A compact energy storage converter device

Abstract

This utility model discloses a compact energy storage converter device, relating to the field of energy storage converters, which can meet the needs of industrial and commercial energy storage for converter power enhancement, miniaturization, and integration. It includes a housing enclosed by a front panel and a rear panel, with at least one and two layers of panels inside the housing. The second layer is located on the inner wall of the housing. Power inductors are mounted on the first layer, and the second layer has an AC board electrically connected to the inductors. The inner wall of the housing has front and rear inductor wiring boards for fixing the inductor leads and facilitating assembly and wiring. The device also includes a split-type three-layer panel. The second layer has an INV inverter board, and the first layer has a CAP board, both fixed and electrically connected by copper studs. The front panel integrates external interfaces and indicator lights, and is equipped with a cooling fan and a removable protective mesh, both operated and fixed from the outside. Support beams on the inner side of the side panels support the second layer, improving practicality and maintenance convenience.

Description

Technical Field

[0001] This solution relates to the field of energy storage converters, specifically a compact energy storage converter device. Background Technology

[0002] In recent years, the commercial and industrial energy storage market has been booming, with large-scale grid connection of distributed photovoltaic power and charging piles to the power system. This has led to numerous problems in distribution areas, such as transformer overload during peak electricity demand, reverse overload of transformers caused by excessive distributed power sources, and three-phase imbalance of transformers. This necessitates innovation in converters in terms of technology iteration and product form to address the challenges brought about by changes in energy storage system integration. In particular, the accelerated application of 300+Ah high-capacity cells in commercial and industrial energy storage has further clarified the demand for increased power output of energy storage converters.

[0003] Meanwhile, end products continue to evolve towards miniaturization and integration, forcing energy storage converters to shrink in size and increasing the number of components integrated within a unit space. This has brought considerable challenges to production, assembly, and subsequent maintenance. High-power energy storage converters, in particular, contain several inductors. To meet high power requirements, the inductor wires must be sufficiently thick, resulting in very stiff wires. Within the integrated, miniaturized enclosure, components need to be layered to maximize space utilization, making it extremely difficult to connect thick, stiff wires across layers. Providing longer wires occupies limited space within the enclosure, while shorter wires lack sufficient operating space during assembly. Furthermore, subsequent converter maintenance often requires complete disassembly of the entire converter to replace even a small part, impacting work efficiency. Summary of the Invention

[0004] The technical problem to be solved by this utility model is to provide a compact energy storage converter device that is easy to assemble and maintain.

[0005] The specific technical solution of this utility model to solve the above-mentioned technical problems is as follows: A compact energy storage converter device includes a housing formed by a front panel, a rear panel, a bottom plate, a top plate, and side plates. The housing contains a plurality of power inductors and at least one layer and two layers of plates, with the two layers of plates connected to the inner wall of the housing. The power inductor is disposed on a first-layer board; an AC board is disposed on the second-layer board, and the AC board is electrically connected to the inductor. The inner wall of the enclosure is provided with a front inductor wiring board and a rear inductor wiring board; these are used to fix the front lead of the inductor on the front inductor wiring board and the rear lead of the inductor on the rear inductor wiring board, and then assemble the two-layer board to facilitate wiring during assembly.

[0006] Furthermore, a support beam is provided on the inner side of the side plate at a position that matches the second layer plate, and the support beam is used to support the second layer plate; the front inductor wiring board and the rear inductor wiring board are disposed on the support beam and / or the rear panel.

[0007] Furthermore, the front and rear inductor wiring boards are equipped with wire guide sleeves to protect the inductor leads and prevent scratches that could damage the insulation layer.

[0008] Furthermore, the support beam is fixed to the side plate with fixing screws, which are screwed in from the outside of the side plate. Because the operating space inside the box is very limited, fixing the support beam from the outside provides ample operating space and facilitates operation.

[0009] Furthermore, it also includes a three-layer board, which is further composed of a three-layer first board, a three-layer second board, and a three-layer third board connected together by screws and rivet nuts. The three-layer first board houses the power supply, the three-layer second board houses the DC board, and the three-layer third board houses the MCU board. The three-layer board is divided into three independent structural boards, which are connected by fixing screws and rivet nuts. They can be combined into a whole board and placed on the upper layer of the converter, or they can be disassembled for use. If it is necessary to check whether the DC board has incorrect wiring with other boards on the lower layer, it is not necessary to remove the entire upper board. Only the lower board needs to be removed to check the wiring, which greatly saves time and facilitates workers' debugging, wiring, and on-site maintenance.

[0010] Furthermore, the second-layer board is also provided with an INV inverter board, and the first-layer board is provided with a CAP board. The INV inverter board and the CAP board are fixedly connected by copper studs, which also realizes electrical connection. The use of copper studs serves two purposes: firstly, it isolates the INV inverter board and the CAP board in space to facilitate heat dissipation; secondly, it realizes electrical connection, eliminating the need for rewiring.

[0011] Furthermore, all external interfaces and indicator lights are located on the front panel.

[0012] Furthermore, a cooling fan is provided on the front panel, and a fan bracket is provided inside the housing. The cooling fan is fixed to the fan bracket by long bolts, and the long bolts are operated to fix the cooling fan from the outside of the front panel. Thus, when the fan needs to be repaired or replaced, it is not necessary to disassemble the whole machine. The cooling fan can be easily disassembled from the outside, avoiding the inconvenience caused by operating from the inside.

[0013] Furthermore, a removable protective mesh is provided on the front panel at the position where it is adapted to the cooling fan. Attached Figure Description

[0014] Figure 1This is a schematic diagram of the internal structure of the compact energy storage converter device of this utility model; Figure 2 This is a schematic diagram of the structure near the cooling fan of the compact energy storage converter device of this utility model; Figure 3 This is a schematic diagram of the front panel of the compact energy storage converter device of this utility model.

[0015] Figure 4 This is a circuit diagram of the compact energy storage converter device of this utility model.

[0016] The following is a list of component names represented by the reference numerals in the attached diagram: 1. Front panel; 2. Rear panel; 3. Front inductor wiring board; 4. Rear inductor wiring board; 5. Power inductor; 6. First layer board; 7. Second layer board; 8. AC board; 9. Support beam; 10. Third layer board; 11. Third layer board; 12. Third layer board; 13. INV inverter board; 14. CAP board; 15. Copper stud; 16. Battery interface; 17. Communication interface; 18. Sampling interface; 19. Indicator light; 20. Mains interface; 21. Cooling fan; 22. Protective mesh; 23. Fan bracket; 24. Long screw. Detailed Implementation

[0017] The principles and features of this utility model are described below with reference to the accompanying drawings. The examples given are only for explaining this utility model and are not intended to limit the scope of this utility model.

[0018] like Figures 1 to 3 As shown, A compact energy storage converter device includes a housing formed by a front panel 1, a rear panel 2, a bottom plate, a top plate, and side plates. The housing contains an AC control board, an upper control board, electrical components, a front inductor wiring board 3, a rear inductor wiring board 4, and copper busbars. The electrical components include several capacitors and power inductors 5. The housing contains at least one layer plate 6 and a second layer plate 7, and the second layer plate 7 is detachably mounted on the inner wall of the housing. The power inductor 5 is disposed on the first layer plate 6; the second layer plate 7 is provided with an AC plate 8, which is electrically connected to the inductor. A support beam 9 is provided on the inner side of the side plate at a position that matches the second-layer plate 7. The front inductor wiring board 3 and the rear inductor wiring board 4 are mounted on the support beam 9. The front inductor wiring board 3 and the rear inductor wiring board 4 are provided with wire-passing sleeves for fixing the front lead of the inductor on the front inductor wiring board 3 and fixing the rear lead of the inductor on the rear inductor wiring board 4 before assembling the second-layer plate 7, which facilitates wiring during assembly.

[0019] The front and rear wiring boards can be easily disassembled and installed separately. During assembly, the power inductor 5 is first placed on the bottom of the housing (i.e., on the first layer board 6), and the front and rear wires of the inductor are passed through the front and rear wiring boards for pre-fixation. Then, the AC board 8 is placed in the middle and fixed to the support beams 9 on both sides. Finally, the front and rear wires of the inductor are fixed, which makes wiring and installation convenient and saves a lot of time.

[0020] The support beam 9 is fixed to the side plate with fixing screws, which are screwed in from the outside of the side plate. Because the operating space inside the box is very limited, fixing the support beam 9 from the outside provides ample operating space and facilitates operation.

[0021] It also includes a three-layer board, which is further composed of a three-layer first board 10, a three-layer second board 11, and a three-layer third board 12 connected together by screws. The three-layer first board 10 is equipped with a power supply, the three-layer second board 11 is equipped with a DC board, and the three-layer third board 12 is equipped with an MCU board. The three-layer board is divided into three independent structural boards, which are connected by fixing screws and rivets. They can be combined into a whole board and placed on the upper layer of the converter, or they can be disassembled for use. If it is necessary to check whether the DC board has a wiring error with other boards on the lower layer, it is not necessary to remove the entire upper board. Only the lower board needs to be removed to check the wiring, which greatly saves time and facilitates workers' debugging, wiring, and on-site maintenance.

[0022] The second-layer board 7 is also provided with an INV inverter board 13, and the first-layer board 6 is provided with a CAP board 14. The INV inverter board 13 and the CAP board 14 are fixedly connected by copper studs 15, and at the same time, they are electrically connected. The use of copper studs 15 serves two purposes: firstly, it isolates the INV inverter board 13 and the CAP board 14 in space, placing them at different heights to facilitate heat dissipation; secondly, it achieves electrical connection, eliminating the need for rewiring.

[0023] The battery interface 16, mains interface 20, communication interface 17, external sampling interface 18, remote signaling and control interface, and status indicator light 19 are all placed on the front panel 1 assembly. Wiring, installation, and debugging can be performed without opening the rear door. It is simple to operate, easy to maintain, highly interchangeable, and has high power density. The specific interfaces of the front panel 1 are as follows: battery interface 16, mains interface 20, external 24V power interface, communication interface 17, external sampling interface 18, remote signaling and control interface, and status indicator light 19. All of them are set on the front panel 1, so electrical connection with the outside can be achieved without opening the box.

[0024] The front panel 1 is equipped with a cooling fan 21, and the housing is equipped with a fan bracket 23. The cooling fan 21 is fixed to the fan bracket 23 by a long screw 24, and the long screw is operated to fix the cooling fan 21 from the outside of the front panel 1. A removable protective net 22 is provided on the front panel 1 at a position that matches the cooling fan 21. Therefore, when the fan needs to be repaired or replaced, it is not necessary to disassemble the whole machine. Just remove the removable protective net 22, and then the cooling fan 21 can be easily disassembled from the outside, avoiding the inconvenience caused by operating from the inside.

[0025] Figure 4 This is the electrical schematic diagram of the converter. The converter takes three-phase four-wire 380V AC power, first passes through AC board 8, where AC main contactor controls the disconnection, and then passes through two sets of inductors for filtering. Each phase of AC power enters an INV inverter board 13 to be converted into DC power. The DC power from the four INV boards is combined on CAP board 14 and enters DC board for filtering. Finally, it is output through DC main contactor and fuse.

[0026] The AC board 8 mainly includes AC filtering, AC output and soft start control, as well as EMI filtering and surge protection functions for the AC port; the INV inverter board 13 mainly includes IGBT power modules, corresponding drive protection and absorption circuits, to realize AC-DC voltage conversion function; the CAP board 14 mainly includes DC bus support capacitors, DC soft start control, DC main relay control, power supply output of the power module, etc.; the DC board mainly realizes the EMI filtering function of the DC port.

[0027] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A compact energy storage converter device, comprising a housing enclosed by a front panel, a rear panel, a bottom plate, a top plate, and side plates, wherein a plurality of power inductors are disposed within the housing, characterized in that, The box body is provided with at least one layer of board and two layers of board, and the two layers of board are connected to the inner wall of the box body; The power inductor is disposed on a first-layer board; an AC board is disposed on the second-layer board, and the AC board is electrically connected to the inductor. The inner wall of the enclosure is provided with a front inductor wiring board and a rear inductor wiring board; these are used to fix the front lead of the inductor on the front inductor wiring board and the rear lead of the inductor on the rear inductor wiring board, and then assemble the two-layer board to facilitate wiring during assembly.

2. The compact energy storage converter device according to claim 1, characterized in that, A support beam is provided on the inner side of the side plate at a position that matches the second layer plate. The support beam is used to support the second layer plate. The front inductor wiring board and the rear inductor wiring board are disposed on the support beam and / or the rear panel.

3. The compact energy storage converter device according to claim 2, characterized in that, The front and rear inductor wiring boards are equipped with cable sheaths.

4. The compact energy storage converter device according to claim 2 or 3, characterized in that, The support beam is fixed to the side plate by fixing screws, and the fixing screws are screwed in from the outside of the side plate.

5. The compact energy storage converter device according to any one of claims 1-3, characterized in that, It also includes a three-layer board, which is further composed of a three-layer first board, a three-layer second board, and a three-layer third board connected together by screws.

6. The compact energy storage converter device according to claim 5, characterized in that, The second-layer board is also provided with an INV inverter board, and the first-layer board is provided with a CAP board. The INV inverter board and the CAP board are fixedly connected by copper studs, and at the same time, they are electrically connected.

7. The compact energy storage converter device according to any one of claims 1-3, characterized in that, All external interfaces and indicator lights are located on the front panel.

8. The compact energy storage converter device according to any one of claims 1-3, characterized in that, A cooling fan is provided on the front panel, and a fan bracket is provided inside the housing. The cooling fan is fixed to the fan bracket by a long bolt, and the long bolt is operated to fix the cooling fan from the outside of the front panel.

9. The compact energy storage converter device according to claim 8, characterized in that, A removable protective mesh is provided on the front panel at the position where it is adapted to the cooling fan.

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