A water-cooled power unit based on a press-fit IGBT left and right structure

Abstract

This utility model relates to the field of power units, and more particularly to a water-cooled power unit based on a left-right structure of press-fitted IGBTs. The power module and capacitor base are arranged sequentially from left to right on the power unit base. The capacitor base houses the capacitor module, which includes capacitor one and capacitor two, fixedly connected by a capacitor connecting plate. The capacitor module and the power module are connected via a composite busbar, which includes a capacitor composite busbar and a power module composite busbar. The capacitor composite busbar is fixedly connected to the capacitor module, and the power module composite busbar is fixedly connected to the power module. The advantages of this utility model are: the left-right structure of the power module and capacitor module design significantly reduces the height and depth of the power unit, adapting to installation areas of different sizes and improving installation flexibility; the copper busbar connection does not use adapters but rather a composite busbar, also saving assembly costs.

Description

Technical Field

[0001] This utility model relates to the field of power units, and in particular to a water-cooled power unit based on a press-fit IGBT left and right structure. Background Technology

[0002] Water-cooled power units are suitable for power quality management equipment such as Static Var Generators (SVG) and Active Power Filters (APF). Currently, the core component of SVGs—the power unit—primarily adopts a modular design, and its structural form directly affects the installation method, heat dissipation performance, and operational reliability of the entire unit. Existing power unit structures mainly suffer from the following problems:

[0003] Traditional power units often use fixed-size cabinets. In some scenarios (such as old substations and distributed photovoltaic power stations), the installation space is limited, making it difficult to optimize the layout of power units and affect the efficiency of equipment deployment. Power units with stacked structures require overall hoisting for disassembly, which is complicated.

[0004] In summary, this limits the scalability and applicability of SVG. Utility Model Content

[0005] The purpose of this invention is to provide a water-cooled power unit based on a press-fit IGBT left-right structure. The power module and capacitor module are separate left-right structures that can be disassembled individually. The structure is compact, small in size, and easy to install and maintain.

[0006] To achieve the above objectives, this utility model employs the following technical solution:

[0007] A water-cooled power unit based on a press-fit IGBT left-right structure is disclosed. The water-cooled power unit includes a power module, a capacitor module, a capacitor base, a capacitor connecting plate, a power unit base, and a composite busbar. The power module and the capacitor base are arranged sequentially on the power unit base from left to right. The capacitor base is provided with a capacitor module, which includes capacitor one and capacitor two. Capacitor one and capacitor two are fixedly connected by a capacitor connecting plate. The capacitor module and the power module are connected by a composite busbar, which includes a capacitor composite busbar and a power module composite busbar. The capacitor composite busbar is fixedly connected to the capacitor module, and the power module composite busbar is fixedly connected to the power module.

[0008] The capacitor connecting plate is fixedly connected to the top of capacitor one and capacitor two respectively.

[0009] The composite busbar is L-shaped and includes positive and negative busbars, which are insulated from each other by an insulating plate. One side of the capacitor composite busbar is fixedly connected to the capacitor module, one side of the power module composite busbar is fixedly connected to the power module, and the other side of the capacitor composite busbar is fixedly connected to the other side of the power module composite busbar.

[0010] Capacitor 1 and Capacitor 2 are connected in parallel via a composite busbar. The power module includes an IGBT module, and the capacitor module and the IGBT module are electrically connected via the composite busbar.

[0011] The power module is housed within the frame, and the power module also includes a bypass contactor, which is located on one side of the frame, while the IGBT module is located on the other side of the frame.

[0012] The power module also includes a trigger board module, a power board module, and a control board module. The bypass contactor is fixedly connected to the lower connection part of the frame. Above the bypass contactor, there are support frames one, two, and three in sequence. The trigger board module, power board module, and control board module are fixedly connected to support frames one, two, and three respectively.

[0013] Support frame one, support frame two, and support frame three are respectively set between the reinforcing beams of the frame and the unit columns of the frame, and support frame one, support frame two, and support frame three are parallel to each other.

[0014] The IGBT module is set inside the IGBT module frame, which is a square frame composed of an upper pressure plate, a lower pressure plate, and a clamping plate. The bottom of the IGBT module rests against the lower pressure plate.

[0015] The IGBT module includes IGBTs and water-cooled heat sinks. The heat sinks and IGBTs are stacked alternately between insulating blocks, and the heat sinks at both ends are provided with insulating blocks. The other side of the insulating blocks at both ends is provided with upper blocks and lower blocks, respectively.

[0016] The upper pressure plate is equipped with a disc spring guide sleeve. The upper pad is placed between the insulating pad and the disc spring guide sleeve. The top bolt is screwed into the disc spring guide sleeve until it touches the upper pad.

[0017] The power module also includes an inlet pipe and an outlet pipe, which are fixedly connected to the unit columns of the frame. The IGBT module is connected to the inlet pipe and the outlet pipe through a water pipe.

[0018] Compared with the prior art, the beneficial effects of this utility model are:

[0019] 1. The power module and capacitor module design with a left-right structure significantly reduces the height and depth of the power unit, making it adaptable to different sized installation areas and improving installation flexibility;

[0020] 2. A modular design is adopted, for example, the upper pressure plate, clamping plate, and lower pressure plate are combined into an IGBT module frame by bolts, which ensures assembly stability, simplifies the assembly process, and improves production efficiency; at the same time, strengthening the beam connection also enhances the stability of the overall structure, thereby ensuring the reliability of the power unit during operation.

[0021] 3. Copper busbar connections do not use adapters but instead use composite busbars, which also saves assembly costs. When installing capacitor composite busbars and power module composite busbars, there is no need to remove the power unit from the frame to the ground for disassembly. Disassembly can be completed on the valve section frame, simplifying the installation and disassembly process and saving manpower and time costs.

[0022] 4. Water cooling is used to dissipate heat from the power unit, which can effectively reduce the temperature of the components during operation, improve the heat dissipation efficiency of the components, ensure that key components such as IGBTs operate in a stable temperature environment, extend their service life, and thus improve the performance and reliability of the entire power unit; the water pipes are connected in series, which saves water pipe usage, reduces depth, and lowers costs. Attached Figure Description

[0023] Figure 1 This is the outline of the water-cooled power unit.

[0024] Figure 2 This is a structural diagram of the power module.

[0025] Figure 3 This is a structural diagram of an IGBT module.

[0026] Figure 4 This is a structural diagram of the power module frame.

[0027] Figure 5 This is a diagram of the capacitor module's outline.

[0028] Figure 6 This is the rear view of the water-cooled power unit.

[0029] Figure 7 This is the installation diagram of the water-cooled power unit.

[0030] Figure 8 It is a power module composite busbar.

[0031] Figure 9 This is a diagram of the composite busbar of the power module without its insulating film.

[0032] Figure 10 It is a composite busbar for capacitor modules.

[0033] Figure 11 This is a diagram of the composite busbar of the capacitor module without the insulating film.

[0034] In the diagram: 1. Power module; 2. Capacitor module; 3. Frame; 4. IGBT module; 5. Water outlet pipe; 6. Control board module; 7. Power board module; 8. Trigger board module; 9. Copper busbar; 10. Bypass contactor; 11. Upper pressure plate; 12. Disc spring guide sleeve; 13. Top bolt; 14. Upper pad; 15. Insulating pad; 16. Water-cooled radiator; 17. IGBT; 18. Clamping plate; 19. Lower pad; 20. Lower pressure plate; 21. Welding on the frame; 22. Unit rear column two; 23. Unit rear column one; 24. Reinforcing beam; 25. Welding under the frame; 26. Capacitor connecting plate; 27. Capacitor; 28. Capacitor base; 29. ​​Capacitor composite busbar; 30. Power module composite busbar; 31. Slide rail; 32. Resin beam; 33. Water inlet pipe; 34. Water pipe. Detailed Implementation

[0035] The present invention will now be described in detail with reference to the accompanying drawings. However, it should be noted that the implementation of the present invention is not limited to the following embodiments.

[0036] The following embodiments are implemented based on the technical solution of this utility model, providing detailed implementation methods and specific operation processes. However, the protection scope of this utility model is not limited to the following embodiments. Unless otherwise specified, the methods used in the following embodiments are conventional methods.

[0037] Example 1

[0038] See Figure 1-11 A water-cooled power unit based on a press-fit IGBT left-right structure, comprising two parts: a power module 1 on the left and a capacitor module 2 on the right. The capacitor module 2 is mounted on a capacitor base 28. The power module 1 and capacitor base 28 are mounted on a power unit base, which is fixedly connected to the power unit base by bolts. The capacitor base 28 is detachable. The capacitor base 28 uses a patent with publication number CN119171253A, entitled "A Reactive Power Compensation Cabinet," but other models can also be used. The capacitor module 2 includes capacitor one and capacitor two. A capacitor connecting plate 26 is fixedly connected to the top of capacitor one and capacitor two respectively. The capacitor connecting plate 26 is made of stainless steel. Capacitor one and capacitor two are connected in parallel via a capacitor composite busbar 29. The composite busbar includes capacitor composite busbar 29 and power module composite busbar 30. Capacitor composite busbar 29 is fixedly connected to capacitor module 2, and power module composite busbar 30 is fixedly connected to power module 1. (See [link to relevant documentation]). Figure 1 , Figure 5 , Figure 6 .

[0039] The composite busbar is L-shaped. Compared with other shapes, the L-shaped composite busbar is easier to install and disassemble, saves space, and reduces stray inductance. The composite busbar includes positive and negative busbars, which are insulated from each other by an insulating plate. One side of the capacitor composite busbar 29 is fixedly connected to the capacitor module 2, and one side of the power module composite busbar 30 is fixedly connected to the power module 1. The other side of the capacitor composite busbar 29 is fixedly connected to the other side of the power module composite busbar 30. (See 6.) Figures 8-11 .

[0040] Several electrical nodes (such as marked positive and negative terminals) are exposed on each layer of copper busbars of capacitor composite busbar 29 and power module composite busbar 30. These electrical connection points can be exposed press-fit copper pillars on the busbar, welded copper pillars on the copper busbar, or punched protrusions on the copper busbar, etc., and are not limited to these. They are used to connect the IGBT17 in capacitor module 2 and power module 1 respectively, so as to realize the electrical connection between capacitor module 2 and power module 1.

[0041] IGBT17 Module 4 Structure, see Figure 3 The upper pressure plate 11, two clamping plates 18, and lower pressure plate 20 are assembled together by bolts to form the IGBT17 module 4 frame. Check the frame's squareness. Place the lower pad 19 on the lower pressure plate 20, and place the insulating pad 15 on the lower pad 19. Place the five water-cooled radiators 16 and four IGBTs 17 alternately on the insulating pad 15, with the bottom two IGBTs 17 having their "C" terminals facing down and the top two IGBTs 17 having their "C" terminals facing up. Place the insulating pad 15 on top of the uppermost radiator. Insert the disc spring guide sleeve 12 from inside the IGBT 17 mounting frame into the upper pressure plate 11 and hold it in place to prevent it from falling. Place the upper pad 14 between the insulating pad 15 and the disc spring guide sleeve 12. Release your hand and gently place the disc spring guide sleeve 12 on the upper pad 14. Tighten the top bolt 13 into the disc spring guide sleeve 12 until it touches the upper pad 14. Tighten the top bolt 13 with a torque wrench until the required tightening torque for the IGBTs 17 is reached. Connect the two explosion-proof plates to the radiators with bolts to prevent the IGBTs 17 from bursting and damaging the water pipes. The IGBT 17 module assembly is complete.

[0042] Power module 1 is installed within the frame, see Figure 4The frame is a square frame, with columns between the upper and lower connecting parts of the frame. The columns include unit rear column one 23 and unit rear column two 22. A reinforcing beam 24 is provided between unit rear column one 23 and unit rear column two 22. Support frame one, support frame two, and support frame three are fixedly connected between the reinforcing beam 24 and the unit rear column. A bypass contactor 10 is provided below support frame three. The bypass contactor 10 is fixedly connected to the lower connecting part of the frame by bolts to reduce the height of the power unit module. The trigger board module 8, power board module 7, and control board module 6 are fixedly connected to support frame one, support frame two, and support frame three, respectively, to increase the installation strength of the trigger board module 8, power board module 7, and control board module 6. The bypass contactor 10 is located on one side of the frame, and the IGBT17 module 4 is located on the other side of the frame for easy installation and removal.

[0043] See Figure 2 The power module 1 also includes an inlet pipe 33 and an outlet pipe 5. The inlet pipe 33 and the outlet pipe 5 are fixedly connected to the rear column 23 of the unit. The IGBT17 module 4 is connected to the inlet pipe 33 through a water pipe 34. The IGBT17 module 4 is also connected to the outlet pipe 5 through a water pipe 34. The water pipe 34 is connected in series to save water pipes. The inlet pipe 33 and the outlet pipe 5 are connected to an external water source. The water pipe 34 is used to cool the IGBT17 module 4. The elimination of the main water pipe of the unit reduces the depth and lowers the cost.

[0044] Work process:

[0045] See Figure 2The power module 1 is assembled by placing the IGBT module 4 from above the frame 3 and connecting it to the frame under welding 25 with bolts, which reduces the height of the power unit. The water pipe 5 is installed and connected to the water-cooled radiator 16, and fixed to the unit's rear column 22 with pipe clamps. The water pipes are connected in series, which saves water pipes and eliminates the main water pipe of the unit, reducing the depth and lowering the cost. Insert the bypass contactor 10 from the front of frame 3 and connect it to the frame under weld 25 with bolts; insert the copper busbar 9 from the front of frame 3 and connect it to IGBT module 4 and bypass contactor 10 with bolts. Eliminating the need for an adapter busbar saves copper busbar, reduces cost, and decreases height and depth; insert the two trigger board modules 8 from the front of frame 3 and connect them to the reinforcing beam 24 with bolts, connecting the trigger wires of their corresponding IGBT 17; connect the power module 7 with cables, insert it from the front of frame 3, and connect it to unit rear column 22, unit rear column 1, and reinforcing beam 24 with bolts. Place the connected cables near the modules to be connected according to the specified path; connect the cables between bypass contactor 10 and power module 7; insert the control board module 6 from the front of frame 3 and connect it to unit rear column 22, unit rear column 1, and reinforcing beam 24 with bolts, connecting the cables; connect the cables between bypass contactor 10 and electrical control board module 6; check that each module is installed correctly and that the cables and bolts are secure. Install two top panels and two side panels. Power module 1 installation complete. See below. Figure 7 Install the slide rail 33 onto the resin beam 34 using bolts, and then install the power module 1 and capacitor module 2 onto their respective slide rails. See Figure 6 The capacitor composite busbar 29 is connected to the capacitor module 2 with bolts, and the power module composite busbar 30 is connected to the power module 1 with bolts. For other types of units, the power unit needs to be taken from the valve section frame to the ground for disassembly when the composite busbar is removed on site. This power unit can be disassembled from the composite busbar on the valve section, making its installation and disassembly easier.

[0046] This invention employs a left-right structure for the power module and capacitor module design, significantly reducing the height and depth of the power unit, adapting to installation areas of different sizes, and improving installation flexibility. A modular design is used, for example, by bolting the upper pressure plate, clamping plate, and lower pressure plate together to form the IGBT module frame, ensuring assembly stability, simplifying the assembly process, and improving production efficiency. Simultaneously, strengthening the beam connections enhances the overall structural stability, thereby ensuring the reliability of the power unit during operation. The copper busbar connection eliminates the need for adapters, further saving assembly costs. When installing the capacitor composite busbar and power module composite busbar, there is no need to remove the power unit from the frame for disassembly; disassembly can be completed on the valve section frame, simplifying the installation and disassembly process and saving labor and time costs. Water cooling is used to dissipate heat from the power unit, effectively reducing the temperature of the components during operation, improving heat dissipation efficiency, ensuring that critical components such as the IGBT operate in a stable temperature environment, extending their service life, and thus improving the overall performance and reliability of the power unit. The water pipes are connected in series, saving on pipe usage, reducing depth, and lowering costs.

Claims

1. A water-cooled power unit based on the structure of a crimped IGBT, characterized in that, The water-cooled power unit includes a power module, a capacitor module, a capacitor base, a capacitor connecting plate, a power unit base, and a composite busbar. The power module and capacitor base are arranged sequentially on the power unit base from left to right. The capacitor base is equipped with a capacitor module, which includes capacitor one and capacitor two. Capacitor one and capacitor two are fixedly connected by a capacitor connecting plate. The capacitor module and the power module are connected by a composite busbar, which includes a capacitor composite busbar and a power module composite busbar. The capacitor composite busbar is fixedly connected to the capacitor module, and the power module composite busbar is fixedly connected to the power module.

2. The water-cooled power unit based on the structure of the crimped IGBT according to claim 1, characterized in that, The capacitor connecting plates are fixedly connected to the tops of capacitor one and capacitor two, respectively.

3. The water-cooled power unit based on the structure of the crimped IGBT according to claim 1, characterized in that, The composite busbar is L-shaped and includes positive and negative busbars, which are insulated from each other by an insulating plate. One side of the capacitor composite busbar is fixedly connected to the capacitor module, one side of the power module composite busbar is fixedly connected to the power module, and the other side of the capacitor composite busbar is fixedly connected to the other side of the power module composite busbar.

4. The water-cooled power unit based on the structure of the crimped IGBT according to claim 1, characterized in that, Capacitor 1 and Capacitor 2 are connected in parallel via a composite busbar. The power module includes an IGBT module, and the capacitor module and the IGBT module are electrically connected via the composite busbar.

5. The water-cooled power unit based on the structure of the crimped IGBT according to claim 4, characterized in that, The power module is housed within the frame, and the power module also includes a bypass contactor, which is located on one side of the frame, while the IGBT module is located on the other side of the frame.

6. The water-cooled power unit based on the structure of the crimped IGBT according to claim 5, characterized in that, The power module also includes a trigger board module, a power supply board module, and a control board module. The bypass contactor is fixedly connected to the lower connecting part of the frame. Above the bypass contactor, there are support frames one, two, and three in sequence. The trigger board module, power supply board module, and control board module are fixedly connected to support frames one, two, and three, respectively.

7. The water-cooled power unit based on the structure of the crimped IGBT according to claim 6, characterized in that, The support frames 1, 2, and 3 are respectively installed between the reinforcing beams of the frame and the unit columns of the frame, and the support frames 1, 2, and 3 are parallel to each other.

8. The water-cooled power unit based on the structure of the crimped IGBT according to claim 1, characterized in that, The IGBT module is set inside the IGBT module frame, which is a square frame composed of an upper pressure plate, a lower pressure plate, and a clamping plate. The bottom of the IGBT module rests against the lower pressure plate. The IGBT module includes IGBTs and water-cooled heat sinks. The heat sinks and IGBTs are stacked alternately between insulating blocks, and the heat sinks at both ends are provided with insulating blocks. The other side of the insulating blocks at both ends is provided with upper blocks and lower blocks, respectively. The upper pressure plate is equipped with a disc spring guide sleeve. The upper pad is placed between the insulating pad and the disc spring guide sleeve. The top bolt is screwed into the disc spring guide sleeve until it touches the upper pad.

9. The water-cooled power unit based on the structure of the crimped IGBT according to claim 5, characterized in that, The power module also includes an inlet pipe and an outlet pipe, which are fixedly connected to the unit columns of the frame, respectively. The IGBT module is connected to the inlet pipe and the outlet pipe through a water pipe.

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