High-power box-type liquid-cooled brake resistor

Abstract

The utility model relates to a high-power box-type liquid-cooled brake resistor, the resistor takes away heat through cooling liquid, the resistor comprises a shell, a resistor unit and a mounting plate, the mounting plate is mounted in the shell, the resistor unit is mounted on the mounting plate, the resistor further comprises a water inlet, a water outlet, a water passing plate and a water channel, the water inlet and the water outlet are installed on the shell, the water passing plate and the water channel are installed inside the shell, the water channel is connected with the water passing plate, one end of the resistor unit is placed in the water channel, and the cooling liquid sequentially passes through the water inlet, the water passing plate, the water channel and the water outlet. According to the utility model, the water channel is arranged, the integrated flow guide (anti-backflow design) design is adopted in the shell, the cooling liquid passes through the tubular resistor from bottom to top, and the temperature controller and the pressure monitoring instrument are arranged, so that the heat dissipation function is exerted to the utmost extent; by arranging the reinforcing ribs, the pressure bearing capacity of the shell can be enhanced, and the deformation amount of the shell in the working pressure bearing process is reduced.

Description

Technical Field

[0001] This invention relates to the field of liquid-cooled braking resistor technology, and in particular to a high-power box-type liquid-cooled braking resistor. Background Technology

[0002] The main functions of high-power box-type liquid-cooled braking resistors are: When large electric drives switch rapidly, they can generate reverse high-power surges that can damage electrical components. To prevent interference and damage to these components and reduce their impact, large power resistor modules are added before the components to intercept and absorb the power surges, thus protecting the electrical components. In today's rapidly developing electrical technology, especially in new energy storage equipment, large heavy trucks, and locomotive equipment, more and more customers require small, high-power braking resistor modules with flexible installation space; high-power box-type liquid-cooled braking resistors precisely meet these current needs.

[0003] Chinese patent application CN113077949A discloses a high-power resistor with a tubular liquid-cooled structure. This patent includes a resistor body and a rapid-cooling inlet structure. The rapid-cooling inlet structure is fixedly connected to one side of the resistor body. This structure is used to rapidly cool and control the temperature of the introduced liquid, giving it a large specific heat capacity. It also includes a quick-locking fastening structure. This patent has a complex structure, relying on a combination of heat pipes and liquid flow pipes for heat dissipation, but only uses a single heat dissipation unit, resulting in poor heat dissipation performance.

[0004] Therefore, providing a high-power box-type liquid-cooled braking resistor with a simple structure and good heat dissipation is an urgent problem to be solved. Utility Model Content

[0005] The purpose of this invention is to overcome the defects of the existing technology and provide a high-power box-type liquid-cooled braking resistor.

[0006] The objective of this utility model can be achieved through the following technical solutions:

[0007] According to one aspect of this utility model, a high-power box-type liquid-cooled braking resistor is provided. The resistor carries away heat through a coolant. The resistor includes a housing, a resistor unit, and a mounting plate. The mounting plate is installed inside the housing, and the resistor unit is installed on the mounting plate. The resistor also includes a water inlet, a water outlet, a water flow plate, and a water channel. The water inlet and water outlet are installed on the housing, and the water flow plate and water channel are installed inside the housing. The water channel is connected to the water flow plate, and one end of the resistor unit is placed in the water channel. The coolant passes through the water inlet, the water flow plate, the water channel, and the water outlet in sequence.

[0008] As a preferred technical solution, the resistor unit includes a tubular resistor, a sealing ring, and a resistor flange plate. The tubular resistor is mounted on the resistor flange plate, and the resistor flange plate is mounted on the mounting plate via the sealing ring.

[0009] As a preferred technical solution, the resistor unit further includes a power connection unit, which is installed at the end of the tubular resistor.

[0010] As a preferred technical solution, the tubular resistor is a resistor tube with a spiral bending structure or a U-shaped structure.

[0011] As a preferred technical solution, the resistor further includes a protective cover and fixing bolts, wherein the protective cover is installed on the top of the housing by the fixing bolts.

[0012] As a preferred technical solution, the water-passing plate is provided with water channel holes, and the water-passing plate is connected to the water channel through the water channel holes.

[0013] As a preferred technical solution, the water-passing plate and the shell form an inlet space, and the inlet is installed on the shell corresponding to the inlet space; the mounting plate, the water-passing plate and the shell form an outlet space, the water channel is located in the outlet space, and the outlet is installed on the shell corresponding to the outlet space.

[0014] As a preferred technical solution, the resistor further includes a temperature controller and a pressure monitoring instrument, which are installed at the water inlet or the water outlet.

[0015] As a preferred technical solution, the resistor further includes a mounting bracket, which is mounted on the housing.

[0016] As a preferred technical solution, the shell is provided with reinforcing ribs.

[0017] Compared with the prior art, the present invention has the following beneficial effects:

[0018] 1. This utility model, by setting up water channels and adopting an integrated internal flow guide (anti-backflow design) design, places the tubular resistor inside the water channels. The coolant flows from bottom to top through the tubular resistor, and is equipped with a temperature controller and pressure monitoring instrument, which maximizes the heat dissipation function.

[0019] 2. By setting reinforcing ribs, this utility model can enhance the pressure-bearing capacity of the shell and reduce the deformation of the shell under working pressure.

[0020] 3. The tubular resistor of this utility model is made of a resistor tube with a spiral bending structure or a U-shaped structure, which has better heat dissipation and the raw materials are simple to obtain and have low cost.

[0021] 4. The box-type liquid-cooled braking resistor of this utility model has a free installation method and is suitable for more sports occasions, including large sports equipment, heavy trucks and locomotives. Attached Figure Description

[0022] Figure 1 This is an exploded view of the overall structure of this utility model;

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

[0024] Figure 3 This is a schematic diagram of the internal structure of the shell of this utility model;

[0025] Figure 4 This is a schematic diagram of the internal structure of the housing with tubular resistor of this utility model.

[0026] 1. Tubular resistor; 2. Housing; 3. Water passage plate; 4. Water channel; 5. Mounting plate; 6. Sealing ring; 7. Protective cover plate; 8. Water outlet; 9. Power connection unit; 10. Water inlet; 11. Water channel hole; 12. Resistor flange plate; 13. Fixing bolts; 14. Mounting bracket; 15. Reinforcing rib. Detailed Implementation

[0027] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some, not all, of the embodiments of the present utility model. Based on the embodiments of the present utility model, all other embodiments obtained by those skilled in the art without creative effort should fall within the protection scope of the present utility model.

[0028] The main functions of high-power box-type liquid-cooled braking resistors are: When large electric drives switch rapidly, they can generate reverse high-power surges that can damage electrical components. To prevent interference and damage to these components and reduce their impact, large power resistor modules are added before the components to intercept and absorb the power surges, thus protecting the electrical components. In today's rapidly developing electrical technology, especially in new energy storage equipment, large heavy trucks, and locomotive equipment, more and more customers require small, high-power braking resistor modules with flexible installation space; high-power box-type liquid-cooled braking resistors precisely meet these current needs.

[0029] This invention provides a high-power box-type liquid-cooled braking resistor. By incorporating water channels and an integrated internal flow-guiding design (anti-backflow design), the tubular resistor is placed within these channels. Coolant flows upwards through the tubular resistor, and a temperature controller and pressure monitoring instrument are included to maximize heat dissipation. Reinforcing ribs enhance the pressure-bearing capacity of the casing, reducing deformation under operational pressure. The tubular resistor is made of a spirally bent or U-shaped resistor tube, resulting in better heat dissipation. Furthermore, the raw materials are readily available and cost-effective. This box-type liquid-cooled braking resistor offers flexible installation options and is suitable for a wider range of applications, including large sports equipment, heavy trucks, and locomotives.

[0030] Example 1

[0031] like Figure 1 As shown, a high-power box-type liquid-cooled braking resistor is disclosed. The resistor removes heat through a coolant. The resistor includes a housing 2, a resistor unit, and a mounting plate 5. The mounting plate 5 is installed inside the housing 2, and the resistor unit is installed on the mounting plate 5. The resistor also includes a water inlet 10, a water outlet 8, a water-passing plate 3, and a water channel 4. The water inlet 10 and the water outlet 8 are installed on the housing 2, and the water-passing plate 3 and the water channel 4 are installed inside the housing 2. The water channel 4 is connected to the water-passing plate 3, and one end of the resistor unit is placed in the water channel 4. The coolant passes through the water inlet 10, the water-passing plate 3, the water channel 4, and the water outlet 8 in sequence.

[0032] like Figure 2 As shown, the resistor unit includes a tubular resistor 1, a sealing ring 6, and a resistor flange plate 12. The tubular resistor 1 is mounted on the resistor flange plate 12, and the resistor flange plate 12 is mounted on the mounting plate 5 through the sealing ring 6.

[0033] The resistor unit also includes a power connection unit 9, which is installed at the end of the tubular resistor 1.

[0034] In this embodiment, the mounting plate 5 is provided with a semi-circular mounting groove, and the resistor flange plate 12 is mounted on the semi-circular mounting groove through a sealing ring 6; two water channels 4 and two semi-circular mounting grooves are provided, and the tubular resistor 1 is accelerated to dissipate heat in the two water channels 4; the housing 2 and other components are all made of stainless steel, such as... Figure 3 , Figure 4As shown, the coolant sequentially passes through the inlet 10, the water-passing plate 3, the water channel 4, and the outlet 8. The water-passing plate 3 is welded or fixed to the outer casing 2. The inlet space serves as a low-temperature buffer zone for the incoming liquid, preventing the backflow of high-temperature liquid. The water channel 4 is then welded and fixed to the water-passing plate 3, guiding the low-temperature fluid through the high-heat zone of the tubular resistor 1 and quickly carrying the heat out of the outlet 8. The internal fluid heat dissipation structure of this enclosure is rationally designed and exhibits high environmental resistance and vibration resistance. The resistor flange plate 12 adopts a multi-groove structure, with multiple auxiliary sealing rings 6 during installation. It features a shock-resistant, environmentally resistant, and leak-proof design, with a pressure resistance ≥0.5 MPa. The tubular resistor 1 is connected to the power supply via the power connection unit 9.

[0035] The tubular resistor 1 is made of a resistor tube with a spiral bending structure or a U-shaped structure. It can be designed as a single-tube insertion type, and a temperature monitoring design can be added in the middle. The tubular resistor 1 is welded and fixed to the resistor flange plate 12 (the weld seam can withstand a pressure of ≥0.5Mpa for ≥3min); this design can meet the installation requirements of high power in small spaces and is a new type of product design.

[0036] The resistor also includes a protective cover plate 7 and a fixing bolt 13, wherein the protective cover plate 7 is mounted on the top of the housing 2 by the fixing bolt 13.

[0037] The water-passing plate 3 is provided with water channel holes 11, and the water-passing plate 3 is connected to the water channel 4 through the water channel holes 11. The coolant enters the water channel 4 through the water channel holes 11 and makes full contact with the tubular resistor 1.

[0038] The water inlet plate 3 and the housing 2 form an inlet space, and the inlet 10 is installed on the housing 2 corresponding to the inlet space; the mounting plate 5, the water inlet plate 3 and the housing 2 form an outlet space, the water channel 4 is located in the outlet space, and the outlet 8 is installed on the housing 2 corresponding to the outlet space.

[0039] The resistor also includes a temperature controller and a pressure monitoring instrument, which are installed at the inlet 10 or the outlet 8. By installing the temperature controller and pressure monitoring instrument to monitor the temperature and pressure of the coolant, the heat exchange process and operation are monitored; this design achieves full transfer of heat power generated during braking and over-protection against abnormal conditions and frequent braking.

[0040] The resistor also includes a mounting bracket 14, which is mounted on the housing 2. The mounting bracket 14 allows for free-space planar mounting or hanging mounting, suitable for both high-speed movement and stationary applications, while meeting a 6g shock resistance requirement.

[0041] The shell 2 is provided with reinforcing ribs 15. The shell 2 is designed with multiple rows of long strip reinforcing ribs 15, which can enhance the pressure-bearing capacity of the shell and reduce the deformation of the shell under working pressure.

[0042] In this embodiment, a structure consisting of an integral square outer shell cavity 2 (the shell is made entirely of stainless steel and is achieved through welding) + protective cover plate 7 is used. The design includes an inlet 10 and an outlet 8 for installing the maximum pressure difference, ensuring sufficient liquid cooling heat exchange. This design structure is stable, has a high overall protection level (IP6K8B or higher), is resistant to harsh environments, and has strong adaptability to installation and application, completely different from conventional cylindrical designs.

[0043] The above description is merely a specific embodiment of this utility model, but the protection scope of this utility model is not limited thereto. Any person skilled in the art can easily conceive of various equivalent modifications or substitutions within the technical scope disclosed in this utility model, and these modifications or substitutions should all be covered within the protection scope of this utility model. Therefore, the protection scope of this utility model should be determined by the scope of the claims.

Claims

1. A high-power box-type liquid-cooled braking resistor, wherein the resistor carries away heat through a coolant, the resistor comprising a housing (2), a resistor unit, and a mounting plate (5), the mounting plate (5) being installed inside the housing (2), and the resistor unit being installed on the mounting plate (5), characterized in that, The resistor also includes an inlet (10), an outlet (8), a water-passing plate (3), and a water channel (4). The inlet (10) and the outlet (8) are installed on the housing (2). The water-passing plate (3) and the water channel (4) are installed inside the housing (2). The water channel (4) is connected to the water-passing plate (3). One end of the resistor unit is placed in the water channel (4). The coolant passes through the inlet (10), the water-passing plate (3), the water channel (4), and the outlet (8) in sequence.

2. A high-power box-type liquid-cooled braking resistor according to claim 1, characterized in that, The resistor unit includes a tubular resistor (1), a sealing ring (6), and a resistor flange plate (12). The tubular resistor (1) is mounted on the resistor flange plate (12), and the resistor flange plate (12) is mounted on the mounting plate (5) through the sealing ring (6).

3. A high-power box-type liquid-cooled braking resistor according to claim 2, characterized in that, The resistor unit also includes a power connection unit (9), which is installed at the end of the tubular resistor (1).

4. A high-power box-type liquid-cooled braking resistor according to claim 2, characterized in that, The tubular resistor (1) is a resistor tube with a spiral bending structure or a U-shaped structure.

5. A high-power box-type liquid-cooled braking resistor according to claim 1, characterized in that, The resistor also includes a protective cover (7) and a fixing bolt (13), the protective cover (7) being mounted on the top of the housing (2) by the fixing bolt (13).

6. A high-power box-type liquid-cooled braking resistor according to claim 1, characterized in that, The water-passing plate (3) is provided with a water channel hole (11), and the water-passing plate (3) is connected to the water channel (4) through the water channel hole (11).

7. A high-power box-type liquid-cooled braking resistor according to claim 1, characterized in that, The water inlet plate (3) and the shell (2) form an inlet space, and the inlet (10) is installed on the shell (2) corresponding to the inlet space; the mounting plate (5), the water inlet plate (3) and the shell (2) form an outlet space, the water channel (4) is located in the outlet space, and the outlet (8) is installed on the shell (2) corresponding to the outlet space.

8. A high-power box-type liquid-cooled braking resistor according to claim 1, characterized in that, The resistor also includes a temperature controller and a pressure monitoring instrument, which are installed at the inlet (10) or the outlet (8).

9. A high-power box-type liquid-cooled braking resistor according to claim 1, characterized in that, The resistor also includes a mounting bracket (14) which is mounted on the housing (2).

10. A high-power box-type liquid-cooled braking resistor according to claim 1, characterized in that, The shell (2) is provided with reinforcing ribs (15).

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