Integrally-designed energy storage system high-voltage control box

Abstract

The utility model relates to an integrally designed energy storage system high-voltage control box, which comprises a box body and an electric appliance element, an operation panel is arranged on the box body, and the electric appliance element is communicated with the operation panel; the device further comprises an electrical isolation plate. The box body comprises an upper shell, a middle shell and a lower shell, the upper shell and the middle shell are assembled to form a high-voltage cavity, the middle shell and the lower shell are assembled to form a low-voltage cavity, the electric appliance elements comprise a plurality of correspondingly communicated high-voltage devices and low-voltage devices, the high-voltage devices are installed in the high-voltage cavity, and the low-voltage devices are installed in the low-voltage cavity. The low-voltage device is mounted in the low-voltage cavity; the electrical isolation plate is connected with the bottom of the upper shell and the top of the middle shell in a clamped mode, a plurality of independent cavities which are matched with the high-voltage devices and separated from one another are formed in the high-voltage cavity, and the high-voltage devices are independently arranged in the independent cavities respectively. According to the utility model, the electrical components are physically separated, so that the isolation of the electrical components is realized, and the electrical safety level and the insulation protection performance are improved.

Description

Technical Field

[0001] The utility model belongs to the technical field of energy storage battery equipment, and in particular relates to a high-voltage control box of an energy storage system with an integrated design. Background Art

[0002] In the field of energy storage high-voltage control boxes, sheet metal has long been widely used as the housing material. This material offers significant advantages in design and processing, such as convenience and plasticity. However, its application in high-voltage control boxes has also exposed some problems.

[0003] First, from a physical property perspective, sheet metal is heavy, which undoubtedly increases the overall weight of the high-voltage control box. Especially during equipment installation, handling, and transportation, the heavier sheet metal material will cause more inconvenience to operators and increase additional labor intensity. Secondly, for the high-voltage control box, its structural design must also take into account the functions of insulation withstand voltage and leakage protection. Although sheet metal can provide certain insulation properties, its insulation withstand voltage design becomes particularly important when faced with higher voltages and more complex electrical environments. This requires not only a deep understanding of the material, but also complex calculations and testing to ensure its safety performance.

[0004] Furthermore, the electrical layout design within the high-voltage control box is a critical task. Because it contains a large number of DC high-voltage components, consideration of electrical clearance and creepage distances becomes particularly important. This requires designers to optimize the layout to maximize space utilization while ensuring safety. However, this is not an easy task, as the placement of electrical components must fully consider their performance and heat dissipation requirements. This often results in inefficient space utilization, increasing the box's size and cost.

[0005] More importantly, it is usually impossible to physically isolate the electrical components inside the high-voltage control box. When the electrical pollution level inside the box decreases, it is easy to cause the electrical insulation level inside the box to decrease, thereby causing safety accidents and seriously affecting system operation.

[0006] Chinese patent CN217469215U discloses a novel energy storage DC high-voltage control box. The control box includes a battery cluster management module, fuses, fuse holders, DC-DC converters, shunts, maintenance isolation switches, and push-button switches. The battery cluster management module, fuses, fuse holders, DC-DC converters, shunts, maintenance isolation switches, and push-button switches are disposed within the inner cavity of the control box. The control box is mounted externally to the lithium battery compartment body, structurally isolated from the battery compartment, and located near the battery cluster and energy storage converter. This design improves heat dissipation efficiency by mounting most electrical components internally and a small portion externally. However, this design fails to isolate the majority of electrical components within the box, preventing the impact of individual component failures on other devices. Utility Model Content

[0007] The technical problem to be solved by the utility model is to provide an energy storage system high-voltage control box with an integrated design, which can achieve isolation of electrical components by physically separating the electrical components, thereby improving the electrical safety level and insulation protection performance.

[0008] The utility model provides an integrated design of a high-voltage control box for an energy storage system, comprising a box body, electrical components, a plurality of positive copper bars and a plurality of negative copper bars, wherein an operation panel is provided on the box body, and the electrical components are connected to the operation panel through the positive copper bars and the negative copper bars; the box body also comprises an electrical isolation plate; the box body comprises an upper shell, a middle shell and a lower shell, the upper shell and the middle shell are assembled to form a high-voltage chamber, the middle shell and the lower shell are assembled to form a low-pressure chamber, the electrical components comprise a plurality of correspondingly connected high-voltage devices and low-voltage devices, the high-voltage devices are installed in the high-voltage chamber, and the low-voltage devices are installed in the low-pressure chamber; the electrical isolation plate is clamped with the bottom of the upper shell and the top of the middle shell, forming a plurality of independent chambers in the high-voltage chamber that match the high-voltage devices and are separated from each other, and the high-voltage devices are respectively and independently placed in single independent chambers.

[0009] Preferably, the high-voltage device includes a positive circuit assembly, a negative circuit assembly, a protection assembly, and a pre-charge circuit assembly. The positive circuit assembly and the negative circuit assembly are respectively connected to the protection assembly and the pre-charge circuit assembly; the positive circuit assembly, the negative circuit assembly, the protection assembly, and the pre-charge circuit assembly are each independently placed in a single independent chamber. The protection assembly is a circuit breaker or an isolating switch, and is used to control the current in the positive circuit assembly and control the on and off of the current in the negative circuit assembly. The pre-charge circuit assembly is used to limit peak current and protect the high-voltage circuit.

[0010] Preferably, the positive circuit assembly includes a positive main circuit fuse, a positive main circuit relay, and a current sensor connected by several positive copper busbars; the negative circuit assembly includes a negative main circuit fuse and a negative main circuit relay connected by several negative copper busbars, and the positive main circuit fuse, positive main circuit relay, current sensor, negative main circuit fuse, and negative main circuit relay are all independently placed in a single independent chamber. The positive main circuit fuse is used for overcurrent protection of the positive circuit assembly; the positive main circuit relay is used to control the on-off of the current in the positive circuit assembly; the current sensor is used to collect the current measurement of the positive circuit assembly; the negative main circuit fuse is used for overcurrent protection of the negative circuit assembly; and the negative main circuit relay is used to control the on-off of the current in the negative circuit assembly.

[0011] Preferably, the pre-charge circuit assembly includes a pre-charge relay, a pre-charge resistor and a pre-charge fuse.

[0012] Preferably, it also includes a high-voltage connector and a protection component controller, the high-voltage connector is connected to the electrical component, the protection component controller is connected to the protection component, the high-voltage connector and the protection component controller are both fixed in the operation panel, and the operation panel is arranged on the outside of the middle shell.

[0013] Preferably, it also includes a plug-in fixing plate, which is installed on the top of the middle shell body. The electrical components are connected to a plurality of low-voltage connectors, and the low-voltage connectors are fixed in the plug-in fixing plate; the plug-in fixing plate is provided with a plurality of first plug-in slots, and the upper shell body is provided with a plurality of second plug-in slots matching the first plug-in slots, and the low-voltage connectors are installed in the first plug-in slots and the second plug-in slots from the inside to the outside.

[0014] Preferably, it also includes a plug-in cover plate, which is connected to the upper shell and covers the second plug-in slot in the upper shell. The plug-in cover plate protects the second plug-in slot and prevents external rain and dust from affecting the internal electrical components.

[0015] Preferably, the low-voltage device includes a switching power supply and a main control panel, which are installed in the low-voltage chamber. The switching power supply is connected to a power button indicator light switch, which is fixed in the operation panel.

[0016] Preferably, it is further provided with two fixing ears, which are respectively installed on the left and right sides of the exterior of the middle shell, so as to facilitate the installation of the box body.

[0017] Preferably, the electrical components are all fixed on the middle housing. The electrical components are all fixed on the middle housing for easy assembly.

[0018] The utility model has the following technical effects:

[0019] 1. By assembling the upper shell and the middle shell, and the middle shell and the lower shell in the box, the box is divided into a high-voltage chamber for installing high-voltage components and a low-voltage chamber for installing low-voltage components. The high and low voltage components are installed in layers, which realizes the isolation of electrical components and improves the electrical safety level and insulation protection performance.

[0020] 2. By connecting the electrical isolation plate with the bottom of the upper shell and the top of the middle shell, several independent chambers that match the high-voltage devices and are separated from each other are formed in the high-voltage chamber. The high-voltage devices are placed independently in a single independent chamber. The method of dividing the independent chamber is used to physically isolate the high-voltage devices, strengthen the insulation protection level, and effectively prevent the failure of individual electrical components from affecting other devices. At the same time, it can also prevent safety problems caused by the reduction of electrical clearance and creepage distance when the environmental pollution level in the box is reduced.

[0021] 3. All electrical components are fixed on the middle shell for easy assembly. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 This is a schematic diagram of the explosion structure of the utility model;

[0023] Figure 2 This is a schematic diagram of the external structure of the utility model;

[0024] Figure 3 This is a top view of the internal structure of the utility model;

[0025] Figure 4 This is a bottom view of the internal structure of the box of the present utility model;

[0026] Figure 5 This is an exploded view of the shell structure assembly in the box of the utility model;

[0027] Figure 6 This is a schematic structural diagram of the electrical isolation plate of the present utility model;

[0028] Figure 7 This is a schematic diagram of the plug-in fixing plate structure of the present utility model.

[0029] In the figure: 1. Box body; 11. Upper shell; 111. Second plug-in slot; 12. Middle shell; 13. Lower shell; 211. Positive main circuit fuse; 212. Positive main circuit relay; 213. Current sensor; 221. Negative main circuit fuse; 222. Negative main circuit relay; 23. Protection component; 231. Protection component controller; 241. Pre-charge relay; 242. Pre-charge resistor; 243. Pre-charge fuse; 3. Operation panel; 31. High-voltage connector; 41. Positive copper busbar; 42. Negative copper busbar; 5. Electrical isolation board; 61. Plug-in fixing plate; 611. First plug-in slot; 62. Plug-in cover; 63. Low-voltage connector; 7. Switching power supply; 71. Power button indicator switch; 8. Main control panel; 9. Fixing ear. DETAILED DESCRIPTION

[0030] In order to make the purpose, technical solutions and advantages of the present invention more clear, the present invention is described in detail below with reference to the accompanying drawings.

[0031] like Figure 1 、 Figure 2 As shown, a high-voltage control box for an energy storage system with an integrated design includes a box body 1, electrical components, several positive copper bars 41 and several negative copper bars 42. An operation panel 3 is provided on the box body 1, and the electrical components are connected to the operation panel 3 through the positive copper bars 41 and the negative copper bars 42; it also includes an electrical isolation plate 5; the box body 1 includes an upper shell 11, a middle shell 12 and a lower shell 13, the upper shell 11 and the middle shell 12 are assembled to form a high-pressure chamber, and the middle shell 12 and the lower shell 13 are assembled to form a low-pressure chamber, the electrical components include several correspondingly connected high-voltage devices and low-voltage devices, the high-voltage devices are installed in the high-voltage chamber, and the low-voltage devices are installed in the low-pressure chamber; the electrical isolation plate 5 is clamped with the bottom of the upper shell 11 and the top of the middle shell 12, forming several independent chambers that match the high-voltage devices and are separated from each other in the high-voltage chamber, and the high-voltage devices are independently placed in single independent chambers. By assembling the upper shell 11 with the middle shell 12, and the middle shell 12 with the lower shell 13 in the box body 1, the box body 1 is divided into a high-voltage chamber for installing high-voltage components and a low-voltage chamber for installing low-voltage components. The high and low voltage components are installed in layers, isolating the electrical components and improving the electrical safety level and insulation protection performance. By snapping the electrical isolation plate 5 to the bottom of the upper shell 11 and the top of the middle shell 12, a number of independent chambers that match the high-voltage components and are separated from each other are formed within the high-voltage chamber. The high-voltage components are each placed independently in a single independent chamber. By dividing the independent chambers, the high-voltage components are physically isolated from each other, strengthening the insulation protection level and effectively preventing the failure of individual electrical components from affecting other components. It also prevents safety issues caused by the reduction of electrical clearance and creepage distance when the environmental pollution level in the box decreases.

[0032] The box body 1 is made of high-temperature resistant, flame-retardant, high-strength insulating plastic material to enhance the insulation protection performance.

[0033] like Figure 3 、 Figure 4 、 Figure 5 、 Figure 6 As shown, the high-voltage device includes a positive circuit assembly, a negative circuit assembly, a protection assembly 23, and a pre-charge circuit assembly. The positive circuit assembly and the negative circuit assembly are respectively connected to the protection assembly 23 and the pre-charge circuit assembly; the positive circuit assembly, the negative circuit assembly, the protection assembly 23, and the pre-charge circuit assembly are each independently placed in a single independent chamber. The protection assembly 23 is a circuit breaker or an isolating switch, and the protection assembly 23 is used to control the current in the positive circuit assembly and control the on and off of the current in the negative circuit assembly. The pre-charge circuit assembly is used to limit the peak current and protect the high-voltage circuit.

[0034] The positive circuit assembly includes a positive main circuit fuse 211, a positive main circuit relay 212, and a current sensor 213 connected by a plurality of positive copper bars 41; the negative circuit assembly includes a negative main circuit fuse 221 and a negative main circuit relay 222 connected by a plurality of negative copper bars 42. The positive main circuit fuse 211, the positive main circuit relay 212, the current sensor 213, the negative main circuit fuse 221, and the negative main circuit relay 222 are all independently placed in a single independent chamber. The positive main circuit fuse 211 is used for overcurrent protection of the positive circuit assembly; the positive main circuit relay 212 is used to control the on-off of the current in the positive circuit assembly; the current sensor 213 is used to collect the current measurement of the positive circuit assembly; the negative main circuit fuse 221 is used for overcurrent protection of the negative circuit assembly; the negative main circuit relay 222 is used to control the on-off of the current in the negative circuit assembly.

[0035] The pre-charge circuit assembly includes a pre-charge relay 241 , a pre-charge resistor 242 and a pre-charge fuse 243 .

[0036] It also includes a high-voltage connector 31 and a protection component controller 231. The high-voltage connector 31 is connected to the electrical components, and the protection component controller 231 is connected to the protection component 23. The high-voltage connector 31 and the protection component controller 231 are both fixed in the operation panel 3, and the operation panel 3 is arranged on the outside of the middle shell 12.

[0037] like Figure 7As shown, it also includes a plug-in fixing plate 61, which is installed on the top of the middle shell 12. The electrical components are connected to a plurality of low-voltage connectors 63, and the low-voltage connectors 63 are fixed in the plug-in fixing plate 61; the plug-in fixing plate 61 is provided with a plurality of first plug-in slots 611, and the upper shell 11 is provided with a plurality of second plug-in slots 111 matching the first plug-in slots 611. The low-voltage connectors 63 are installed in the first plug-in slots 611 and the second plug-in slots 111 from the inside to the outside.

[0038] It also includes a plug-in cover 62, which is connected to the upper shell 11 and covers the second plug-in slot 111 in the upper shell 11. The plug-in cover 62 protects the second plug-in slot 111 and prevents external rain and dust from affecting the internal electrical components.

[0039] The low-voltage device includes a switching power supply 7 and a main control panel 8, which are installed in the low-voltage chamber. The switching power supply 7 is connected to a power button indicator light switch 71, and the power button indicator light switch 71 is fixed in the operation panel 3.

[0040] It is also provided with two fixing ears 9, which are respectively installed on the left and right sides of the outside of the middle shell 12. The fixing ears 9 facilitate the installation of the box body 1.

[0041] The electrical components are all fixed on the middle housing 12. The electrical components are all fixed on the middle housing 12 for easy assembly.

[0042] An assembly method for an integrated energy storage system high-voltage control box is as follows:

[0043] Install the positive circuit assembly, negative circuit assembly, protection assembly 23, and pre-charge circuit assembly to the top surface of the middle shell 12, install the switching power supply 7 and the main control panel 8 to the bottom surface of the middle shell 12, assemble the lower shell 13 and the middle shell 12 to form a low-voltage cavity, install the plug-in fixing plate 61 to the top surface of the middle shell 12, install the low-voltage connector 63 in the plug-in fixing plate 61, and install the high-voltage connector 31, protection assembly controller 231 and power button indicator switch 71 on the operation panel. 3, insert the electrical isolation plate 5 into the top of the middle housing 12 and snap it into place. Then, install the upper housing 11, snapping the electrical isolation plate 5 into place with the upper housing 11 to form several independent cavities within the high-voltage chamber. These independent cavities physically isolate the positive circuit assembly, negative circuit assembly, protection assembly 23, and pre-charge circuit assembly at the top of the middle housing 12. Then, install the plug-in cover 62 onto the upper housing 11, and install the fixing ears 9 on the left and right sides of the middle housing 12 to complete the assembly. The high-voltage control box can then be installed in the desired location using the fixing ears 9 as needed.

[0044] The embodiments described above are merely preferred embodiments of the present invention and are not intended to limit the scope of the present invention. Without departing from the spirit of the present invention, various modifications and improvements to the technical solutions of the present invention made by ordinary technicians in this field should fall within the scope of protection determined by the claims of the present invention.

Claims

1. An integrated high-voltage control box for an energy storage system, comprising a box body, electrical components, a plurality of positive copper bars, and a plurality of negative copper bars; an operation panel is provided on the box body; the electrical components are connected to the operation panel via the positive copper bars and the negative copper bars; and the box body is provided with an operation panel. It also includes an electrical isolation plate; the box body includes an upper shell, a middle shell and a lower shell, the upper shell and the middle shell are assembled to form a high-pressure chamber, the middle shell and the lower shell are assembled to form a low-pressure chamber, the electrical components include a number of corresponding connected high-voltage devices and low-voltage devices, the high-voltage devices are installed in the high-voltage chamber, and the low-voltage devices are installed in the low-pressure chamber; the electrical isolation plate is clamped with the bottom of the upper shell and the top of the middle shell, forming a number of independent chambers in the high-pressure chamber that match the high-voltage devices and are separated from each other, and the high-voltage devices are independently placed in single independent chambers.

2. The integrated high-voltage control box for an energy storage system according to claim 1, characterized in that: The high-voltage device includes a positive circuit assembly, a negative circuit assembly, a protection assembly, and a pre-charge circuit assembly. The positive circuit assembly and the negative circuit assembly are connected to the protection assembly and the pre-charge circuit assembly respectively; the positive circuit assembly, the negative circuit assembly, the protection assembly, and the pre-charge circuit assembly are all independently placed in a single independent chamber.

3. The integrated high-voltage control box for an energy storage system according to claim 2, characterized in that: The positive circuit assembly includes a positive main circuit fuse, a positive main circuit relay and a current sensor connected by several positive copper bars; the negative circuit assembly includes a negative main circuit fuse and a negative main circuit relay connected by several negative copper bars. The positive main circuit fuse, positive main circuit relay, current sensor, negative main circuit fuse and negative main circuit relay are all independently placed in a single independent chamber.

4. The integrated high-voltage control box for an energy storage system according to claim 2, characterized in that: The pre-charge circuit assembly includes a pre-charge relay, a pre-charge resistor and a pre-charge fuse.

5. The integrated high-voltage control box for an energy storage system according to claim 2, characterized in that: It also includes a high-voltage connector and a protection component controller, the high-voltage connector is connected to the electrical component, the protection component controller is connected to the protection component, and the high-voltage connector and the protection component controller are both fixed in the operation panel, and the operation panel is arranged on the outside of the middle shell.

6. The integrated high-voltage control box for an energy storage system according to claim 1, characterized in that: It also includes a plug-in fixing plate, which is installed on the top of the middle shell. The low-voltage device is connected to a plurality of low-voltage connectors, and the low-voltage connectors are fixed in the plug-in fixing plate; the plug-in fixing plate is provided with a plurality of first plug-in slots, and the upper shell is provided with a plurality of second plug-in slots matching the first plug-in slots. The low-voltage connectors are installed in the first plug-in slots and the second plug-in slots from the inside to the outside.

7. The integrated high-voltage control box for an energy storage system according to claim 6, characterized in that: It also includes a plug-in cover plate, which is connected to the upper shell and covers the second plug-in slot in the upper shell.

8. The integrated high-voltage control box for an energy storage system according to claim 1, characterized in that: The low-voltage device includes a switching power supply and a main control panel, which are installed in the low-voltage chamber. The switching power supply is connected to a power button indicator light switch, which is fixed in the operation panel.

9. The integrated high-voltage control box for an energy storage system according to claim 1, characterized in that: It is also provided with two fixing ears, which are respectively installed on the left and right sides of the outside of the middle shell.

10. The integrated high-voltage control box for an energy storage system according to claim 1, characterized in that: The electrical components are all fixed on the middle shell.

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