A fully immersed liquid-cooled charging system

Abstract

The application discloses a full-submersion liquid cooling charging system, which comprises a cabinet, a plurality of power modules, a radiator, a circulating pipeline and a circulating pump, the cabinet has a top plate and a bottom plate which are oppositely arranged in the height direction of the cabinet; the plurality of power modules are arranged in the interior of the cabinet, the power module has a high-temperature oil outlet and a low-temperature oil inlet which are arranged at intervals in the height direction of the cabinet, and the high-temperature oil outlet is located between the corresponding low-temperature oil inlet and the top plate; the radiator is arranged in the interior of the cabinet, and the radiator has a liquid inlet and a liquid outlet; the circulating pipeline comprises a high-temperature oil pipeline and a low-temperature oil pipeline, the high-temperature oil pipeline is communicated with the high-temperature oil outlet of each power module and the liquid inlet of the radiator, and the low-temperature oil pipeline is communicated with the low-temperature oil inlet of each power module and the liquid outlet of the radiator; the circulating pump is arranged on the low-temperature oil pipeline. The full-submersion liquid cooling charging system has lower manufacturing cost and higher safety.

Description

Technical Field

[0001] This application relates to the field of charging system technology, and in particular to a fully immersion liquid-cooled charging system. Background Technology

[0002] With the rapid development of new energy vehicles, the demand for high-power, high-current fast charging is becoming increasingly urgent, and high-power, high-current charging equipment has high heat dissipation requirements.

[0003] Currently, high-power liquid-cooled charging equipment on the market mainly involves installing cold-plate liquid-cooled power modules inside the charging equipment cabinet. Cold-plate liquid-cooled power modules are power modules with cold plates installed inside. A liquid-air radiator is installed on the top of the charging equipment cabinet. The cold plate and the radiator are connected by pipes. The cooling medium flows horizontally inside the liquid-air radiator. The cooling medium is usually a mixture of pure water and ethylene glycol antifreeze.

[0004] However, in the aforementioned charging equipment solutions using cold-plate liquid-cooled power modules, the flow channels of the cooling medium in the cold plate must pass through all the areas where heat-generating devices and high-temperature sensitive devices are located within the power module to meet the heat dissipation requirements of the power module. The flow channels also need to be designed and laid out according to the heat generation and temperature resistance of the internal devices of the power module to provide a suitable temperature environment for the internal devices. This results in a relatively complex overall design of the cold-plate power module, a large power module size, and higher costs for both the charging equipment and maintenance. Furthermore, since the cold-plate liquid-cooled power module cannot isolate the internal devices and circuits from oxygen, when arcing or fire occurs in the internal devices or circuits of the power module, the fire can spread due to contact with oxygen, resulting in poor safety. Utility Model Content

[0005] The main purpose of this application is to provide a fully immersion liquid-cooled charging system, which aims to solve the problems of high cost and maintenance cost and poor safety of traditional charging equipment products.

[0006] To achieve the above objectives, this application provides a fully immersion liquid-cooled charging system. This system includes a cabinet, multiple power modules, a heat sink, a circulation pipeline, and a circulation pump. The cabinet has a top plate and a bottom plate arranged opposite each other along its height. Multiple power modules are housed inside the cabinet. Each power module includes a sealed housing and a PCBA assembly housed within the sealed housing. The PCBA assembly includes power electronic devices and control circuitry. Each power module has a high-temperature oil outlet and a low-temperature oil inlet spaced apart along the height of the cabinet, with the high-temperature oil outlet located between the corresponding low-temperature oil inlet and the top plate. The heat sink is located inside the cabinet and between the multiple power modules and the top plate. The heat sink includes a high-temperature side manifold, a low-temperature side manifold, and multiple heat dissipation pipes connected between the high-temperature side manifold and the low-temperature side manifold. The high-temperature side manifold has an inlet, and the low-temperature side manifold has an outlet. The circulation pump is located on the low-temperature oil pipeline.

[0007] Optionally, the fully immersion liquid-cooled charging system further includes a cooling fan, which is mounted on the cabinet, and the airflow direction of the cooling fan forms an angle with the plane formed by the multiple cooling pipes.

[0008] Optionally, the fully immersion liquid-cooled charging system further includes an expansion oil tank, which is located inside the cabinet and connected to the cryogenic oil pipeline. The expansion oil tank is located between the power module and the top plate and is arranged horizontally alongside the radiator. In the cryogenic oil pipeline, the expansion oil tank is located between the circulation pump and the outlet of the radiator.

[0009] Optionally, the fully immersion liquid-cooled charging system also includes multiple liquid level sensors, which are spaced apart on the inside of the expansion tank in the height direction of the cabinet.

[0010] Optionally, the fully immersed liquid-cooled charging system further includes a filter screen disposed inside the expansion oil reservoir to filter the insulating oil entering the expansion oil reservoir.

[0011] Optionally, the fully immersion liquid-cooled charging system further includes multiple temperature and pressure sensors, which are respectively disposed at at least one of three locations: the power module, the high-temperature oil pipeline, and the low-temperature oil pipeline.

[0012] Optionally, the fully immersion liquid-cooled charging system further includes a valve, which is connected in parallel with the circulating pump on the cryogenic oil pipeline; wherein the valve and the circulating pump constitute a power assembly, and there are two power assemblies connected in parallel on the cryogenic oil pipeline.

[0013] Optionally, the high-temperature side manifold is higher than the low-temperature side manifold in the direction of gravity, and multiple heat dissipation pipes are arranged sequentially along the axial direction of the high-temperature side manifold on its outer periphery, wherein the axial direction of the heat dissipation pipes forms an angle with the horizontal plane; the high-temperature side manifold, the low-temperature side manifold, and the multiple heat dissipation pipes constitute a heat dissipation module, and the heat sink is composed of a heat dissipation assembly, which includes at least one heat dissipation module; wherein, when the heat dissipation assembly includes multiple heat dissipation modules, the multiple heat dissipation modules within the same heat dissipation assembly are arranged sequentially along the axial direction of the high-temperature side manifold, the high-temperature side manifolds within adjacent heat dissipation modules are interconnected, and the low-temperature side manifolds within adjacent heat dissipation modules are interconnected.

[0014] Optionally, the heat dissipation components are at least two sets and arranged in a horizontal direction perpendicular to the axial direction of the high-temperature side manifold.

[0015] Optionally, the heat dissipation assembly has two sets and the two sets of heat dissipation assemblies have an included angle.

[0016] This application proposes a fully immersion liquid-cooled charging system in which the power module is directly connected to the heat sink via a circulation pipeline. The cooling medium is insulating oil, which flows through the interior of the power module and the heat sink under the drive of a circulation pump. The insulating oil carries the heat generated by the internal components of the power module to the heat sink, where a cooling fan dissipates heat. This eliminates the need for a cold plate that contacts the internal components of the power module, thus eliminating the need for cold plate flow channels, making it more convenient and cost-effective. Furthermore, since all heat-generating components and circuits in the power module are immersed in insulation, and all surfaces of the heat-generating components and circuits are in direct contact with the insulating cooling oil, the heat is directly transferred to the insulating cooling oil, increasing the heat transfer area of ​​the heat-generating components and circuits, resulting in more direct and efficient heat dissipation. Furthermore, the insulating oil completely isolates the possibility of oxygen coming into contact with the heating devices and circuits. When the devices and circuits experience quality problems such as aging, resulting in high temperatures or arcing, the insulating oil will extinguish the arc and cool them down. Since they cannot come into contact with oxygen, they will not produce open flames, thus ensuring higher safety. In terms of the cabinet's height, the high-temperature oil outlet is above the low-temperature oil inlet. This allows the high-temperature insulating oil in the power module to expand, rise, and flow out from the high-temperature oil outlet, making the flow process more reasonable and smooth. Moreover, the insulating oil at the high-temperature oil outlet will not repeatedly cross with the insulating oil at the low-temperature oil inlet, further increasing the temperature and density difference between the insulating oil in the low-temperature oil pipeline and the insulating oil in the high-temperature oil pipeline. As the insulating oil temperature rises, its viscosity decreases, resulting in lower flow resistance and facilitating the circulation pump to drive the insulating oil to circulate and dissipate heat. Attached Figure Description

[0017] To more clearly illustrate the prior art and the present invention, the accompanying drawings used in the description of the prior art and the embodiments of the present invention will be briefly introduced below. Obviously, the drawings described below are merely exemplary, and those skilled in the art can derive other drawings from the provided drawings without any creative effort.

[0018] The structures, proportions, sizes, etc. illustrated in this specification are only for the purpose of assisting those skilled in the art in understanding and reading the content disclosed herein, and are not intended to limit the conditions under which this utility model can be implemented. Any modifications to the structure, changes in the proportions, or adjustments to the size, without affecting the effects and purposes that this utility model can produce, should still fall within the scope of the technical content disclosed in this utility model.

[0019] Figure 1 This is a schematic diagram of the overall structure of an immersion liquid-cooled charging system proposed in an embodiment of this application;

[0020] Figure 2 for Figure 1 A structural breakdown diagram of the Chinese embodiment;

[0021] Figure 3 for Figure 1 A schematic diagram of the internal structure of the Chinese embodiment;

[0022] Figure 4 This is a schematic diagram of the heat sink structure in the embodiments of this application. Figure 1 ;

[0023] Figure 5 This is a schematic diagram of the heat sink structure in the embodiments of this application. Figure 2 ;

[0024] Figure 6 Figure 5 Another perspective structural diagram of the embodiment;

[0025] Figure 7 This is a schematic diagram of the insulating oil circulation path in an embodiment of this application.

[0026] Figure 8 This is a simplified diagram of the internal structure of the cabinet in an embodiment of this application;

[0027] Figure 9 This is a schematic diagram of the heat dissipation module layout in an embodiment of this application. Figure 1 ;

[0028] Figure 10 This is a schematic diagram of the heat dissipation module layout in an embodiment of this application. Figure 2 .

[0029] In the diagram: 1. Cabinet; 11. Temperature and pressure sensor; 2. Power module; 3. Heat sink; 31. High-temperature side manifold; 32. Low-temperature side manifold; 33. Heat sink pipe; 4. Circulation pipeline; 41. High-temperature oil pipeline; 42. Low-temperature oil pipeline; 5. Circulation pump; 6. Expansion oil reservoir; 61. Liquid level sensor; 7. Valve; 8. Cooling fan; 91. Front manifold of the heat sink; 92. Rear manifold of the heat sink; 93. Diverter bend pipe; 94. Intermediate manifold.

[0030] The realization of the purpose, functional features and advantages of this application will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0031] 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.

[0032] It should be noted that all directional indicators (such as up, down, left, right, front, back, etc.) in this utility model embodiment are only used to explain the relative positional relationship and movement of each component in a certain specific posture (as shown in the figure). If the specific posture changes, the directional indicator will also change accordingly.

[0033] In this utility model, unless otherwise explicitly specified and limited, the terms "connection" and "fixation" should be interpreted broadly. For example, "fixation" can mean a fixed connection, a detachable connection, or an integral part; it can mean a mechanical connection or an electrical connection; it can mean a direct connection or an indirect connection through an intermediate medium; it can mean the internal communication of two components or the interaction between two components, unless otherwise explicitly limited. Those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.

[0034] Furthermore, if the embodiments of this utility model involve descriptions such as "first" or "second," these descriptions are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined with "first" or "second" may explicitly or implicitly include at least one of those features. Additionally, the meaning of "and / or" throughout the text includes three parallel solutions. For example, "A and / or B" includes solution A, solution B, or a solution where both A and B are satisfied. Furthermore, the technical solutions of the various embodiments can be combined with each other, but this must be based on the ability of those skilled in the art to implement them. When the combination of technical solutions is contradictory or impossible to implement, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection claimed by this utility model.

[0035] The present application will now be described in detail with reference to the accompanying drawings and embodiments.

[0036] Figure 1 This is a schematic diagram of the overall structure of an immersion liquid-cooled charging system proposed in an embodiment of this application; Figure 2 for Figure 1 A structural breakdown diagram of the Chinese embodiment; Figure 3 for Figure 1 A schematic diagram of the internal structure of the Chinese embodiment; Figure 4 This is a schematic diagram of the heat sink structure in the embodiments of this application. Figure 1 ; Figure 5 This is a schematic diagram of the heat sink structure in the embodiments of this application. Figure 2 ; Figure 6 Figure 5 Another perspective structural diagram of the embodiment; Figure 7 This is a schematic diagram of the insulating oil circulation path in the embodiments of this application; Figure 8 This is a simplified diagram of the internal structure of the cabinet in an embodiment of this application; Figure 9 This is a schematic diagram of the heat dissipation module layout in an embodiment of this application. Figure 1 ; Figure 10 This is a schematic diagram of the heat dissipation module layout in an embodiment of this application. Figure 2 .

[0037] in, Figure 7 The black arrows indicate the flow direction of the insulating oil. The green sections are low-temperature pipelines, and the red sections are high-temperature pipelines.

[0038] refer to Figures 1-10 It should be understood that Figure 2 The connections between the various components should be like Figure 1 As compact as in the middle, this is only for illustrative purposes and will Figure 2To facilitate understanding, some components are shown disassembled in this application embodiment. This embodiment provides a fully immersion liquid-cooled charging system, which may include a cabinet 1, multiple power modules 2, a heat sink 3, a circulation pipeline 4, and a circulation pump 5. The cabinet 1 has a top plate and a bottom plate arranged opposite each other in its height direction. Multiple power modules 2 are all disposed inside the cabinet 1. Each power module 2 includes a sealed housing and a PCBA assembly disposed inside the sealed housing. The PCBA assembly includes power electronic devices and control circuitry. The power modules 2 have [a certain function / function] within the cabinet 1. The high-temperature oil outlet and low-temperature oil inlet are spaced apart in the height direction, and the high-temperature oil outlet is located between the corresponding low-temperature oil inlet and the top plate; the radiator 3 is located inside the cabinet 1 and between multiple power modules 2 and the top plate. The radiator 3 includes a high-temperature side manifold 31, a low-temperature side manifold 32 and multiple heat dissipation pipes 33. The multiple heat dissipation pipes 33 are connected between the high-temperature side manifold 31 and the low-temperature side manifold 32. The high-temperature side manifold 31 is provided with a liquid inlet and the low-temperature side manifold 32 is provided with a liquid outlet; the circulation pump 5 is provided on the low-temperature oil pipeline 42.

[0039] This application proposes a fully immersion liquid-cooled charging system. The power module 2 is directly connected to the heat sink 3 via a circulation pipe 4. The cooling medium is insulating oil. Driven by a circulation pump 5, the insulating oil flows through the interior of the power module 2 and the heat sink 3, carrying the heat generated by the components inside the power module 2 to the heat sink 3. A cooling fan 8 dissipates heat from the heat sink 3. This eliminates the need for a cold plate to contact the internal components of the power module 2, thus eliminating the need for cold plate flow channels, making it more convenient and cost-effective. Simultaneously, all heat-generating components and circuits in the power module 2 are immersed in insulation, with each surface of the heat-generating components and circuits directly contacting the insulating cooling oil, directly transferring heat to the oil. This increases the heat transfer area of ​​the heat-generating components and circuits, making heat dissipation more direct and effective. Furthermore, the insulating oil completely isolates oxygen from the heat generated. The possibility of contact between components and circuits is reduced. When components and circuits experience quality problems such as aging, high temperatures or arcing may occur. These issues are extinguished and cooled by the insulating oil, preventing contact with oxygen and thus avoiding open flames, resulting in higher safety. In the height direction of cabinet 1, the high-temperature oil outlet is above the low-temperature oil inlet. This allows the high-temperature insulating oil in power module 2 to expand, rise, and flow out from the high-temperature oil outlet, making the flow process more reasonable and smooth. Furthermore, the insulating oil at the high-temperature oil outlet will not repeatedly cross with the insulating oil at the low-temperature oil inlet, further increasing the temperature and density difference between the insulating oil in the low-temperature oil pipeline 42 and the insulating oil in the high-temperature oil pipeline 41, which facilitates the natural circulation and convection of the insulating oil (the natural circulation and convection of insulating oil will be explained later). Of course, the increased temperature and decreased viscosity of the insulating oil result in lower flow resistance, which is also beneficial for the circulation pump 5 to drive the insulating oil circulation and heat dissipation.

[0040] In an exemplary embodiment, the fully immersion liquid-cooled charging system further includes a cooling fan 8, which is mounted on the cabinet 1, and the airflow direction of the cooling fan 8 forms an angle with the plane formed by the multiple heat dissipation pipes 33.

[0041] It should be understood that, when using the cabinet 1, it is usually placed on a flat surface so that the height direction of the cabinet 1 is the same as the direction of gravity. The bottom plate and the top plate are two plates that are set opposite each other in the direction of gravity of the cabinet 1, with the top plate located above the bottom plate.

[0042] Additionally, the circulating pump 5 can be a gear pump; the specific arrangement of the multiple power modules 2 is not limited here, they can be arranged in a horizontal array, a spatial array, or other arrangements; the area where the multiple power modules 2 are located can be referred to as the heat-generating area, and the area where the heat sink 3 is located can be referred to as the heat-dissipating area. To facilitate the installation of the heat sink 3, a partition can be added between the heat-generating area and the heat-dissipating area to mount the heat sink 3 on the partition; of course, the partition should also have holes for the circulation pipe 4 to pass through.

[0043] The airflow path of the cooling fan 8 refers to the flow path of the airflow blown out by the cooling fan 8. The cooling fan 8 typically has blades rotating around a fixed axis to blow air. Usually, the airflow path is the same as the axial direction of the fixed axis, meaning the airflow path of the cooling fan 8 can be changed by adjusting the axial direction of the fixed axis. The airflow direction of the cooling fan 8 forms an angle with the plane formed by the multiple heat dissipation pipes 33. This can be understood as an angle between the axial direction of the fixed axis inside the cooling fan 8 and the plane formed by the multiple heat dissipation pipes 33, allowing the airflow blown out by the cooling fan 8 to directly blow onto the heat dissipation pipes 33. In this embodiment, as shown... Figure 2 and Figure 3 As shown, the cooling fan 8 can be installed through the top plate, and the airflow direction of the cooling fan 8 is the same as the height direction of the cabinet 1. When the two heat dissipation components are arranged in a "V" shape (explained later), the cooling fan 8 located at the top plate (i.e. above the "V") blows the airflow downwards, which makes it easier for the cooling fan 8 to blow the airflow to each heat dissipation pipe 3 in the two heat dissipation components, thereby achieving the maximum airflow area and better heat dissipation effect.

[0044] Furthermore, in this embodiment, the high-temperature side manifold 31 is higher than the low-temperature side manifold 32 in the direction of gravity, and multiple heat dissipation pipes 33 are arranged sequentially on the outer periphery of the high-temperature side manifold 31 along the axial direction of the high-temperature side manifold 31, wherein the axial direction of the heat dissipation pipes 33 has an angle with the horizontal plane.

[0045] It should be noted that the high-temperature side manifold 31 is higher than the low-temperature side manifold 32 in the direction of gravity, and the axial direction of the heat dissipation pipe 33 has an angle with the horizontal plane, which means that the angle between the axial direction of the heat dissipation pipe 33 and the horizontal plane is greater than 0° and less than or equal to 90°. Multiple heat dissipation pipes 33 are arranged sequentially along the axial direction of the high-temperature side manifold 31 on the outer periphery of the high-temperature side manifold 31, forming a plate-like component composed of heat dissipation pipes 33. Each heat dissipation pipe 33 has an angle with the horizontal plane, and the angles are the same. If the angle between the heat dissipation pipe 33 and the horizontal plane is too large, such as 90°, then if the cooling fan 8 is set at the top plate and blows air vertically downwards, the air delivery path is parallel to the axial direction of the heat dissipation pipe 33, the contact area between the airflow and the heat dissipation pipe 33 is too small, and the airflow does not directly blow onto the heat dissipation pipe 33, resulting in poor heat dissipation. In this case, the air delivery direction of the cooling fan 8 can be adjusted so that the air delivery direction of the cooling fan 8 has a larger angle with the plane formed by the multiple heat dissipation pipes 33, thereby increasing the contact area between the airflow blown by the cooling fan 8 and the heat dissipation pipe 33, and ensuring that the airflow blows directly onto the heat dissipation pipe 33, thus improving the heat dissipation effect. Of course, if the angle between the heat dissipation pipe 33 and the horizontal plane is too large, such as 90°, the heat dissipation fan 8 can be set on the side wall of the cabinet 1, so that the heat dissipation fan 8 and the heat sink 3 are parallel in the horizontal direction. The airflow direction of the heat dissipation fan 8 is perpendicular to the plane formed by multiple heat dissipation pipes 33, so that the airflow blown out by the heat dissipation fan 8 blows directly on the heat dissipation pipes 33, and the heat dissipation effect is also better. However, this solution of setting the heat dissipation fan 8 on the side wall of the cabinet 1 is only suitable for the case of one heat dissipation component. In the case of multiple heat dissipation components, the heat dissipation components far away from the heat dissipation fan 8 receive less airflow and have poor heat dissipation effect.

[0046] Furthermore, ventilation holes can be opened on the side wall of the heat dissipation area of ​​the cabinet 1 to improve the heat dissipation effect of the heat sink 3.

[0047] It should be noted that power module 2 is a fully submerged power module, mainly composed of a sealed housing and a PCBA assembly. The sealed housing forms a completely sealed cavity to ensure that the insulating oil does not leak; the PCBA assembly contains power electronic devices and control circuits, all of which are submerged in the insulating oil for direct heat dissipation.

[0048] The working principle of power module 2 is as follows: When power module 2 is put into operation, the heat generated by the power devices is directly absorbed by the surrounding insulating oil, causing the temperature of the insulating oil to gradually rise. The built-in temperature detection device collects the temperature data of the insulating coolant in real time. When the temperature reaches a certain threshold, the controller of the charging system starts the external cold source circulation device, such as circulation pump 5. At this time, the high-temperature insulating oil is pumped out of the cavity of power module 2, while the low-temperature insulating oil after being treated by the external cooling system is injected into the cavity, forming a closed-loop heat exchange.

[0049] The power module 2 generates heat during operation. The insulating oil absorbs the heat, its density decreases, and due to the high temperature, the insulating oil expands upward and flows naturally into the high-temperature side manifold 31. It then flows evenly into each heat dissipation pipe 33 for heat dissipation. Each heat dissipation pipe 33 has an angle with the horizontal plane. The cooling medium flowing into the heat dissipation pipe 33 will converge in the low-temperature side manifold 32 and flow back into the power module 2 to continue cooling the power module 2. In this way, the insulating oil can achieve natural convection and circulation heat dissipation during operation, without the need for the circulation pump 5 to work, resulting in lower costs and more convenient maintenance.

[0050] In an exemplary embodiment, the fully submerged liquid-cooled charging system also includes a valve 7, which is connected in parallel with the circulating pump 5 on the cryogenic oil line 42.

[0051] It should be understood that valve 7 can be a one-way valve. When the insulating oil is naturally circulated and convected in the circulation pipeline 4 for heat dissipation, the insulating oil flow rate and pressure are low due to the meshing of gears in the circulation pump 5. The insulating oil will be blocked by the meshing gears in the cavity of the circulation pump 5. At this time, the pressure of the insulating oil flow will push open the flap in the one-way valve to pass through the one-way valve, thereby realizing the natural circulation and convection heat dissipation of the insulating oil between the circulation pipeline 4, the radiator 3, and the power module 2. There is no need to turn on the circulation pump 5, which effectively improves the service life of the circulation pump 5 and reduces the heat dissipation cost of the charging system.

[0052] It should be noted that the high-temperature side manifold 31 is located between the low-temperature side manifold 32 and the top plate, and the axial direction of the heat dissipation pipe 33 is at an angle to the horizontal plane. In this way, when the insulating oil flows from the high-temperature side manifold 31 to the low-temperature side manifold 32, it flows downward at an angle, making the flow smoother and facilitating natural convection of the insulating oil.

[0053] It should be noted that the insulating oil in this application can be a liquid with a large coefficient of thermal expansion. The larger the coefficient of thermal expansion, the greater the volume expansion of the insulating oil after absorbing the same amount of heat, and the faster the flow rate of the insulating oil in the radiator 3, resulting in better heat dissipation.

[0054] For example, in the embodiments of this application, the insulating oil can be an insulating oil with a thermal expansion coefficient of 5% per 60-degree temperature difference, or a mineral oil-based insulating oil with a thermal expansion coefficient of 0.07% to 0.1% per degree Celsius, such as transformer oil; or a silicone oil or synthetic ester insulating oil with a thermal expansion coefficient of 0.1% to 0.12% per degree Celsius.

[0055] Furthermore, the flow rate of the cooling medium is also related to its viscosity. The higher the temperature of the insulating oil used in this application, the lower its viscosity, thus reducing the flow resistance of the insulating oil. The insulating oil has the characteristic of upward heat transfer, with heated oil naturally convection upward and cooled oil naturally convection downward. This allows the insulating oil to be heated by the heat generated during the operation of the power module 2 in a low-temperature environment. The heated insulating oil fluid naturally convections upward, and the low-temperature insulating oil fluid, after being cooled by the radiator 3, naturally convections downward, achieving natural convection and circulating heat dissipation of the insulating oil within the charging system, eliminating the need for the circulation pump 5 to operate.

[0056] It should be understood that the axial horizontal arrangement of the high-temperature side current collector 31 allows the insulating oil entering the high-temperature side current collector 31 to flow into each heat dissipation pipe 33 more evenly for heat dissipation.

[0057] In addition, when using the radiator 3, the high-temperature side current collector 31 is higher than the low-temperature side current collector 32 in the direction of gravity, so that the insulating oil in the heat dissipation pipe 33 flows from top to bottom. In this way, under the limitation of the height of the charging system, the number of heat dissipation pipes 33 can be increased in the horizontal direction to meet the heat dissipation requirements of the high-power charging system without increasing the length of a single heat dissipation pipe 33. The flow resistance of the insulating oil is lower, and the flow is smoother, thereby increasing the flow rate of the insulating oil, increasing the flow rate of the insulating oil, and further increasing the heat dissipation effect.

[0058] It should be noted that traditional heat dissipation pipes have longer paths. When the insulating oil enters the front end of the heat dissipation pipe, its temperature is higher, resulting in a larger temperature difference with the outside and better heat dissipation. However, when the insulating oil enters the rear end of the heat dissipation pipe, its temperature drops, resulting in a smaller temperature difference with the outside and poorer heat dissipation, as well as greater flow resistance. In the embodiment of this application, the heat dissipation pipe 33 has a shorter path. When the insulating oil flows to the outlet of the low-temperature side manifold 32, there is still a certain temperature difference between the insulating oil and the ambient temperature. This ensures that the insulating oil has a higher temperature in the heat dissipation pipe 33, maintaining a large temperature difference with the outside and resulting in better heat dissipation. This also reduces the flow resistance and increases the flow velocity of the insulating oil within the heat dissipation pipe 33, further increasing the flow rate of the insulating oil and thus improving the heat dissipation efficiency of the radiator 3.

[0059] In addition, temperature detection devices are installed at both the high-temperature oil outlet and the low-temperature oil inlet of power module 2. These devices can interact with the external cold source control system in real time via communication protocols such as CAN, 485, or 232 to control the circulation of the insulating oil. Both the high-temperature oil outlet and the low-temperature oil inlet employ specially designed check valve structures to effectively prevent the insulating coolant from flowing back and ensure unidirectional circulation.

[0060] It should be understood that the high-temperature oil outlet is used for insulating oil to flow out of the power module 2 and into the high-temperature oil pipeline 41, while the low-temperature oil inlet is used for insulating oil in the low-temperature oil pipeline 42 to flow into the power module 2. Since the insulating oil carries away the heat from the heating devices or heating circuits inside the power module 2, the temperature of the insulating oil in the low-temperature oil pipeline 42 is lower than that in the high-temperature oil pipeline 41. Therefore, setting the circulation pump 5 on the low-temperature oil pipeline 42 can prevent high temperature from damaging the circulation pump 5 and effectively improve the service life of the circulation pump 5.

[0061] Meanwhile, the circulation pump 5 is located at the low-temperature oil pipeline 42, which can increase the pressure at the low-temperature oil pipeline 42, making it easier to press the low-temperature insulating oil into the power module 2 to dissipate heat from the power module 2.

[0062] Furthermore, in the height direction of cabinet 1, the high-temperature oil outlet is above the low-temperature oil inlet. This allows the high-temperature insulating oil in the power module 2 to expand, rise, and flow out from the high-temperature oil outlet, making the flow process more reasonable and smooth. Moreover, the insulating oil at the high-temperature oil outlet will not repeatedly cross with the insulating oil at the low-temperature oil inlet, further increasing the temperature and density difference between the insulating oil in the low-temperature oil pipeline 42 and the insulating oil in the high-temperature oil pipeline 41, which is more conducive to the natural circulation and convection of the insulating oil (the natural circulation and convection of insulating oil will be explained later). Of course, the viscosity of the insulating oil decreases as the temperature rises, resulting in lower flow resistance and facilitating the circulation pump 5 to drive the insulating oil circulation and heat dissipation.

[0063] If the high-temperature oil outlet is located below the low-temperature oil inlet, the insulating oil at the high-temperature oil outlet in the power module 2 will expand and rise, repeatedly crossing with the insulating oil at the low-temperature oil inlet, affecting the heat dissipation effect.

[0064] Furthermore, valve 7 is connected in parallel with circulation pump 5 on low-temperature oil pipeline 42. In low-temperature environments, when power module 2 heats up, the thermal expansion and contraction characteristics of insulating oil itself can be used for heat dissipation. Specifically, the insulating oil in power module 2 expands due to heat and enters high-temperature oil pipeline 41. The insulating oil in high-temperature oil pipeline 41 has a high temperature and a lower density, so it floats and flows into the high-temperature side manifold 31 of radiator 3. The insulating oil in low-temperature oil pipeline 42 has a low temperature and a higher density, so it sinks and flows. In the charging system, the insulating oil naturally circulates and convects in circulation pipeline 4 to dissipate heat. The greater the temperature difference between high-temperature oil pipeline 41 and low-temperature oil pipeline 42 in the charging system, the greater the natural circulation flow rate and pressure of the insulating oil in the charging system.

[0065] It should be understood that when the controller of the charging system detects that the temperature of the device with the highest temperature in any two or more power modules 2 or the temperature of the insulating oil in the module exceeds the set threshold, it can control the circulation pump 5 to start running. A negative pressure will be formed in the front pipe of the inlet of the circulation pump 5, and a positive pressure fluid will be formed in the pipe at the rear of the outlet of the circulation pump 5 to push the flap of the one-way valve to close, so that the insulating oil can only pass through the circulation pump 5 and cannot pass through the one-way valve. That is, the circulation pump 5 drives the insulating oil to circulate and dissipate heat for the power module 2, which is more effective.

[0066] It should be noted that when using the circulating pump 5 to drive the insulating oil to circulate and dissipate heat, heat dissipation can be carried out normally regardless of whether the environment is low temperature.

[0067] Furthermore, valve 7 can also be a solenoid valve or an electric valve. When it is necessary to utilize the natural circulation flow formed by the temperature difference and density difference of the insulating oil in the high-temperature oil pipeline 41 and the low-temperature oil pipeline 42 to dissipate heat, valve 7 can be opened without starting the gear circulation pump 5. When it is necessary to start the circulation pump 5 to drive the insulating oil to circulate and dissipate heat, valve 7 can be closed and the circulation pump 5 can be started.

[0068] In an exemplary embodiment, valve 7 and circulation pump 5 constitute a set of power components, and there are two sets of power components that are connected in parallel on circulation pipeline 4.

[0069] It should be understood that the power assembly can be installed on the cryogenic oil pipeline 42. When two sets of power assemblies are installed in parallel on the cryogenic oil pipeline 42, only the circulation pump 5 in one set of power assemblies will work at the same time. When one of the circulation pumps 5 fails, the circulation pump 5 in the other power assembly can be used to continue to provide circulation power for the insulating oil.

[0070] Furthermore, if valve 7 is a check valve, when it is necessary to utilize the natural circulation flow formed by the temperature difference and density difference of the insulating oil in the high-temperature oil pipeline 41 and the low-temperature oil pipeline 42 for heat dissipation, both circulation pumps 5 are closed. The insulating oil can flow through one of the two valves 7 or simultaneously through both valves 7. When it is necessary to start the circulation pump 5 to drive the insulating oil to circulate and dissipate heat, one of the circulation pumps 5 is turned on. A positive pressure fluid will be formed in the pipeline at the rear end of the outlet of the circulation pump 5 to push the flaps of the two check valves to close, so that the insulating oil can only pass through the circulation pump 5 and cannot pass through the check valve. That is, the circulation pump 5 drives the insulating oil to circulate and dissipate heat for the power module 2.

[0071] In an exemplary embodiment, the axial direction of the heat dissipation pipe 33 is perpendicular to the axial direction of the high-temperature side manifold 31, and the axial direction of the low-temperature side manifold 32 is parallel to the axial direction of the high-temperature side manifold 31. Thus, with the total flow rate of the multiple heat dissipation pipes 33 remaining constant, the arrangement of the heat dissipation pipes 33 with the high-temperature side manifold 31 and the low-temperature side manifold 32 is more compact, occupying less space. The parallelism between the low-temperature side manifold 32 and the high-temperature side manifold 31 ensures that the length of each heat dissipation pipe 33 is the same, so the heat dissipation effect of the insulating oil in different heat dissipation pipes 33 is similar, and the heat dissipation is more uniform.

[0072] In an exemplary embodiment, the heat sink 33 is a flat tube, and the cross-section of the heat sink 33 perpendicular to its own axis is rectangular. The rectangle has a long side and a short side, and the direction of the short side is parallel to the axis of the high-temperature side manifold 31.

[0073] Specifically, in traditional solutions, the heat dissipation pipes of the radiator are mostly circular. Compared with circular pipes, flat pipes can be arranged more densely, thereby increasing the total flow of multiple heat dissipation pipes 33 in the radiator 3, and thus improving the heat dissipation efficiency.

[0074] Furthermore, since the direction of the short side is parallel to the axis of the high-temperature side manifold 31, the direction of the short side can be understood as the thickness direction of the flat tube. Therefore, the arrangement of multiple heat dissipation tubes 33 can be understood as multiple heat dissipation tubes 33 being arranged in layers in their own thickness direction. In this way, on the one hand, the heat dissipation tubes 33 can be arranged more densely, and on the other hand, the heat dissipation tubes 33 can be extended in the direction of the long side, that is, the length of the long side of the rectangle can be increased, thereby increasing the area of ​​the rectangle and further increasing the flow rate of the heat dissipation tubes 33 to improve the heat dissipation effect.

[0075] In an exemplary embodiment, the angle between the axial direction of the heat pipe 33 and the horizontal plane is n, and 40°≤n≤60°.

[0076] Specifically, when the heat sink 3 is installed on the top of the cabinet 1, the heat dissipation pipe 33 can be arranged vertically in the cabinet 1, that is, the angle between the heat dissipation pipe 33 and the horizontal plane is 90°. In a preferred embodiment, in order to reduce the size of the charging system, the heat dissipation pipe 33 is arranged obliquely, so that the heat dissipation pipe 33 has an angle with the horizontal plane. The angle between the heat dissipation pipe 33 and the horizontal plane is greater than 0° and less than 90°, for example, it can be 30°, 60°, 90°, etc. The axial angle between the heat dissipation pipe 33 and the horizontal plane can be further specified to 40° to 50°, for example, it can be 40°, 43°, 45°, 47°, 50°, etc. This makes the two ends of the heat dissipation pipe 33 have a height difference, which not only facilitates the natural flow of insulating oil, but also makes the overall height occupied by the heat sink 3 smaller.

[0077] refer to Figure 3 and Figure 7In an exemplary embodiment, the immersion liquid-cooled charging system may further include an expansion oil tank 6, which is disposed inside the cabinet 1 and connected to the cryogenic oil pipeline 42. The expansion oil tank 6 is located between the power module 2 and the top plate and is arranged in parallel with the radiator 3 in the horizontal direction. The expansion oil tank 6 is located between the circulation pump 5 and the outlet of the radiator 3 on the cryogenic oil pipeline 42.

[0078] like Figure 3 As shown, the expansion oil can 6 is also located in the top area of ​​the cabinet 1 and is arranged side by side with the heat sink 3. Specifically, the expansion oil can 6 can be set at the end of the high temperature side manifold 31 of the heat sink 3, so that the low temperature side manifold 32 can be connected to the side wall of the expansion oil can 6, and at the same time, it is convenient to lead out the pipe from the bottom of the expansion oil can 6 to connect to each of the power modules 2.

[0079] In this way, the expansion oil can 6 is filled with insulating oil and is placed on the low temperature oil line 42 instead of the high temperature oil line 41. This can also prevent high temperature from damaging the expansion oil can 6 and effectively improve the service life of the expansion oil can 6.

[0080] In addition, the expansion oil tank 6 is located between the outlet of the circulating pump 5 and the radiator 3. In this way, when the circulating pump 5 is working, the expansion oil tank 6 can ensure that the circulating pump 5 can always draw insulating oil and will not run dry, thus affecting the service life of the circulating pump 5.

[0081] Meanwhile, by placing the circulation pump 5 after the expansion oil tank 6 on the cryogenic oil line 42, the expansion oil tank 6 can be prevented from being subjected to excessive pressure from the circulation pump 5, ensuring that the expansion oil tank 6 will not be damaged or leak.

[0082] The expansion oil reservoir 6 can effectively balance the pressure within the system. When the temperature of the insulating oil in the charging system rises and its volume increases, the level of the insulating oil in the expansion oil reservoir 6 rises. When the temperature of the insulating oil in the system drops and its volume decreases, the level of the insulating oil in the expansion oil reservoir 6 drops. In addition, the mouth of the expansion oil reservoir 6 usually has a pressure relief cap to balance the internal pressure of the expansion oil reservoir 6. There are many existing solutions for the containment structure with pressure relief, which will not be elaborated here.

[0083] refer to Figure 7 In an exemplary embodiment, the immersion liquid-cooled charging system may further include a plurality of liquid level sensors 61, which are spaced apart on the inside of the expansion tank 6 in the height direction of the cabinet 1.

[0084] In this embodiment, there are three liquid level sensors 61, which are referred to as the first liquid level sensor 61, the second liquid level sensor 61, and the third liquid level sensor 61 from top to bottom. When the temperature of the insulating oil in the charging system is too high and it begins to expand, causing the level of the insulating oil in the expansion oil tank 6 to reach or exceed the first liquid level sensor 61, the circulation pump 5 and / or the cooling fan 8 can be turned on, or the power of the circulation pump 5 and / or the cooling fan 8 can be increased to reduce the temperature of the insulating oil in the charging system and prevent the insulating oil in the expansion oil tank 6 from overflowing.

[0085] Among them, such as Figure 7 As shown, Figure 7 The three black dots inside the expansion oil reservoir 6 represent the three liquid level sensors 61.

[0086] When the insulating oil level in the expansion oil reservoir 6 is too low, below the third level sensor 61, insulating oil can be added to the expansion oil reservoir 6 until the insulating oil level in the expansion oil reservoir 6 reaches the second level sensor 61. The addition of insulating oil can be automated by cooperating with the second level sensor 61 and the third level sensor 61. For example, when the liquid level is detected to be lower than the first level sensor 61, the adding mechanism is activated until the liquid level reaches the second level sensor 61. Of course, automatic adding is not the scope of protection of this application. This is only an example of a solution, so the adding mechanism will not be described in detail.

[0087] In an exemplary embodiment, the immersion liquid-cooled charging system may further include a filter screen disposed inside the expansion oil reservoir 6 to filter the insulating oil entering the expansion oil reservoir 6.

[0088] The filter screen is installed inside the oil reservoir, allowing it to filter the insulating oil when the expansion oil reservoir 6 is filled with oil. At the same time, the filter screen also filters the insulating oil from the radiator 3. As a result, the insulating oil flowing to the circulation pump 5 is filtered, effectively intercepting impurities mixed in the insulating oil, preventing damage to the circulation pump 5, and effectively improving the service life of the circulation pump 5.

[0089] refer to Figure 7 In an exemplary embodiment, the immersion liquid-cooled charging system may further include a plurality of temperature and pressure sensors 11, which are respectively disposed at at least one of three locations: in the power module 2, on the high-temperature oil line 41, and on the low-temperature oil line 42.

[0090] It should be understood that the temperature and pressure sensor 11 can be used to detect the temperature and pressure of the insulating oil in the power module 2, the low-temperature oil pipeline 42, and the high-temperature oil pipeline 41; the temperature and pressure of the insulating oil in the low-temperature oil pipeline 42 are recorded as the first temperature and the first pressure, the temperature and pressure of the insulating oil in the high-temperature oil pipeline 41 are recorded as the second temperature and the second pressure, and the temperature and pressure of the insulating oil in the power module 2 are recorded as the third pressure.

[0091] In this embodiment, temperature and pressure sensors 11 are provided in the power module 2, on the high-temperature oil line 41, and on the low-temperature oil line 42.

[0092] The insulating oil carries away the heat inside the power module 2 after passing through it, causing the temperature of the insulating oil to rise. This results in the second temperature being greater than the first temperature, and the heat dissipation effect of the power module 2 can be judged by the difference between the second and first temperatures.

[0093] Furthermore, the heat dissipation effect of the power module 2 can be judged based on the change in the difference between the second temperature and the first temperature of the circulating pump 5 under different power levels. This facilitates subsequent improvements to the charging system or predictions of the heat dissipation effect of this type of heat dissipation method.

[0094] Alternatively, the third temperature value can be used to determine whether the circulation pump 5 or the cooling fan 8 needs to be turned on for heat dissipation. The specific determination method will be explained later.

[0095] Furthermore, for the detected first, second, and third pressures, the results of comparing the preset pressure ranges of the three pressures can be used to determine whether there is a leak or blockage in the charging system. For example, taking the first pressure as an example, if the first pressure is within its corresponding preset pressure range, the charging system is working normally; if the first pressure is less than the minimum value within its corresponding preset pressure range, it indicates a leak in the charging system, causing a decrease in the insulating oil pressure, requiring maintenance; if the first pressure is greater than the maximum value within its corresponding preset pressure range, it indicates a blockage in the charging system, causing an increase in the insulating oil pressure, requiring maintenance. This effectively improves the safety performance of the charging system and allows for timely maintenance and repair.

[0096] refer to Figure 4 In an exemplary embodiment, the high-temperature side manifold 31, the low-temperature side manifold 32, and multiple heat dissipation pipes 33 constitute a heat dissipation module, and the heat sink 3 is composed of a heat dissipation assembly, which includes at least one heat dissipation module.

[0097] When the heat dissipation assembly includes multiple heat dissipation modules, the multiple heat dissipation modules in the same heat dissipation assembly are arranged sequentially in the axial direction of the high-temperature side manifold 31, the high-temperature side manifold 31 in adjacent heat dissipation modules are interconnected, and the low-temperature side manifold 32 in adjacent heat dissipation modules are interconnected.

[0098] Specifically, the heat sink 3 is modularized, allowing its heat dissipation components to be assembled from a variable number of heat dissipation modules. This enables the size of the heat sink 3 to be adjusted by disassembling and assembling heat dissipation modules according to the size of the charging device. In addition, if a heat dissipation module malfunctions, such as by leaking, the individual heat dissipation module can be disassembled and replaced for maintenance without replacing the entire heat sink 3. This makes maintaining the heat sink 3 more convenient, faster, and less costly.

[0099] Of course, the axis of the high-temperature side current collector 31 is parallel to the horizontal plane, so that no matter how many heat dissipation modules are assembled in the same heat dissipation component, it will not affect the overall height of the charging device; the heat dissipation pipe 33 in the heat dissipation component can also maintain an angle of 40° to 50° with the horizontal plane.

[0100] In this embodiment, the heat dissipation assembly contains three heat dissipation modules.

[0101] refer to Figures 8-10 In an exemplary embodiment, the heat dissipation components are at least two sets and are arranged in a horizontal direction perpendicular to the axial direction of the high-temperature side manifold 31.

[0102] Among them, the horizontal direction perpendicular to the axis of the high-temperature side manifold 31 is... Figure 8 The horizontal direction in the diagram can be denoted as the first direction. Multiple heat dissipation components are arranged in the first direction, such as... Figure 8 The diagram shows that all heat dissipation components are parallel and vertically arranged. Vertical arrangement means that the angle between the heat pipe 33 inside the heat dissipation component and the horizontal plane is 90°. Figure 9 As shown, the heat dissipation components are also arranged parallel to each other, but the angle between each heat dissipation component and the horizontal plane is relatively larger than that of the horizontal plane. Figure 8 Make changes; such as Figure 10 As shown, the two sets of heat dissipation components on the left are parallel to each other, the two sets of heat dissipation components on the right are parallel to each other, and the two sets of heat dissipation components on the left are set at an angle to the two sets of heat dissipation components on the right.

[0103] It should be noted that having at least two sets of heat dissipation components is a preferred arrangement, but using only one set of heat dissipation components will not affect the normal use of the heat sink 3.

[0104] In an exemplary embodiment, there are two sets of heat dissipation components and the two sets of heat dissipation components are at an angle to each other.

[0105] Among them, such as Figure 3 and Figure 5 As shown, the minimum distance between the high-temperature side current collectors 31 in the two sets of heat dissipation components is a, and the minimum distance between the low-temperature side current collectors 32 in the two sets of heat dissipation components is b, and a > b. Therefore, when the heat sink 3 is installed on the top of the charging device, the two sets of heat dissipation components are arranged in a "V" shape. The angle between the heat dissipation pipe 33 and the horizontal plane can be 40° to 50°, so the angle between the two sets of heat dissipation components arranged in a "V" shape can be 80° to 100°. This not only ensures the heat dissipation requirements of the high-power charging device, but also occupies a smaller overall height of the charging device.

[0106] In addition, if a < b, then when the heat sink 3 is installed on the top of the charging device, the two heat dissipation components can be arranged in an inverted "V" shape.

[0107] It should be noted that the two sets of heat dissipation components arranged in a "V" shape can be fixedly connected. For example, connecting plates can be welded to the outer periphery of the low-temperature side manifold 32 or the high-temperature side manifold 31 of the two sets of heat dissipation components. Through holes are opened on the connecting plates, and the two sets of heat dissipation components are fixed by passing bolts through the two connecting plates and pushing the two connecting plates to fit together. When the two connecting plates are fitted together, the two sets of heat dissipation components form a "V" shape. There are many traditional methods for fixing the two sets of heat dissipation components, which will not be elaborated here.

[0108] It should be understood that the radiator 3 is not limited to having only two sets of heat dissipation components. If the direction of multiple sets of heat dissipation components is perpendicular to the direction of heat dissipation modules within the heat dissipation components, multiple sets of heat dissipation components can also be arranged in the corresponding direction to improve the heat dissipation effect. When using, it is sufficient to ensure that the high-temperature side manifold 31 in each heat dissipation component is located above the low-temperature side manifold 32.

[0109] It should be noted that, Figure 3 and Figure 5 The diagram shows a scenario where both sets of heat dissipation components contain three heat dissipation modules. This is merely an example; for instance, both sets of heat dissipation components could each contain one heat dissipation module, in which case the two heat dissipation modules could be arranged in the "V" shape described above. Of course, the number of heat dissipation modules contained in the two sets of heat dissipation components can also be different. For example, one heat dissipation component can contain one heat dissipation module, while the other heat dissipation component can contain three heat dissipation modules, and so on. There are many different arrangements, which will not be elaborated on here.

[0110] In this embodiment, for low-power charging systems (e.g., below 120KW), only a single heat dissipation module is needed within the system, i.e., only one heat dissipation component is set, and the heat dissipation component contains only one heat dissipation module. For a 360KW charging system, two heat dissipation modules can be used for heat dissipation. The two heat dissipation modules can be arranged in a "V" shape, i.e., two sets of heat dissipation components arranged at an angle, each heat dissipation component containing only one heat dissipation module. This facilitates the cooling fan 8 located at the top of the cabinet 1 to blow air onto the two heat dissipation modules, and the two heat dissipation modules occupy less space. Furthermore, for a 720KW charging system, six heat dissipation modules can be used, forming two sets of heat dissipation components arranged in a "V" shape, i.e., two sets of heat dissipation components arranged at an angle, each heat dissipation component containing three heat dissipation modules, such as... Figure 3 As shown, this allows the cooling fan 8, located at the top of the cabinet 1, to blow air onto the six cooling modules while keeping the space occupied by the six cooling modules relatively small.

[0111] In an exemplary embodiment, the heat dissipation modules included in the two sets of heat dissipation components correspond one-to-one, and the corresponding heat dissipation modules share the low-temperature side manifold 32.

[0112] Specifically, for ease of understanding, let's take two corresponding heat dissipation modules as an example. The two heat dissipation modules share a low-temperature side manifold 32, while the high-temperature side manifolds 31 of the two heat dissipation modules are independent of each other. In this way, the two heat dissipation modules can naturally be arranged in a "V" shape, which also saves more materials.

[0113] It should be understood that if a design with a shared low-temperature side manifold 32 is adopted, the two high-temperature side manifolds 31, multiple heat pipes 33, and one low-temperature side manifold 32 of the two heat dissipation modules can be combined to form a new heat dissipation module. The new heat dissipation module can be arranged sequentially along the axial direction of the high-temperature side manifold 31. In the axial direction of the high-temperature side manifold 31, adjacent high-temperature side manifolds 31 are interconnected, and adjacent low-temperature side manifolds 32 are interconnected.

[0114] Of course, if the above-mentioned inverted "V" shaped arrangement is adopted, the two heat dissipation modules can share the high-temperature side manifold 31.

[0115] It should be noted that the “V” shape in this application refers to the cross-sectional shape of the liquid cooler perpendicular to the axis of the high-temperature side manifold 1.

[0116] refer to Figure 7In an exemplary embodiment, both the radiator 3 and the power module 2 are provided with connecting pipes to connect the high-temperature oil pipe 41 and the low-temperature oil pipe 42. Specifically, at the connecting pipes on the radiator 3, the connection point between the high-temperature oil pipe 41 and the connecting pipe is the front shunt pipe interface of the radiator, and the connection point between the low-temperature oil pipe 42 and the connecting pipe is the rear shunt pipe interface of the radiator. When the insulating oil flows from the front shunt pipe interface of the radiator sequentially through the connecting pipe, each heat dissipation module, and the connecting pipe to reach the rear shunt pipe interface of the radiator, the insulating oil travels the same distance through different heat dissipation modules. Similarly, at the connecting pipes on the power module 2, the connection point between the high-temperature oil pipe 41 and the connecting pipe is the rear shunt pipe interface of the module, and the connection point between the low-temperature oil pipe 42 and the connecting pipe is the front shunt pipe interface of the module. When the insulating oil flows from the front shunt pipe interface of the module sequentially through the connecting pipe, each power module 2, and the connecting pipe to reach the rear shunt pipe interface of the module, the insulating oil travels the same distance through different power modules.

[0117] like Figure 7 As shown, two sets of heat dissipation components are used here, each containing three heat dissipation modules. This is used as an example for illustration. It should be understood that this is not a schematic diagram of the arrangement of the two sets of heat dissipation components, but only an illustration of the pipe connection relationship. For a detailed schematic diagram of the arrangement of the heat dissipation components and power module 2, please refer to [reference needed]. Figure 3 .

[0118] Specifically, taking the connecting pipe at radiator 3 as an example, the connecting pipe includes a front-end manifold 91, a rear-end manifold 92, a branch bend pipe 93, and an intermediate manifold 94. Each heat dissipation component has a front-end manifold 91 that connects to the liquid inlet of each heat dissipation module within the heat dissipation component through multiple branch bend pipes 93. Each heat dissipation component also has a rear-end manifold 92 that connects to the liquid outlet of each heat dissipation module within the heat dissipation component through multiple branch bend pipes 93. The bending angle or structure of each branch bend pipe 93 is the same.

[0119] When two sets of heat dissipation components are used, such as Figure 7 As shown, the high-temperature oil line 41 is directly connected to the central area of ​​the two radiator front manifolds 91 that are close to each other, so that the high-temperature oil line 41 is connected to the two radiator front manifolds 91 at the same time; the low-temperature oil line 42 is connected to the two radiator rear manifolds 92 that are far apart from each other through the intermediate manifold 94, and the low-temperature oil line 42 is connected to the center of the intermediate manifold 94, so that the low-temperature oil line 42 is connected to the two radiator rear manifolds 92 at the same time.

[0120] It should be understood that the two ends that are closer together and the two ends that are farther apart are only in the context of... Figure 7 As shown, in actual assembly, such as Figure 3If the two front-end manifolds 91 of the radiator are placed close to each other... Figure 3 If the left end is considered as the end that is close to each other, then the two radiator rear manifolds 92 are close to each other. Figure 3 The right end is considered as the end that is far away from each other.

[0121] The connection area between the high-temperature oil pipeline 41 and the two front-end manifolds 91 of the radiator is designated as the radiator front branch pipe interface, and the connection area between the low-temperature oil pipeline 42 and the intermediate manifold 94 is designated as the radiator rear branch pipe interface. The insulating oil is branched from the radiator front branch pipe interface and flows through each heat dissipation module before converging at the radiator rear branch pipe interface. During this process, the multiple insulating oils branched from the radiator front branch pipe interface flow into different heat dissipation modules until they converge at the radiator rear branch pipe interface, where the length of the flow path is consistent. This ensures that the fluid flow rate of the insulating oil through each heat dissipation module is automatically distributed and highly consistent. The balanced distribution of the insulating oil ensures that the heat dissipation capacity of each radiator and the heat dissipation effect of each power module 2 are consistent.

[0122] It should be noted that the above-described uniform distribution scheme of insulating oil can also be used for multiple power modules 2. Power modules 2 can be treated similarly to heat dissipation modules, with the high-temperature oil outlet of power module 2 corresponding to the outlet of the heat dissipation module, and the low-temperature oil inlet of power module 2 corresponding to the inlet of the heat dissipation module. Multiple power modules 2 arranged side-by-side can be considered as heat dissipation components. In this way, the corresponding connecting pipelines can be set up as described above to achieve uniform distribution of insulating oil to each power module 2. Specific details of the scheme will not be elaborated here. Figure 7 The diagram shown at point 2 of the medium power module is only one feasible pipeline connection method and is not the pipeline structure corresponding to the uniform flow distribution scheme mentioned above.

[0123] refer to Figure 5 and Figure 6 In an exemplary embodiment, both ends of the high-temperature side manifold 31 and both ends of the low-temperature side manifold 32 are open, and the liquid inlet and liquid outlet are respectively disposed on the outer periphery of each high-temperature side manifold 31 and each low-temperature side manifold 32; the heat dissipation assembly may also include multiple caps and two manifolds, the multiple caps being connected one-to-one to both ends of each high-temperature side manifold 31 and both ends of each low-temperature side manifold 32; each of the two manifolds is closed at one end and open at the other end, the outer periphery of one manifold is connected to the liquid inlet on each high-temperature side manifold 31; the outer periphery of the other manifold is connected to the liquid outlet on each low-temperature side manifold 32.

[0124] Taking the high-temperature side manifold 31 as an example, internal threads can be provided at both ends of the high-temperature side manifold 31, and external threads can be provided on the outer periphery of the cover. In this way, the cover can block both ends of the high-temperature side manifold 31. At this time, the insulating oil heated in the power module 2 will first enter the corresponding manifold and flow to the liquid inlet of each high-temperature side manifold 31. The insulating oil flowing out from the liquid outlet of each low-temperature side manifold 32 will also first enter the corresponding manifold and then flow into the power module 2 to dissipate heat from the power module 2.

[0125] It should be understood that the axis of the manifold connected to the inlet of the high-temperature side manifold 31 should be parallel to the horizontal plane so that the oil can flow into each high-temperature side manifold 31 more evenly.

[0126] In an exemplary embodiment, both ends of the high-temperature side manifold 31 and both ends of the low-temperature side manifold 32 are open; the heat dissipation assembly may also include multiple adapter pipes and two caps, the multiple adapter pipes being connected between adjacent high-temperature side manifolds 31 and between adjacent low-temperature side manifolds 32 respectively; one cap is connected to the end of a high-temperature side manifold 31 without an adapter pipe; the other cap is connected to the end of a low-temperature side manifold 32 without an adapter pipe.

[0127] Taking the high-temperature side manifold 31 as an example, both ends of the high-temperature side manifold 31 can be provided with internal threads, one end of which can be used as the liquid inlet of the high-temperature side manifold 31. Both ends of the adapter pipe can be provided with external threads, so that the adapter pipe can be screwed into the adjacent high-temperature side manifold 31 to connect the adjacent high-temperature side manifold 31. At this time, the interconnected high-temperature side manifold 31 has only two open ends. One end is sealed by the cap, so that the interconnected high-temperature side manifold 31 has only one open end as the liquid inlet to connect with the power module 2. The connection method of multiple low-temperature side manifolds 32 is the same, and will not be described in detail here.

[0128] In this way, the heated insulating oil in the power module 2 will first enter the inlet of the interconnected high-temperature side manifold 31, and then flow through the heat dissipation pipes 33 in each heat dissipation module to the outlet of the interconnected low-temperature side manifold 32, and finally flow into the power module 2 to dissipate heat from the power module 2.

[0129] It should be understood that two connection methods are provided here. Taking the high-temperature side manifold 31 as an example, the first method is that the high-temperature side manifolds 31 are connected to each other through a transfer pipe; the second method is that the high-temperature side manifolds 31 are independent of each other and are combined through a manifold. The same applies to the low-temperature side manifold 32. In this embodiment, both the high-temperature side manifold 31 and the low-temperature side manifold 32 adopt the second method of combining through a manifold.

[0130] It should be noted that the interconnection scheme of the high-temperature side manifold 31 and the interconnection scheme of the low-temperature side manifold 32 can be either of the two schemes mentioned above.

[0131] It should be noted that the two manifolds here are the aforementioned front manifold 91 and rear manifold 92 of the radiator. If the above-mentioned scheme of setting up connecting pipes to make the insulating oil evenly distributed is to be adopted, then only the scheme of independent high-temperature side manifolds 31 and converging through manifolds can be adopted here. The same applies to the low-temperature side manifold 32.

[0132] Based on the above embodiments, this application also provides an example of the control process of an immersion liquid-cooled charging system, applied to the above-mentioned immersion liquid-cooled charging system. The immersion liquid-cooled charging system includes a controller, which is electrically connected to the circulating pump 5 and the cooling fan 8. The control process may specifically include the following steps:

[0133] S100. Real-time acquisition of key parameters and preset conditions in the immersion liquid-cooled charging system, wherein the preset conditions include the first condition;

[0134] S200, Determine whether the key parameters meet the first condition;

[0135] S210. If the key parameters meet the first condition, a first control signal is output to the first mechanism and the second mechanism. The first control signal is used to instruct the first mechanism and the second mechanism to stop. The first mechanism is either the circulating pump 5 or the cooling fan 8, and the second mechanism is the other one of the circulating pump 5 and the cooling fan 8. The insulating oil in the circulating pipeline 4 flows at a first flow rate.

[0136] In step S100, the key parameters can be any one or more of the following: circulation pipeline temperature, radiator temperature, power module temperature, liquid flow rate in the radiator, charging system power, and charging system current.

[0137] It should be understood that the key parameters can be one or more of the above parameters, and the specific one can be determined according to the actual application situation; each key parameter has a corresponding preset condition.

[0138] For example, if the key parameter is the power module temperature value, there will be a first condition corresponding to the power module temperature value. The first condition can be a temperature range. When the detected power module temperature value is within the temperature range corresponding to the first condition, it is considered that the detected power module temperature value meets the first condition.

[0139] At this point, both the circulating pump 5 and the cooling fan 8 can be shut down. The insulating oil expands when heated, thus allowing natural convection in the circulating pipe 4 to dissipate heat from the power module 2. The flow rate of the insulating oil in the circulating pipe 4 at this time is the first flow rate, and the first flow rate is not zero. The specific convection process of the insulating oil can be referred to the relevant natural convection description in the above-mentioned immersion liquid-cooled charging system, which will not be repeated here.

[0140] In an exemplary embodiment, the preset conditions further include a second condition and a third condition, wherein the first to third conditions do not overlap; after step S200, the method further includes:

[0141] S300, Determine whether the key parameters meet the second condition;

[0142] S400, Determine whether the key parameters meet the third condition;

[0143] S310. If the key parameters meet the second condition, a second control signal is output to the first mechanism and the second mechanism. The second control signal is used to instruct the first mechanism to work in a low-power state and to instruct the second mechanism to stop.

[0144] S410. If the key parameters meet the third condition, a third control signal is output to the first mechanism and the second mechanism. The third control signal is used to indicate that both the first mechanism and the second mechanism are working in a low-power state.

[0145] In an exemplary embodiment, the preset conditions further include a fourth condition and a fifth condition, wherein the first to fifth conditions do not overlap; after determining whether the key parameter satisfies the third condition, the method further includes:

[0146] S500, Determine whether the key parameters meet the fourth condition;

[0147] S600, Determine whether the key parameters meet the fifth condition;

[0148] S510. If the key parameters meet the fourth condition, then output the fourth control signal to the first mechanism and the second mechanism. The fourth control signal is used to indicate that the first mechanism works in a high-power state and to indicate that the second mechanism works in a low-power state.

[0149] S610. If the key parameters meet the fifth condition, then the fifth control signal is output to the first mechanism and the second mechanism. The fifth control signal is used to indicate that both the first mechanism and the second mechanism are working in a high-power state.

[0150] It should be understood that, taking the power module temperature value as a key parameter as an example, the preset conditions include the first to fifth conditions corresponding to the power module temperature value, which are five temperature ranges that increase sequentially.

[0151] Taking the second condition and the first condition as examples, the temperature range that increases sequentially means that the minimum temperature value of the temperature range in the second condition is greater than or equal to the maximum temperature value of the first temperature range.

[0152] Furthermore, four temperature thresholds can be defined in ascending order: the first threshold to the fourth threshold, and the minimum initial threshold.

[0153] The first condition can be greater than the initial threshold and less than or equal to the first threshold; the second condition can be greater than the first threshold and less than or equal to the second threshold; the third condition can be greater than the second threshold and less than or equal to the third threshold; the fourth condition can be greater than the third threshold and less than or equal to the fourth threshold; the fifth condition can be greater than the fifth threshold; the power module temperature value will only satisfy one condition at a time, that is, the first to fifth conditions do not overlap.

[0154] It should be understood that, based on the working states of the circulating pump 5 and the cooling fan 8 corresponding to the first to fifth conditions, the heat dissipation effect increases progressively. Thus, the working states of the circulating pump 5 and the cooling fan 8 can be changed at any time according to the specific temperature value inside the power module 2 to achieve frequency conversion, reduce energy waste, reduce heat dissipation costs, and improve the service life of the circulating pump 5 and the cooling fan 8. The temperature value of the power module is the third temperature mentioned above, which is measured by the temperature and pressure sensor inside the power module 2.

[0155] For ease of understanding, steps S210, S310, S410, S510, and S610 can be understood as five heat dissipation levels, namely, level one to level five heat dissipation. In other words, the heat dissipation level of the charging system can be determined based on the comparison results of key parameters and preset conditions. For example, if the power value of the charging system meets the fourth condition, then the heat dissipation level corresponding to the power value of the charging system is level four heat dissipation.

[0156] It should be noted that there can be multiple key parameters in the above content. In this case, the maximum value of the heat dissipation level can be taken. For example, when the key parameters are the charging system power value, the heat sink temperature value, and the power module temperature value, if the heat dissipation level corresponding to the charging system power value is level one, and the heat dissipation level corresponding to the heat sink temperature value and the power module temperature value is level two, then the charging system can be cooled according to the level two heat dissipation steps.

[0157] The following example uses the charging system power value as the key parameter. The five power thresholds corresponding to the first to fifth conditions are the initial threshold, the first threshold, and the fourth threshold, which increase sequentially. The process of determining the charging system power value is as follows:

[0158] Compare the charging system power value with the initial threshold and the first to fourth thresholds;

[0159] If the power value of the charging system is greater than the initial threshold and less than or equal to the first threshold, then a first control signal is sent to the first mechanism and the second mechanism;

[0160] If the power value of the charging system is greater than the first threshold and less than or equal to the second threshold, a second control signal is sent to the first mechanism and the second mechanism.

[0161] If the power value of the charging system is greater than the second threshold and less than or equal to the third threshold, a third control signal is sent to the first and second mechanisms.

[0162] If the power value of the charging system is greater than the third threshold and less than or equal to the fourth threshold, then a fourth control signal is sent to the first and second mechanisms.

[0163] If the power value of the charging system is greater than the fourth power threshold, a fifth control signal is sent to the first and second mechanisms.

[0164] Specifically, taking the circulating pump 5 as an example, the power value of the charging system is acquired and compared in real time. Therefore, when the charging system first starts working, the power value should be less than the initial threshold. At this time, the temperature of the power module 2 is not high and no heat dissipation is required. When the charging system continues to work, and the power value of the charging system is greater than the initial threshold but less than or equal to the first power threshold, both the circulating pump 5 and the cooling fan 8 are in standby mode. At this time, the heat dissipation requirements of the charging system can be met by the natural convection of the insulating oil, which saves costs and is more convenient. As the power value of the charging system gradually increases and exceeds the first threshold... When the power value of the charging system is less than or equal to the second threshold, the circulation pump 5 is turned on to drive the insulating oil circulation for heat dissipation; when the power value of the charging system is greater than the second threshold and less than or equal to the third threshold, the cooling fan 8 can be turned on to accelerate the heat dissipation of the radiator 3; when the power value of the charging system is greater than the third threshold and less than the fourth threshold, the power of the circulation pump 5 is increased to increase the flow rate of the insulating oil, thereby improving the heat dissipation effect; when the power value of the charging system is greater than the fourth power threshold, the power of the cooling fan 8 can be increased to increase the speed of the cooling fan 8, thereby improving the heat dissipation effect of the radiator 3, and further improving the heat dissipation effect of the power module 2.

[0165] The above are merely preferred embodiments of this application and do not limit the patent scope of this application. Any equivalent structural or procedural transformations made using the content of this application's specification and drawings, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of this application.

Claims

1. A fully immersion liquid-cooled charging system, characterized in that, include: The cabinet (1) has a top plate and a bottom plate that are arranged opposite each other in the direction of its own height; Multiple power modules (2) are all disposed inside the cabinet (1). Each power module (2) includes a sealed housing and a PCBA assembly disposed inside the sealed housing. The PCBA assembly includes power electronic devices and control circuits. Each power module (2) has a high-temperature oil outlet and a low-temperature oil inlet spaced apart in the height direction of the cabinet (1), and the high-temperature oil outlet is located between the corresponding low-temperature oil inlet and the top plate. A heat sink (3) is disposed inside the cabinet (1) and located between the multiple power modules (2) and the top plate. The heat sink (3) includes a high-temperature side manifold (31), a low-temperature side manifold (32) and multiple heat dissipation pipes (33). The multiple heat dissipation pipes (33) are connected between the high-temperature side manifold (31) and the low-temperature side manifold (32). The high-temperature side manifold (31) is provided with a liquid inlet, and the low-temperature side manifold (32) is provided with a liquid outlet. The circulation pipeline (4) includes a high-temperature oil pipeline (41) and a low-temperature oil pipeline (42). The high-temperature oil pipeline (41) connects the high-temperature oil outlet of each power module (2) to the liquid inlet of the radiator (3). The low-temperature oil pipeline (42) connects the low-temperature oil inlet of each power module (2) to the liquid outlet of the radiator (3). A circulating pump (5) is installed on the cryogenic oil pipeline (42).

2. The fully immersion liquid-cooled charging system as described in claim 1, characterized in that, The fully immersion liquid-cooled charging system also includes: A cooling fan (8) is installed on the cabinet (1), and the air supply direction of the cooling fan (8) has an angle with the plane formed by the multiple cooling pipes (33).

3. The fully immersion liquid-cooled charging system as described in claim 1, characterized in that, The fully immersion liquid-cooled charging system also includes: An expansion oil tank (6) is installed inside the cabinet (1) and connected to the low-temperature oil pipeline (42). The expansion oil tank (6) is located between the power module (2) and the top plate and is arranged in parallel with the radiator (3) in the horizontal direction. In the low-temperature oil pipeline (42), the expansion oil tank (6) is located between the outlet of the circulation pump (5) and the radiator (3).

4. The fully immersion liquid-cooled charging system as described in claim 3, characterized in that, The fully immersion liquid-cooled charging system also includes: Multiple liquid level sensors (61) are spaced apart on the inside of the expansion tank (6) in the height direction of the cabinet (1).

5. The fully immersion liquid-cooled charging system as described in claim 3, characterized in that, The fully immersion liquid-cooled charging system also includes: A filter screen is installed inside the expansion oil reservoir (6) to filter the insulating oil entering the expansion oil reservoir (6).

6. The fully immersion liquid-cooled charging system as described in claim 1, characterized in that, The fully immersion liquid-cooled charging system also includes: Multiple temperature and pressure sensors (11) are respectively installed in at least one of three locations: in the power module (2), on the high-temperature oil pipeline (41), and on the low-temperature oil pipeline (42).

7. The fully immersion liquid-cooled charging system as described in claim 1, characterized in that, The fully immersion liquid-cooled charging system also includes: The valve (7) is connected in parallel with the circulating pump (5) on the cryogenic oil pipeline (42); The valve (7) and the circulating pump (5) constitute a power assembly, and there are two power assemblies that are connected in parallel on the cryogenic oil pipeline (42).

8. The immersion liquid-cooled charging system as described in claim 1, characterized in that, The high-temperature side manifold (31) is higher than the low-temperature side manifold (32) in the direction of gravity. Multiple heat dissipation pipes (33) are arranged sequentially along the axial direction of the high-temperature side manifold (31) on the outer periphery of the high-temperature side manifold (31). The axial direction of the heat dissipation pipes (33) has an angle with the horizontal plane. The high-temperature side manifold (31), the low-temperature side manifold (32), and the multiple heat dissipation pipes (33) form a heat dissipation module. The heat sink (3) is composed of a heat dissipation component, which includes at least one of the heat dissipation modules. When the heat dissipation assembly includes multiple heat dissipation modules, the multiple heat dissipation modules in the same heat dissipation assembly are arranged sequentially in the axial direction of the high-temperature side manifold (31), the high-temperature side manifolds (31) in adjacent heat dissipation modules are interconnected, and the low-temperature side manifolds (32) in adjacent heat dissipation modules are interconnected.

9. The immersion liquid-cooled charging system as described in claim 8, characterized in that, The heat dissipation components are at least two sets and are arranged in a horizontal direction perpendicular to the axis of the high-temperature side manifold (31).

10. The immersion liquid-cooled charging system as described in claim 9, characterized in that, The heat dissipation components are in two sets, and there is an angle between the two sets of heat dissipation components.

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