Modular mobile energy storage box-type power supply

Abstract

The application provides a modular mobile energy storage box-type power supply, and relates to the technical field of mobile energy storage. All functional units required by an energy storage system are integrated in a standardized prefabricated cabin, so that the energy storage system becomes an energy storage module capable of independent operation. When deployed, a user can flexibly select and splice one or more prefabricated cabins on a bearing chassis according to actual power and capacity requirements on site, so that the flexibility and economy of energy deployment are improved. A three-layer space arrangement architecture in the vertical direction is adopted. The battery assembly with the largest mass is arranged on the middle layer, so that the gravity center of the whole cabin is lowered and the stability of vehicle transportation is enhanced. The power conversion and liquid cooling temperature control equipment with large heat emission are arranged on the upper layer, so that heat dissipation management is facilitated. The power distribution and external functional interface area requiring manual operation are arranged on the lower layer, so that the use convenience is improved. The problems of disordered cables and accessories in the split scheme are reduced, and the problems of high gravity center and uneven heat dissipation are solved.

Description

Technical Field

[0001] This application relates to the field of mobile energy storage technology, and in particular to a modular mobile energy storage box-type power supply. Background Technology

[0002] With the rapid development of the new energy industry, the demand for mobile energy storage devices in emergency response, outdoor operations, and new energy consumption is increasing. To meet the mobile deployment needs in different scenarios, energy storage systems are usually integrated into easily transportable carriers to form mobile energy storage box-type power supplies.

[0003] To achieve the above objectives, the relevant technologies mainly employ the following two integration methods. The first is an integrated containerized energy storage system. This approach typically uses a standard shipping container as the outer shell, centrally installing and fixing all the functional components required for the energy storage system, such as battery packs, battery management systems, bidirectional converters, and auxiliary systems, inside a large container. The second is a modular energy storage system. This approach encapsulates different functional devices in independent cabinets, such as independent battery cabinets, combiner cabinets, and power cabinets, and then arranges these separate functional cabinets on a supporting chassis.

[0004] However, both of the aforementioned existing technologies have revealed inherent drawbacks in practical applications. For integrated containerized energy storage systems, all functional components are fixed into an inseparable whole, resulting in a predetermined size and capacity at the factory. When customers require lower capacity, the only solution is to reduce the number of internal battery packs, but the larger container still occupies the entire space of the chassis, leading to poor deployment flexibility and economy. For split-type energy storage systems, although each functional cabinet can be arranged independently, maintenance passages and heat dissipation distances must be reserved between the independent cabinets, resulting in low space utilization. Furthermore, exposed cables between cabinets are prone to aging and wear, and the independent cabinets generally have a high center of gravity, making them more susceptible to tilting and swaying when mounted on a vehicle frame, posing challenges to structural stability and operational safety. Summary of the Invention

[0005] This application provides a modular mobile energy storage box-type power supply, which improves integration and stability while ensuring the flexibility and economy of energy deployment.

[0006] In the first aspect, this application provides a modular mobile energy storage box-type power supply, comprising: several prefabricated compartments, the internal space of which is divided into three layers along the vertical direction by a partition plate, from bottom to top: a power distribution and external functional interface area, located in the lower layer of the prefabricated compartment; an energy storage battery storage area, located in the middle layer of the prefabricated compartment, which houses multiple battery modules; and a power conversion and liquid cooling temperature control area, located in the upper layer of the prefabricated compartment, which houses power components and liquid cooling units; the bottom of the prefabricated compartment is provided with multiple sets of container lock holes and threaded holes for splicing and locking multiple prefabricated compartments along the length direction onto the supporting chassis.

[0007] By adopting the above technical solution, this application integrates all functional units required for the energy storage system, including battery modules, power components, power distribution, and temperature control, into a standardized prefabricated compartment, making it an independently operable energy storage module. During deployment, users can flexibly choose to splice one or more prefabricated compartments on the supporting chassis according to the actual power and capacity requirements on site. This improves the flexibility and economy of energy deployment. A three-layer spatial architecture is adopted along the vertical direction. The heaviest battery modules are placed in the middle layer, lowering the center of gravity of the entire compartment and enhancing the stability of vehicle transportation; the power conversion and liquid-cooled temperature control equipment with high heat generation are placed in the upper layer for easy heat dissipation management; and the power distribution and external functional interface areas that require manual operation are placed in the lower layer, improving ease of use. This reduces the problems of messy external cables and independent components in the split solution, and also solves the problems of high center of gravity and uneven heat dissipation.

[0008] In some embodiments of the first aspect, the power conversion and liquid cooling temperature control area is divided into a power component compartment and a liquid cooling unit compartment. The power component is located in the power component compartment, which is equipped with an exhaust fan. A first air inlet and a first air outlet connecting the power component compartment are opened on the outer wall of the prefabricated compartment that is not spliced ​​with other prefabricated compartments. The first air outlet is located facing the exhaust side of the exhaust fan. The liquid cooling unit is located in the liquid cooling unit compartment. A second air inlet and a second air outlet connecting the liquid cooling unit compartment are opened on the other outer wall of the prefabricated compartment that is not spliced ​​with other prefabricated compartments. A ventilation opening connecting to the energy storage battery storage area is opened in the area at the bottom of the liquid cooling unit compartment.

[0009] By adopting the above technical solution, the power conversion and liquid cooling temperature control areas are further separated into independent power component compartments and liquid cooling unit compartments. Each compartment is equipped with its own independent first and second air inlets and outlets, and independent heat dissipation ducts are constructed to prevent interference. Furthermore, ventilation openings at the bottom of the liquid cooling unit compartment can guide cool air from the upper layer into the energy storage battery storage area, providing auxiliary heat dissipation for the batteries and ensuring the safety of the energy storage battery storage area.

[0010] In conjunction with some embodiments of the first aspect, in some embodiments: the power distribution and external function interface area further includes a controller; when multiple prefabricated modules are spliced ​​along the length direction to form a side-by-side array, the controller is configured to perform the following operations: control the power devices in the prefabricated modules located at the beginning and end of the array to output according to a set first power value, and calculate the remaining total power to be allocated based on the target total power; calculate and determine the second power value and the third power value respectively based on the remaining total power to be allocated, the second power allocation ratio, the third power allocation ratio, and the number of prefabricated modules in the middle of the array; wherein, the first power value The second power value is greater than the third power value; the second power value is greater than the third power value; the second power value and the third power value are alternately distributed to the power devices in each prefabricated compartment located in the middle of the array for output; the speed of the exhaust fan in each prefabricated compartment located in the middle of the array is controlled; wherein, the speed of the exhaust fan in the prefabricated compartment outputting the second power value is greater than the speed of the exhaust fan in the prefabricated compartment outputting the third power value; when the set switching threshold is reached, the second power value and the third power value allocated to each prefabricated compartment located in the middle of the array are alternately output in reverse, and the speed of the corresponding exhaust fan is synchronously switched.

[0011] By adopting the above technical solution, when multiple prefabricated modules are spliced ​​together and arranged in an array, the controller first ensures that the power components at the beginning and end of the array, where the heat dissipation conditions are optimal, maintain a constant high power output; then, the remaining power to be allocated is distributed alternately between high and low power among the prefabricated modules in the middle of the array. This redistributes the heat source in space and time, enabling the entire device to avoid localized heat islands in a simple way, without requiring structural changes and ensuring normal operation, thus guaranteeing the overall reliability of the device under high-density deployment.

[0012] In some embodiments, in conjunction with the first aspect, the following are some embodiments: There are multiple power attachments; a prefabricated frame is installed inside the power attachment compartment; multiple power attachments are arranged side-by-side in groups within the prefabricated frame; the prefabricated frame includes a bottom frame and multiple top pressure beams; the bottom frame has threaded holes and is fixedly connected to the ear plate holes at the bottom of the power attachments by bolts; multiple top pressure beams are distributed and pressed onto the upper surfaces of multiple power attachments, and rubber pads are provided at the contact points between the top pressure beams and the upper surfaces of the power attachments; wherein, the top pressure beams located on the front and rear sides have threaded holes and are fastened to the upper ear plate screw holes of the power attachments by screws, so that multiple power attachments are fixed as a whole with the bottom frame and the top pressure beams.

[0013] By adopting the above technical solution, multiple power mounts are fixed together using a prefabricated frame. The bottom frame is bolted to the lower ear plate holes of each mount, forming a robust bottom load-bearing plane. Multiple top pressure beams are distributed and pressed onto the upper surface of each mount, and are fastened to the upper ear plate screw holes with front and rear screws. This design integrates the dispersed stress points into a frame-like overall load-bearing structure, enhancing the power mount assembly's resistance to shear forces. In particular, the cooperation between the top pressure beams and rubber pads provides a top-down pre-tightening buffer force for the mounts, suppressing vertical bouncing of the mounts when the vehicle bumps.

[0014] In conjunction with some embodiments of the first aspect, in some embodiments: a battery rack for supporting the battery assembly is provided in the energy storage battery storage area. The battery rack is composed of angular bent plates and is welded to the columns in the prefabricated compartment. A baffle for positioning restriction is welded to the end of the battery rack. Multiple threaded holes are provided on both the left and right sides of the bottom of the battery assembly. A bottom crossbeam is provided below the battery assembly, spanning between two opposite threaded holes. A rubber shock-absorbing pad is sandwiched between the bottom crossbeam and the bottom of the battery assembly. Multiple sets of long bolts pass through the bottom crossbeam and the rubber shock-absorbing pad in sequence and are threaded into the corresponding threaded holes of the battery assembly.

[0015] By adopting the above technical solution, the angled bent plates constituting the battery rack are integrally welded to the columns of the prefabricated compartment, improving the overall torsional resistance of the load-bearing structure. The end-welded baffle provides a longitudinal limiting reference for the battery pack, effectively preventing the battery pack from sliding forward or backward during rapid acceleration and deceleration of the vehicle. Furthermore, a bottom crossbeam is installed below the battery pack, with a rubber damping pad sandwiched between it and the battery pack. Multiple sets of long bolts pass through the crossbeam and the damping pad for locking. This provides a flexible fixing interface with buffering capabilities for the battery pack, absorbing high-frequency vibrations from the chassis and improving the structural stability and service life of the battery pack under harsh road conditions.

[0016] In conjunction with some embodiments of the first aspect, in some embodiments: the rubber shock-absorbing pad is an elastic composite module with embedded conductive contacts; on the left and right sides of the bottom of the battery assembly, at the positions corresponding to the elastic composite modules, each pair of communication contacts is led out; the pairs of communication contacts on the left and right sides of the battery assembly are connected in series in the electrical circuit and connected to the circuit between the battery assembly and the power distribution and external functional interface area; when the long bolts on the left and right sides of the battery assembly are simultaneously tightened and both reach the set preload state, the battery assembly and the bottom crossbeam compress the elastic composite module between them to a state of compression deformation, so that the conductive contacts embedded in the elastic composite module and the corresponding communication contacts form a close contact and conduction.

[0017] By adopting the above technical solution, the original rubber shock-absorbing pads are upgraded to elastic composite modules with embedded conductive contacts, and communication contacts connected in series to the start-up circuit are set at the bottom of the battery assembly. When the long bolts reach the set preload, the mechanical clamping force forces the conductive contacts in the elastic composite module to adhere to the communication contacts, forming a physical closed circuit, thereby enabling the battery assembly to enter the working state. Once the preload of any bolt on either side decreases during operation, the rebound of the elastic module will cause the contacts to physically separate, cutting off the enable circuit, thus achieving structural loosening monitoring and isolation protection.

[0018] In conjunction with some embodiments of the first aspect, in some embodiments: a DC combiner box, a cluster high-voltage box, a human-machine interface panel, and an AC / DC socket box are provided in the power distribution and external functional interface area; a waterproof box is installed on the front outer wall of the prefabricated cabin, the human-machine interface panel is located in the waterproof box, and the waterproof box has a lockable cover; a prefabricated frame is provided at the rear of the prefabricated cabin, and the AC / DC socket box is installed in the prefabricated frame.

[0019] By adopting the above technical solution, all DC combiner boxes, high-voltage cluster boxes, human-machine interface panels, and AC / DC socket boxes that require manual operation or external wiring are integrated into the power distribution and external functional interface area on the lower layer of the prefabricated cabin. After the prefabricated cabin is hoisted onto the supporting chassis, the height of this area will be naturally raised to a position that matches the line of sight and operating height of the standing maintenance personnel, eliminating the risks of climbing operations during maintenance.

[0020] In conjunction with some embodiments of the first aspect, in some embodiments: the cover of the AC / DC socket box is a hinged flip-top structure; through holes are provided on the circumferential walls of the AC / DC socket box, and multiple screws pass through the through holes to fasten the AC / DC socket box to the prefabricated frame; a sealant layer is applied to the fastening joint between the wall of the AC / DC socket box and the prefabricated frame.

[0021] By adopting the above technical solution, the cover of the AC / DC socket box uses a hinged flip-top structure, which is more convenient to open and close and less likely to fall off due to vibration compared to a snap-on structure. The box itself is firmly secured to the prefabricated frame at the rear of the prefabricated compartment through multiple through holes and screws on the circumferential box wall, ensuring its structural stability during vehicle operation.

[0022] In conjunction with some embodiments of the first aspect, in some embodiments: the top of the prefabricated compartment is provided with a hoisting hole, and the bottom of the prefabricated compartment is provided with a forklift hole.

[0023] By adopting the above technical solution, this structural design with dual top and bottom handling interfaces increases the compatibility of handling methods for a single prefabricated module under different work sites and conditions.

[0024] In some embodiments, in conjunction with the first aspect, the vehicle chassis is also included; the prefabricated modules are arranged and spliced ​​sequentially along the length of the vehicle chassis and locked with the vehicle chassis to form an integral working platform.

[0025] By adopting the above technical solution, and by including a vehicle chassis and locking each prefabricated compartment to the vehicle chassis through container lock holes or standard threaded holes at its bottom, the entire mobile energy storage device is transformed from a single, indivisible giant box into an open platform architecture consisting of a vehicle chassis and prefabricated compartments.

[0026] One or more technical solutions provided in the embodiments of this application have at least the following technical effects or advantages:

[0027] This application integrates all functional units required for an energy storage system, including battery modules, power components, power distribution, and temperature control, into a standardized prefabricated compartment, making it an independently operating energy storage module. During deployment, users can flexibly choose to splice one or more prefabricated compartments onto a supporting chassis based on the actual power and capacity requirements at the site. This improves the flexibility and economy of energy deployment. A three-layer spatial architecture is adopted along the vertical direction. The heaviest battery modules are placed in the middle layer, lowering the overall center of gravity and enhancing stability during vehicle transport; the power conversion and liquid-cooled temperature control equipment, which generate significant heat, are placed in the upper layer for easier heat dissipation management; and the power distribution and external interface areas, requiring manual operation, are placed in the lower layer, improving ease of use. This reduces the problems of messy external cables and independent components found in split-type solutions, while also solving issues such as a high center of gravity and uneven heat dissipation. Attached Figure Description

[0028] Figure 1 This is a front view of the prefabricated compartment of the modular mobile energy storage box-type power supply in the embodiments of this application;

[0029] Figure 2 yes Figure 1 A cross-sectional view of AA;

[0030] Figure 3 yes Figure 1 A cross-sectional view of BB;

[0031] Figure 4 This is a rear view of the prefabricated compartment of the modular mobile energy storage box-type power supply in the embodiments of this application;

[0032] Figure 5 This is a cross-sectional view of the fixed structure of the battery assembly in an embodiment of this application.

[0033] Figure 6 This is a schematic diagram of the usage status of the modular mobile energy storage box power supply in the embodiments of this application.

[0034] Attached diagram descriptions: 1. Alarm panel; 2. Human-machine interface panel; 3. Lifting hole; 4. Prefabricated cabin; 5. Fire exhaust; 6. Fire air intake; 7. Forklift hole; 8. DC combiner box; 9. Power connector; 10. Exhaust fan; 11. Battery assembly; 12. Cluster voltage box; 13. AC combiner box; 14. Liquid cooling unit; 15. AC socket box; 16. DC socket box; 17. Battery rack; 18. Bottom crossbeam; 19. Long bolt; 20. Flexible composite module. Detailed Implementation

[0035] The terminology used in the following embodiments of this application is for the purpose of describing particular embodiments only and is not intended to be limiting of this application. As used in the specification and appended claims of this application, the singular expressions a, an, said, the above, and this are intended to also include the plural expressions unless the context clearly indicates otherwise. It should also be understood that the terms used in this application refer to and / or include any or all possible combinations of one or more of the listed items.

[0036] Hereinafter, the terms "first" and "second" are used for descriptive purposes only and should not be construed as implying or suggesting relative importance or implicitly indicating the number of indicated technical features. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature, and in the description of the embodiments of this application, unless otherwise stated, "multiple" means two or more.

[0037] Please see Figure 6 , Figure 6 This is a schematic diagram illustrating the usage state of the modular mobile energy storage box-type power supply in this embodiment of the application. The modular mobile energy storage box-type power supply consists of several standardized prefabricated compartments 4. Each prefabricated compartment 4 integrates all the functional units required by the energy storage system, making it an independently operable energy storage module. In practical applications, one or more prefabricated compartments 4 can be flexibly selected and spliced ​​along the length of the vehicle chassis according to the power and capacity requirements on site. These compartments are then locked to the vehicle chassis via container lock holes or threaded holes at the bottom of the prefabricated compartment 4, forming an integrated working platform.

[0038] Please see Figure 1 , Figure 2 and Figure 3 , Figure 1 This is a front view of the prefabricated compartment of the modular mobile energy storage box-type power supply in the embodiments of this application; Figure 2 yes Figure 1 A cross-sectional view of AA; Figure 3 yes Figure 1The cross-sectional view of BB; to physically separate and optimize the layout of various functional components within the prefabricated cabin 4, the internal space of each prefabricated cabin 4 is divided into three layers in the vertical direction by horizontally set partitions. These three layers, from bottom to top, are: the power distribution and external functional interface area in the lower layer of the prefabricated cabin 4, the energy storage battery storage area in the middle layer of the prefabricated cabin 4, and the power conversion and liquid cooling temperature control area in the upper layer of the prefabricated cabin 4.

[0039] Specifically, the energy storage battery storage area accommodates the largest battery modules 11. By placing them in the middle layer, the physical center of gravity of the entire prefabricated compartment 4 is effectively lowered, improving its lateral stability when mounted on the vehicle chassis. The power conversion and liquid cooling temperature control area centrally houses the high-heat-generating power components 9 and liquid cooling units 14. Utilizing the physical principle of hot air rising, heat is easily dissipated, optimizing thermal management within the compartment. The power distribution and external functional interface area integrates all electrical units requiring manual operation or external wiring. Once the prefabricated compartment 4 is installed on the vehicle chassis, the height of this area is naturally raised, improving the ease of use for maintenance personnel.

[0040] Through the aforementioned overall modular and layered architecture, this application integrates all functional units required for the energy storage system, including battery modules 11, power components 9, power distribution, and temperature control, into a standardized prefabricated compartment 4, making it an independently operable energy storage module. During deployment, users can flexibly choose to splice one or more prefabricated compartments 4 on the supporting chassis according to the actual power and capacity requirements on site. This improves the flexibility and economy of energy deployment. A three-layer spatial architecture is adopted along the vertical direction. The heaviest battery module 11 is placed in the middle layer, lowering the overall center of gravity and enhancing the stability of vehicle transportation; the power conversion and liquid-cooled temperature control equipment, which generate a lot of heat, are placed in the upper layer for easy heat dissipation management; and the power distribution and external functional interface areas, which require manual operation, are placed in the lower layer, improving ease of use. This reduces the problems of messy external cables and independent components found in split-type solutions, while also solving problems such as a high center of gravity and uneven heat dissipation. The specific optimized structures of each functional area will be described in detail later.

[0041] Furthermore, the preferred structures for each region are described in detail:

[0042] Preferred implementation method for the upper-layer power conversion and liquid cooling temperature control zone:

[0043] Please see Figure 2 and Figure 3 , Figure 2 yes Figure 1 A cross-sectional view of AA; Figure 3 yes Figure 1A cross-sectional view of BB; In a preferred embodiment, to achieve refined management of different heat sources, the power conversion and liquid cooling temperature control zone is divided into two independent compartments by a physical partition vertically arranged along the width of the prefabricated compartment 4: the power component compartment and the liquid cooling unit compartment. This physical isolation design aims to create independent heat dissipation ducts that do not interfere with each other.

[0044] Within the power component compartment, multiple power components 9 are installed. To achieve forced air cooling of the large amount of heat generated during the operation of the power components 9, an exhaust fan 10 is also installed within the power component compartment. On the outer wall of the prefabricated compartment 4 that is not spliced ​​with other prefabricated compartments 4, a first air inlet and a first air outlet are correspondingly provided, connecting to the power component compartment. The first air inlet is used to draw in cool air from the outside environment, while the first air outlet is positioned directly opposite the exhaust side (i.e., the air outlet surface) of the exhaust fan 10, for efficiently dissipating the heat generated by the power components 9.

[0045] In some embodiments, an AC combiner box 13 is also provided in the power mount compartment. The AC combiner box 13 is electrically connected to the AC output terminals of the plurality of power mounts 9.

[0046] When multiple power modules 9 operate simultaneously and invert the DC power from the battery pack 11 into AC power, the AC combiner box 13 is responsible for collecting, integrating, and protecting these AC power sources from different power modules 9 that are of the same frequency and phase. Specifically, it integrates circuit breakers, fuses, and other protective components to provide overcurrent and short-circuit protection for each input AC power source and safely connects all protected AC power to a unified main output busbar. Finally, this main output busbar is connected to the AC socket box 15 located in the lower-level power distribution and external functional interface area or to the external power grid interface. By setting up the AC combiner box 13, not only is the orderly management and safe protection of multiple AC power sources achieved, but the main cable wiring from the upper-level power conversion area to the lower-level output interface is also simplified.

[0047] Inside the liquid-cooled unit compartment, the liquid-cooled unit 14 is installed. Similarly, on the other outer wall of the prefabricated compartment 4, a second air inlet and a second air outlet are also provided specifically for the liquid-cooled unit 14 to dissipate heat from the compressor and condenser of the liquid-cooled unit 14. In addition, to further enhance the thermal management capability of the compartment, on the partition plate dividing the power conversion and liquid-cooled temperature control area from the energy storage battery storage area, a ventilation opening is provided in the area corresponding to the bottom of the liquid-cooled unit compartment, connecting to the energy storage battery storage area below, which can realize cross-area cold energy transfer or air circulation.

[0048] As can be seen, the power conversion and liquid cooling temperature control areas are further separated into independent power component compartments and liquid cooling unit compartments, each equipped with its own independent first and second air inlets and outlets, and constructed with independent heat dissipation ducts that do not interfere with each other. In addition, the ventilation openings at the bottom of the liquid cooling unit compartment can introduce cool air from the upper layer into the energy storage battery storage area, providing auxiliary heat dissipation for the battery module 11 and ensuring the safety of the energy storage battery storage area.

[0049] To mitigate the impact of the vehicle's bumpy environment on the power mounts 9, a prefabricated frame is installed inside the power mount compartment for group reinforcement. This prefabricated frame consists of a bottom frame and multiple top pressure beams. During assembly, multiple power mounts 9 are bolted together through the ear plate holes at their lower ends and the pre-drilled holes on the bottom frame, forming a robust bottom support. Subsequently, multiple top pressure beams are laterally distributed and pressed onto the upper surfaces of each power mount 9, with rubber pads placed between the pressure beams and the upper surfaces of the mounts to provide cushioning and pre-tension. Finally, the top pressure beams located at the front and rear of the array are fastened to the upper ear plate screw holes of the power mounts 9 below them using screws. Through the bottom fixing of the bottom frame and the downward pressing and front-to-back locking of the top pressure beams, three-dimensional integrated reinforcement of multiple groups of power mounts 9 in the lateral and longitudinal directions is achieved, fixing them as a whole.

[0050] As can be seen, multiple power hangers 9 are fixed together by a prefabricated frame, with the bottom frame bolted to the lower ear plate holes of each hanger, forming a robust bottom bearing surface. Multiple top pressure beams are distributed and pressed onto the upper surface of each hanger, and secured to the upper ear plate screw holes with front and rear screws. This design integrates the dispersed stress points into a frame-like overall load-bearing structure, enhancing the power hanger assembly (power hanger group 9)'s resistance to shear forces. In particular, the cooperation between the top pressure beams and rubber pads provides a top-down pre-tightening buffer force for the hangers, suppressing vertical bouncing of the hangers when the vehicle bumps.

[0051] In actual use, when multiple prefabricated compartments 4 are arranged side by side, the first air inlet and first air outlet of each prefabricated compartment 4 will form an adjacent staggered array of first air inlet-first air outlet-first air inlet-first air outlet... Because the exhaust fan 10 in the power component compartment has high outlet kinetic energy, the high-temperature exhaust gas discharged through the first air outlet will undergo turbulent diffusion in the front space of the prefabricated compartment 4. In this array structure, the first air inlet in the middle position is more likely to simultaneously draw in the high-temperature exhaust gas discharged from the first air outlets on both sides. This backflow phenomenon causes the middle first air inlet to passively draw in high-temperature hot airflow for a long time, thus forming a local heat island problem that is difficult to eliminate. This easily leads to high ambient temperature in the corresponding power component compartment, ultimately causing damage to the corresponding power component 9.

[0052] Therefore, in some embodiments, the power distribution and external function interface area also includes a controller;

[0053] When multiple prefabricated modules 4 are spliced ​​together along the length to form a side-by-side array, the controller is configured to perform the following operations:

[0054] In some embodiments, the controller detects through an internal bus or external sensors that multiple prefabricated cabins 4 have been mechanically assembled and formed a physical array with electrical connection conditions, thereby triggering subsequent power scheduling strategies.

[0055] The power connectors 9 located in the prefabricated cabins 4 at the beginning and end of the array output according to the set first power value, and calculate the remaining total power to be allocated based on the target total power.

[0056] Among them, the first power value refers to the high power output benchmark value set for the prefabricated cabins 4 located at both ends of the array and having optimal heat dissipation boundary conditions; the target total power refers to the total electrical power that needs to be output to the outside at the current moment, determined according to the external power grid dispatch instructions or local load demand; the remaining unallocated total power refers to the power portion that needs to be shared by the prefabricated cabins 4 in the middle of the array after subtracting the actual output power of all the prefabricated cabins 4 on both the front and rear sides from the target total power.

[0057] In some embodiments, the controller first identifies the prefabricated modules 4 located at the first and last positions in the physical array. Since the outer walls of these two prefabricated modules 4 are not adjacent to other prefabricated modules 4, their first air inlets can directly draw in cool ambient air, resulting in optimal heat dissipation. Therefore, the controller issues commands to the power connectors 9 within these two prefabricated modules 4 to maintain a constant output at a first power value close to or equal to their rated power, maximizing their heat dissipation advantage. Simultaneously, the controller subtracts the sum of the power outputs from these two prefabricated modules 4 from the received target total power to obtain a remaining total power value to be allocated, which needs to be shared by all other intermediate prefabricated modules 4.

[0058] Based on the remaining total power to be allocated, the second power allocation ratio, the third power allocation ratio, and the number of prefabricated modules 4 in the middle of the array, the second power value and the third power value are calculated and determined respectively; wherein, the first power value is greater than the second power value, and the second power value is greater than the third power value;

[0059] The second power allocation ratio refers to the power coefficient set for the intermediate prefabricated module 4 under the high power output state; the third power allocation ratio refers to the power coefficient set for the intermediate prefabricated module 4 under the low power output state.

[0060] In some embodiments, this step is the core calculation for asymmetric power allocation. After obtaining the remaining total power to be allocated, the controller invokes preset second power allocation ratios (e.g., 70%) and third power allocation ratios (e.g., 30%). The remaining total power to be allocated is multiplied by these ratios, and combined with the total number of intermediate prefabricated modules 4 participating in the alternating allocation, to calculate the second power value that each prefabricated module 4 in a high-power state should bear, and the third power value that each prefabricated module 4 in a low-power state should bear under the current operating condition. The control algorithm ensures that the calculated second power value is greater than the third power value, and both are less than or equal to the first power value, providing clear power instructions for subsequent alternating allocation.

[0061] The second and third power values ​​are alternately distributed to the power devices 9 in each prefabricated cabin 4 located in the middle of the array for output;

[0062] In some embodiments, the controller, based on the physical arrangement of the intermediate prefabricated compartments 4, sequentially assigns the second power value (high power) and the third power value (low power) calculated in the previous step to the power mounts 9 in a high-low-high-low pattern, counting from one end of the array. For example, the first intermediate prefabricated compartment 4 immediately adjacent to the first side is assigned the second power value, the second intermediate prefabricated compartment 4 is assigned the third power value, and so on. Through this alternating assignment method, two physically adjacent intermediate prefabricated compartments 4 are positioned such that one is in a high-heat state and the other is in a low-heat state, thereby spatially interrupting the continuous arrangement of high-temperature heat sources.

[0063] Control the rotation speed of the exhaust fan 10 in each prefabricated compartment 4 located in the middle of the array; wherein the rotation speed of the exhaust fan 10 in the prefabricated compartment 4 with the second power value is greater than the rotation speed of the exhaust fan 10 in the prefabricated compartment 4 with the third power value.

[0064] In some embodiments, the controller's power allocation command and fan speed control command are issued synchronously. For the prefabricated compartment 4 allocated a second power value (high power), the controller simultaneously issues a high-speed command to the exhaust fan 10 in its power accessory compartment to increase the initial kinetic energy of the high-temperature exhaust gas ejected outward through the first exhaust vent, enabling it to cross the air intake range of the adjacent prefabricated compartment 4. For the prefabricated compartment 4 allocated a third power value (low power), the controller issues a low-speed command to its exhaust fan 10. This aims to physically weaken the negative air pressure formed at its first air intake due to fan suction, reducing its ability to actively draw in adjacent high-temperature exhaust gas. Through the positive correlation between fan speed and power, active suppression of exhaust gas backflow at the hydrodynamic level is achieved.

[0065] When the set switching threshold is reached, the second power value and the third power value allocated to each prefabricated compartment 4 located in the middle of the array are reverse-interleaved and output, and the speed of the corresponding exhaust fan 10 is synchronously switched.

[0066] The switching threshold refers to the critical condition used to trigger the power distribution state reversal. It can be a preset time or a preset temperature, and is not limited here.

[0067] In some specific embodiments, the switching threshold can be set to a fixed time period. An internal timer is started in the controller, and each time the timer reaches a preset duration, a reverse interleaving is automatically triggered to ensure that the operating time of each intermediate prefabricated compartment 4 is relatively balanced between high and low power states; this is not limited here. In other specific embodiments, the switching threshold can be set to a dynamic temperature value. The controller collects temperature data in real time from each power-mounted compartment in the high-power state. Once the temperature of any compartment exceeds the set safety limit, a reverse interleaving is immediately triggered to switch the compartment to the low-power state for cooling; this is not limited here either.

[0068] At the moment of state switching, the total output power may fluctuate or drop briefly due to the simultaneous power adjustment of multiple power modules 9, affecting power quality. To address this issue, the controller's switching command is not a simple simultaneous flip, but rather employs pre-synchronization slope control logic. Specifically, before triggering the switch, the controller sends a power ramp-up preparation command to the module 4 about to increase from low to high power, and a power descent preparation command to the module 4 about to decrease from high to low power. At the instant the switching command is issued, one module linearly increases power with a set positive slope, while the other linearly decreases power with a matching negative slope. The integral of the power curves of both modules remains constant throughout the switching cycle, thus ensuring that the total output power remains smooth and seamless during the switching process.

[0069] As can be seen, when multiple prefabricated modules 4 are spliced ​​together to form an array, the controller first ensures that the power connectors 9 at the beginning and end of the array, where the heat dissipation conditions are optimal, maintain a constant high power output; then, the remaining power to be distributed is allocated alternately between high and low power among the prefabricated modules 4 in the middle of the array. This redistributes the heat source in space and time, enabling the entire device to avoid local heat islands in a simple way without changing its structure and ensuring normal operation, thus guaranteeing the overall reliability of the device under high-density deployment.

[0070] Preferred implementation method for the middle layer energy storage battery storage area:

[0071] Please see Figure 2 , Figure 3 , Figure 5 , Figure 2 yes Figure 1 A cross-sectional view of AA; Figure 3 yes Figure 1 A cross-sectional view of BB; Figure 5 This is a cross-sectional view of the fixed structure of the battery assembly in an embodiment of this application.

[0072] In a preferred embodiment, to provide stable support and vibration damping for the battery assembly 11, a battery rack 17 is provided within the energy storage battery storage area. The battery rack 17 is constructed of angular bent plates and is welded integrally with the columns within the prefabricated compartment 4 to improve the overall torsional stiffness of the load-bearing structure. A baffle for positioning is welded to the end of the battery rack 17, used for quick pre-positioning of the battery assembly 11 during installation and to prevent longitudinal slippage during vehicle acceleration and deceleration.

[0073] To achieve flexible fixing of the battery assembly 11, multiple threaded holes are provided on both the left and right sides of its bottom. Please refer to the relevant documentation. Figure 5 A bottom crossbeam 18 is provided below the battery assembly 11, spanning between two opposite threaded holes. A rubber damping pad is sandwiched between the bottom crossbeam 18 and the battery assembly 11. Multiple sets of long bolts 19 pass sequentially through the bottom crossbeam 18 and the rubber damping pad, and are finally threaded into the corresponding threaded holes in the battery assembly 11. This structure provides vertical preload with the long bolts 19, lateral rigid support with the bottom crossbeam 18, and absorption and dissipation of high-frequency micro-vibrations from the chassis with the rubber damping pad.

[0074] As can be seen, the integrated welding of the angled bent plates constituting the battery rack with the columns of the prefabricated compartment 4 enhances the overall torsional resistance of the load-bearing structure. The end-welded baffle provides a longitudinal limiting reference for the battery pack 11, effectively preventing the battery pack 11 from sliding forward or backward during rapid acceleration and deceleration of the vehicle. Furthermore, by setting a bottom crossbeam 18 below the battery pack 11 and sandwiching a rubber damping pad between it and the battery pack 11, and then locking it in place by multiple sets of long bolts 19 sequentially passing through the bottom crossbeam 18 and the rubber damping pad, a flexible fixing interface with buffering capacity is provided for the battery pack 11. This absorbs high-frequency vibrations from the chassis, improving the structural stability and service life of the battery pack 11 under harsh road conditions.

[0075] In practical use, modular mobile energy storage boxes operate under harsh conditions such as unpaved roads, mines, or construction sites, resulting in frequent high-frequency vibrations and significant longitudinal impacts from sudden acceleration and deceleration. The aforementioned embodiments often employ bolted assembly, resulting in low torsional stiffness; furthermore, the battery modules 11 are typically rigidly connected to the metal frame, failing to effectively absorb high-frequency vibrations transmitted from the chassis. Over time, the battery modules 11 are prone to displacement, potentially leading to a loss of control.

[0076] Furthermore, in order to achieve real-time monitoring and safety redundancy protection of the fixed state of battery modules in the mid-level energy storage battery storage area, this application also provides a hardware-level interlocking scheme for electromechanical coupling.

[0077] Please refer to Figure 5 , Figure 5 This is a cross-sectional view of the fixing structure of the battery assembly in an embodiment of this application.

[0078] Specifically, in another optional embodiment, the rubber damping pad employs an elastic composite module 20 with embedded conductive contacts. For example... Figure 5 As shown, the elastic composite module 20 is sandwiched between the battery holder 17 and the battery assembly 11. When the elastic composite module 20 is not under pressure, its internal conductive contacts are wrapped in elastic material and insulated from the outside; when it is subjected to sufficient external pressure and deforms, its internal conductive contacts will be exposed or form an electrical connection with the outside.

[0079] Correspondingly, at the bottom of the battery assembly 11 and on both the left and right sides corresponding to the flexible composite module 20, a pair of communication contacts are led out or pre-installed. Electrically, these two independent pairs of communication contacts (one pair on the left and one pair on the right) are connected in series to the start-up enable circuit of the battery management system or controller located in the power distribution and external functional interface area. This series design constitutes an electrical logic AND gate; that is, both pairs of contacts must be simultaneously conducting for the entire circuit to close.

[0080] In actual assembly and dynamic operation, the working principle of this electromechanical interlock structure is as follows:

[0081] When the two sets of long bolts 19 located on the left and right sides of the battery assembly 11 are simultaneously screwed and tightened to reach the set mechanical preload, the long bolts 19 push the bottom crossbeam 18 upward, so that the weight of the battery assembly 11 and the upward force of the bottom crossbeam 18 together compress the elastic composite module 20 between them into a state of compression deformation. In this state, the conductive contact embedded in the elastic composite module 20 will form a stable physical contact and conduction with the communication contact at the bottom of the battery assembly 11, and the entire series start-up enable circuit will be connected. Only after the controller receives the closing signal will it authorize the battery assembly 11 to connect to the grid and output high voltage.

[0082] Conversely, if, during prolonged bumpy operation of the vehicle, any one of the long bolts 19 experiences a slight loosening, resulting in a loss of preload on that side, the elastic composite module 20 on that side will spring back due to its own elastic potential energy, restoring its initial shape. This physical springback will physically separate the embedded conductive contacts from the communication contacts, causing the entire series circuit to be disconnected at the hardware level. Upon detecting the disconnection of the enable circuit, the controller will immediately execute safety strategies, such as disconnecting the high-voltage relay of the battery assembly 11 and triggering a location alarm.

[0083] As can be seen, the original rubber shock-absorbing pads have been upgraded to elastic composite modules with embedded conductive contacts, and communication contacts connected in series to the start-up circuit have been set at the bottom of the battery assembly 11. When the long bolt 19 reaches the set preload, the mechanical clamping force forces the conductive contacts inside the elastic composite module 20 to adhere to the communication contacts, forming a physical closed circuit, thereby enabling the battery assembly 11 to enter the working state. Once the preload of the long bolt 19 on either side decreases during operation, the rebound of the elastic composite module 20 will cause the contacts to physically separate, cutting off the enable circuit, thus realizing structural loosening monitoring and isolation protection.

[0084] In some preferred embodiments, an alarm panel 1, a fire exhaust fan 5, and a fire intake fan 6 connected to the middle-layer energy storage battery storage area can also be installed on the outer wall of the prefabricated cabin 4.

[0085] Preferred implementation method for the lower-level power distribution and external functional interface area:

[0086] Please see Figures 1 to 4 , Figure 1 This is a front view of the prefabricated compartment 4 of the modular mobile energy storage box-type power supply in the embodiments of this application; Figure 2 yes Figure 1 A cross-sectional view of AA; Figure 3 yes Figure 1 A cross-sectional view of BB; Figure 4 This is a rear view of the prefabricated compartment 4 of the modular mobile energy storage box-type power supply in the embodiments of this application;

[0087] In a preferred embodiment, the power distribution and external function interface area includes a DC combiner box 8, a high-voltage cluster box 12, a human-machine interface panel 2, an AC socket box 15, and a DC socket box 16. To achieve high-level protection and zoned operation, the human-machine interface panel 2 is housed in a waterproof box mounted on the front outer wall of the prefabricated cabin 4. This waterproof box has a lockable cover. The AC socket box 15 and DC socket box 16 are installed within the prefabricated frame at the rear of the prefabricated cabin 4. Their covers are hinged flip-tops, with through holes on their circumferential walls, and are secured to the prefabricated frame with multiple screws. A sealant layer is applied to the joint between the box wall and the prefabricated frame to improve its waterproof and dustproof rating.

[0088] As can be seen, all the DC combiner boxes 8, high-voltage boxes 12, human-machine interface panels 2, AC socket boxes 15, and DC socket boxes 16 that require manual operation or external wiring are integrated into the power distribution and external functional interface area on the lower layer of the prefabricated cabin 4. After the prefabricated cabin 4 is hoisted onto the supporting chassis, the height of this area will be naturally raised to a position that matches the line of sight and operating height of the standing maintenance personnel, eliminating the risk of climbing operations during maintenance.

[0089] Based on any of the above embodiments, in order to facilitate handling operations in different scenarios, the top of the prefabricated cabin 4 can be provided with a hoisting hole 3, and the bottom can be provided with a forklift hole 7.

[0090] It is evident that this dual top and bottom handling interface design increases the compatibility of handling methods for a single prefabricated cabin 4 under different work sites and conditions.

[0091] The above-described embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit it. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this application.

Claims

1. A modular mobile energy storage box power supply, characterized by, include: Several prefabricated modules, the internal space of which is divided into three layers along the vertical direction by partitions, arranged from bottom to top as follows: The power distribution and external function interface area is located on the lower level of the prefabricated cabin; The energy storage battery storage area, located in the middle layer of the prefabricated compartment, houses multiple battery modules; The power conversion and liquid cooling temperature control area is located on the upper level of the prefabricated cabin and houses the power components and liquid cooling units. The bottom of the prefabricated cabin is provided with multiple sets of container lock holes and threaded holes, which are used to splice and lock multiple prefabricated cabins along the length direction onto the load-bearing chassis.

2. The modular mobile energy storage box-type power supply according to claim 1, characterized in that: The power conversion and liquid cooling temperature control area is divided into a power component compartment and a liquid cooling unit compartment. The power attachment is located in the power attachment compartment, and the power attachment compartment is equipped with an exhaust fan. The outer wall of the prefabricated compartment that is not spliced ​​with other prefabricated compartments is provided with a first air inlet and a first air outlet that connect to the power attachment compartment. The first air outlet is set facing the exhaust side of the exhaust fan. The liquid cooling unit is located in the liquid cooling unit compartment. A second air inlet and a second air outlet are provided on the other outer side wall of the prefabricated compartment that is not spliced ​​with other prefabricated compartments, which connect to the liquid cooling unit compartment. A ventilation opening is provided at the bottom of the liquid cooling unit compartment, which connects to the energy storage battery storage area.

3. The modular mobile energy storage tank according to claim 2, wherein: The power distribution and external function interface area also includes a controller; When multiple prefabricated modules are spliced ​​together along their length to form a side-by-side array, the controller is configured to perform the following operations: The power components located in the prefabricated compartments at the beginning and end of the array are controlled to output according to the set first power value, and the remaining total power to be allocated is calculated based on the target total power. Based on the remaining total power to be allocated, the second power allocation ratio, the third power allocation ratio, and the number of prefabricated modules in the middle of the array, the second power value and the third power value are calculated and determined respectively; wherein, the first power value is greater than the second power value, and the second power value is greater than the third power value; The second power value and the third power value are alternately distributed to the power devices located in each prefabricated compartment in the middle of the array for output; Control the rotation speed of the exhaust fans in each prefabricated compartment located in the middle of the array; wherein the rotation speed of the exhaust fans in the prefabricated compartment outputting the second power value is greater than the rotation speed of the exhaust fans in the prefabricated compartment outputting the third power value. When the set switching threshold is reached, the second power value and the third power value allocated to each prefabricated compartment located in the middle of the array are reverse-interleaved and output, and the speed of the corresponding exhaust fan is synchronously switched.

4. A modular mobile energy storage box-type power supply according to claim 2, characterized in that: The number of power attachments is multiple, and a prefabricated frame is installed inside the power attachment cabin. Multiple power attachments are arranged in groups and side by side within the prefabricated frame. The prefabricated frame includes a bottom frame and multiple top pressure beams; The bottom frame is provided with threaded holes and is fixedly connected to the ear plate holes at the bottom of the power bracket by bolts. Multiple top pressure beams are distributed and pressed onto the upper surfaces of multiple power hangers, and rubber pads are provided at the contact points between the top pressure beams and the upper surfaces of the power hangers; The top pressure beams located on the front and rear sides are provided with threaded holes, and are fastened to the upper ear plate screw holes of the power hangers by screws, so that the multiple power hangers are fixed together with the bottom frame and the top pressure beams as a whole.

5. A modular mobile energy storage box-type power supply according to claim 1, characterized in that: The energy storage battery storage area is equipped with a battery rack for supporting the battery assembly. The battery rack is made of angular bent plates and is welded to the columns in the prefabricated compartment. The battery rack has a baffle welded to its end for positioning restriction; The battery assembly has multiple threaded holes on both the left and right sides of its bottom; a bottom crossbeam is provided below the battery assembly, which spans between two opposite threaded holes; and a rubber shock-absorbing pad is sandwiched between the bottom crossbeam and the bottom of the battery assembly. Multiple sets of long bolts pass through the bottom crossbeam and the rubber shock-absorbing pad in sequence, and are threaded into the threaded holes of the corresponding battery components.

6. A modular mobile energy storage box-type power supply according to claim 5, characterized in that: The rubber shock-absorbing pad is an elastic composite module with embedded conductive contact pieces; On the left and right sides of the bottom of the battery assembly, at the positions corresponding to the elastic composite module, each pair of communication contacts is led out; the pairs of communication contacts on the left and right sides of the battery assembly are connected in series in the electrical circuit and connected to the circuit between the battery assembly and the power distribution and external function interface area. When the long bolts located on the left and right sides of the battery assembly are simultaneously tightened and both reach the set preload, the battery assembly and the bottom crossbeam compress the elastic composite module between them to a state of compression deformation, so that the conductive contact embedded in the elastic composite module forms a contact and conduction with the corresponding communication contact.

7. A modular mobile energy storage box-type power supply according to claim 1, characterized in that: The power distribution and external function interface area is equipped with a DC combiner box, a cluster high-voltage box, a human-machine interface panel, and an AC / DC socket box. A waterproof box is installed on the front outer wall of the prefabricated cabin, the human-machine interface panel is located inside the waterproof box, and the waterproof box has a lockable lid. The rear of the prefabricated compartment is provided with a prefabricated frame, and the AC / DC socket box is installed inside the prefabricated frame.

8. The modular mobile energy storage tank according to claim 7, wherein, The cover of the AC / DC socket box is a hinged flip-top structure; Through holes are provided on the circumferential walls of the AC / DC socket box, and multiple screws pass through the through holes to fasten the AC / DC socket box to the prefabricated frame. A sealant layer is applied to the joint between the AC / DC socket box wall and the prefabricated frame.

9. The modular mobile energy storage tank according to claim 1, wherein, The top of the prefabricated compartment is provided with a hoisting hole, and the bottom of the prefabricated compartment is provided with a forklift hole.

10. The modular mobile energy storage tank according to claim 1, wherein, It also includes the vehicle chassis; The prefabricated modules are arranged and spliced ​​sequentially along the length of the vehicle chassis and locked together with the vehicle chassis to form an integrated working platform.

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