Air-cooled energy storage converter and energy storage system

Abstract

This utility model provides an air-cooled energy storage converter and energy storage system. The air-cooled energy storage converter includes: a housing, external terminals disposed outside the housing and fixed to the panel of the housing, and mounting components, a power module, a control module, a filter module, and a heat dissipation component disposed inside the housing. The mounting components include: a horizontal bracket and a vertical bracket; the horizontal bracket is vertically connected to the vertical bracket and fixed to the first and second side plates of the housing. The heat dissipation component includes: a first fan module, a second fan module, and a heat sink; the first fan module is fixed to the vertical bracket; the second fan module is fixed to the back plate of the housing, and the heat sink is fixed to the bottom plate of the housing; the panel, back plate, and second side plate of the housing are all provided with multiple ventilation holes. The air-cooled energy storage converter and energy storage system provided by this utility model can effectively improve the space utilization rate inside the housing and significantly improve the heat dissipation efficiency.

Description

Technical Field

[0001] This utility model relates to the field of power electronics technology, and in particular to an air-cooled energy storage converter and energy storage system. Background Technology

[0002] With the continuous upgrading of power systems and the ongoing advancements in electrochemical energy storage, energy storage systems have been applied to various scenarios, including residential, industrial, and base station applications, thanks to their advantages such as convenience and safety. As the core power conversion device in energy storage systems, the power converter system (PCS) directly impacts heat dissipation performance through its air-cooling system layout, electrical component integration, and adaptation technologies for complex environments.

[0003] The existing structural design of air-cooled energy storage converters is usually based on the heat dissipation logic of traditional power electronic equipment. This results in problems such as unreasonable space utilization of the internal structure, lack of systematic optimization of the air duct structure design, and low heat dissipation efficiency. In addition, there are also problems with the internal structure in terms of air duct planning, air recirculation, and uneven air volume. In actual working conditions, its structural defects gradually become apparent, making it difficult to adapt to the upgrading needs of the energy storage industry, and it is urgent to improve it. Utility Model Content

[0004] The purpose of this utility model is to provide an air-cooled energy storage converter and energy storage system, so as to at least solve the technical problems of low heat dissipation efficiency and low internal space utilization of existing air-cooled energy storage converters.

[0005] This utility model provides an air-cooled energy storage converter, comprising: a housing, external terminals, a mounting assembly, a power module, a control module, a filter module, and a heat dissipation assembly; the mounting assembly includes: a horizontal bracket and a vertical bracket; the horizontal bracket is vertically connected to the vertical bracket, and the horizontal bracket is fixed to the first side plate and the second side plate of the housing; the heat dissipation assembly includes: a first fan module, a second fan module, and a radiator; the first fan module is fixed to the vertical bracket; the second fan module is fixed to the back plate of the housing, and the radiator is fixed to the bottom plate of the housing; the front panel, back plate, and second side plate of the housing are all provided with multiple ventilation holes; the mounting assembly, power module, control module, filter module, and heat dissipation assembly are all located inside the housing, and the external terminals are located outside the housing and are fixed through the front panel of the housing.

[0006] Preferably, the vertical support divides the interior of the housing into a front chamber and a rear chamber along the direction from the front panel to the back plate, and the horizontal support divides the front chamber into an upper chamber and a lower chamber along the direction from the cover plate to the bottom plate.

[0007] Preferably, the power module includes: an inductor, a capacitor, a power switch module, a power board, and a contactor; the control module includes: a control board, a power supply board, a fan board, and a Hall current sensor; the inductor, capacitor, fan board, power switch module, first fan module, second fan module, and heat sink are all located in the rear cavity; the control board and power supply board are both located in the upper cavity; and the filter module, power board, contactor, and Hall current sensor are all located in the lower cavity.

[0008] Preferably, along the direction from the cover plate to the bottom plate, the power switch module is located between the capacitor and the heat sink; along the direction from the front panel to the back panel, the power board, control board, and power board are all located on one side of the first fan module, and the inductor is located on the other side of the first fan module; the control board is located between the power board and the second side panel; the filter module is located between the front panel and the power board and near the ventilation hole of the second side panel; the contactor and the Hall current sensor are located between the first side panel and the filter module, and the contactor is located between the front panel and the Hall current sensor.

[0009] Preferably, there are two fan plates, one fan plate is located between the first fan module and the cover plate, and the other fan plate is located between the heat sink and the second fan module.

[0010] Preferably, the external terminals include: multiple wiring terminals and multiple communication interfaces; the wiring terminals are electrically connected to the filter module; the contactor is electrically connected to the capacitor, the filter module, and the power board; the power switch module is electrically connected to the inductor and the capacitor; the power board is electrically connected to the inductor, the filter module, and the control board; the control board is electrically connected to the power board, the fan board, the Hall current sensor, the power switch module, the first fan module, the second fan module, and the communication interfaces; the fan board is electrically connected to the first fan module and the second fan module.

[0011] Preferably, the vertical support has holes corresponding to the first fan module.

[0012] Preferably, the cover plate includes: a cover plate body and a baffle fixed on the cover plate body; the panel is provided with a pair of first handles and a pair of second handles respectively provided on the first side plate and the second side plate.

[0013] Preferably, the back panel includes: a frame, a mounting plate, and a partition; the partition is obliquely fixed to the frame and located inside the housing; the mounting plate is detachably fixed to the frame; the second fan module is fixed to the mounting plate and located between the mounting plate and the partition.

[0014] This utility model also provides an energy storage system, including the air-cooled energy storage converter as described above.

[0015] The air-cooled energy storage converter and energy storage system provided by this utility model divides the interior of the housing into front and rear sections by installing components, and divides the front chamber into upper and lower layers. This structural layout can effectively improve the space utilization rate inside the housing, thereby reducing the overall volume. It can also make the air ducts of each chamber relatively independent, with low interference, preventing air circulation inside and avoiding the generation of eddies. In addition, the air-cooled energy storage converter of this embodiment adopts a method of simultaneous air intake at the front and one side and air exhaust at the rear, which effectively increases the ventilation volume, achieves precise heat dissipation, and significantly improves heat dissipation efficiency by combining a heat sink with a fan module. Attached Figure Description

[0016] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0017] Figure 1 This is a schematic diagram of an air-cooled energy storage converter according to an embodiment of the present invention.

[0018] Figure 2 This is a schematic diagram of the internal space of the air-cooled energy storage converter according to an embodiment of the present invention.

[0019] Figure 3 This is another schematic diagram of the internal space of the air-cooled energy storage converter according to an embodiment of the present utility model.

[0020] Figure 4 for Figure 2 A diagram illustrating the installation components.

[0021] Figure 5 for Figure 1 A schematic diagram of the explosion structure.

[0022] Figure 6 for Figure 1 A schematic diagram of the internal structure.

[0023] Figure 7 for Figure 1 A cross-sectional schematic diagram.

[0024] Figure 8 for Figure 1 A schematic diagram of the cover plate.

[0025] Reference numerals: 1. Housing; 10. Cover plate; 100. Cover plate body; 101. Baffle; 11. Base plate; 12. Panel; 120. Panel ventilation hole; 121. First handle; 13. Back plate; 130. Frame; 131. Mounting plate; 132. Partition; 14. First side plate; 140. Second handle; 15. Second side plate; 150. Side plate ventilation hole; 16. Front chamber; 17. Rear chamber; 18. Upper chamber; 19. Lower chamber; 2. External terminal; 20. Wiring terminal; 21. Communication interface; 3. Mounting assembly; 30. Horizontal bracket; 31. Vertical bracket; 32. Mounting bracket; 40. Inductor; 41. Capacitor; 42. Power switch module; 43. Power board; 44. Control board; 50. Power supply board; 51. Fan board; 52. Hall current sensor; 53. Filtering module; 6. Heat dissipation assembly; 7. First fan module; 70. Second fan module; 71. Heat sink; 72. Detailed Implementation

[0026] To make the above-mentioned objectives, features, and advantages of this utility model more apparent and understandable, the specific embodiments of this utility model will be described in detail below with reference to the accompanying drawings. It should be understood that many specific details are set forth in the following description to provide a full understanding of this utility model; however, this utility model can be implemented in many other ways different from those described herein, and those skilled in the art can make similar modifications without departing from the spirit of this utility model. Therefore, this utility model is not limited to the specific embodiments disclosed below.

[0027] like Figures 1 to 7 As shown, this embodiment provides an air-cooled energy storage converter, including: a housing 1, external terminals 2, mounting components 3, a power module, a control module, a filter module 6, and a heat dissipation component 7.

[0028] The power module is used to achieve bidirectional conversion between DC and AC, and the control module controls the operation of the power module through generated control commands. The filter module 6 can improve signal quality and stability, protect the energy storage converter from electromagnetic interference, reduce the failure rate, and extend the equipment life and make its operation more stable.

[0029] like Figures 1 to 3 As shown, the housing 1 includes: a cover plate 10, a bottom plate 11, a front panel 12, a back plate 13, and two side plates (a first side plate 14 and a second side plate 15). Here, the cover plate 10 and the bottom plate 11 are arranged opposite to each other, the front panel 12 and the back plate 13 are arranged opposite to each other, and the two side plates are arranged opposite to each other.

[0030] Preferably, the housing 1 is a hollow cuboid structure, and the internal space is used to house the mounting component 3, power module, control module, filter module 6 and heat dissipation component 7. That is, the mounting component 3, power module, control module, filter module 6 and heat dissipation component 7 are all located inside the housing 1; the external terminal 2 is located outside the housing 1 and is fixed through the panel 12.

[0031] Preferably, the panel 12, the back panel 13, and the second side panel 15 are each provided with multiple ventilation holes.

[0032] like Figure 8 As shown, the cover plate 10 includes a cover plate body 100 and a baffle 101 fixed to the cover plate body 100. Here, the baffle 101 is located inside the housing 1.

[0033] like Figure 2 and combined Figure 3 As shown, the back panel 13 includes a frame 130, a mounting plate 131, and a partition 132. The partition 132 is obliquely fixed to the frame 130 and located inside the housing 1; the mounting plate 131 is detachably fixed to the frame 130, for example, by bolts. The frame 130 is fixed to the cover body 100, the bottom plate 11, and the two side plates.

[0034] Here, multiple ventilation holes on the back panel 13 are located on the mounting plate 131.

[0035] As an example, the shell 1 is made of cold-rolled steel.

[0036] like Figure 1 As shown, a pair of first handles 121 are provided on the panel 12; a pair of second handles are provided on the two side plates, that is, a pair of second handles 140 are respectively provided on the first side plate 14 and the second side plate 15.

[0037] like Figure 4 As shown, the mounting assembly 3 includes a horizontal bracket 30 and a vertical bracket 31.

[0038] The horizontal support 30 is vertically connected to the vertical support 31, and the horizontal support 30 is fixed on the first side plate 14 and the second side plate 15.

[0039] As an example, the horizontal bracket 30 and the vertical bracket 31 can be an integrally formed structure. The horizontal bracket 30 is fixed to the inner wall of the two side plates to fix the mounting component 3 inside the housing 1.

[0040] As another example, the horizontal support 30 and the vertical support 31 can be separate structures, with the horizontal support 30 fixed to the inner walls of the two side plates and the vertical support 31 fixed to the horizontal support 30.

[0041] Preferably, the vertical support 31 is located in the middle of the accommodating space, the vertical support 31 is perpendicular to the cover plate body 100 and the bottom plate 11, and the horizontal support 30 is parallel to the cover plate body 100 and the bottom plate 11.

[0042] like Figure 2 and combined Figure 4 As shown, the vertical support 31 divides the interior of the housing 1 into a front chamber 16 and a rear chamber 17 along the direction from the panel 12 to the back plate 13, and the horizontal support 30 divides the front chamber 16 into an upper chamber 18 and a lower chamber 19 along the direction from the cover plate 10 to the bottom plate 11.

[0043] It should be understood that the sizes of the front chamber, rear chamber, upper chamber, and lower chamber can be set according to actual needs, and this utility model is not limited thereto.

[0044] like Figure 7 As shown, the heat dissipation assembly 7 includes: a first fan module 70, a second fan module 71, and a heat sink 72. The first fan module 70 is fixed on the vertical bracket 31, thereby forming a heat dissipation assembly located in the middle of the housing 1; the second fan module 71 is fixed on the back plate 13, specifically, the second fan module 71 is fixed on the mounting plate 131 and located between the mounting plate 131 and the partition plate 132, thereby forming a heat dissipation assembly located at the rear end of the housing 1; the heat sink 72 is fixed on the base plate 11.

[0045] like Figure 4 As shown, the vertical bracket 31 has holes corresponding to the first fan module 70 for fan airflow.

[0046] like Figure 2 and Figure 7 As shown, the radiator 72 is fixed to the base plate 11 by the mounting bracket 32.

[0047] As an example, the first fan module 70 includes four fans with a size of 80mm*80mm, and the second fan module 71 includes four fans with a size of 120mm*120mm.

[0048] like Figures 5 to 7 As shown, the power module includes: inductor 40, capacitor 41, power switch module 42, power board 43, and contactor 44.

[0049] The control module includes: a control board 50, a power supply board 51, a fan board 52, and a Hall current sensor 53.

[0050] Here, the power board 51 has auxiliary power and pre-charge functions.

[0051] As an example, there are two fan boards 52, which are used to control the first fan module 70 and the second fan module 71 respectively.

[0052] In this embodiment, as Figure 6 and Figure 7 As shown, inductor 40, capacitor 41, fan plate 52, power switch module 42, first fan module 70, second fan module 71, and heat sink 72 are all located in the rear chamber 17; control board 50 and power board 51 are all located in the upper chamber 18; filter module 6, power board 43, contactor 44, and Hall current sensor 53 are all located in the lower chamber 19. Preferably, power switch module 42 is fixed on heat sink 72. Along the direction from cover plate 10 to bottom plate 11 (i.e., from top to bottom), power switch module 42 is located between capacitor 41 and heat sink 72; along the direction from front panel 12 to back panel 13 (i.e., from front to back), inductor 40 is located behind first fan module 70, and power board 51 and control board 50 are located in front of first fan module 70; along the direction from first side plate 14 to second side plate 15, control board 50 is located between power board 51 and second side plate 15. The filter module 6 is located between the panel 12 and the power board 43, near the side panel ventilation hole 150 on the second side panel 15. The power board 43 is located on one side (i.e., in front) of the first fan module 70. The contactor 44 and the Hall current sensor 53 are located between the first side panel 14 and the filter module 6, with the contactor 44 located between the panel 12 and the Hall current sensor 53. The fan plate for controlling the first fan module 70 is located between the first fan module 70 and the cover plate 10, and the fan plate for controlling the second fan module 71 is located between the heat sink 72 and the second fan module 71.

[0053] In this embodiment, each component is installed with a safety clearance reserved according to relevant electrical specifications. These clearances prevent components from stacking and serve as heat dissipation channels to facilitate airflow, thereby accelerating heat dissipation. Further details are omitted here. It is understood that the installation clearance can be set according to actual needs; for example, an installation clearance of 7.1 mm or more.

[0054] like Figure 6 and Figure 7As shown, the main heat-generating area in the front-end chamber 16 is the filter module 6 near the second side plate 15. Therefore, multiple side plate ventilation holes 150 are provided on the second side plate 15 corresponding to the front-end chamber 16. Cool air is drawn in through the panel ventilation holes 120 and the side plate ventilation holes 150. The cool air flows through the control board 50 and power board 51 in the upper chamber 18 and the filter module 6, power board 43, contactor 44 and Hall current sensor 53 in the lower chamber 19, dissipating heat for the components in the front-end chamber 16. The first fan module 70 draws in the air flowing through the front-end chamber 16. The components in the front-end chamber 16 are low-heat-generating components, so the temperature of the air passing through the first fan module 70 remains within the normal operating temperature range. This layout can effectively improve the service life of the first fan module 70, avoid fan failure due to excessive temperature and frequent maintenance and replacement, and significantly reduce costs.

[0055] Because the inductor 40 generates a large amount of heat, the air drawn in by the first fan module 70 from the front chamber 16 is directly blown onto the inductor 40 in the rear chamber 17. Through the air duct formed by the mounting gaps around the inductor 40, the vertical bracket 31, and the baffle 101, air can be blown onto every side of the inductor 40, achieving uniform heat dissipation and stabilizing the operating temperature of the inductor 40 within a safe range. The air flowing through the inductor 40 then flows to the capacitor 41 and the heat sink 72. The heat sink 72 dissipates heat from the power switch module 42. The second fan module 71 is positioned corresponding to the power switch module 42. The second fan module 71 draws air from the heat sink 72 through the air duct formed by the partition 132 and the mounting gaps on the lower surface of the capacitor 41, thereby removing the heat generated by the power switch module 42. At the same time, the second fan module 71 also dissipates heat through the mounting gaps of the components inside the housing 1. Finally, the hot air is blown to the outside of the housing through the ventilation holes on the back plate 13.

[0056] Since the hot air flowing through the second fan module 71 can affect the lifespan of the fan, the second fan module 71 needs to be maintained and replaced regularly. In this embodiment, the second fan module 71 adopts an independent design, and the back plate 13 on the housing 1 is detachable (for example, the back plate 13 is fixed to the cover plate 10 and the bottom plate 11 by bolts). The second fan module 71 is directly fixed to the back plate 13. When the second fan module 71 needs to be maintained or replaced, the back plate 13 can be removed directly, and the second fan module 71 can be removed along with it, so as to maintain and update the fan, effectively reducing maintenance costs and making the operation convenient.

[0057] In this embodiment, cold air is introduced simultaneously through the panel ventilation hole 120 and the side panel ventilation hole 150. The air flowing through the front chamber 16 enters the rear chamber 17 through the first fan module 70, and finally is blown to the outside of the housing through the ventilation hole on the back panel 13 via the second fan module 71.

[0058] like Figure 1As shown, the external terminal 2 includes: multiple wiring terminals 20 and multiple communication interfaces 21.

[0059] It should be understood that the number of wiring terminals 20 and communication interfaces 21 can be set according to actual needs, and this utility model is not limited thereto.

[0060] In this embodiment, terminal 20 is electrically connected to filter module 6 via copper busbar; contactor 44 is electrically connected to capacitor 41 and filter module 6 via copper busbar, and contactor 44 is electrically connected to power board 51 via wiring harness; power switch module 42 is electrically connected to inductor 40 via copper busbar, and electrically connected to capacitor 41 via PCB; power board 43 is electrically connected to inductor 40 and filter module 6 via copper busbar, and power board 43 is electrically connected to control board 50 via wiring harness; control board 50 is electrically connected to power board 51, fan board 52, Hall current sensor 53, power switch module 42, power board 43, first fan module 70, second fan module 71 and communication interface 21 via wiring harness; fan board 52 is electrically connected to first fan module 70 and second fan module 71 via wiring harness.

[0061] As an example, the material of the heat sink 72 may be aluminum alloy or aluminum alloy with copper tubes embedded on the upper surface, etc.

[0062] As an example, power switch module 42 is a silicon carbide module.

[0063] This embodiment also provides an energy storage system, including the air-cooled energy storage converter described above. It is understood that the energy storage system also includes: grid devices, energy storage batteries, etc.

[0064] The air-cooled energy storage converter in this embodiment divides the interior of the housing into front and rear sections using mounting components, and divides the front-end chamber into upper and lower layers. This structural layout effectively improves the space utilization within the housing, thereby reducing the overall volume. It also allows for relatively independent air ducts in each chamber, minimizing interference and preventing internal air circulation, thus avoiding the generation of eddies. Furthermore, the air-cooled energy storage converter in this embodiment employs a method of simultaneous air intake at the front and one side, and air exhaust at the rear, effectively increasing ventilation volume and achieving precise heat dissipation. The combination of a radiator and a fan module significantly improves heat dissipation efficiency.

[0065] The above-described embodiments are merely illustrative of several implementations of this utility model, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of this utility model patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this utility model, and these all fall within the protection scope of this utility model. Therefore, the protection scope of this utility model should be determined by the appended claims.

Claims

1. An air-cooled energy storage converter, characterized in that, include: Housing, external terminals, mounting components, power module, control module, filter module, and heat dissipation components; The mounting assembly includes: a horizontal support and a vertical support; the vertical support divides the interior of the housing into a front chamber and a rear chamber along the direction from the front panel to the back plate of the housing, and the horizontal support divides the front chamber into an upper chamber and a lower chamber along the direction from the cover plate to the bottom plate of the housing; The heat dissipation assembly includes: a first fan module, a second fan module, and a heat sink; The first fan module is fixed on the vertical bracket; the second fan module is fixed on the back plate; and the heat sink is fixed on the base plate. The power module includes: inductors, capacitors, power switch modules, power boards, and contactors; The control module includes: a control board, a power board, a fan board, and a Hall current sensor; The inductor, capacitor, fan board, power switch module, first fan module, second fan module, and heat sink are all located in the rear cavity; the control board and power board are all located in the upper cavity; the filter module, power board, contactor, and Hall current sensor are all located in the lower cavity. The front panel, the back panel, and the second side panel of the housing are all provided with multiple ventilation holes; The external terminal is located outside the housing and is fixed through the panel.

2. The air-cooled energy storage converter according to claim 1, characterized in that, Along the direction from the cover plate to the bottom plate, the power switch module is located between the capacitor and the heat sink; along the direction from the front panel to the back panel, the power board, control board, and power board are all located on one side of the first fan module, and the inductor is located on the other side of the first fan module; the control board is located between the power board and the second side panel; the filter module is located between the front panel and the power board and near the ventilation hole of the second side panel; the contactor and the Hall current sensor are located between the first side panel and the filter module, and the contactor is located between the front panel and the Hall current sensor.

3. The air-cooled energy storage converter according to claim 2, characterized in that, There are two fan plates: one fan plate is located between the first fan module and the cover plate, and the other fan plate is located between the heat sink and the second fan module.

4. The air-cooled energy storage converter according to claim 1, characterized in that, The external terminals include: multiple wiring terminals and multiple communication interfaces; The terminal block is electrically connected to the filter module; the contactor is electrically connected to the capacitor, the filter module, and the power board; the power switch module is electrically connected to the inductor and the capacitor; the power board is electrically connected to the inductor, the filter module, and the control board; the control board is electrically connected to the power board, the fan board, the Hall current sensor, the power switch module, the first fan module, the second fan module, and the communication interface; the fan board is electrically connected to the first fan module and the second fan module.

5. The air-cooled energy storage converter according to claim 1, characterized in that, The horizontal support is vertically connected to the vertical support, and the horizontal support is fixed to the first side plate and the second side plate of the housing.

6. The air-cooled energy storage converter according to claim 5, characterized in that, The panel is provided with a pair of first handles and a pair of second handles respectively located on the first side panel and the second side panel.

7. The air-cooled energy storage converter according to claim 1, characterized in that, The vertical support has holes corresponding to the first fan module.

8. The air-cooled energy storage converter according to claim 1, characterized in that, The cover plate includes: a cover plate body and a baffle fixed on the cover plate body.

9. The air-cooled energy storage converter according to claim 1, characterized in that, The back panel includes: a frame, a mounting plate, and a partition; The partition is obliquely fixed to the frame and located inside the housing; the mounting plate is detachably fixed to the frame; The second fan module is fixed on the mounting plate and located between the mounting plate and the partition.

10. An energy storage system, characterized in that, include: The air-cooled energy storage converter as described in any one of claims 1 to 9.

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