960KW immersed liquid cooling heat management system

Abstract

The utility model discloses a 960KW immersed liquid cooling heat management system, and belongs to the technical field of charging piles. Direct plugging of the charging modules is realized through the slideways, and maintenance personnel can replace and maintain a single charging module without complex operation, so that the maintenance time is greatly shortened, the maintenance efficiency is improved, and the maintenance cost is reduced. The immersion liquid cooling technology is adopted, cooling liquid can directly make contact with the charging module, and the heat dissipation effect is obviously better than that of a traditional air cooling heat dissipation mode. Meanwhile, due to the reasonable design of the air duct and the cooperative use of the dry cooler and the fan, the heat dissipation efficiency is further improved, and it is ensured that the charging pile can keep a stable working temperature during high-power operation. In addition, the CDU control panel automatically adjusts the rotating speed of the fan and the flow of the pump according to actual requirements, unnecessary energy consumption is avoided, the energy-saving buffering design is achieved, and the operation cost of the charging pile is reduced.

Description

A 960KW immersion liquid-cooled thermal management system Technical Field

[0001] This utility model relates to the field of charging pile technology, and more specifically to a 960KW immersion liquid-cooled thermal management system. Background Technology

[0002] With the booming development of the new energy vehicle industry, the market demand for charging piles, as a key supporting facility for electric vehicles, has exploded. High-power charging piles, with their advantage of fast charging speed, play an important role in meeting the rapid energy replenishment needs of electric vehicles. However, during high-power charging, the charging module generates a large amount of heat. If heat cannot be dissipated in a timely and efficient manner, it will seriously affect the performance and lifespan of the charging pile.

[0003] Traditional air-cooling methods exhibit numerous limitations when dealing with high-power charging stations. Due to air's low specific heat capacity, its ability to carry heat is relatively weak. When charging stations generate significant power and heat, air-cooling systems struggle to dissipate heat quickly and effectively, leading to excessively high internal temperatures in the charger. This results in decreased charger performance, increased failure rates, and a significantly shortened lifespan. Furthermore, air-cooling systems are highly susceptible to environmental factors. In complex environments such as underground mines, the large amounts of dust, moisture, and other impurities in the air easily adhere to fan blades, duct walls, and the surfaces of heat-generating components. This not only affects fan speed and airflow, reducing heat dissipation efficiency, but can also corrode and damage the electrical components of the charging station, further increasing the equipment's failure rate.

[0004] While immersion liquid cooling technology offers good heat dissipation, existing immersion liquid-cooled charging stations present several maintenance challenges. For example, some products have flawed structural designs, leading to high maintenance difficulty and costs for the charging modules. Some tank enclosures are open, which hinders the flow rate of the oil pump in the circulation pipes. To ensure the entire charging station is sealed, the dry cooler is placed on top and cannot be opened; therefore, if the charging module malfunctions, the entire charging station must be replaced, increasing maintenance costs and reducing its efficiency.

[0005] Therefore, proposing a 960KW immersion liquid cooling thermal management system that is both highly efficient in heat dissipation and easy to maintain is a problem that urgently needs to be solved by those skilled in the art. Summary of the Invention

[0006] In view of this, the present invention provides a 960KW immersion liquid cooling thermal management system, which solves the problems of poor heat dissipation and inconvenient maintenance of existing high-power charging piles, improves the performance and service life of charging piles, and reduces maintenance costs.

[0007] To achieve the above objectives, the present invention adopts the following technical solution:

[0008] A 960KW immersion liquid-cooled thermal management system includes a tank structure consisting of two independent tank housings, the interior of which is filled with coolant; two dry coolers are arranged on both sides of the tank structure.

[0009] For each tank box, the structure is as follows:

[0010] The sealed top cover is connected to the top of the tank via a hinge;

[0011] The tank enclosure includes a power connector array, a slide rail, multiple charging modules, and a liquid pump. The power connector array is fixedly installed on one side of the inner wall of the tank enclosure. The charging modules are connected to the power connector array via the slide rail. The liquid pump is installed at the bottom of the tank enclosure.

[0012] The inlet of the dry cooler is connected to the liquid pump via a pipe; a fan is installed on one side of the dry cooler, and the air duct adopts a front-to-back airflow configuration.

[0013] Preferably, the length and width of the slide are matched with the size of the charging module.

[0014] Preferably, the plurality of charging modules consists of 12 40KW charging modules, arranged in 2... 6 arrays or 1 Arrange them in an array of 12.

[0015] Preferably, the dry cooler has multiple heat exchange channels inside, which allow the coolant to flow within the heat exchange channels and exchange heat with the outside air.

[0016] Preferably, a temperature sensor is mounted on the surface of the charging module; the power monitoring module is installed in the charging circuit of the charging module.

[0017] Preferably, a 960KW immersion liquid cooling thermal management system further includes a control panel, in which a CDU control board is installed. The CDU control board is connected to the temperature sensor, the power monitoring module, the fan, and the liquid pump via a data cable, and is used to adjust the fan speed and the liquid pump flow rate based on the data fed back by the temperature sensor and the power monitoring module.

[0018] As can be seen from the above technical solution, this utility model discloses a 960KW immersion liquid-cooled thermal management system, which has the following beneficial technical effects compared with the prior art:

[0019] 1. The tank enclosure is equipped with an openable sealed top cover to prevent coolant leakage and ensure normal coolant circulation within the enclosure. The openable design also facilitates maintenance personnel to plug and unplug the charging module for maintenance.

[0020] 2. The structure combining the power connector array with the slide rail allows the charging module to be directly plugged in and unplugged via the slide rail, greatly improving the maintainability of the charging module and contrasting sharply with traditional complex wiring connections and fixing methods.

[0021] 3. The entire coolant circulation cooling system utilizes a liquid pump to circulate the coolant, carrying away the heat from the charging module, and then dissipating the heat through a dry cooler and a fan. This immersion liquid cooling method offers better cooling performance than traditional air cooling, effectively ensuring the stability of the charging module during high-power operation.

[0022] 4. The front-to-rear airflow design ensures that the air fully contacts the cooler, improving heat dissipation efficiency and is an important component of the heat dissipation system.

[0023] 5. The CDU control board controls the fan speed and liquid pump flow rate, achieving an energy-saving buffer design. By automatically adjusting relevant parameters based on the real-time temperature and power requirements of the charging module, energy saving is achieved, improving the system's energy utilization efficiency. Attached Figure Description

[0024] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on the provided drawings without creative effort.

[0025] Figure 1 is a schematic diagram of the overall structure provided by this utility model;

[0026] Figure 2 is a schematic diagram of the internal slide support structure of the tank box provided by this utility model;

[0027] Figure 3 is a schematic diagram of the external structure of the tank box provided by this utility model.

[0028] In the diagram, 1-dry cooler, 2-sealed top cover, 3-tank housing, 4-liquid pump, 5-structure of the internal slide support of the tank, 51-power connector array, 52-slide, 53-charging module, 6-sealing ring, 7-tank filling port. Detailed Implementation

[0029] 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 of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0030] Referring to Figure 1, this embodiment proposes a 960KW immersion liquid-cooled thermal management system, including a tank structure composed of two independent tank boxes 3. The inside of the tank box 3 is filled with coolant, and the coolant is injected into the tank box 3 through the tank box injection port 7; two dry coolers 1 are arranged on both sides of the tank structure.

[0031] Each tank housing 3 is a cuboid structure with a height of 1.2 meters. It is made of high-strength, corrosion-resistant metal material, which ensures both the structural strength of the housing and prevents the coolant from corroding it. The internal slide support structure 5 of the tank housing is shown in Figure 2, and the external structure is shown in Figure 3. Specifically, the structure shown in Figure 2 is installed in the external frame of Figure 3.

[0032] The sealing cover 2 is connected to the top of the tank body via a hinge, and a sealing ring 6 is provided on the edge of the cover to ensure the seal when the cover is closed.

[0033] The tank housing 3 internally includes a power connector array 51, a slide rail 52, multiple charging modules 53, and a liquid pump 4. The power connector array 51 is fixedly installed on one side of the inner wall of the tank housing, and each power connector is connected to an external circuit. The charging modules 53 are connected to the power connector array 51 via the slide rail 52. During implementation, the length and width of the slide rail 52 match the size of the charging module 53 to ensure that the charging module 53 can slide smoothly on the slide rail 52. The back of the charging module 53 is provided with a plug corresponding to the power connector. When the charging module 53 is inserted along the slide rail 52, the plug can accurately connect with the power connector.

[0034] In this embodiment, 24 40kW charging modules are placed in two tanks to achieve a power output of 960kW. Within a single tank, the 40kW charging modules can be arranged in two... 6 arrays or 1 The 12 arrays are arranged in a flexible layout that can meet the diverse power and space requirements of charging piles in different application scenarios, improving the system's adaptability and practicality. Furthermore, this structural design allows for easy conversion into a 480kW immersion liquid-cooled thermal management system.

[0035] The cooling system includes a liquid pump 4, a cooler 1, and a fan. The liquid pump 4 is installed at the bottom of the tank and connected to the inlet of the cooler 1 via a pipe. The cooler 1 has a copper coil and aluminum fin structure, with two coolers 1 installed on the left and right sides of the tank structure. Multiple heat exchange channels are installed inside, where the coolant flows and exchanges heat with the outside air. The fan is installed on one side of the cooler 1. When the fan starts, using a front-to-back airflow design, outside air flows over the surface of the cooler 1, absorbs the heat dissipated by the coolant, and is then discharged from the outlet.

[0036] In this embodiment, the heat dissipation system first uses the liquid pump 4 to circulate the coolant, carrying away the heat from the charging module 53, and then dissipates the heat through the dry cooler 1 and the fan.

[0037] Furthermore, the CDU control board is installed in the control panel of the 960KW immersion liquid-cooled thermal management system proposed in this utility model. The CDU control board is connected to the temperature sensor, power monitoring module, fan, and liquid pump 4 via data cables. The temperature sensor is installed on the surface of the charging module 53 to monitor the temperature of the charging module 53 in real time; the power monitoring module is installed in the charging circuit of the charging module 53 to monitor the power of the charging module 53 in real time. Based on the data fed back by the temperature sensor and the power monitoring module, the CDU control board automatically adjusts the fan speed and the flow rate of the liquid pump 4 through the control circuit.

[0038] The various embodiments in this specification are described in a progressive manner, with each embodiment focusing on its differences from other embodiments. Similar or identical parts between embodiments can be referred to interchangeably. For the apparatus disclosed in the embodiments, since they correspond to the methods disclosed in the embodiments, the description is relatively simple; relevant parts can be referred to in the method section.

[0039] The above description of the disclosed embodiments enables those skilled in the art to make or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A 960KW immersion liquid-cooled thermal management system, characterized in that, The system comprises a tank structure consisting of two independent tank enclosures, each filled with coolant. Two dry coolers are positioned on either side of the tank structure. Each tank enclosure has the following structure: a sealed top cover is hinged to the top of the tank enclosure; the interior of each tank enclosure includes a power connector array, a slide rail, multiple charging modules, and a liquid pump; the power connector array is fixedly mounted on one side of the inner wall of the tank enclosure; the charging modules are connected to the power connector array via the slide rail; the liquid pump is mounted at the bottom of the tank enclosure; the inlet of each dry cooler is connected to the liquid pump via a pipe; a fan is installed on one side of each dry cooler, with the airflow arranged in a front-to-back configuration.

2. The 960KW immersion liquid-cooled thermal management system according to claim 1, characterized in that, The length and width of the slide are matched to the size of the charging module.

3. A 960KW immersion liquid-cooled thermal management system according to claim 1, characterized in that, The multiple charging modules consist of 12 40KW charging modules, arranged in a 2*6 array or a 1*12 array.

4. A 960KW immersion liquid-cooled thermal management system according to claim 1, characterized in that, The dry cooler has multiple heat exchange channels inside, which allow the coolant to flow within the channels and exchange heat with the outside air.

5. A 960KW immersion liquid-cooled thermal management system according to claim 1, characterized in that, A temperature sensor is mounted on the surface of the charging module; a power monitoring module is installed in the charging circuit of the charging module.

6. A 960KW immersion liquid-cooled thermal management system according to claim 5, characterized in that, It also includes a control panel, which is equipped with a CDU control board. The CDU control board is connected to the temperature sensor, the power monitoring module, the fan, and the liquid pump via a data cable. It is used to adjust the fan speed and the liquid pump flow rate based on the data fed back by the temperature sensor and the power monitoring module.

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