Water-cooled high-frequency power supply rectifier

Abstract

The utility model relates to the technical field of power rectifiers, in particular to a water-cooled high-frequency power rectifier which comprises a rectifier shell, an L-shaped suspension support, a rectifying mechanism, a door plate, an air cooling mechanism and a water cooling mechanism. A rectifying bin is formed in the rectifier shell, a bin opening is formed in the front end of the rectifying shell, a door plate used for sealing the bin opening is arranged at the outer end of the bin opening in a matched mode, an L-shaped suspension support playing a role in suspension supporting is arranged in the rectifying bin, a rectifying mechanism is arranged above the L-shaped suspension support, and air tunnels are formed in the two side walls of the rectifying bin. Air cooling mechanisms are arranged in the two groups of wind tunnels; a water cooling mechanism is arranged at the top of the rectifier shell; through cooperative work of the water cooling mechanism and the air cooling mechanism, the temperature in the rectifier can be effectively reduced, the curved heat dissipation pipes in the water cooling mechanism are evenly distributed, heat generated by the rectifying mechanism can be fully absorbed, and the air cooling mechanism further takes away heat by accelerating air flow.

Description

Technical Field

[0001] This application relates to the field of power rectifier technology, and more particularly to water-cooled high-frequency power rectifiers. Background Technology

[0002] A high-frequency power rectifier is a power electronic device that uses fast switching devices and advanced control technology to efficiently convert alternating current (AC) into direct current (DC). It is widely used in fields with strict requirements for size and energy efficiency, such as communication power supplies, industrial frequency converters, and new energy power generation systems. A water-cooled high-frequency power rectifier is a high-frequency power rectifier that uses water cooling for heat dissipation.

[0003] Traditional water-cooled high-frequency power rectifiers typically rely on a single water cooling system for cooling during operation. The straight-pipe water cooling circuit layout limits the heat dissipation area, which can easily lead to localized overheating and uneven temperature distribution, affecting the lifespan of the device.

[0004] Therefore, to address the problems of traditional water-cooled high-frequency power rectifiers that rely solely on water cooling for heat dissipation and have limited heat dissipation area, a water-cooled high-frequency power rectifier can be designed. By using curved pipes to optimize the water cooling pipe layout, the heat dissipation area can be increased, and water cooling and air cooling can be combined to solve the above problems. Utility Model Content

[0005] In order to overcome the shortcomings of traditional water-cooled high-frequency power rectifiers, which typically rely on a single water cooling system for cooling during operation and employ a straight-pipe water cooling circuit layout, resulting in a limited heat dissipation area, which can easily lead to localized overheating and uneven temperature distribution, thus affecting the service life of the device.

[0006] The technical solution is as follows: A water-cooled high-frequency power rectifier includes a rectifier housing, an L-shaped suspended bracket, a rectifier mechanism, a door panel, an air-cooling mechanism, and a water-cooling mechanism. The rectifier housing has a rectifier compartment inside and a compartment opening at the front end. A door panel for sealing the compartment opening is provided at the outer end of the opening. The rectifier compartment has an L-shaped suspended bracket inside, which provides suspension support. A rectifier mechanism for power rectification is located above the L-shaped suspended bracket. Wind tunnels are provided on both sides of the rectifier compartment. Air-cooling mechanisms for air cooling are provided inside both sets of wind tunnels. A water-cooling mechanism for water cooling is located on the top of the rectifier housing.

[0007] Furthermore, two sets of pipe openings are provided diagonally along the top edge of the rectifier housing. The two sets of pipe openings penetrate the top of the rectifier housing and connect with the rectifier compartment. A bracket is provided between the two sets of pipe openings.

[0008] Furthermore, the water cooling mechanism includes curved heat dissipation pipes, which are evenly distributed at the bottom and sides of the L-shaped suspended bracket. The two ends of the curved heat dissipation pipes extend through two sets of pipe openings to the top of the rectifier housing.

[0009] Furthermore, a water tank is provided at one end of the curved heat dissipation tube, and a cooling box corresponding to the water tank is provided at the upper end of the bracket. A primary connecting pipe for connecting the water tank and the cooling box is provided between the water tank and the cooling box.

[0010] Furthermore, a water pump is provided at the other end of the curved heat dissipation pipe, and a secondary connecting pipe for connecting the water pump and the cooling box is provided between the water pump and the cooling box.

[0011] Furthermore, the air-cooling mechanism includes an air duct located inside the wind tunnel. A rotating shaft is located at the center of the air duct, and six sets of fan blades are arranged around the outer end of the rotating shaft. A motor is located at the end of the rotating shaft away from the rectifier chamber, and the rotating shaft is connected to the output shaft of the motor. A support frame connected to the air duct is located at the outer end of the motor.

[0012] Furthermore, a fixed frame is provided at the end of the air duct away from the rectifier chamber, and multiple sets of heat dissipation aluminum fins are evenly arranged inside the fixed frame.

[0013] Furthermore, a movable connecting sleeve is provided between the door panel and the storage opening, and the door panel and the storage opening are movably connected through the movable connecting sleeve.

[0014] The beneficial effects are that, compared to traditional water-cooled high-frequency power rectifiers, which rely on a single water cooling system and have limited heat dissipation area, this application effectively reduces the internal temperature of the rectifier through the coordinated work of a water-cooling mechanism and an air-cooling mechanism. The curved heat dissipation pipes in the water-cooling mechanism are evenly distributed and can fully absorb the heat generated by the rectifier mechanism, while the air-cooling mechanism further removes heat by accelerating airflow. Compared with the traditional single heat dissipation method, this dual heat dissipation system can keep the rectifier at a lower temperature during long-term operation, improving the stability and reliability of the rectifier. The L-shaped suspended bracket not only supports the rectifier mechanism but also provides space for the arrangement of the curved heat dissipation pipes, making full use of the internal space of the rectifier. The entire rectifier has a compact structure and relatively small size, making it suitable for installation and use in different working environments. Attached Figure Description

[0015] Figure 1 This is a three-dimensional structural diagram of the water-cooled high-frequency power rectifier of this application.

[0016] Figure 2 This is a three-dimensional structural diagram of the rectifier housing and door panel assembly of this application;

[0017] Figure 3 This is a three-dimensional structural diagram of the shaft and fan blade assembly of this application;

[0018] Figure 4 This is a three-dimensional structural diagram of the combination of the fixing frame and the heat sink aluminum sheet in this application;

[0019] Figure 5 This is a three-dimensional structural diagram of the water-cooling mechanism of this application.

[0020] Explanation of reference numerals in the attached drawings: 1. Rectifier housing; 101. Rectifier compartment; 102. Compartment opening; 2. L-shaped suspended bracket; 3. Rectification mechanism; 4. Door panel; 5. Air-cooling mechanism; 501. Air duct; 502. Support frame; 503. Motor; 504. Shaft; 505. Fan blade; 506. Fixing frame; 507. Heat sink fins; 6. Water-cooling mechanism; 601. Cooling box; 602. Water pump; 603. Water tank; 604. Primary connecting pipe; 605. Secondary connecting pipe; 606. Curved heat sink; 7. Movable connecting sleeve; 8. Wind tunnel; 9. Bracket; 10. Pipe opening. Detailed Implementation

[0021] The present application will be described in detail below with reference to the accompanying drawings and specific embodiments.

[0022] High-frequency power rectifiers, as crucial equipment in the field of power electronics, play an irreplaceable role in many aspects of modern industrial production, scientific research experiments, and daily life. They efficiently convert alternating current (AC) into direct current (DC), providing reliable power support for various devices that require a stable DC power supply.

[0023] The core principle of a high-frequency power rectifier is based on the switching characteristics of power electronic devices. First, the input AC power passes through a rectifier circuit, typically a diode bridge, converting both the positive and negative half-cycles of the AC power into DC power. This step results in DC power with significant ripple. Next, to reduce this ripple, a filter circuit is introduced, commonly using capacitor filtering, inductor filtering, or a combination of both (LC filtering). Energy storage elements smooth the current. However, even after simple rectification and filtering, the DC power still exhibits some ripple, and the voltage may be unstable. To obtain a more stable and pure DC output, the high-frequency power rectifier also employs high-frequency conversion technology. Through a control circuit, it inverts the rectified and filtered DC power into high-frequency AC power, typically at frequencies of tens of kilohertz or even higher. Then, a high-frequency transformer performs voltage transformation, increasing or decreasing the voltage according to actual needs. The high-frequency rectifier circuit then converts the high-frequency AC power back into DC power. Finally, after filtering and voltage regulation, a stable DC voltage that meets the requirements is output.

[0024] Compared to traditional line-frequency power rectifiers, high-frequency power rectifiers, due to their higher operating frequency, allow for significant reductions in the size and weight of transformers and inductors, as well as lower switching losses, resulting in higher conversion efficiencies, typically exceeding 90%. This significantly reduces energy consumption. Through advanced control circuits and precise voltage regulation, high-frequency power rectifiers provide extremely stable DC output voltages with ripple factors typically kept low, meeting the demands of applications requiring high power stability, such as powering high-precision electronic equipment. The control circuitry of high-frequency power rectifiers can quickly respond to load changes, adjusting output voltage and current promptly. In the event of sudden load changes, they can rapidly restore stable output, ensuring the normal operation of the equipment.

[0025] In the electroplating process, a stable DC power supply is required to ensure uniform deposition of metal ions on the workpiece surface. High-frequency power rectifiers, due to their good output stability and high current regulation accuracy, can effectively improve electroplating quality and reduce plating defects, and are widely used in decorative electroplating, functional electroplating, and other fields.

[0026] For example, in water electrolysis for hydrogen production and the chlor-alkali industry, the high-current, stable DC power provided by high-frequency power rectifiers is crucial for the smooth operation of the electrolysis reaction, helping to improve electrolysis efficiency and reduce production costs. Various devices in communication base stations require stable DC power; the small size, light weight, and high efficiency of high-frequency power rectifiers make them an ideal choice for communication base station power systems, providing reliable power while saving space and reducing energy consumption. In medical equipment such as MRI machines and X-ray machines, the stability and purity of the power supply are extremely important. High-frequency power rectifiers can meet the stringent requirements of these devices, ensuring the precise operation of medical equipment and providing reliable support for medical diagnosis and treatment.

[0027] High-frequency power rectifiers, with their unique working principle, rational structural design, and excellent performance advantages, have been widely used in many fields. With the continuous development of power electronics technology, high-frequency power rectifiers will continue to be innovated and optimized, playing an even more important role in improving energy efficiency and promoting technological progress in various industries.

[0028] High-frequency power rectifiers, as key devices for converting alternating current (AC) to direct current (DC), are widely used in electroplating, electrolysis, induction heating, and many other fields. However, during operation, their internal power electronic components, such as diodes, thyristors, and IGBTs, generate significant heat due to conduction resistance and switching losses during the power conversion process. Taking the electroplating industry as an example, a 100kW high-frequency power rectifier may experience a rapid increase in internal temperature within a short period if heat dissipation measures are inadequate.

[0029] When a high-frequency power rectifier generates significant heat, failure to dissipate it effectively and promptly can lead to a series of serious consequences. Excessive temperatures can degrade the performance of power electronic devices, increasing their on-state voltage drop, further increasing power consumption and heat generation, creating a vicious cycle. Prolonged exposure to high temperatures can drastically shorten the reliability and lifespan of devices, leading to frequent failures, affecting the continuity and stability of production, and increasing maintenance costs and downtime losses. For example, in semiconductor manufacturing, unstable operation of a high-frequency power rectifier can cause deviations in chip manufacturing processes, reducing product yield. To meet the heat dissipation requirements of high-frequency power rectifiers of no less than 600W, water cooling is a common and fundamental heat dissipation method that utilizes circulating coolant to absorb heat.

[0030] Example 1

[0031] like Figures 1-5 As shown, the water-cooled high-frequency power rectifier includes a rectifier housing 1, an L-shaped suspended bracket 2, a rectifier mechanism 3, a door panel 4, an air-cooling mechanism 5, and a water-cooling mechanism 6. The rectifier housing 1 has a rectifier chamber 101 inside and a chamber opening 102 at the front end. The outer end of the chamber opening 102 is fitted with a door panel 4 for closing the chamber opening 102. The rectifier chamber 101 has an L-shaped suspended bracket 2 inside, which provides suspension support. The rectifier mechanism 3 for rectifying the power supply is located above the L-shaped suspended bracket 2. Both sides of the rectifier chamber 101 have wind tunnels 8. Both sets of wind tunnels 8 have air-cooling mechanisms 5 inside for air cooling. The top of the rectifier housing 1 has a water-cooling mechanism 6 for water cooling.

[0032] Two sets of pipe openings 10 are provided diagonally at the top edge of the rectifier housing 1. The two sets of pipe openings 10 pass through the top of the rectifier housing 1 and are connected to the rectifier compartment 101. A bracket 9 is provided between the two sets of pipe openings 10. The two sets of pipe openings 10 arranged diagonally are supported by the bracket 9 to form a symmetrical circulating water path, avoid dead zones in the flow of coolant, and improve the uniformity of heat dissipation.

[0033] The water cooling mechanism 6 includes curved heat dissipation pipes 606, which are evenly distributed on the bottom and sides of the L-shaped suspended bracket 2. The two ends of the curved heat dissipation pipes 606 pass through two sets of pipe openings 10 and extend to the top of the rectifier housing 1. By cooperating with the L-shaped suspended bracket 2, the curved heat dissipation pipes 606 fit against the bottom and sides of the L-shaped bracket, which increases the heat dissipation area and can directly cool the key heat-generating area.

[0034] One end of the curved heat dissipation pipe 606 is provided with a water tank 603, and the upper end of the bracket 9 is provided with a cooling box 601 corresponding to the water tank 603. A primary connecting pipe 604 is provided between the water tank 603 and the cooling box 601 for connecting the water tank 603 and the cooling box 601. By combining the water tank 603 and the cooling box 601, the water can flow back to the water tank 603 and then flow into the cooling box 601 to dissipate excess heat energy, forming a staged cooling.

[0035] The other end of the curved heat dissipation pipe 606 is equipped with a water pump 602. A secondary connecting pipe 605 is provided between the water pump 602 and the cooling box 601 to connect the water pump 602 and the cooling box 601. The water pump 602, the curved heat dissipation pipe 606, the water tank 603 and the cooling box 601 are combined to form a closed loop, so that the coolant can circulate.

[0036] The air-cooling mechanism 5 includes a wind duct 501 located inside the wind tunnel 8. A rotating shaft 504 is located at the center of the wind duct 501. Six sets of fan blades 505 are arranged around the outer end of the rotating shaft 504. A motor 503 is located at the end of the rotating shaft 504 away from the rectifier chamber 101. The rotating shaft 504 is connected to the output shaft of the motor 503. A support frame 502 connected to the wind duct 501 is located at the outer end of the motor 503. By combining the rotating shaft 504 with the six sets of fan blades 505, the rotating shaft 504 drives the six sets of fan blades 505 to rotate under the drive of the motor 503.

[0037] A fixed frame 506 is provided at the end of the air duct 501 away from the rectifier chamber 101. Multiple sets of heat dissipation aluminum fins 507 are evenly arranged inside the fixed frame 506. By combining multiple sets of heat dissipation aluminum fins 507, the air-cooled heat exchange area is increased, and efficient heat dissipation is achieved in conjunction with the airflow of the air duct 501.

[0038] A movable connecting sleeve 7 is provided between the door panel 4 and the compartment opening 102. The door panel 4 and the compartment opening 102 are movably connected by the movable connecting sleeve 7, which allows the door panel 4 to rotate and open.

[0039] When working, first, place the rectifier in a suitable working position and ensure that it is stable. Then, open the door panel 4 through the movable connecting sleeve 7. Next, connect the power supply to the rectifier mechanism 3 through the compartment opening 102 and ensure that the connection is firm. Then, turn on the power switch of the rectifier. At this time, the rectifier mechanism 3 starts to work and rectifies the input high-frequency AC power into DC power.

[0040] At the same time, the water pump 602 and the motor 503 are started. The water pump 602 starts to circulate the cooling water between the curved heat dissipation pipe 606, the water tank 603, the cooling box 601 and the secondary connecting pipe 605; the motor 503 drives the fan blade 505 to rotate, and begins to carry out air cooling.

[0041] After completing the work, first turn off the power switch of the rectifier to stop the operation of the rectifier mechanism 3, then turn off the water pump 602 and the motor 503 to stop the operation of the water cooling and air cooling systems, and finally unplug the power supply and close the door panel 4.

[0042] Its working principle is as follows: when the power supply is connected to the rectifier mechanism 3, the rectifier mechanism 3 rectifies the input high-frequency AC power. According to the rectification principle, the negative half-cycle of the AC power is converted into the positive half-cycle, thereby converting the high-frequency AC power into DC power and providing a stable DC power supply for external equipment.

[0043] After the water pump 602 starts, it draws out the cooling water from the water tank 603 and enters the curved heat dissipation pipe 606 through one end. Since the curved heat dissipation pipe 606 is evenly distributed at the bottom and sides of the L-shaped suspended bracket 2, and the rectifier mechanism 3 is located above the L-shaped suspended bracket 2, the cooling water can absorb the heat generated by the rectifier mechanism 3 when it flows in the curved heat dissipation pipe 606. The cooling water that has absorbed the heat flows out from the other end of the curved heat dissipation pipe 606 and enters the cooling box 601 through the secondary connecting pipe 605. In the cooling box 601, the heat of the cooling water is dissipated. The cooled water then flows back to the water tank 603 through the primary connecting pipe 604, completing one cycle.

[0044] Motor 503 drives shaft 504 and fan blade 505 to rotate. The rotation of fan blade 505 generates wind power, which dissipates heat from rectifier chamber 101 through air duct 501. After passing through heat dissipation aluminum fins 507 in fixed frame 506, the heat dissipation aluminum fins 507 can further increase the heat dissipation area and accelerate the heat exchange between air and the outside. Then the air enters rectifier chamber 101, carrying away the heat around rectifier mechanism 3, and finally is discharged from wind tunnel 8 on the other side, realizing air cooling.

[0045] Its beneficial effects are significant. Through the coordinated work of the water-cooling mechanism 6 and the air-cooling mechanism 5, the internal temperature of the rectifier can be effectively reduced. The curved heat dissipation pipes 606 in the water-cooling mechanism 6 are evenly distributed and can fully absorb the heat generated by the rectifier mechanism 3. The air-cooling mechanism 5 further removes heat by accelerating airflow. Compared with the traditional single heat dissipation method, this dual heat dissipation system can keep the rectifier at a lower temperature during long-term operation, improving the stability and reliability of the rectifier. The L-shaped suspended bracket 2 not only supports the rectifier mechanism 3, but also provides space for the arrangement of the curved heat dissipation pipes 606, making full use of the internal space of the rectifier. The entire rectifier has a compact structure and relatively small size, making it suitable for installation and use in different working environments.

Claims

1. A water-cooled high-frequency power rectifier, comprising a rectifier housing (1); characterized in that, It also includes an L-shaped suspended bracket (2), a rectifier mechanism (3), a door panel (4), an air-cooling mechanism (5), and a water-cooling mechanism (6); the rectifier housing (1) has a rectifier compartment (101) inside, and a compartment opening (102) is opened at the front end of the rectifier housing. The outer end of the compartment opening (102) is matched with a door panel (4) for closing the compartment opening (102). The rectifier compartment (101) has an L-shaped suspended bracket (2) inside, which plays a role in suspension support. The rectifier mechanism (3) for rectifying the power supply is provided above the L-shaped suspended bracket (2). Both sides of the rectifier compartment (101) have wind tunnels (8). Both wind tunnels (8) have an air-cooling mechanism (5) for air cooling. The top of the rectifier housing (1) has a water-cooling mechanism (6) for water cooling.

2. The water-cooled high-frequency power rectifier according to claim 1, characterized in that, Two sets of pipe openings (10) are provided diagonally at the top edge of the rectifier housing (1). The two sets of pipe openings (10) penetrate the top of the rectifier housing (1) and communicate with the rectifier compartment (101). A bracket (9) is provided between the two sets of pipe openings (10).

3. The water-cooled high-frequency power rectifier according to claim 2, characterized in that, The water cooling mechanism (6) includes curved heat dissipation pipes (606), which are evenly distributed on the bottom and sides of the L-shaped suspended bracket (2). The two ends of the curved heat dissipation pipes (606) pass through two sets of pipe openings (10) and extend to the top of the rectifier housing (1).

4. The water-cooled high-frequency power rectifier according to claim 3, characterized in that, A water tank (603) is provided at one end of the curved heat dissipation pipe (606), and a cooling box (601) corresponding to the water tank (603) is provided at the upper end of the bracket (9). A primary connecting pipe (604) for connecting the water tank (603) and the cooling box (601) is provided between the water tank (603) and the cooling box (601).

5. The water-cooled high-frequency power rectifier according to claim 4, characterized in that, The other end of the curved heat dissipation pipe (606) is equipped with a water pump (602), and a secondary connecting pipe (605) for connecting the water pump (602) and the cooling box (601) is provided between the water pump (602) and the cooling box (601).

6. The water-cooled high-frequency power rectifier according to claim 5, characterized in that, The air-cooling mechanism (5) includes a wind duct (501), which is located inside the wind tunnel (8). A rotating shaft (504) is provided at the center of the wind duct (501). Six sets of fan blades (505) are arranged around the outer end of the rotating shaft (504). A motor (503) is provided at the end of the rotating shaft (504) away from the rectifier chamber (101). The rotating shaft (504) is connected to the output shaft of the motor (503). A support frame (502) connected to the wind duct (501) is provided at the outer end of the motor (503).

7. The water-cooled high-frequency power rectifier according to claim 6, characterized in that, The end of the air duct (501) away from the rectifier chamber (101) is provided with a fixing frame (506), and multiple sets of heat dissipation aluminum fins (507) are evenly arranged inside the fixing frame (506).

8. The water-cooled high-frequency power rectifier according to claim 2, characterized in that, A movable connecting sleeve (7) is provided between the door panel (4) and the storage opening (102), and the door panel (4) and the storage opening (102) are movably connected through the movable connecting sleeve (7).

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