling control board processes the sensor signals and transmits them to the control system. Simultaneously, it receives control commands to drive the electric ball valve and heating rod, achieving closed-loop control. This dedicated sampling control board integrates multiple interfaces, including PT100 temperature acquisition, 4-20mA pressure acquisition, digital input / output, and analog output, making it more suitable for the specific control requirements of water-cooled modules. It boasts higher integration and faster response speed.

[0033] In another embodiment of the present invention, the plate heat exchanger is a corrugated plate heat exchanger with a cooling capacity of 11kW; the main circulation pump is a horizontal centrifugal pump with a circulation flow rate of 1.5m³ / h, a head of 38m, a pump body material of 304 stainless steel, and a motor insulation class of F.

[0034] In another embodiment of the present invention, the piping system of the cooling module adopts 316 stainless steel pipes or PPH pipes. The pipe connections are constructed using an automatic argon arc welding structure, and the welded joints are ground. The pipes and containers undergo pressure resistance testing, with the pipe testing pressure ranging from 0.8 MPa to 1.0 MPa and the container testing pressure being 1.5 times the working pressure. The nominal diameter of the main circuit is DN25. This design ensures high pressure resistance and high cleanliness of the system, effectively reducing the risk of leakage. Comparative documents 1-6 do not involve a piping treatment process of automatic argon arc welding + multi-stage cleaning and passivation + system pressure resistance testing. The seawater corrosion resistance of 316 stainless steel and the chemical stability of PPH material make the piping system particularly suitable for marine seawater cooling environments.

[0035] In another embodiment of the present invention, the cooling module further includes an electromagnetic interference suppression structure, the electromagnetic interference suppression structure comprising: An LC filter is installed at the power input terminal. The LC filter consists of a 10μF capacitor and a 100mH inductor and is used to attenuate electromagnetic interference in the 10kHz to 100MHz frequency band. The double-shielded cable installed on the control signal line has an outer layer grounded and an inner layer for differential transmission, with a shielding effectiveness greater than 60dB. The system also features a multi-point grounding system, with the cabinet connected to the grounding busbar via a 4mm² copper braided strip. The connection impedance between the cabinet and the grounding busbar is less than 0.1Ω.

[0036] Through the above-mentioned triple electromagnetic interference suppression measures, the power supply circuit, acquisition circuit, and control circuit can all pass the GJB151B-2013 electromagnetic compatibility test. A complete electromagnetic interference suppression system has been constructed at three levels: the power supply end (LC filter), the signal transmission end (double-shielded cable), and the system grounding end (multi-point grounding), which is more targeted and more reliable.

[0037] In another embodiment of the present invention, a module housing is further included, the module housing having external dimensions of 620mm×300mm×580mm, a slide rail at the bottom of the module housing, and a positioning pin at the back.

[0038] In another embodiment of the present invention, the intelligent temperature control system is configured as follows: When the temperature sensor detects that the internal circulating water temperature is below 20°C, it controls the electric ball valve to close slightly to reduce the flow rate of external water into the plate heat exchanger and controls the heating rod to start heating. When the temperature and humidity sensor detects that the ambient humidity is greater than 95% or the ambient temperature is lower than 5°C, the heating rod is triggered to work. When the temperature sensor detects that the internal circulation return water temperature is greater than 45°C, it controls the electric ball valve to increase the opening degree to increase the external water flow.

[0039] By employing a dual-synergistic anti-condensation mechanism—active heating of the heating element combined with electric ball valve regulation of external water flow—precise control of the internal circulating water temperature is achieved within the range of 20–45°C, ensuring that the cold plate temperature remains consistently above the ambient dew point. Comparative document 1 uses a "heater + electric three-way valve" scheme but is a single-loop structure, while comparative document 2 relies solely on regulating the external circulating flow; neither achieves coordinated control of heating and flow regulation. The synergistic control mechanism of this invention—actively heating the heating element while simultaneously closing the electric ball valve to reduce cold input at low temperatures, and opening the electric ball valve to increase heat dissipation at high temperatures—achieves a wider temperature range, greater precision, and more energy-efficient temperature control.

[0040] like Figure 3 As shown, Figure 3This is a functional diagram of the water-cooled control board of the intelligent temperature-controlled anti-condensation cooling module described in this invention.

[0041] Figure 3 In the circuit, J1 is a single power supply interface, providing an external DC 15V power supply; J2 is an eight-channel quantitative input interface, acquiring switch quantity information; J3 is a four-channel digital output interface, providing passive contact output; J4 is a two-channel 4-20mA signal output, driving the electric ball valve; J5 is a four-channel 4-20mA signal acquisition circuit, acquiring pressure sensor signals; and J6 is a four-channel PT100 temperature signal acquisition circuit, acquiring temperature sensor signals.

[0042] In this embodiment of the invention, a smart temperature-controlled anti-condensation cooling module features an external water inlet / outlet with DN25 threaded interfaces, adopting the CB / T4328-2013A flat-shoulder thread standard for quick connection to seawater pipelines. A plate heat exchanger, located in the center of the module, has a 60μm PVDF filter on the external water side and a main filter (60μm stainless steel filter element) connected to the internal water side to prevent rigid particles from damaging the heat exchanger. A water storage tank has a built-in level switch (Φ38) that automatically drains water when the water level exceeds the overflow port and also serves as a filling port. A heating rod is installed at the bottom of the tank; the immersion heating design ensures uniform water temperature. The control circuit integrates a temperature transmitter (PCT300), a pressure transmitter (PCM300), and an electric ball valve actuator, communicating with a host computer via a 4-20mA signal to achieve closed-loop control.

[0043] The system operation process includes: Start-up phase: Connect AC220V power supply, start the main circulation pump, and start the internal circulation: Heat-carrying pure water enters the module from the "load return water port", and after the load return water pressure transmitter (PT2) detects the pressure, it flows into the water storage tank for gas-liquid separation (to remove air and protect the pump motor); the liquid level switch (Φ38) detects the liquid level in the water storage tank. If the liquid level is too low, an alarm signal is sent to the control system to stop the pump operation.

[0044] Cooling stage: After gas-liquid separation, the pure water is pressurized by the main circulation pump (outlet pressure 0.3MPa) and enters the plate heat exchanger; at the same time, seawater enters from the "external water inlet", is filtered by the external water filter (60μm), and also enters the plate heat exchanger to exchange heat with the internal circulation pure water (internal water releases heat, seawater absorbs heat); after heat exchange, the internal water is filtered by the main filter (60μm) to remove rigid particles, and after the load inlet water temperature transmitter (TT1) and pressure transmitter (PT1) detect the parameters, it returns to the object being cooled from the "load inlet", completing one internal circulation; the seawater after heat exchange is discharged from the "external water return outlet".

[0045] Temperature control adjustment stage: If TT1 / TT2 detects that the internal water temperature is too low (e.g., <20℃), the control system sends a command: on the one hand, to start the heating rod (1kW) in the water storage tank to heat the pure water; on the other hand, to adjust the opening of the electric ball valve (reduce the flow rate of external water into the plate heat exchanger) to reduce the heat exchange efficiency until the internal water temperature rises back to the normal range (45℃~51℃). If the internal water temperature is normal, the heating rod is turned off and the electric ball valve is fully opened to ensure heat exchange efficiency.

[0046] Exception handling phase: If PT1 / PT2 detects excessive pressure (e.g., >0.6MPa system design pressure), the safety valve will automatically release pressure. If the level switch detects that the water level in the storage tank is too high, the excess water will be discharged from the overflow port; If you need to change the coolant, open the drain port to drain the old coolant and add new coolant (75% pure water + 25% ethylene glycol) through the overflow port.

[0047] Maintenance phase: When the external water filter / main filter element becomes scaled (e.g., due to increased pressure differential), clean or replace it after shutting down the machine.

[0048] The control process includes: Normal operating mode: The main circulation pump runs continuously, maintaining an internal circulation flow rate of 25 L / min.

[0049] The temperature transmitter monitors the inlet / outlet water temperature (TT1 / TT2) of the load in real time. When the return water temperature is >45℃, the opening of the electric ball valve increases, increasing the external water flow to enhance heat dissipation.

[0050] Low temperature protection mode: When the internal circulating water temperature is <20℃, the electric ball valve closes the external water inlet, and at the same time the heating rod starts to raise the water temperature to above 25℃.

[0051] When the temperature and humidity sensor (H / T) detects that the ambient humidity is >95%, it triggers the heating rod to work for 10 minutes to reduce the humidity inside the cabinet to below 90%.

[0052] Fault diagnosis: The pressure transmitter (PT1 / PT2) monitors the system pressure in real time. When the pressure difference is greater than 0.2MPa, it determines that the filter element is clogged, triggers an alarm, and prompts for replacement.

[0053] When the level switch detects that the water level in the storage tank is less than 20%, it automatically cuts off the power to the main circulation pump to prevent damage from dry running.

[0054] Electromagnetic interference mitigation measures include: Grounding design: The cabinet is made of 316 stainless steel and is connected to the grounding busbar through a 4mm² copper braided strip, with a grounding resistance of <0.1Ω.

[0055] Filtering circuit: An LC filter consisting of a 10μF capacitor and a 100mH inductor is connected in parallel at the AC220V power input terminal to attenuate electromagnetic interference in the 10kHz-100MHz frequency band.

[0056] Shielding measures: The control signal line uses a double-shielded cable, with the outer layer grounded and the inner layer for differential transmission, and the shielding effectiveness is >60dB.

[0057] In this embodiment of the invention, the external water flow rate is dynamically adjusted by an electric ball valve, combined with heating rod compensation, to ensure that the cold plate temperature is always higher than the ambient dew point temperature. The exposed part of the cold plate is wrapped with anti-condensation foam, and the module cavity is sealed with IP54 rating to block moisture intrusion. Dual closed-loop control: Temperature closed-loop (0.5% accuracy) and humidity closed-loop (±3% RH) work together to achieve stable operation over a wide temperature range of -10℃ to +40℃. Adaptive adjustment: Cooling power is automatically matched according to load loss (2.10kW~3.2kW), increasing the system's coefficient of performance (COP) to over 3.5. Modular layout: 18 components, including the circulating pump, heat exchanger, and water storage tank, are integrated into a 620mm×300mm×580mm housing, achieving a volumetric density of 0.12kW / L. Quick disassembly and assembly structure: The sliding rail and positioning pin design allows for module replacement within 3 minutes, improving maintenance efficiency by 3 times. It passes the GJB150.11A salt spray test (no corrosion after 500 hours) and the GJB150.10A mold test (no growth after 14 days), making it suitable for high salt spray and high humidity environments below the ship deck. Electromagnetic compatibility enhancement: Grounding, filtering, and shielding triple measures ensure electromagnetic radiation (RE) <30dBμV / m (30MHz-1GHz), meeting the requirements of GJB151B-2013 Class A.

[0058] This invention provides an intelligent temperature-controlled anti-condensation cooling module, comprising a closed-loop cooling circuit, which includes an inner loop and an outer loop. The inner loop includes a cooling object interface, a main circulation pump, the inner water side of a plate heat exchanger, and a main filter, all connected sequentially via pipes. A water storage tank is connected in series in the inner loop. The outer loop includes an external water inlet and an external water return outlet connected to the external water side of the plate heat exchanger via pipes. An external water filter is provided between the external water inlet and the external water side of the plate heat exchanger. An intelligent temperature control system includes a temperature sensor installed in the inner loop, a temperature and humidity sensor installed inside the module cavity, and an electric flow regulating valve connected in series between the inlet and return water pipes in the outer loop. The intelligent temperature control system controls the operation of the heating rod and the electric flow regulating valve based on the detection signals from the temperature sensor and the temperature and humidity sensor.

[0059] The technical solution of this invention can simultaneously solve the technical problems existing in the cooling system of existing high-power frequency converter control devices, such as insufficient cooling efficiency, high risk of condensation, insufficient temperature control accuracy, poor structural compactness, weak anti-electromagnetic interference capability, imperfect impurity filtration, and insufficient pipeline process and sealing.

[0060] The above are preferred embodiments of the present invention. It should be noted that, for those skilled in the art, several improvements and modifications can be made without departing from the principle of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. A smart temperature-controlled anti-condensation cooling module, characterized in that, The cooling module includes: A closed-loop cooling circuit, comprising an inner loop and an outer loop; The internal circulation loop includes the cooled object interface, the main circulation pump, the inner water side of the plate heat exchanger, and the main filter, which are connected in sequence through pipelines to form the circulation loop. A water storage tank is also connected in series in the internal circulation loop, and an immersion heating rod is provided in the water storage tank. The external circulation loop includes an external water inlet and an external water return outlet connected to the external water side of the plate heat exchanger via a pipeline, and an external water filter is provided between the external water inlet and the external water side of the plate heat exchanger. The intelligent temperature control system includes a temperature sensor installed on the inner circulation loop, a temperature and humidity sensor installed in the module cavity, and an electric flow regulating valve connected in series between the inlet pipe and the return pipe of the outer circulation loop. The heating rod and the electric flow regulating valve are electrically connected to the intelligent temperature control system, and the intelligent temperature control system controls the operation of the heating rod and the electric flow regulating valve according to the detection signals of the temperature sensor and the temperature and humidity sensor. The electric flow regulating valve is an electric ball valve, and its valve body is made of PPH.

2. The intelligent temperature-controlled anti-condensation cooling module according to claim 1, characterized in that, The filtration accuracy of both the external water filter and the main filter is 60μm. The filter element of the external water filter is made of PVDF, and the filter element of the main filter is made of stainless steel.

3. The intelligent temperature-controlled anti-condensation cooling module according to claim 1, characterized in that, The water storage tank is equipped with a level switch, which is electrically connected to the control circuit of the main circulation pump and the heating rod, and is used to cut off the power supply to the main circulation pump and the heating rod when the liquid level is lower than a preset value.

4. The intelligent temperature-controlled anti-condensation cooling module according to claim 1, characterized in that, The temperature sensor includes a first temperature transmitter disposed on the inlet side of the internal circulation loop and a second temperature transmitter disposed on the return side of the internal circulation loop; the internal circulation loop is also provided with a first pressure transmitter and a second pressure transmitter, the first pressure transmitter being disposed on the inlet side of the internal circulation loop and the second pressure transmitter being disposed on the return side of the internal circulation loop; the first temperature transmitter and the second temperature transmitter have a range of -50℃ to 80℃, an accuracy of ±0.5%, and output a 4 to 20mA signal; the first pressure transmitter and the second pressure transmitter have a range of 0 to 10 Bar, an accuracy of ±0.5%, and output a 4 to 20mA signal.

5. The intelligent temperature-controlled anti-condensation cooling module according to claim 1, characterized in that, It also includes a sampling control board, which is equipped with a PT100 temperature signal acquisition circuit, a 4-20mA pressure signal acquisition circuit, a digital input interface, a digital output interface, and a 4-20mA analog signal output interface. The temperature sensor is connected to the sampling control board through the PT100 temperature signal acquisition circuit, the pressure sensor is connected to the sampling control board through the 4-20mA pressure signal acquisition circuit, and the electric flow regulating valve is connected to the sampling control board through the 4-20mA analog signal output interface.

6. The intelligent temperature-controlled anti-condensation cooling module according to claim 1, characterized in that, The plate heat exchanger is a corrugated plate heat exchanger with a cooling capacity of 11kW; the main circulation pump is a horizontal centrifugal pump with a circulation flow rate of 1.5m³ / h, a head of 38m, a pump body material of 304 stainless steel, and a motor insulation class of F.

7. The intelligent temperature-controlled anti-condensation cooling module according to claim 1, characterized in that, The cooling module's piping system uses 316 stainless steel pipes or PPH pipes. The pipe connections are constructed using an automatic argon arc welding structure, and the welded joints are polished. The pipes and containers undergo pressure resistance testing. The pipe testing pressure is 0.8 MPa to 1.0 MPa, and the container testing pressure is 1.5 times the working pressure. The nominal diameter of the main circuit is DN25.

8. The intelligent temperature-controlled anti-condensation cooling module according to claim 1, characterized in that, The cooling module further includes an electromagnetic interference suppression structure, which includes: An LC filter is installed at the power input terminal. The LC filter consists of a 10μF capacitor and a 100mH inductor and is used to attenuate electromagnetic interference in the 10kHz to 100MHz frequency band. The double-shielded cable installed on the control signal line has an outer layer grounded and an inner layer for differential transmission, with a shielding effectiveness greater than 60dB. The system also features a multi-point grounding system, with the cabinet connected to the grounding busbar via a 4mm² copper braided strip. The connection impedance between the cabinet and the grounding busbar is less than 0.1Ω.

9. The intelligent temperature-controlled anti-condensation cooling module according to claim 1, characterized in that, It also includes a module housing with external dimensions of 620mm×300mm×580mm. The bottom of the module housing is equipped with a slide rail, and the back is equipped with a positioning pin.

10. A smart temperature-controlled anti-condensation cooling module according to claim 1, characterized in that, The intelligent temperature control system is configured as follows: When the temperature sensor detects that the internal circulating water temperature is below 20°C, it controls the electric ball valve to close slightly to reduce the flow rate of external water into the plate heat exchanger and controls the heating rod to start heating. When the temperature and humidity sensor detects that the ambient humidity is greater than 95% or the ambient temperature is lower than 5°C, the heating rod is triggered to work. When the temperature sensor detects that the internal circulation return water temperature is greater than 45°C, it controls the electric ball valve to increase the opening degree to increase the external water flow.

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