High-voltage-resistant high-power air-cooled resistor module
By designing a high-voltage and high-power air-cooled resistor module, an insulating seat and an insulating frame structure are adopted, the resistor rods are fixed by perforations, the metal shell is equipped with a resistor component and magnesium oxide filler, and the terminal blocks are connected by copper busbars. The problems of the existing air-cooled load resistor module, such as low power density, general heat dissipation effect, large size, large footprint, and difficult assembly, are solved, and the effects of high power density, good heat dissipation effect, small size, small footprint, and simple assembly are achieved.
Patent Information
- Application Number
- CN202422377019.X
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-09-29
- Publication Date
- 2025-09-09
- Estimated Expiration
- 2034-09-29
AI Technical Summary
Existing air-cooled load resistor modules have low power density, average heat dissipation effect, large size, large floor space, and difficulty in assembly, and cannot meet the requirements of working conditions.
A high-voltage, high-power, air-cooled resistor module was designed. It adopts the structure of an insulating seat and an insulating frame. The resistor rods are fixed by perforations. The resistor components and magnesium oxide fillers are arranged in the metal shell. The terminal blocks are connected by copper busbars to realize modular design.
The resistor module has high power density, good heat dissipation effect, small size, small footprint, simple assembly, easy production implementation, and meets market demand.
Smart Images
Figure CN223321086U_ABST
Abstract
Description
Technical Field
[0001] The utility model relates to the technical field of resistor modules, in particular to a high-voltage resistant and high-power air-cooled resistor module. Background Art
[0002] Common ways to consume regenerative power include: 1) Feeding back to the grid, achieved through energy-regeneration units such as active front-ends. This method is generally suitable for larger power applications, allowing for full utilization of regenerative power and offering advanced technology, but also comes with high production and maintenance costs. 2) Converting it into heat and dissipating it in a cooling medium (such as coolant or air), using a load resistor module to achieve energy conversion and consumption. This method eliminates the risk of grid contamination, making it a more economical and reliable option and, therefore, more widely used.
[0003] However, the existing air-cooled load resistor module cannot meet the requirements of working conditions due to its low power density, average heat dissipation effect, large size, large footprint, and difficulty in assembly.
[0004] In view of this, the present utility model is proposed. Summary of the Invention
[0005] In order to overcome the above-mentioned defects, the utility model provides a high-voltage resistant and high-power air-cooled resistor module, which has the advantages of simple and reasonable structure, controllable size, high power, good heat dissipation effect, simple and convenient processing and assembly, etc. It meets the market demand very well and has a very broad application market.
[0006] The technical solution adopted by the present invention to solve the technical problem is: a high-voltage resistant high-power air-cooled resistor module, comprising:
[0007] The mounting base includes a plurality of insulating bases stacked in a stack and an insulating frame for fixing the plurality of insulating bases together; each insulating base is provided with a plurality of through holes, and at least one side surface of each insulating base is also provided with a ventilation slot;
[0008] The resistor rods are provided in a plurality of numbers and are fixedly inserted into the plurality of the through holes in a one-to-one correspondence; each of the resistor rods is provided with a metal shell and a resistor assembly, the resistor assembly is provided with a resistor wire group consisting of a plurality of resistor wires connected in series and / or in parallel, and two terminal blocks fixedly connected to the two ends of the resistor wire group, the resistor assembly is inserted into the metal shell, and the two terminal blocks are sealed and extended out of the opposite ends of the metal shell, and magnesium oxide filler is tightly filled between the resistor assembly and the inner wall of the metal shell; in addition, the terminal blocks on the plurality of resistor rods are connected in series and / or in parallel through copper busbars.
[0009] As a further improvement of the present invention, a plurality of the insulating seats are arranged in a matrix, and the ventilation slot is recessed on at least one of the two opposite side surfaces of each two adjacent insulating seats located in the same column.
[0010] As a further improvement of the present invention, the ventilation slot is recessed on one of the two opposite side surfaces of each of the two adjacent insulating seats located in the same row.
[0011] As a further improvement of the present invention, the ventilation grooves are recessed on the opposite side surfaces of the two adjacent insulating seats in the same column, and the ventilation grooves on the two adjacent insulating seats are arranged one by one or alternately staggered.
[0012] As a further improvement of the present invention, the insulating seat is a rectangular block structure, and the through hole and the ventilation slot both extend along the length direction of the insulating seat and respectively pass through the two side surfaces of the insulating seat in the length direction.
[0013] As a further improvement of the present invention, the cross-section of the through hole along the height direction of the insulating seat is circular, and the cross-section of the ventilation groove along the height direction of the insulating seat is U-shaped or inverted U-shaped.
[0014] As a further improvement of the present invention, the insulating frame is provided with a plurality of string tubes and a plurality of connecting plates, the plurality of string tubes are arranged in rows and columns through a plurality of stacked insulating seats, and the two ends of the plurality of string tubes in the same row are also fixedly connected together by the connecting plates.
[0015] As a further improvement of the present invention, the metal shell is a hollow cylindrical structure made of stainless steel material, and insulating plugs are sealed at both axial ends of the metal shell.
[0016] As a further improvement of the present invention, the resistance wire is made of copper-nickel alloy material; the wiring terminal adopts a rod-shaped structure made of copper material, and the wiring terminal and the metal shell are arranged with a coaxial line.
[0017] As a further improvement of the present invention, the outer fixing sleeve of the metal shell is provided with a fixing clamp. When the resistor rod is passed through the through hole, the fixing clamp is placed outside the through hole and is detachably fixedly connected to the insulating seat.
[0018] The beneficial effects of the present invention are as follows: the air-cooled resistor module of the present invention has the following advantages: ① The resistor rod has the advantages of high power, small size, and easy modular / integrated design. In this way, on the basis of meeting the design requirements of high-power resistors well, it will not occupy too much space and increase costs, thereby effectively controlling the overall volume and floor space of the air-cooled resistor module. ② The resistor rod has the advantage of high heat dissipation efficiency, that is, the resistor rod can quickly and efficiently conduct / dissipate the heat generated inside it, and then combined with the ventilation slot, it can well realize the cooling and heat dissipation of the resistor rod, so that the resistor rod can continue to work normally for a long time. ③ By means of the mounting seat structure, the assembly of the air-cooled resistor module can be made very quick, simple, and compact, thereby greatly improving the assembly efficiency and assembly quality, and facilitating production implementation. BRIEF DESCRIPTION OF THE DRAWINGS
[0019] Figure 1 This is a structural diagram of the high-voltage and high-power air-cooled resistor module described in Example 1 of the present utility model;
[0020] Figure 2 for Figure 1 The enlarged schematic diagram of the installation state of the resistor rod assembled on the insulating seat is shown in FIG;
[0021] Figure 3 for Figure 1 The structural diagram of the insulating seat shown in ;
[0022] Figure 4 for Figure 1 A schematic diagram of a partial structure of an insulating frame shown in FIG.
[0023] Figure 5 for Figure 1 Schematic diagram of the three-dimensional structure of the resistor rod shown in;
[0024] Figure 6 for Figure 5 Schematic diagram of the cross-sectional structure of the resistor rod shown in;
[0025] Figure 7 This is a structural schematic diagram of the insulating seat described in Example 2 of the utility model.
[0026] The following description is made with reference to the accompanying drawings:
[0027] 1. Mounting base; 10. Insulation base; 11. Insulation frame; 110. String tube; 111. Connecting plate; 12. Perforation; 13. Ventilation slot; 2. Resistor rod; 20. Metal housing; 21. Resistance wire assembly; 22. Terminal block; 23. Magnesium oxide filler; 24. Insulation plug; 25. Fixing clamp; 3. Copper busbar. DETAILED DESCRIPTION
[0028] The preferred embodiments of the present invention are described in detail below with reference to the accompanying drawings.
[0029] Example 1:
[0030] Please see the attached Figure 1 To the attached Figure 6 As shown, this embodiment 1 provides a high-voltage resistant high-power air-cooled resistor module, which includes a mounting base 1 and a plurality of resistor rods 2, wherein the mounting base 1 is provided with a plurality of insulating bases 10 stacked in a stack and an insulating frame 11 for fixing the plurality of insulating bases 10 together, each of the insulating bases 10 is provided with a plurality of through-holes 12, and a ventilation slot 13 is also recessed on one side of each of the insulating bases 10; the plurality of resistor rods 2 are fixedly penetrated in the plurality of through-holes 12 in a one-to-one correspondence, and each of the resistor rods 2 is provided with a metal shell 20 and a resistor assembly, and the resistor assembly is provided with a plurality of electrical A resistance wire group 21 composed of resistance wires connected in series and / or in parallel, and two wiring terminals 22 respectively fixedly connected to the two ends of the resistance wire group 21, the resistance assembly is placed in the metal shell 20, and at the same time, the two wiring terminals 22 are also sealed and extended out of the opposite ends of the metal shell 20, and the resistance assembly and the inner wall of the metal shell 20 are also tightly filled with magnesium oxide filler 23 that plays a role in heat conduction and heat dissipation; in addition, the wiring terminals 22 on several of the resistance rods 2 are also connected in series and / or in parallel through a copper bus 3 to meet the electrical design requirements of the product.
[0031] As can be seen from the above, the air-cooled resistor module provided in this embodiment 1 has the following advantages: ① The resistor rod has the advantages of high power, small size, and easy modular / integrated design. In this way, on the basis of meeting the design requirements of high-power resistors well, it will not take up too much space and increase costs, thereby effectively controlling the overall volume and floor space of the air-cooled resistor module. ② The resistor rod has the advantage of high heat dissipation efficiency, that is, the resistor rod can quickly and efficiently conduct / dissipate the heat generated inside it, and then combined with the ventilation slot 13, it can well realize the cooling and heat dissipation of the resistor rod 2, so that the resistor rod can continue to work normally for a long time. ③ By means of the mounting seat structure, the assembly of the air-cooled resistor module can be very quick, simple, and compact, thereby greatly improving the assembly efficiency and assembly quality.
[0032] The specific structure of the high-voltage and high-power air-cooled resistor module described in this embodiment is described in detail below.
[0033] First, let's talk about the structure of the mounting base 1.
[0034] In this embodiment 1, the main functions of the mounting base 1 are: protecting the resistor rod 2 from direct contact, providing insulating support, and providing an air cooling channel for the resistor rod 2 (i.e., providing the ventilation slot 13); that is, the mounting base 1 is used to insulate, support, and cool the resistor rod 2. Regarding the material of the mounting base 1, insulating materials such as polytetrafluoroethylene, nylon, or silicone are preferably used. Furthermore, the materials used for the insulating base 10 and the insulating frame 11 in this embodiment 1 may be the same or different, depending on the specific product design requirements.
[0035] In this embodiment 1, the stacked insulating seats 10 are arranged in a matrix, and the ventilation slots 13 are recessed on one of the two opposite side surfaces of each adjacent two insulating seats 10 in the same column. Figure 1 The plurality of insulating seats 10 shown in the figure are arranged in a vertical row as a reference. Each insulating seat 10 has a ventilation slot 13 recessed on its upper side, and the lower side of each insulating seat 10 is flat. It is understood that, depending on product design requirements, this embodiment may also have a ventilation slot 13 recessed on the lower side of each insulating seat 10. In this case, the upper side of each insulating seat 10 is flat.
[0036] For further information, please refer to the attached Figure 1 To the attached Figure 3 As shown, in accordance with product design requirements, the insulating base 10 in this embodiment 1 is a rectangular block structure. Accordingly, the through-holes 12 and the ventilation slots 13 both extend along the length of the insulating base 10 and respectively penetrate the two side surfaces of the insulating base 10 in the length direction. It can be understood that the layout of the ventilation slots 13 is the same as that of the through-holes 12, thereby achieving good and uniform cooling and heat dissipation of the resistor rod 2.
[0037] Furthermore, the plurality of through holes 12 on each insulating seat 10 are arranged side by side along the width direction of the insulating seat 10 , and the cross-section of the through holes 12 along the height direction of the insulating seat 10 is circular to match the shape of the resistor rod 2 .
[0038] Each of the insulating seats 10 is also provided with a plurality of ventilation grooves 13 to enhance the cooling and heat dissipation effect of the resistor rod 2, and the plurality of ventilation grooves 13 are also arranged side by side along the width direction of the insulating seat 10, and the cross-section of the ventilation grooves 13 along the height direction of the insulating seat 10 is U-shaped (when the ventilation grooves 13 are formed on the upper side of the insulating seat 10) or inverted U-shaped (when the ventilation grooves 13 are formed on the lower side of the insulating seat 10).
[0039] Furthermore, each of the insulating seats 10 is an integral injection-molded structure and is easy to process and manufacture.
[0040] In this embodiment 1, in order to realize the fixed connection of several insulating seats 10 and simplify the fixed connection method, this embodiment also optimizes the structure of the insulating frame 11, specifically: Please continue to refer to the attached Figure 1 and attached Figure 4 As shown, the insulating frame 11 is provided with a plurality of string tubes 110 and a plurality of connecting plates 111. The plurality of string tubes 110 are arranged in rows and columns through a plurality of stacked insulating seats 10, and the two ends of the plurality of string tubes 110 in the same row are also fixedly connected together by the connecting plates 111.
[0041] Furthermore, in this embodiment 1, the string tube 110 is inserted into the insulating seat 10 by providing a through-hole A at the periphery of the insulating seat 10 , and the string tube 110 is inserted into the through-hole A.
[0042] Furthermore, in this embodiment 1, plastic screws or plastic rivets are used to securely connect the string tube 110 and the connecting plate 111 together.
[0043] Next, let's discuss the structure of the resistor rod 2.
[0044] Please continue to refer to the attached Figure 2 , Attachment Figure 5 and attached Figure 6 As shown, the metal shell 20 in this embodiment 1 is a hollow cylindrical structure made of stainless steel material, and in order to ensure and optimize the sealing performance of the resistor rod 2, this embodiment forms an insulating plug 24 by pouring epoxy resin into the axial ends of the metal shell 20 and curing it. That is, this embodiment seals the insulating plug 24 at the axial ends of the metal shell 20, so that the resistor rod 2 has an excellent sealing effect. In addition, by the attached Figure 6 It can also be seen that the connection terminal 22 is partially embedded in the insulating plug 24, which can greatly improve the voltage resistance level of the resistor rod to the ground.
[0045] Furthermore, in this embodiment 1, the resistance wire is made of copper-nickel alloy material. Copper-nickel alloy has good electrical conductivity, corrosion resistance, and high temperature resistance, and can be well used in high-power electronic devices.
[0046] Furthermore, based on the structure of the metal housing 20, when the resistor assembly is inserted into the metal housing 20, the copper rod-shaped terminal 22 is arranged concentrically with the metal housing 20. Due to the position of the terminal 22 relative to the metal housing 20, the resistor wire assembly 21 is also arranged concentrically with the metal housing 20 as much as possible, thereby ensuring uniform filling and distribution of the magnesium oxide filler 23 and even heat dissipation.
[0047] For further information, please refer to the attached Figure 2 and attached Figure 5 As shown, in this embodiment 1, a fixing ring 25 is fixedly sleeved on the outside of the metal housing 20. When the resistor rod 2 is inserted into the through-hole 12, the fixing ring 25 is placed outside the through-hole 12 and can be detachably fixedly connected to the insulating base 10. Specifically, in this embodiment, the fixing ring 25 is locked to the insulating base 10 using plastic screws.
[0048] Example 2:
[0049] This embodiment 2 also provides a high-voltage resistant and high-power air-cooled resistor module, and compared with embodiment 1, the air-cooled resistor module of this embodiment 2 has the following differences: ① In this embodiment 2, the ventilation grooves 13 are recessed on the opposite side surfaces of the two adjacent insulating seats 10 located in the same column, so that the cooling and heat dissipation effect of the resistor rod 2 is better.
[0050] Specifically, regarding the above-mentioned difference ①, in order to realize that the ventilation grooves 13 are recessed on the opposite sides of each of the two adjacent insulating seats 10, this embodiment 2 is realized by the following structural design: Figure 7 As shown, the ventilation slots 13 are recessed on the opposite sides (i.e., the upper and lower sides) of each insulating seat 10. It is understandable that the opening directions of the ventilation slots 13 on the opposite sides of the insulating seat 10 are opposite.
[0051] Furthermore, the ventilation slots 13 on each of the two adjacent insulating seats 10 in the same column are arranged one by one relative to each other or arranged in an alternating staggered manner, which can be determined according to product design requirements.
[0052] Note: In addition to the above-mentioned differences, other structures in the air-cooled resistor module described in this embodiment 2, such as: the stacking arrangement of the insulating base 10, the number and specific shape of the through holes 12 and the ventilation slots 13, the structure of the insulating frame 11 and the connection method between it and the insulating base 10, the structure of the resistor rod 2 and the assembly method of installing it on the insulating base 10, etc.; can all adopt the same technical means as in embodiment 1, so they will not be described here.
[0053] To sum up, the high-voltage and high-power air-cooled resistor module described in the present invention has the advantages of simple and reasonable structure, controllable size, high power, good heat dissipation effect, simple and convenient processing and assembly, etc. It meets the market demand very well and has a very broad application market.
[0054] In the above description, many specific details are set forth in order to fully understand the present invention. However, the above description is only a preferred embodiment of the present invention. The present invention can be implemented in many other ways different from those described herein, so the present invention is not limited by the specific implementation disclosed above. At the same time, any person skilled in the art can use the above-disclosed methods and technical contents to make many possible changes and modifications to the technical solution of the present invention without departing from the scope of the technical solution of the present invention, or modify it into an equivalent embodiment of equivalent changes. Any simple modification, equivalent change and modification made to the above embodiments based on the technical essence of the present invention without departing from the content of the technical solution of the present invention still falls within the scope of protection of the technical solution of the present invention.
Claims
1. A high-voltage, high-power, air-cooled resistor module, characterized by: include: A mounting seat (1) is provided with a plurality of insulating seats (10) stacked in a stack and an insulating frame (11) for fixing the plurality of insulating seats (10) together; each insulating seat (10) is provided with a plurality of through holes (12), and at least one side surface of each insulating seat (10) is also provided with a ventilation slot (13); A plurality of resistor rods (2) are provided and fixedly penetrated in the plurality of through-holes (12) in a one-to-one correspondence; each resistor rod (2) is provided with a metal shell (20) and a resistor assembly; the resistor assembly is provided with a resistor wire group (21) consisting of a plurality of resistor wires connected in series and / or in parallel, and two wiring terminals (22) fixedly connected to the two ends of the resistor wire group (21); the resistor assembly is inserted into the metal shell (20), and the two wiring terminals (22) are sealed and extended out of the opposite ends of the metal shell (20); a magnesium oxide filler (23) is tightly filled between the resistor assembly and the inner wall of the metal shell (20); in addition, the wiring terminals (22) on the plurality of resistor rods (2) are connected in series and / or in parallel via a copper busbar (3).
2. The high-voltage, high-power, air-cooled resistor module according to claim 1, characterized in that: The plurality of insulating seats (10) are arranged in a matrix, and the ventilation slot (13) is recessed on at least one of the two opposite side surfaces of each two adjacent insulating seats (10) located in the same column.
3. The high-voltage, high-power, air-cooled resistor module according to claim 2, characterized in that: The ventilation slot (13) is recessed on one of the two opposite side surfaces of the two adjacent insulating seats (10) located in the same row.
4. The high-voltage, high-power, air-cooled resistor module according to claim 2, characterized in that: The ventilation slots (13) are recessed on opposite side surfaces of two adjacent insulating seats (10) located in the same row, and the ventilation slots (13) on the two adjacent insulating seats (10) are arranged one by one relative to each other or are arranged alternately and staggered.
5. The high-voltage, high-power, air-cooled resistor module according to claim 1, characterized in that: The insulating seat (10) is a rectangular block structure, and the through hole (12) and the ventilation slot (13) both extend along the length direction of the insulating seat (10) and respectively penetrate the two side surfaces of the insulating seat (10) in the length direction.
6. The high-voltage, high-power, air-cooled resistor module according to claim 5, characterized in that: The cross section of the through hole (12) along the height direction of the insulating seat (10) is circular, and the cross section of the ventilation slot (13) along the height direction of the insulating seat (10) is U-shaped or inverted U-shaped.
7. The high-voltage, high-power, air-cooled resistor module according to claim 1, characterized in that: The insulating frame (11) is provided with a plurality of string tubes (110) and a plurality of connecting plates (111). The plurality of string tubes (110) are arranged in rows and columns through a plurality of stacked insulating seats (10), and the two ends of the plurality of string tubes (110) in the same row are fixedly connected together by the connecting plates (111).
8. The high-voltage, high-power, air-cooled resistor module according to claim 1, characterized in that: The metal shell (20) is a hollow cylindrical structure made of stainless steel, and insulating plugs (24) are sealed at both axial ends of the metal shell (20).
9. The high-voltage, high-power, air-cooled resistor module according to claim 8, characterized in that: The resistance wire is made of copper-nickel alloy material; The connecting terminal (22) is a rod-shaped structure made of copper material, and the connecting terminal (22) and the metal shell (20) are arranged on the same central axis.
10. The high-voltage, high-power, air-cooled resistor module according to claim 1, characterized in that: The outer fixed sleeve of the metal shell (20) is provided with a fixing ring (25); when the resistor rod (2) is inserted into the through hole (12), the fixing ring (25) is placed outside the through hole (12) and is detachably fixedly connected to the insulating seat (10).