Ultrahigh-power water-cooled rectifier for plateau
By adopting a four-in-four-out bidirectional double-flow cooling system and a non-standard busbar design in the rectifier for high-altitude areas, the problems of insufficient cooling and insulation strength of traditional water-cooled rectifiers in high-altitude areas have been solved, achieving efficient and stable operation.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-04-18
- Publication Date
- 2026-04-03
AI Technical Summary
Traditional high-power water-cooled rectifiers are difficult to operate efficiently and stably in high-altitude areas. Insufficient cooling water flow and insufficient insulation strength lead to safety hazards, especially under low air pressure. Existing technologies are unable to meet the technical challenges of electrolytic aluminum production. The traditional water flow is insufficient, especially under low air pressure. Existing technologies are unable to address the problems of reduced insulation strength and decreased cooling efficiency caused by low air pressure in high-altitude areas.
It adopts a four-in-four-out bidirectional double-flow cooling structure and an irregular busbar design. By staggering the AC input busbars of the upper and lower busbar frames, the spacing between the same-phase reverse parallel windings is increased. Flexible conductive aluminum plates and temperature sensors are used to monitor the temperature of the heat dissipation frame to ensure cooling water flow and insulation strength.
It effectively prevents busbar short circuits, improves the safety and reliability of the rectifier, ensures efficient cooling and stable operation, and meets the power demands of high-altitude environments.
Smart Images
Figure CN224083866U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of power electronics technology, and in particular to an ultra-high power water-cooled rectifier for use in high-altitude areas. Background Technology
[0002] In the design of traditional high-power water-cooled rectifiers, with the continuous growth of power demand and the constant changes in the application environment, especially the significant increase in demand from heavy industries such as electrolytic aluminum in plateau regions, traditional water-cooling systems and rectifier designs are gradually becoming unable to meet the requirements of efficient and stable operation.
[0003] The low air pressure at high altitudes leads to a decrease in air density, causing a sharp drop in the efficiency of traditional air cooling. If the water cooling system follows the design of the plains, the cooling water flow will be insufficient, which can easily cause local overheating and affect the stability of the rectifier. Furthermore, the air insulation strength in the high-altitude environment is much lower than that in the plains. The existing AC input busbar layout of the rectifier (insufficient spacing between the same-phase reverse parallel windings) is prone to short circuits due to contact between the soft connection parts, posing a serious safety hazard. Utility Model Content
[0004] The purpose of this invention is to improve the safety and cooling efficiency of the rectifier.
[0005] To achieve the above objectives, the present invention adopts the following technical solution: an ultra-high power water-cooled rectifier for high-altitude applications, comprising a rectifier cabinet and a heat dissipation frame fixed inside it. The inlet and outlet of the cooling water on the heat dissipation frame are a four-inlet, four-outlet, bidirectional compound water flow cooling structure. The rectifier cabinet is equipped with an upper busbar frame AC input busbar and a lower busbar frame AC input busbar that are horizontally staggered. The upper busbar frame AC input busbar and the lower busbar frame AC input busbar have a bent irregular structure that can increase the phase distance between the same-phase and anti-parallel windings.
[0006] Furthermore, the heat dissipation frame is equipped with a temperature sensor for monitoring its temperature.
[0007] Furthermore, the AC input busbar of the upper busbar frame is made of flexible conductive aluminum plate and is bent by a hydraulic press with a capacity of over 60 tons.
[0008] Furthermore, the AC input busbars of the upper busbar frame and the AC input busbars of the lower busbar frame are respectively connected in parallel straight lines to the transformer valve side.
[0009] In summary, due to the adoption of the above technical solution, the beneficial effects of this utility model are:
[0010] 1. By bending the AC input busbar of the rectifier cabinet into an irregular shape and staggering the AC input terminals of the upper and lower busbars, short circuits are effectively prevented in the flexible connection parts on the busbar connecting the transformer and the rectifier cabinet. Especially in high-altitude areas, where the air pressure is low and the insulation strength is reduced, this staggered design can effectively improve the safety and reliability of the system.
[0011] 2. The heat dissipation frame adopts a "two-way duplex water flow" cooling design, which uses the outer water flow to cool the inner water flow. By increasing the cooling water flow rate, the heat dissipation effect is improved, ensuring that the temperature rise of each section of the busbar remains balanced, thereby avoiding the impact of overheating on the rectifier performance and ensuring the efficient cooling and stable operation of the rectifier. Attached Figure Description
[0012] Figure 1 The diagram shows the arrangement of the upper busbar frame and the lower busbar frame of the rectifier cabinet of this utility model;
[0013] Figure 2 A schematic diagram of the irregularly shaped conductive busbar of this utility model is shown;
[0014] Figure 3 This diagram shows the AC (valve side) connection busbar arrangement between the transformer and rectifier of this utility model (staggered upper and lower rows);
[0015] Figure 4 This diagram shows a conventional (non-misaligned) AC (valve side) connection busbar arrangement between the transformer and rectifier according to the present invention;
[0016] Figure 5 A schematic diagram of the water channel connection (bidirectional duplex water flow) of the heat dissipation frame of this utility model is shown.
[0017] Legend:
[0018] 10. Heat dissipation frame; 11. Rectifier cabinet; 12. Upper busbar frame AC input busbar; 13. Lower busbar frame AC input busbar. Detailed Implementation
[0019] 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 embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of the present utility model.
[0020] Please see Figures 1-5This utility model provides a technical solution: an ultra-high power water-cooled rectifier for high-altitude applications, including a heat dissipation frame 10 and a rectifier cabinet 11. The AC input terminals of the upper busbar frame AC input busbar 12 and the lower busbar frame AC input busbar 13 installed inside the rectifier cabinet 11 are staggered by 170mm in the horizontal direction, and both are bent irregular structures.
[0021] By bending the AC input busbar of rectifier cabinet 11 into an irregular shape and staggering the AC input busbar 12 of the upper busbar frame and the AC input busbar 13 of the lower busbar frame by 170mm, the soft connection part on the connecting busbar between transformer 14 and rectifier cabinet 11 (two sets of windings connected in opposite parallel phases) can be effectively prevented from short-circuiting. Especially in high-altitude areas, where the air pressure is low and the insulation strength is reduced, this staggered design can effectively improve the safety and reliability of the system.
[0022] Furthermore, the AC input busbar 12 of the upper busbar frame and the AC input busbar 13 of the lower busbar frame are respectively connected in parallel straight lines to the valve side of the transformer 14, reducing unnecessary bends and improving the stability of the electrical connection.
[0023] Furthermore, while meeting conductivity requirements, a softer conductive aluminum plate is selected as the AC incoming line connection plate. Because the AC incoming line connection plate is very thick and has a small bending radius, special processes and tooling are required (using a hydraulic press of 60 tons or more, making special tooling according to the bending dimensions of the irregularly shaped busbar parts processing drawings, making special stainless steel pressure plate pads according to the roughness requirements of the conductive overlap surface of the irregularly shaped busbar, and adopting heating or cold pressing methods and other guarantee measures according to the copper and aluminum material requirements of the conductive busbar) to ensure that the conductive aluminum plate does not crack during the bending process.
[0024] Furthermore, the heat dissipation frame 10 fixed inside the rectifier cabinet 11 adopts bidirectional dual-flow cooling, using the outer water flow to cool the inner water flow. By increasing the cooling water flow rate, the heat dissipation effect is improved, ensuring that the temperature rise of each section of the busbar remains balanced, thereby avoiding the impact of overheating on the performance of the rectifier 15, and ensuring efficient cooling and stable operation.
[0025] like Figure 5 As shown, the existing heat dissipation frame design has 2 inlets and 2 outlets. In this application, the heat dissipation frame 10 is changed to 4 inlets and 4 outlets, thereby effectively increasing the cooling water flow rate by about 100%. This cooling design can significantly improve the overall heat transfer capability of the rectifier 15, enabling it to perform thermal energy management efficiently and maintain a low temperature rise in various bus sections and semiconductor devices within the rectifier 15.
[0026] The above description is only a preferred embodiment of the present utility model, but the protection scope of the present utility model is not limited thereto. Any equivalent substitutions or changes made by those skilled in the art within the technical scope disclosed in the present utility model, based on the technical solution and the inventive concept of the present utility model, should be included within the protection scope of the present utility model.
Claims
1. A high-power water-cooled rectifier for high-altitude applications, comprising a rectifier cabinet (11) and a heat dissipation frame (10) fixed therein, characterized in that: The cooling water inlet and outlet of the heat dissipation frame (10) are a four-inlet, four-outlet bidirectional compound water flow cooling structure. The rectifier cabinet (11) is equipped with an upper busbar frame AC input busbar (12) and a lower busbar frame AC input busbar (13) that are staggered in the horizontal direction. The upper busbar frame AC input busbar (12) and the lower busbar frame AC input busbar (13) have a bent irregular structure that can increase the phase distance between the same phase reverse parallel windings.
2. The ultra-high power water-cooled rectifier for high-altitude applications according to claim 1, characterized in that: The heat dissipation frame (10) is provided with a temperature sensor for monitoring its temperature.
3. The ultra-high power water-cooled rectifier for high-altitude applications according to claim 1, characterized in that: The upper busbar frame AC input busbar (12) is made of flexible conductive aluminum plate.
4. The ultra-high power water-cooled rectifier for high-altitude applications according to claim 1, characterized in that: The upper busbar frame AC input busbar (12) and the lower busbar frame AC input busbar (13) are respectively connected in parallel straight lines to the valve side of the transformer (14).