A dual heat sink air-cooled power unit

Abstract

This utility model discloses a dual-heatsink air-cooled power unit, comprising a housing, a rectifier assembly, an inverter assembly, a thin-film capacitor, and a unit main control board. The rectifier assembly consists of a rectifier heatsink, a rectifier bridge, and a rectifier busbar. The inverter assembly consists of an inverter heatsink, an IGBT module, and an inverter busbar. The input terminal of the rectifier bridge is connected to a three-phase input busbar, and the output terminal of the IGBT module is connected to a unit output busbar. The key feature is that the fins of the inverter heatsink and the rectifier heatsink are located within a heat dissipation duct, the heat absorption surface of the inverter heatsink is located in a side cavity, and the rectifier bridge and IGBT module are respectively fixed to the heat absorption surfaces of the rectifier heatsink and the inverter heatsink. In this utility model, the dual-heatsink air-cooled power unit completely isolates the rectifier bridge and IGBT devices with an isolation plate, thereby allowing the rectifier and inverter heatsinks to operate independently, each performing its own function without mutual interference, thus improving the reliability of air cooling.

Description

Technical Field

[0001] This utility model relates to an air-cooled power unit, and more specifically, to a dual-heater air-cooled power unit, belonging to the field of power electronics technology. Background Technology

[0002] In recent years, the demand for high-voltage frequency converters has become increasingly urgent due to the growing demand from high-power loads. Currently, most high-power high-voltage frequency converters use water cooling, which is not only costly but also carries the risk of cooling water leakage, leading to poor reliability. Traditional air cooling is limited to lower power applications, thus necessitating an increase in the applicable power of air-cooled power units to reduce product costs. This increase in power inevitably requires a corresponding improvement in heat dissipation performance. Current air-cooled power units typically employ a single-unit cooling method, where the rectifier and inverter components are mounted on a single heatsink. This method has limited cooling capacity, and traditional single-heatsink air-cooled power units are generally insufficient to meet system cooling requirements. Therefore, there is an urgent need to develop a new dual-heatsink air-cooled power unit to overcome these technical challenges.

[0003] In addition, the power units of existing high-voltage frequency converters usually adopt a "power unit + capacitor unit" combination mode, that is, the power unit that realizes rectification and inversion and the capacitor unit that stabilizes the bus voltage are set up independently. This arrangement makes the power unit larger and more difficult to assemble, which does not conform to the development trend of miniaturization of high-voltage frequency converters. Summary of the Invention

[0004] In order to overcome the shortcomings of the above-mentioned technical problems, this utility model provides a dual-heater air-cooled power unit.

[0005] This utility model discloses a dual-heater air-cooled power unit, comprising a housing and a rectifier assembly, an inverter assembly, a thin-film capacitor, and a unit main control board located within the housing. An isolation plate is provided inside the housing, with heat dissipation channels and side cavities formed between the isolation plate and the housing on both sides, respectively. The rectifier assembly consists of a rectifier heat sink, a rectifier bridge, and a rectifier busbar. The inverter assembly consists of an inverter heat sink, an IGBT module, and an inverter busbar. The input end of the rectifier bridge is connected to phase A, phase B, and phase C inputs extending from the bottom of the front side of the housing. The output end of the IGBT module is connected to a unit output line extending from the upper part of the front side of the housing. The key feature is that the fins of the inverter heat sink and the rectifier heat sink are located within the heat dissipation channels, the heat absorption surface of the inverter heat sink is located within the side cavity, and the rectifier bridge and IGBT module are located within the heat dissipation channels and side cavities, respectively. The rectifier bridge and IGBT module are fixed to the heat absorption surfaces of the rectifier heat sink and the inverter heat sink, respectively.

[0006] The dual-heat sink air-cooled power unit of this utility model has an output terminal of the rectifier bridge connected to the rectifier busbar, an input terminal of the IGBT module connected to the inverter busbar, and the rectifier busbar and inverter busbar connected via a component connection bar. Thin film capacitors are fixed in parallel on the capacitor bar and connected to the inverter busbar via the capacitor bar. Both the component connection bar and the thin film capacitors are located in the heat dissipation air duct.

[0007] The present invention relates to a dual-heater air-cooled power unit, wherein both the rectifier heat sink and the inverter heat sink are vertically arranged, the rectifier bridge is fixed from top to bottom on the heat-absorbing surface of the rectifier heat sink, and the inverter heat sink is fixed from top to bottom on the heat-absorbing surface of the inverter heat sink.

[0008] The dual-heat sink air-cooled power unit of this utility model has a capacitor bank that is a slender strip-shaped copper busbar.

[0009] In this utility model, a dual-heater air-cooled power unit has fuses connected in series in both the A-phase input bar and the B-phase input bar.

[0010] The present invention relates to a dual-heater air-cooled power unit, which includes an absorption capacitor and a resistor plate. The absorption capacitor, the resistor plate and the unit main control board are all located in the side cavity. The unit main control board is fixed to the outside of the IGBT module, the absorption capacitor is fixed to the inverter busbar and the resistor plate is fixed to the outside of the inverter busbar.

[0011] The dual-heater air-cooled power unit of this utility model has handles fixed at the upper and bottom of the front side of the housing, and slotted handles are provided at the upper ends of both sides of the housing.

[0012] The beneficial effects of this utility model are as follows: The dual-heater air-cooled power unit of this utility model is provided with a housing and a rectifier assembly, an inverter assembly, a thin-film capacitor, and a unit main control board located in the housing. The isolation plate in the housing divides its inner cavity into a heat dissipation channel and a side cavity. The fins of the inverter heat sink and the rectifier heat sink are located in the heat dissipation channel, and the heat absorption surface of the inverter heat sink is located in the side cavity. The rectifier bridge and the IGBT module are respectively fixed to the heat absorption surfaces of the rectifier heat sink and the inverter heat sink. In this way, during the operation of the power unit, the heat generated during the operation of the rectifier bridge is conducted to the rectifier heat sink and flows through the heat dissipation channel. The airflow carries away the heat generated by the inverter, which is conducted to the inverter heat sink and carried away by the airflow through the cooling duct. Compared with the existing system where the rectifier and inverter use the same heat sink, the rectifier heat sink can effectively share the heat dissipation burden of the inverter heat sink, resulting in better heat dissipation. This can improve the utilization rate of the devices to a certain extent and provide the possibility of increasing the operating power of air-cooled devices. At the same time, the isolation plate completely isolates the rectifier bridge and IGBT devices, so that the rectifier and inverter heat sinks are independent and perform their respective functions without interfering with each other, improving the reliability of air-cooled devices and facilitating the formation of higher power air-cooled power units.

[0013] Furthermore, the thin-film capacitors and the component connection bars connecting the rectifier busbar and the inverter busbar are all located within the heat dissipation duct, which is conducive to heat dissipation during capacitor operation, effectively improving capacitor utilization and lifespan, and facilitating heat dissipation of the component connection bars under high-power operation, further enhancing the stability of the power unit operation.

[0014] Furthermore, since the rectifier, inverter, unit control board, thin-film capacitor, capacitor bank and component connectors are all located in the same housing, the resulting power unit is smaller and lighter than the commonly used "power unit + capacitor unit" combination mode.

[0015] Furthermore, both the rectifier and inverter components are arranged vertically, which makes the unit width dimension smaller, which helps to reduce the overall structural footprint and make the product size more compact.

[0016] Furthermore, the capacitor bus adopts a slender strip-shaped copper bus, and the design of the inverter bus can effectively reduce the stray inductance of the power unit. The long strip-shaped capacitor bus can significantly reduce the material cost of the power unit. Attached Figure Description

[0017] Figure 1 This is a front view of the dual-heater air-cooled power unit of this utility model.

[0018] Figure 2 This is a rear view of the dual-heater air-cooled power unit of this utility model;

[0019] Figure 3 This is a left view of the dual-heater air-cooled power unit of this utility model;

[0020] Figure 4 This is a right view of the dual-heater air-cooled power unit of this utility model;

[0021] Figure 5 This is a top view of the dual-heater air-cooled power unit of this utility model;

[0022] Figure 6 This is a bottom view of the dual-heater air-cooled power unit of this utility model;

[0023] Figure 7 , Figure 8 All of these are perspective views of the dual-heater air-cooled power unit of this utility model;

[0024] Figure 9 , Figure 10 All are perspective views of the dual-heater air-cooled power unit of this utility model after the housing has been removed;

[0025] Figure 11 , Figure 12This is a perspective view of the dual-heater air-cooled power unit of this utility model after removing the casing and some components.

[0026] In the diagram: 1. Housing; 2. Rectifier assembly; 3. Inverter assembly; 4. Rectifier heat sink; 5. Inverter heat sink; 6. Rectifier bridge; 7. IGBT module; 8. Thin-film capacitor; 9. Unit main control board; 10. Heat dissipation duct; 11. Isolation plate; 12. Side cavity; 13. A-phase input busbar; 14. B-phase input busbar; 15. C-phase input busbar; 16. Rectifier busbar; 17. Inverter busbar; 18. Unit output busbar; 19. Component connection busbar; 20. Capacitor busbar; 21. Fuse; 22. Fuse output busbar; 23. Absorption capacitor; 24. Resistor board; 25. Capacitor mounting holes; 26. Handle; 27. Buckle. Detailed Implementation

[0027] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0028] like Figures 1 to 6 As shown, the front view, right view, left view, top view, and bottom view of the dual-heatsink air-cooled power unit of this utility model are given respectively. Figure 7 and Figure 8 Its 3D diagram is given. Figure 9 and Figure 10 A 3D view of it after the shell is removed is provided. Figure 11 and Figure 12 A perspective view of the dual-heater air-cooled power unit after removing the casing and some components is provided. The dual-heater air-cooled power unit consists of a casing 1 and a rectifier assembly 2, an inverter assembly 3, a thin-film capacitor 8, and a unit main control board 9 located within the casing 1. The rectifier assembly 2 consists of a rectifier heatsink 4, a rectifier bridge 6, and a rectifier busbar 16. The inverter assembly 3 consists of an inverter heatsink 5, an IGBT module 7, and an inverter busbar 17. A vertical isolation plate 11 is provided in the internal cavity of the casing 1. The isolation plate 11 not only fixes the thin-film capacitor 8, but also, together with the heat-absorbing surfaces of the inverter busbar 17 and the inverter heatsink 5, divides the internal cavity of the casing 1 into a heat dissipation channel 10 and a side cavity 12.

[0029] Both the rectifier heat sink 4 and the inverter heat sink 5 are vertically arranged, which can significantly reduce the width of the power unit, resulting in a more compact product size. The heat dissipation fins of the inverter heat sink 5 and the rectifier heat sink 4 are located in the heat dissipation duct 10. The rectifier bridge 6 is fixed from top to bottom to the heat absorption surface of the rectifier heat sink 4, and the IGBT module 7 is fixed from top to bottom to the heat absorption surface of the inverter heat sink 5. Thus, the rectifier bridge 6 is located in the heat dissipation duct 10, and the IGBT module 7 is located in the side cavity 12. The input terminals of the rectifier bridge 6 are connected to phase A input bus 13, phase B input bus 14, and phase C input bus 15. These three input bus 13, phase B input bus 14, and phase C input bus 15 extend from the lower part of the front side of the housing 1 and are connected to the three-phase AC power supply. The output terminals of the rectifier bridge 6 are connected to the rectifier bus 16.

[0030] The input terminal of the IGBT module 7 is connected to the inverter busbar 17, and the output terminal of the IGBT module 7 is connected to the unit output busbar 18. The unit output busbar 18 extends from the upper part of the front side of the housing 1. The unit output busbars 18 of multiple power units are cascaded to form an AC high-voltage output. The rectifier busbar 16 is connected to the inverter busbar 17 via the component connection busbar 19. Both the rectifier busbar 16 and the inverter busbar 17 are composed of a positive busbar and a negative busbar separated by an insulating partition. The film capacitors 8 are fixed on the capacitor bank 20 and connected in parallel via the capacitor plate 20. The parallel film capacitors 8 are connected to the inverter busbar 17 via the capacitor bank 20.

[0031] During operation, the AC power input from the three-phase input busbars (A-phase input busbar 13, B-phase input busbar 14 and C-phase input busbar 15) is rectified by the rectifier bridge 6 and converted into DC power, which is then input to the rectifier busbar 16 and the inverter busbar 17. The IGBT module 7 converts the AC power on the inverter busbar 17 into AC power with controllable phase and frequency, which is then output through the unit output busbar 18.

[0032] During the rectification and inversion process of the power unit, the heat generated by the rectifier bridge 6 during rectification is conducted to the rectifier heat sink 4 and carried away by the air flowing through the cooling duct 10; the heat generated by the IGBT module 7 during inversion is conducted to the inverter heat sink 5 and carried away by the air flowing through the cooling duct 10. Compared with the traditional single heat sink power unit, the rectifier heat sink can effectively share the heat dissipation burden of the inverter heat sink, resulting in better heat dissipation. This can improve the utilization rate of the device to a certain extent and provide the possibility of improving the operating power of air cooling. The rectifier heat sink 4 and the inverter heat sink 5 are independent of each other and perform their respective functions without interfering with each other, thus improving the reliability of air cooling.

[0033] The thin-film capacitor 8 shown is located in the heat dissipation duct 10, which facilitates heat dissipation during operation, effectively improving capacitor utilization and lifespan. It also aids in heat dissipation of the component connection bar under high-power operation, further enhancing the stability of the power unit. The connection bar 19 uses a slender strip-shaped copper busbar, which effectively reduces stray inductance of the power unit. The long strip-shaped capacitor busbar significantly reduces the material cost of the power unit.

[0034] A fuse 21 is connected in series on both phase A input bus 13 and phase B input bus 14. The output terminal of the fuse 21 is connected to the input terminal of the rectifier bridge 6 via the fuse output bus 22. The fuse 21 provides overcurrent protection for the input bus.

[0035] The main control board 9 shown is located in the side cavity 12 and is fixed to the outside of the IGBT module 7. The main control board 9 is used to control the operation of the power devices in the IGBT module 7. The side cavity 12 also contains an absorption capacitor 23 and a resistor plate 24. The resistor plate 24 is used to release residual charge after the equipment is shut down. Capacitor mounting holes 25 are provided on the isolation plate 11 at the end of the capacitor bank 20, providing convenient conditions for subsequent capacity expansion and upgrades of the power unit, and facilitating the expansion of the unit's application power range.

[0036] The upper and lower parts of the front side of the housing 1 shown are fixed with handles 26, and the upper parts of both sides of the housing 1 are provided with slotted handles 27. The handles 26 and handles 27 are used for disassembling and moving the power unit, which improves the portability of the power unit and is beneficial for on-site assembly and subsequent operation and maintenance.

Claims

1. A dual-heater air-cooled power unit, comprising a housing (1) and a rectifier assembly (2), an inverter assembly (3), a thin-film capacitor (8), and a unit main control board (9) located within the housing, wherein an isolation plate (11) is provided inside the housing, and heat dissipation air ducts (10) and side cavities (12) are formed between the two sides of the isolation plate and the housing, respectively; the rectifier assembly is composed of a rectifier heat sink (4), a rectifier bridge (6), and a rectifier busbar (16), and the inverter assembly is composed of an inverter heat sink (5), an IGBT module (7), and an inverter busbar (17), wherein the input end of the rectifier bridge is connected to an A-phase input busbar (13), a B-phase input busbar (14), and a C-phase input busbar (15) led out from the bottom of the front side of the housing, and the output end of the IGBT module is connected to a unit output busbar (18) led out from the upper part of the front side of the housing; characterized in that: The fins of the inverter heat sink and the rectifier heat sink are located in the heat dissipation duct. The heat absorption surface of the inverter heat sink is located in the side cavity. The rectifier bridge and IGBT module are located in the heat dissipation duct and the side cavity, respectively. The rectifier bridge and IGBT module are fixed on the heat absorption surfaces of the rectifier heat sink and the inverter heat sink, respectively.

2. The dual-heatsink air-cooled power unit according to claim 1, characterized in that: The output end of the rectifier bridge (6) is connected to the rectifier bus (16), the input end of the IGBT module (7) is connected to the inverter bus (17), and the rectifier bus and the inverter bus are connected through the component connection bar (19); the film capacitor (8) is fixed in parallel on the capacitor bar (20) and connected to the inverter bus through the capacitor bar. The component connection bar and the film capacitor are both located in the heat dissipation duct (10).

3. The dual-heatsink air-cooled power unit according to claim 1 or 2, characterized in that: The rectifier heat sink (4) and the inverter heat sink (5) are both vertically arranged. The rectifier bridge is fixed from top to bottom on the heat absorption surface of the rectifier heat sink, and the inverter heat sink is fixed from top to bottom on the heat absorption surface of the inverter heat sink.

4. The dual-heatsink air-cooled power unit according to claim 2, characterized in that: The capacitor bar (20) shown is a long and thin strip of copper.

5. The dual-heatsink air-cooled power unit according to claim 1 or 2, characterized in that: Both the A-phase input bar (13) and the B-phase input bar (14) are connected in series with fuses (21).

6. The dual-heatsink air-cooled power unit according to claim 1 or 2, characterized in that: The unit includes an absorption capacitor (23) and a resistor plate (24). The absorption capacitor, resistor plate and unit main control board (9) are all located in the side cavity (12). The unit main control board is fixed on the outside of the IGBT module (7), the absorption capacitor is fixed on the inverter busbar (17), and the resistor plate is fixed on the outside of the inverter busbar.

7. The dual-heatsink air-cooled power unit according to claim 1 or 2, characterized in that: Handles (26) are fixed to the upper and lower ends of the front side of the housing (1), and slotted handles (27) are provided on the upper ends of both sides of the housing.

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