A smart zoned heat dissipation system for frequency converters

Abstract

This utility model discloses an intelligent zoned heat dissipation system for frequency converters, including a chassis, a low-temperature zone module, a medium-temperature zone module, a high-temperature zone module, a temperature sensor network module, and an intelligent control unit module. An isolation structure is provided between the medium-temperature zone module and the low-temperature zone module. The medium-temperature zone module is equipped with a second air intake channel that directly introduces ambient cooling air from outside the chassis and a main cooling fan. Temperature sensors monitor the temperature of each zone, and the intelligent control unit dynamically adjusts the speed of the main cooling fan based on the temperature data. This utility model effectively isolates thermal crosstalk between temperature zones by providing an independent, high-quality cold source for the core heat-generating areas and achieves intelligent on-demand heat dissipation, thereby improving heat dissipation efficiency, reducing energy consumption and noise, and enhancing the reliability and lifespan of the frequency converter. It is mainly applied to the heat dissipation of power electronic equipment such as frequency converters and inverters.

Description

Technical Field

[0001] This utility model relates to the field of heat dissipation technology for power electronic equipment, and specifically to an intelligent zoned heat dissipation system for frequency converters. Background Technology

[0002] As a key piece of equipment in industrial automation and electric drive fields, frequency converters integrate a large number of power semiconductor devices (such as IGBT modules and rectifier bridges) and passive components (such as reactors and capacitors). These components generate significant heat during operation. If this heat cannot be dissipated effectively and in a timely manner, the component temperatures will become too high, affecting the operational stability of the frequency converter, reducing its lifespan, and even causing malfunctions. Therefore, an efficient and reliable heat dissipation system is crucial for frequency converters.

[0003] In existing technologies, the main heat dissipation methods for frequency converters are as follows:

[0004] Integrated cooling: This method places all heat-generating components within the same heat dissipation space or airflow channel, using a uniform fan for forced air cooling. While relatively simple in design, this approach suffers from low heat dissipation efficiency and difficulty in implementing precise thermal management for components with varying heat generation and temperature tolerance. Typically, to maintain the temperature of the highest-heat-generating components (such as IGBT modules), high-power fans and large heatsinks are required. This not only increases cost and size but also leaves lower-heat-generating components (such as control circuit boards) in an over-cooled state, or even negatively affected by the heat radiation and conduction from the high-temperature components.

[0005] Simple zoned cooling: To improve the shortcomings of overall cooling, some frequency converters employ simple zoned cooling designs. For example, they physically isolate high-heat-generating power devices from low-heat-generating control devices, or create approximate "high-temperature zones" and "low-temperature zones." However, such zoning is often quite crude, with air duct designs typically in series or partially series configurations. Cool air enters through the inlet and flows through different zones sequentially, causing the air temperature to gradually increase during flow. This means that the cooling air received by components in later zones is not the initial low-temperature air, resulting in reduced cooling effectiveness and a so-called heat accumulation effect. Furthermore, this type of design usually lacks independent and dynamic control over the cooling intensity of each zone, making it difficult to adapt to changes in the frequency converter's cooling requirements under different loads and ambient temperatures, potentially leading to energy waste or insufficient localized cooling.

[0006] In summary, existing inverter cooling systems still have room for improvement in terms of heat dissipation efficiency, temperature control accuracy, energy utilization, and adaptability to different operating conditions. In particular, effectively isolating airflow between regions with different heat levels, providing a high-quality cold source for core heat-generating components, and achieving intelligent on-demand cooling remain pressing technical challenges in this field. Summary of the Invention

[0007] Purpose of the invention: The purpose of this utility model is to provide an intelligent zoned heat dissipation system for frequency converters, which addresses the shortcomings of existing technologies and solves problems such as low heat dissipation efficiency, easy heat crosstalk accumulation, and lack of intelligent and refined thermal management in existing frequency converters.

[0008] Technical Solution: To achieve the above objectives, the technical solution adopted by this utility model is: an intelligent zoned heat dissipation system for a frequency converter, including a chassis; a low-temperature zone module (Zone L), disposed within the chassis, for accommodating a first type of heat-generating component, the low-temperature zone module being configured with a first air intake channel for introducing a first cooling airflow; a medium-temperature zone module (Zone M), disposed within the chassis, for accommodating a second type of heat-generating component with a heat output greater than that of the first type of heat-generating component, an isolation structure for isolating the medium-temperature zone module and the low-temperature zone module on the main airflow path, the medium-temperature zone module being configured with a second air intake channel directly connected to the outside of the chassis to introduce ambient cooling air and at least one main cooling fan, the main cooling fan being used to guide the ambient cooling air introduced via the second air intake channel to the second type of heat-generating component and exhaust it; a high-temperature zone module (Zone M), disposed within the chassis, for accommodating a second type of heat-generating component with a heat output greater than that of the first type of heat-generating component, the medium-temperature zone module being configured with a second air intake channel for introducing ambient cooling air and at least one main cooling fan, the main cooling fan being used to guide the ambient cooling air introduced via the second air intake channel to the second type of heat-generating component and exhaust it; a high-temperature zone module (Zone M), the medium ... H), disposed within the chassis, is used to house a third type of heat-generating component with high temperature resistance. The heat dissipation airflow of the high-temperature zone module originates at least partially from the air exhausted from the medium-temperature zone module. The temperature sensor network module includes multiple temperature sensors respectively disposed near the low-temperature zone module, the medium-temperature zone module, the high-temperature zone module, and the inlet of the second air intake channel or in the external environment, for real-time monitoring of the temperature at each corresponding location. The intelligent control unit module is electrically connected to the temperature sensor network module and the main cooling fan. The intelligent control unit module is used to dynamically adjust the speed of the main cooling fan based on the temperature data collected by the temperature sensor network module.

[0009] To further improve the above technical solution, the isolation structure includes a physical partition disposed between the low-temperature zone module and the medium-temperature zone module.

[0010] Furthermore, the low-temperature zone module is also equipped with at least one auxiliary cooling fan. The intelligent control unit module is electrically connected to the auxiliary cooling fan and dynamically adjusts the speed of the auxiliary cooling fan according to the temperature data collected by the temperature sensor network module.

[0011] Furthermore, the first air intake channel of the low-temperature zone module introduces external cooling air through the opening at the bottom of the chassis, and the low-temperature zone module introduces the first cooling airflow from the first air intake channel by utilizing the negative pressure effect generated when the main cooling fan is working.

[0012] Furthermore, the medium-temperature heating zone module includes a heat sink for cooling the main heating component in the second type of heating element, the outlet of the second air inlet channel is directly facing the heat sink, and the main cooling fan is arranged upstream or downstream of the heat sink to form forced convection.

[0013] Furthermore, the intelligent control unit module uses a PID controller to adjust the speed of the main cooling fan.

[0014] Furthermore, the high-temperature zone module is located downstream of the main airflow discharge path of the medium-temperature zone module.

[0015] Furthermore, the second type of heat-generating component includes an IGBT module, and at least one temperature sensor in the temperature sensor network module is directly arranged next to the heat sink of the IGBT module.

[0016] Beneficial effects: Compared with the prior art, the advantages of this utility model are:

[0017] (1) Improve the heat dissipation efficiency of core components: By setting up an independent second air intake channel for the medium temperature zone module (Zone M) to directly introduce ambient cooling air from outside the chassis, and in conjunction with the main cooling fan, it is ensured that the main heat-generating components such as IGBT can obtain high-quality, unheated cooling air, which significantly improves their heat dissipation efficiency and effectively controls their operating temperature.

[0018] (2) Reduce heat crosstalk between temperature zones: The isolation structure between the low temperature zone module (Zone L) and the medium temperature zone module (Zone M), as well as their independent or semi-independent air intake designs, effectively reduce the heat crosstalk between different temperature zones and avoid the adverse effects of the high heat of Zone M on the temperature-sensitive components in Zone L.

[0019] (3) Achieving intelligent on-demand heat dissipation and energy saving and noise reduction: The intelligent control unit module dynamically adjusts the speed of the main cooling fan (and possible auxiliary cooling fans) according to the real-time temperature of each area, achieving on-demand heat dissipation. Under low load or low temperature conditions, the fan runs at low speed to reduce energy consumption and noise; under high load or high temperature conditions, the fan runs at high speed to ensure heat dissipation performance.

[0020] (4) Optimize overall thermal management and improve reliability: By rationally partitioning and designing targeted air ducts for components with different heating characteristics and temperature resistance, and combining them with intelligent temperature control, the overall temperature distribution inside the inverter is more reasonable, and each component operates within a suitable temperature range, thereby improving the overall operational reliability and service life of the inverter.

[0021] (5) Structural optimization and cost-effectiveness: Through refined thermal management, it may be possible to optimize the heat dissipation configuration of some components (such as low-temperature components) or select more economical models. At the same time, the improved heat dissipation efficiency also helps to increase power density, which has good cost-effectiveness overall. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of the overall structure of an embodiment of an intelligent partitioned heat dissipation system for frequency converters according to this utility model.

[0023] Figure 2 This is a schematic diagram of the control flow of an embodiment of an intelligent partitioned heat dissipation system for frequency converters according to this utility model. Detailed Implementation

[0024] The technical solution of this utility model will be described in detail below with reference to the accompanying drawings, but the protection scope of this utility model is not limited to the described embodiments.

[0025] Example 1: Refer to Figure 1 The intelligent zoned heat dissipation system for frequency converters provided by this utility model is installed inside the chassis 1. The chassis 1 is divided into at least three main functional areas: a low temperature zone module (Zone L) 2, a medium temperature zone module (Zone M) 3, and a high temperature zone module (Zone H) 4.

[0026] The low-temperature zone module (Zone L) 2 is typically located at the bottom or one side of the chassis 1, and is used to house first-class heat-generating components, such as rectifier bridges, input filters, contactors, control circuit boards, and other components with relatively low heat generation or high temperature sensitivity. Zone L 2 is equipped with a first air intake channel 21, which can be an air intake vent opened from a specific location on the chassis 1 (such as the front lower panel) to directly introduce external cooling air, or it can be designed to utilize the negative pressure effect generated when the main cooling fan of Zone M 3 is working to guide airflow from other non-high-temperature areas of the chassis. In this embodiment, the first air intake channel 21 is a grille air intake at the bottom of the chassis.

[0027] The intermediate temperature zone module (Zone M) 3 is the main heat-generating area of ​​the inverter, used to house the second type of heat-generating components, mainly referring to power semiconductor devices such as IGBT power modules and freewheeling diode modules, and may also include switching power supply modules. An isolation structure 5, such as a physical partition, is provided between the intermediate temperature zone module 3 and the low temperature zone module 2 to isolate them along the main airflow path, preventing hot air generated by the intermediate temperature zone module 3 from directly flowing back or radiating and affecting the low temperature zone module 2. The core feature of the intermediate temperature zone module 3 is that it is equipped with a second air intake channel 31 that directly connects to the outside of the chassis 1 to introduce ambient cooling air and at least one main cooling fan 32. In this embodiment, the second air intake channel 31 corresponds to the air intake side of the main cooling fan 32. The main cooling fan 32 draws in the ambient low temperature air through the second air intake channel 31, forcibly blowing it across the heat sink 33 where the IGBT modules are installed, carrying away the heat generated by the IGBT modules, and then the hot air is discharged upwards or backwards from the chassis.

[0028] The high-temperature zone module 4 is used to house third-class heat-generating components with high temperature resistance, such as DC reactors and braking resistors (if built-in). In this embodiment, the high-temperature zone module 4 is located downstream of the main airflow discharge of the medium-temperature zone module 3, for example, at the top of the chassis 1. In this way, the air discharged from the medium-temperature zone module 3, which has already increased in temperature but still has a certain flow rate, can continue to be used to cool the components in the high-temperature zone module 4, realizing the cascade utilization of thermal energy.

[0029] The system also includes a temperature sensor network module 6 and an intelligent control unit module 7. The temperature sensor network module 6 consists of multiple temperature sensors, such as NTC thermistors. These sensors include a temperature sensor 61 located in the low-temperature zone module 2, a temperature sensor 62 located in the medium-temperature zone module 3 (e.g., on the surface of the IGBT heatsink 33), a temperature sensor 63 located in the high-temperature zone module 4, and a temperature sensor 64 located in the external environment. The signal outputs of all temperature sensors are connected to the intelligent control unit module 7.

[0030] The intelligent control unit module 7 typically consists of a microcontroller (MCU) and its peripheral circuitry. The MCU is electrically connected to the main cooling fan 32 (and possibly auxiliary fans, such as…). Figure 1 The auxiliary fan 22 that can be installed in the medium and low temperature zone module 2 can be controlled by means of PWM (pulse width modulation) and other methods.

[0031] Example 2: Refer to Figure 2 The control flow diagram shows the working process of the intelligent control unit module 7 as follows:

[0032] After the system is powered on, the MCU initializes and begins to periodically (e.g., once per second) collect temperature data reported by all temperature sensors.

[0033] The MCU calculates the ideal operating speed of the main cooling fan 32 and the auxiliary fan 22 based on the preset control algorithm (such as PID control algorithm) and the collected temperature values ​​at various points (especially the temperature T_M of the IGBT heat sink 33 in the medium temperature zone module 3 and the ambient temperature T_amb).

[0034] The MCU outputs a corresponding PWM signal to the fan drive circuit to adjust the fan speed. For example, when T_M is low, the fan runs at low speed or stops; when T_M rises above a certain threshold, the fan speed increases accordingly; when T_M approaches or exceeds a dangerous threshold, the fan runs at full speed and may trigger an alarm or protection mechanism.

[0035] This process is repeated continuously, forming a closed-loop dynamic temperature control system that ensures that the frequency converter can obtain appropriate heat dissipation under various operating conditions.

[0036] In an alternative implementation, the first air intake channel 21 of the low-temperature zone module (Zone L) 2 can introduce external cooling air through a specific opening in the chassis. The low-temperature zone module 2 can utilize the negative pressure effect generated when the main cooling fan 32 is operating to introduce a first cooling airflow from the first air intake channel 21 through its structural design. This means that the cooling of Zone L can be passive, relying on the pressure difference created by the exhaust fan of the mid-temperature zone module for air exchange, further simplifying the structure and reducing costs.

[0037] In another alternative implementation, the low-temperature zone module (Zone L) 2 can be configured with an auxiliary cooling fan 22, which is also independently speed-controlled by the intelligent control unit module 7 according to the temperature of Zone L 2, providing more proactive and precise heat dissipation for Zone L 2.

[0038] Through the above structure and control method, the inverter intelligent zone heat dissipation system of this utility model can effectively provide differentiated and intelligent heat dissipation for components in different temperature zones, significantly improving heat dissipation performance and system reliability.

[0039] As described above, although the present invention has been shown and described with reference to specific preferred embodiments, it should not be construed as limiting the present invention itself. Various changes in form and detail may be made to the present invention without departing from the spirit and scope of the appended claims.

Claims

1. A smart zoned heat dissipation system for frequency converters, characterized in that, include: Chassis; A low-temperature zone module is disposed inside the chassis and is used to house the first type of heat-generating components. The low-temperature zone module is equipped with a first air inlet channel, which is used to introduce a first cooling airflow. A medium-temperature zone module, disposed within the chassis, is used to accommodate a second type of heat-generating element with a heat output greater than that of the first type of heat-generating element. An isolation structure is provided between the medium-temperature zone module and the low-temperature zone module to achieve isolation in the airflow path. The medium-temperature zone module is equipped with a second air intake channel that directly connects to the outside of the chassis to introduce ambient cooling air and at least one main cooling fan. The main cooling fan is used to guide the ambient cooling air introduced through the second air intake channel to the second type of heat-generating element and exhaust it. A high-temperature zone module is disposed inside the chassis and is used to house a third type of heat-generating component. The heat dissipation airflow of the high-temperature zone module originates at least partly from the air discharged from the medium-temperature zone module. The temperature sensor network module includes multiple temperature sensors respectively disposed near the low temperature zone module, the medium temperature zone module, the high temperature zone module, and the inlet of the second air intake channel or in the external environment, for real-time monitoring of the temperature at each corresponding location; The intelligent control unit module is electrically connected to the temperature sensor network module and the main cooling fan. The intelligent control unit module is used to dynamically adjust the speed of the main cooling fan based on the temperature data collected by the temperature sensor network module.

2. The inverter intelligent zoned heat dissipation system according to claim 1, characterized in that, The isolation structure includes a physical partition disposed between the low-temperature zone module and the medium-temperature zone module.

3. The inverter intelligent zoned heat dissipation system according to claim 1, characterized in that, The low-temperature zone module is also equipped with at least one auxiliary cooling fan. The intelligent control unit module is electrically connected to the auxiliary cooling fan and dynamically adjusts the speed of the auxiliary cooling fan according to the temperature data collected by the temperature sensor network module.

4. The intelligent zoned heat dissipation system for frequency converters according to claim 1, characterized in that, The first air intake channel of the low-temperature zone module introduces external cooling air through the opening at the bottom of the chassis, and the low-temperature zone module introduces the first cooling airflow from the first air intake channel by utilizing the negative pressure effect generated when the main cooling fan is working.

5. The inverter intelligent zoned heat dissipation system according to claim 1 or 3, characterized in that, The medium-temperature zone module includes a heat sink for cooling the main heat-generating component in the second type of heat-generating components. The outlet of the second air inlet channel faces directly toward the heat sink. The main cooling fan is arranged upstream or downstream of the heat sink to form forced convection.

6. The inverter intelligent zoned heat dissipation system according to claim 1, characterized in that, The intelligent control unit module uses a PID controller to adjust the speed of the main cooling fan.

7. The intelligent zoned heat dissipation system for frequency converters according to claim 1, characterized in that, The high-temperature zone module is located downstream of the main airflow discharge path of the medium-temperature zone module.

8. The intelligent zoned heat dissipation system for frequency converters according to claim 1, characterized in that, The second type of heat-generating component includes an IGBT module, and at least one temperature sensor in the temperature sensor network module is directly arranged next to the heat sink of the IGBT module.

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