High-power water-cooling integrated bypass power unit

Abstract

The utility model relates to a high-power water-cooling integrated bypass power unit, which comprises a rectification and inversion bypass integrated module, a capacitor module and a capacitor laminated composite busbar, the rectification and inversion bypass integrated module is electrically connected with the capacitor module through the capacitor laminated composite busbar, the rectification and inversion bypass integrated module and the capacitor module are both box-type structures, and the rectification and inversion bypass integrated module is electrically connected with the capacitor module through the capacitor laminated composite busbar. The capacitor module and the rectification and inversion integrated module are arranged side by side; a water inlet is formed in the lower part of the rectification and inversion bypass integrated module, and a water outlet is formed in the upper part of the rectification and inversion bypass integrated module and used for cooling water circulation heat dissipation of the rectification and inversion bypass integrated module. The water-cooling frequency conversion power unit has the advantages of compact structure, integrated design, reduced size, convenience in maintenance, strong environmental adaptability and lower cost compared with a conventional water-cooling frequency conversion power unit.

Description

Technical Field

[0001] The utility model belongs to the technical field of frequency converters, and in particular relates to a high-power water-cooled integrated bypass power unit. Background Art

[0002] As a core component of the inverter, the power cell module is crucial for its proper operation. To prevent module failure and ensure the normal operation of the inverter, a power cell bypass module is required. When a power cell fails, the bypass module activates and removes the faulty power cell from the circuit, allowing current to bypass the power cell and continue flowing through the bypass channel without affecting overall system operation. Meanwhile, other functioning power cells continue to transmit and convert power, maintaining system output performance. The structure, size, and safe and stable operation of high-power power cell modules integrated with the bypass module are crucial issues.

[0003] Currently, water cooling is the primary method for dissipating heat in high-power power units. Due to their high voltage and heat generation, existing high-power water-cooled power units are often designed with a rectifier module, inverter module, capacitor module, and other components. The bypass module is used as an independent module in conjunction with the power unit module. This design not only has disadvantages such as large size and high manufacturing cost, but also results in a correspondingly large power cabinet, resulting in high manufacturing cost and difficulty in transportation. The connection between the bypass module and the power unit is also very difficult, and consideration must also be given to the insulation between the connection point and other connecting copper bars, as well as between the connection point and the cabinet frame. Summary of the Invention

[0004] The purpose of this utility model is to provide a high-power water-cooled integrated bypass power unit, which splits the power unit of the high-voltage inverter into two independent functional boxes, and integrates the rectifier module, inverter module and bypass module into a multifunctional box. This split power unit structure has the advantages of strong scalability, easy maintenance, compact structure, safety and stability.

[0005] To achieve the above objectives, the present invention is implemented through the following technical solutions:

[0006] A high-power water-cooled integrated bypass power unit includes a rectifier-inverter-bypass integrated module, a capacitor module, and a capacitor laminated composite busbar. The rectifier-inverter-bypass integrated module and the capacitor module are electrically connected via the capacitor laminated composite busbar. Both the rectifier-inverter-bypass integrated module and the capacitor module are box-type structures, and the capacitor module and the rectifier-inverter-bypass integrated module are arranged side by side. A water inlet is provided at the bottom of the rectifier-inverter-bypass integrated module and a water outlet is provided at the top, which are used for circulating cooling water and dissipating heat in the rectifier-inverter-bypass integrated module.

[0007] The rectifier-inverter bypass integrated module includes an integrated module box, a water-cooled plate assembly, a drive plate assembly, a bypass contactor assembly, a composite busbar, a fuse, a transformer assembly, an IGBT module, a temperature-controlled switch, a rectifier bridge, a bypass busbar 1, a bypass busbar 2, and an output copper busbar. The water-cooled plate assembly is fixed in the rectifier-inverter box, and the electrical components in the water-cooled plate assembly are electrically connected to the fuse through the composite busbar; the drive plate assembly is fixedly connected to the rectifier-inverter box, and the drive plate assembly is electrically connected to the transformer assembly, the IGBT module, the temperature-controlled switch, and the fuse through cables; the IGBT module, the temperature-controlled switch, and the rectifier bridge are fixedly connected to the water-cooled plate assembly; the bypass contactor assembly is electrically connected to the output copper busbar through the bypass busbar 1, the bypass busbar 2, and bolts, and the composite busbar is electrically connected to the capacitor stack composite busbar.

[0008] The water-cooling plate assembly includes a water inlet, a water outlet, and a water-cooling plate. The water-cooling plate is fixedly connected to the IGBT module, the temperature control switch, and the rectifier bridge by bolts. The upper and lower ends of the side of the water-cooling plate are respectively connected to the water outlet and the water inlet.

[0009] The water cooling plate is assembled and fixed on the front lower part of the integrated module box.

[0010] The driving board is assembled and fixed on the upper front end of the integrated module box.

[0011] The front end of the integrated module box is fixedly connected with a handle.

[0012] The capacitor module includes a capacitor module box, a connecting column, and a capacitor. A connecting column is fixed in the middle of the front end of the capacitor module box for connecting to the capacitor stack busbar; the capacitor is encapsulated in the capacitor module box; the capacitor is electrically connected to the capacitor stack busbar through the connecting column.

[0013] The front end of the capacitor module box is fixedly connected with a handle.

[0014] Compared with the prior art, the beneficial effects of the present invention are:

[0015] 1. The utility model has a compact structure and adopts an integrated design, which reduces the volume, is easy to maintain, has strong environmental adaptability, and is lower in cost than conventional water-cooled variable frequency power units.

[0016] 2. This utility model divides the power unit into two independent boxes, modifying the internal configuration. The rectifier module, inverter module, and bypass module are integrated into the same box, equipped with a water-cooled plate assembly. The capacitor module is housed in another box, significantly reducing the overall volume. Simultaneously, by modifying the internal configuration of the integrated rectifier, inverter, and bypass module and increasing or decreasing the number of capacitors in the capacitor module, the design power of the power unit can be increased or decreased, resulting in greater scalability and consistency.

[0017] 3. The rectifier-inverter-bypass integrated module and the capacitor module of the present invention are electrically connected via a capacitor stack busbar. When any of the modules fails, the failed module can be removed for maintenance simply by removing the capacitor stack busbar. This facilitates disassembly and maintenance of the power unit because the weight of a single module is much lighter than that of the entire power unit.

[0018] 4. When the utility model is installed on the power cabinet, the water inlets and outlets of the rectifier, inverter and bypass integrated module are connected in parallel to achieve cooling and heat dissipation, thereby improving the heat dissipation effect of the rectifier, inverter and bypass integrated module. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 This is a schematic diagram of the structure of the utility model Figure 1 (front view).

[0020] Figure 2 This is a schematic diagram of the structure of the utility model Figure 2 (Rear view).

[0021] Figure 3 It is a structural diagram of the rectifier, inverter and bypass integrated module.

[0022] Figure 4 It is a structural diagram of the water cooling plate assembly.

[0023] Figure 5 It is a structural diagram of the capacitor module.

[0024] In the figure: 1-Integrated module box 2-Capacitor module box 3-Capacitor laminated busbar 4-Handle 5-Output copper busbar 6-Bypass busbar 1 7-Input copper busbar 8-Bypass busbar 2 9-Compound busbar 10-Water cooling plate assembly 11-Drive board assembly 12-Fuse 13-Transformer assembly 14-Bypass contactor assembly 15-Water outlet 16-Water inlet 17-IGBT module 18-Water cooling plate 19-Temperature control switch 20-Resistor 21-Rectifier bridge DETAILED DESCRIPTION

[0025] The present invention will be described in detail below with reference to the accompanying drawings. However, it should be noted that the implementation of the present invention is not limited to the following embodiments.

[0026] Example 1

[0027] See Figure 1 、 Figure 2A high-power, water-cooled, integrated bypass power unit includes a rectifier-inverter-bypass integrated module, a capacitor module, and a capacitor laminated composite busbar 9. The rectifier-inverter-bypass integrated module and the capacitor module are electrically connected via the capacitor laminated composite busbar 9. Both the rectifier-inverter-bypass integrated module and the capacitor module are box-type structures, with the capacitor module and the rectifier-inverter integrated module arranged side by side. A water inlet 16 is provided at the bottom of the rectifier-inverter-bypass integrated module, and a water outlet 15 is provided at the top, for circulating cooling water and dissipating heat within the rectifier-inverter-bypass integrated module.

[0028] See Figure 2 、 Figure 3 The rectifier-inverter-bypass integrated module includes an integrated module box 1 and various components inside the box. The components include a water-cooled plate assembly 10, a drive board assembly 11, a bypass contactor assembly 14, a fuse 12, a transformer assembly 13, a composite busbar 9, a fuse 12, a transformer assembly 13, an IGBT module, a temperature control switch 19, a rectifier bridge 20, a bypass connecting row 1 6, a bypass connecting row 2 8, and an output copper bus 5. The water-cooled plate assembly 10 is fixed to the lower front end of the integrated module box 1. The electrical components in the water-cooled plate assembly 10 are as follows: The components (rectifier bridge, IGBT, etc.) are electrically connected to the fuse 12 via the composite busbar 9. The driver board assembly 11 is fixed to the upper front end of the integrated module housing 1 and is electrically connected to the transformer assembly 13, IGBT module, temperature control switch 19, and fuse 12 via cables. The IGBT module, temperature control switch 19, rectifier bridge 20 are fixedly connected to the water-cooled plate assembly 10. The bypass contactor assembly 14 is electrically connected to the output copper busbar 5 via bypass busbar 1 6 and bypass busbar 2 8 using bolts. The external wiring for the output copper busbar 5 and input copper busbar 7 is located outside the integrated module housing 1. The composite busbar 9 is electrically connected to the capacitor stack busbar 3 via bolts.

[0029] See Figure 4 The water-cooled plate assembly 10 includes a water inlet, a water outlet, and a water-cooled plate 18. The water-cooled plate 18 is fixedly connected to the IGBT module 17, the temperature control switch 19, the rectifier bridge 20, and the resistor 20 by bolts. The resistor 20 is electrically connected to the composite busbar 9 by cables. The upper and lower ends of the side of the water-cooled plate 18 are respectively connected to the water outlet 15 and the water inlet 16, which are used for cooling water circulation and heat dissipation of the rectifier module and the inverter module. When the power unit is installed on the power cabinet, the water inlet 16 of the rectifier, inverter and bypass integrated module is connected in parallel through the water inlet pipe, and the water outlet 15 is connected in parallel through the water outlet pipe. The cooling water cools the inverter and rectifier integrated module to dissipate heat, so that the power unit has better heat dissipation performance.

[0030] See Figure 5The capacitor module includes a capacitor module box 2, a connecting column, and a capacitor. A connecting column is fixed at the middle of the front end of the capacitor module box 2 for connecting to the capacitor stack busbar 3; the capacitor is encapsulated in the capacitor module box 2; the capacitor is electrically connected to the capacitor stack busbar 3 through the connecting column.

[0031] Example 2

[0032] Based on Example 1, a handle 4 is fixedly attached to the front end of the capacitor module housing 2; a handle 4 is also fixedly attached to the front end of the integrated module housing 1. If a malfunction occurs in the integrated rectifier, inverter, and bypass module or the capacitor module, the faulty module can be removed and maintained by simply removing the capacitor stack busbar 3 and dragging the handle 4. The bottoms of the integrated module housing 1 and capacitor module housing 2 are slidably connected to rails fixed to the cabinet.

[0033] The utility model adopts a split and modular design; this design form can increase or decrease the design power of the power unit by modifying the internal configuration of the rectifier, inverter and bypass integrated module and increasing or decreasing the number of capacitors in the capacitor module, so that the power unit has strong scalability and consistency.

[0034] Through the above specific embodiments, those skilled in the art can easily implement the present invention. However, it should be understood that the present invention is not limited to the above specific embodiments. Based on the disclosed embodiments, those skilled in the art can arbitrarily combine different technical features to achieve different technical solutions. Due to space limitations and to keep the specification concise, each solution formed by these combinations is not described one by one. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention shall be included in the scope of protection of the present invention.

Claims

1. A high-power water-cooled integrated bypass power unit, characterized in that: It includes a rectifier, inverter and bypass integrated module, a capacitor module, and a capacitor laminated composite busbar. The rectifier, inverter and bypass integrated module and the capacitor module are electrically connected through the capacitor laminated composite busbar. The rectifier, inverter and bypass integrated module and the capacitor module are both box-type structures. The capacitor module and the rectifier, inverter and bypass integrated module are arranged side by side. The rectifier, inverter and bypass integrated module is provided with a water inlet at the bottom and a water outlet at the top for cooling water circulation and heat dissipation of the rectifier, inverter and bypass integrated module.

2. A high-power water-cooled integrated bypass power unit according to claim 1, characterized in that: The rectifier-inverter bypass integrated module includes an integrated module box, a water-cooled plate assembly, a drive plate assembly, a bypass contactor assembly, a fuse, a transformer assembly, a composite busbar, an IGBT module, a temperature-controlled switch, a rectifier bridge, a bypass link 1, a bypass link 2, and an output copper busbar. The water-cooled plate assembly is fixed in the rectifier-inverter box, and the electrical components in the water-cooled plate assembly are electrically connected to the fuse through the composite busbar; the drive plate assembly is fixedly connected to the rectifier-inverter box, and the drive plate assembly is electrically connected to the transformer assembly, the IGBT module, the temperature-controlled switch, and the fuse through cables; the IGBT module, the temperature-controlled switch, and the rectifier bridge are fixedly connected to the water-cooled plate assembly; the bypass contactor assembly is electrically connected to the output copper busbar through the bypass link 1, the bypass link 2, and bolts, and the composite busbar is electrically connected to the capacitor stack composite busbar.

3. A high-power water-cooled integrated bypass power unit according to claim 2, characterized in that: The water-cooling plate assembly includes a water inlet, a water outlet, and a water-cooling plate. The water-cooling plate is fixedly connected to the IGBT module, the temperature control switch, and the rectifier bridge by bolts. The upper and lower ends of the side of the water-cooling plate are respectively connected to the water outlet and the water inlet.

4. A high-power water-cooled integrated bypass power unit according to claim 2, characterized in that: The water cooling plate is assembled and fixed on the front lower part of the integrated module box.

5. The high-power water-cooled integrated bypass power unit according to claim 2, characterized in that: The driving board is assembled and fixed on the upper front end of the integrated module box.

6. The high-power water-cooled integrated bypass power unit according to claim 2, characterized in that: The front end of the integrated module box is fixedly connected with a handle.

7. The high-power water-cooled integrated bypass power unit according to claim 1, characterized in that: The capacitor module includes a capacitor module box, a connecting column, and a capacitor. A connecting column is fixed in the middle of the front end of the capacitor module box for connecting to the capacitor stack busbar; the capacitor is encapsulated in the capacitor module box; the capacitor is electrically connected to the capacitor stack busbar through the connecting column.

8. The high-power water-cooled integrated bypass power unit according to claim 7, characterized in that: The front end of the capacitor module box is fixedly connected with a handle.

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