A novel integrated energy storage converter structure

Abstract

The utility model discloses a novel integrated energy storage converter structure, including the BDU and control module of setting in the upper layer, drive module, direct current PCB board, set in the filter module of lower layer, inductance module, radiator, set in the terminal module and BCU module of front end, the utility model discloses adopt the rigid connection of PCB to replace the soft wire, reduce the number of contact surface, reduce the failure rate, simplify assembly process and reduce the number of parts simultaneously, reduce the volume.

Description

Technical Field

[0001] This utility model relates to the field of energy storage converters, specifically to a novel integrated energy storage converter structure. Background Technology

[0002] A power storage converter (PCS) is a bidirectional power conversion device that connects a battery system to the power grid. It consists of a DC / AC bidirectional converter, a control unit, and other components. Its main functions include controlling the battery charging and discharging process, regulating grid power, and acquiring real-time battery system status information through a communication interface.

[0003] Traditional energy storage converters have the following disadvantages: 1. Too many internal wire connections result in problems such as high contact resistance, easy aging, and poor vibration resistance; 2. Dense cabling increases the risk of EMI (electromagnetic interference), affecting control accuracy; 3. The complex internal structure and messy wiring increase assembly difficulty and failure rate. 4. The separate design of the high-voltage box (BDU) and the energy storage converter (PCS) increases system complexity, occupies more space, and has low integration. 5. The assembly process is complicated, requires a high level of skill from workers, and is inconvenient to maintain. Utility Model Content

[0004] The technical problem to be solved by this utility model is to provide a new integrated energy storage converter structure, which uses rigid PCB connection to replace soft wires, reduces the number of contact surfaces, lowers the failure rate, and simplifies the assembly process, reduces the number of parts, and reduces the size.

[0005] To address the aforementioned technical problems, this utility model provides a novel integrated energy storage converter structure, comprising a BDU and control module, a drive module, and a DC PCB board disposed on the upper layer; a filter module, an inductor module, and a heat sink disposed on the lower layer; and a terminal module and a BCU module disposed on the front end.

[0006] Furthermore, it includes a fan module located at the rear end, which is connected to the BDU and control module via a fan cable.

[0007] Furthermore, the terminal module includes a terminal board, and the BDU and control module are connected to the terminal board via a first ribbon cable and to the drive module via a second ribbon cable.

[0008] Furthermore, a first cable and a second cable are respectively provided on both sides of the BDU and the control module to connect to the filter module.

[0009] Furthermore, the drive module is connected to the BDU, control module, and DC PCB board via a third cable.

[0010] Furthermore, the drive module is provided with conductive posts, three of which correspond to the positive, negative and N poles respectively, and the DC PCB board is connected to the drive module through the conductive posts; the bottom of the drive module is provided with IGBTs for connecting to the heat sink.

[0011] Furthermore, it includes a first busbar and a second busbar for connecting the positive and negative terminals of the DC PCB board, BDU, and control module.

[0012] Furthermore, the filter module is connected and fixed via terminals on the inductor module.

[0013] Furthermore, the inductor module is provided with a third conductive bus, which is connected to the drive module.

[0014] Furthermore, the BCU module includes a fixing plate and a BCU body, which are fixed to the terminal module by non-detachable screws.

[0015] The beneficial effects of this utility model are: 1. Improved space utilization and reduced product costs; 2. Reducing cabling can indirectly improve system efficiency, lower the cost per kilowatt-hour, and reduce cable failure rate; 3. After the structure is simplified, the failure rate is reduced by 30%-50%, maintenance costs are reduced, and the internal structure is neat and orderly; 4. Through integrated and hard-connected design, it can easily meet the 96% efficiency threshold, enhancing market competitiveness; 5. BDU and PCS combined: Reduces the number of components and increases system power density. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the overall structure of this utility model.

[0017] Figure 2 This is a wiring diagram of the internal structure of this utility model.

[0018] Figure 3 This is a partial structural schematic diagram of the present invention.

[0019] Figure 4 This is a schematic diagram of the drive module structure of this utility model.

[0020] Figure 5 This is a schematic diagram of the terminal module + BCU module structure of this utility model.

[0021] The following are the labeling instructions in the diagram: 1. BDU and control module; 11. First ribbon cable; 12. First cable; 13. Third cable; 14. Second cable; 2. Drive module; 21. Second ribbon cable; 22. IGBT; 23. Conductive post; 3. DC PCB board; 31. First conductive busbar; 32. Second conductive busbar; 4. Filter module; 5. Inductor module; 51. Third conductive busbar; 6. Heat sink; 7. Terminal module; 71. Terminal board; 8. BCU module; 81. Mounting plate; 82. BCU body; 83. Locking screw; 9. Fan module; 91. Fan cable. Detailed Implementation

[0022] The present invention will be further described below with reference to the accompanying drawings and specific embodiments, so that those skilled in the art can better understand and implement the present invention. However, the embodiments are not intended to limit the present invention.

[0023] In the description of this utility model, it should be understood that the terms "center", "longitudinal", "transverse", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential", etc., indicating the orientation or positional relationship are based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this utility model and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this utility model.

[0024] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this utility model, "a plurality of" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0025] In this utility model, unless otherwise explicitly specified and limited, the terms "installation," "connection," "joining," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to 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.

[0026] In this utility model, unless otherwise explicitly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "on top of," and "over" the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0027] It should be noted that when an element is referred to as being "fixed to" or "set on" another element, it can be directly on the other element or there may be an intervening element. When an element is considered to be "connected to" another element, it can be directly connected to the other element or there may be an intervening element. The terms "vertical," "horizontal," "upper," "lower," "left," "right," and similar expressions used herein are for illustrative purposes only and do not represent the only possible implementation.

[0028] Reference Figures 1 to 5 As shown, an embodiment of a novel integrated energy storage converter structure according to this utility model is presented: I. Overall Layout Division The energy storage converter structure is divided into an upper region, a lower region, a front-end region, and a back-end region according to its spatial location: Upper area: The BDU and control module, drive module 2, and DC PCB board are integrated and arranged in sequence along the horizontal direction to ensure that the signal transmission path is short and interference is low; Lower layer area: Directly below the upper layer module, filter module 4, inductor module 5, and heat sink 6 are set. Heat sink 6 is set to fit the bottom of the lower layer area to provide a heat dissipation channel for the heat-generating components of the upper layer. Front-end area: Located on the operating side of the entire converter structure, it houses terminal module 7 and BCU module, facilitating wiring and parameter debugging by staff; Rear end area: Fan module 9 is installed, and the air outlet of fan module 9 is directed towards heat sink 6 to form a directional cooling airflow.

[0029] II. Specific Structure and Connection Relationships of Each Module (a) Connections related to BDU and control module 1 Connection to terminal module 7: Terminal module 7 includes a rectangular terminal board 71. BDU and control module 1 are connected to the signal interface of terminal board 71 through first ribbon cable 11. The first ribbon cable 11 is a shielded ribbon cable, which effectively reduces external electromagnetic interference and ensures stable transmission of control signals. Connection to drive module 2: BDU and control module 1 are connected to the signal input terminal of drive module 2 via the second ribbon cable 21 to send control commands to drive module 2; Connection to filter module 4: The first cable 12 and the second cable 14 are respectively led out from both sides of the BDU and control module 1. One end of each cable is soldered to the power interface of the BDU and control module 1, and the other end is fixed to the corresponding terminal of the filter module 4 by bolts to form a power circuit. Connection to DC PCB board 3: The connection is achieved through the first conductive bus 31 and the second conductive bus 32, wherein the first conductive bus 31 corresponds to the positive terminal and the second conductive bus 32 corresponds to the negative terminal. The two ends of the two conductive buses are respectively fixed to the positive and negative output terminals of BDU and control module 1 and the positive and negative input terminals of DC PCB board 3 by screws. The conductive buses are made of copper to reduce current transmission loss.

[0030] (II) Specific structure and connection of driver module 2 The conductive post 23 is set vertically on the top of the drive module 2. Three cylindrical conductive posts 23 are marked as positive conductive post 23, negative conductive post 23 and N-pole conductive post 23 respectively. The DC PCB board 3 has mounting holes at the corresponding positions to fix the DC PCB board 3 on the conductive post 23, so as to realize the electrical connection between the DC PCB board 3 and the drive module 2. IGBT22 connected to heat sink 6: IGBT22 (insulated gate bipolar transistor) is fixedly installed at the bottom of the drive module 2. The bottom surface of IGBT22 is in close contact with the top surface of heat sink 6 in the lower area, and thermal grease is applied between the two to enhance the heat conduction efficiency and ensure that the heat generated by IGBT22 during operation can be quickly transferred to heat sink 6. Connection with inductor module 5: A third conductive bus 51 is provided on the top of inductor module 5. One end of the third conductive bus 51 is fixed to the output terminal of inductor module 5 by bolts, and the other end is connected to the power input terminal of drive module 2 to realize current transmission between inductor module 5 and drive module 2.

[0031] (III) Connection between filter module 4 and inductor module 5 The filter module 4 is positioned close to the inductor module 5. The inductor module 5 has multiple threaded fixing terminals pre-set on its outer shell. The bottom of the filter module 4 has corresponding mounting holes. By passing bolts through the mounting holes and engaging with the fixing terminals on the inductor module 5, the filter module 4 and the inductor module 5 are connected and fixed. At the same time, the terminals of the two are directly connected by wires to reduce circuit redundancy.

[0032] (iv) Installation structure of BCU module 8 The BCU module 8 consists of a fixing plate 81 and a BCU body 82. The fixing plate 81 is equipped with a captive screw 83. The corresponding position of the housing of the terminal module 7 is provided with a positioning hole. By inserting the captive screw 83 into the positioning hole and tightening it, the BCU module 8 can be fixed on the terminal module 7. This connection method can be completed without additional tools, which facilitates the inspection and replacement of the BCU module 8.

[0033] (v) Connection of fan module 9 The fan module 9 contains multiple axial fans arranged in parallel. The power input terminal of the fan module 9 is connected to the fan control interface of the BDU and control module 1 through the fan cable 91. The BDU and control module 1 can adjust the fan speed according to the temperature feedback of the heat sink 6 to achieve intelligent heat dissipation.

[0034] III. Implementation Advantages This embodiment adopts a layered and partitioned layout, making the layout of each module compact and reducing the overall size of the converter. At the same time, the connection between each module adopts standardized methods such as ribbon cables and conductive busbars, which reduces wiring complexity and improves assembly efficiency and reliability. In addition, the directional heat dissipation design effectively protects the operating temperature of each component and extends the service life of the converter.

[0035] The above-described embodiments are merely preferred embodiments provided to fully illustrate the present invention, and the scope of protection of the present invention is not limited thereto. Equivalent substitutions or modifications made by those skilled in the art based on the present invention are all within the scope of protection of the present invention. The scope of protection of the present invention is defined by the claims.

Claims

1. A novel integrated energy storage converter structure, characterized in that, It includes the BDU and control module (1), drive module (2), and DC PCB board (3) located on the upper layer; The filter module (4), inductor module (5), and heat sink (6) are located in the lower layer; Terminal module (7) and BCU module (8) are located at the front end; It includes a fan module (9) located at the rear end, which is connected to the BDU and control module (1) via a fan cable (91); The terminal module (7) includes a terminal board (71). The BDU and control module (1) are connected to the terminal board (71) via a first cable (11) and to the drive module (2) via a second cable (21).

2. The novel integrated energy storage converter structure as described in claim 1, characterized in that, The BDU and control module (1) are respectively provided with a first cable (12) and a second cable (14) on both sides, which are connected to the filter module (4).

3. The novel integrated energy storage converter structure as described in claim 1, characterized in that, The drive module (2) is connected to the BDU, control module (1), and DC PCB board (3) via a third cable (13).

4. The novel integrated energy storage converter structure as described in claim 1, characterized in that, The drive module (2) is provided with conductive posts (23), and there are three conductive posts (23) respectively corresponding to the positive, negative and N poles. The DC PCB board (3) is connected to the drive module (2) through the conductive posts (23). The bottom of the drive module (2) is provided with an IGBT (22) for connecting to the heat sink (6).

5. The novel integrated energy storage converter structure as described in claim 1, characterized in that, It includes a first busbar (31) and a second busbar (32) for connecting the positive and negative terminals of the DC PCB board (3) and the BDU and control module (1).

6. The novel integrated energy storage converter structure as described in claim 1, characterized in that, The filter module (4) is connected and fixed through the terminals on the inductor module (5).

7. The novel integrated energy storage converter structure as described in claim 1, characterized in that, The inductor module (5) is provided with a third conductive bus (51), which is connected to the drive module (2).

8. The novel integrated energy storage converter structure as described in claim 1, characterized in that, The BCU module (8) includes a fixing plate (81) and a BCU body (82), which are fixed to the terminal module (7) by a non-detachable screw (83).

Images