Energy storage system high-voltage box based on modular design

Abstract

The utility model discloses a kind of high voltage box of energy storage system based on modularization design, to solve the problem of low space utilization of traditional high voltage box, poor heat dissipation effect, installation and maintenance inconvenience and compatibility deficiency. The high voltage box includes portable dismounting type box, primary device module, secondary control module and composite heat dissipation system. The utility model is layered layout by modularization zoning design, reduces wiring space 20%;Primary device integrated optimization layout, significantly improve the performance and maintenance efficiency of equipment, shorten maintenance time 30%;The design of heat dissipation system independent air duct effectively avoids airflow interference, so that high voltage box operates more stably, reliably and efficiently, while the physical isolation design of heat dissipation system and electrical module, both avoid heat cross interference, and reduce space conflict, realize three-dimensional space efficient use.

Description

Technical Field

[0001] This utility model relates to the field of energy storage equipment technology, specifically a high-voltage box for energy storage systems based on modular design. It is particularly suitable for high-voltage electrical integration and safety protection between battery clusters and converters (PCS). Through standardized interface and functional partition design, it solves the problems of cumbersome disassembly and assembly, insufficient heat dissipation and poor compatibility of traditional high-voltage boxes, significantly improving equipment maintenance efficiency, space utilization and heat dissipation performance, while enhancing the reliability and compatibility of the system, and is suitable for large-scale energy storage system integration. Background Technology

[0002] In current energy storage and power systems, high-voltage boxes, as key integrated electrical devices, directly impact system safety and operational efficiency. However, traditional high-voltage boxes generally suffer from the following technical bottlenecks: structural redundancy and low space utilization, insufficient maintenance and expandability, weak heat dissipation and safety design, lack of intelligence and compatibility, and limited adaptability to various scenarios. For example, existing high-voltage boxes mostly adopt a fixed structure, with fixed installation for individual components, resulting in complex internal wiring, high coupling between components, and the need to disassemble a large number of parts for repair in case of failure, which is time-consuming and costly. In addition, the dense and scattered layout of components in traditional high-voltage boxes leads to low space utilization, resulting in heat accumulation and a lack of active heat dissipation mechanisms, posing a risk of high temperatures. Summary of the Invention

[0003] To overcome the shortcomings of existing high-voltage boxes, such as low space utilization, poor heat dissipation, and inconvenient installation and maintenance, this utility model provides a modular design that categorizes and installs components, achieves separation of primary and secondary electrical components, and groups heat-generating components into separate modules for active heat dissipation, which will significantly reduce the problem of excessively high temperature inside the high-voltage box.

[0004] The technical solution adopted by this utility model to solve its technical problem is: a high-voltage box for an energy storage system based on modular design, including a portable and detachable box, a primary device module, a secondary control module and a composite heat dissipation system. The portable, detachable enclosure is made of Q235 carbon steel and is internally divided into a primary device module area, a secondary control module area, and a composite heat dissipation system area. Each area is physically isolated by a detachable cover plate. The primary device module includes molded case circuit breakers, a main positive relay, a pre-charge relay, a shunt, and fuses. These components are connected by L-shaped copper busbars with optimized topology to form a modular circuit, which is integrated into a detachable functional unit module mounting plate. The composite heat dissipation system consists of two sets of IES switches and an aluminum alloy heat sink. The aluminum alloy heat sink is fixed to the side wall of the enclosure by a heat sink bracket, and its surface is decorated with staggered heat dissipation fins. The heat dissipation fins are 12±0.5mm high and 2.5±0.2mm apart. It is equipped with an independent air duct and an axial flow fan. The air duct adopts a tapered S-shaped guide structure, and the ratio of the inlet cross-sectional area to the outlet cross-sectional area of ​​the air duct is 1:0.8, forming forced convection. The portable, detachable housing features a quick-release mechanism on its front panel, including a top interlocking buckle and a bottom rotating limiting pin. The back of the housing has a fixing interface, and the front panel primarily houses primary and secondary terminals. The primary component module area adopts a layered layout. Molded case circuit breakers are remotely tripped via a circuit breaker lever. Fuses and shunts are arranged perpendicularly, with a copper busbar connection path length ≤150mm. The composite heat dissipation system uses an S-shaped airflow structure. The axial fan's speed is adjustable from 0.5-3m / s, and the aluminum alloy heat sink surface has a fin array with a fin spacing of 2.5mm ± 0.2mm. The axial fan has a temperature-speed linkage control module; when the IES switch surface temperature is ≥60℃, it automatically switches to high-speed mode with a speed not lower than 2500rpm. A 1mm thick thermal grease pad is placed on the contact surface between the aluminum alloy heat sink and the IES switch. This utility model achieves rapid assembly and flexible maintenance through modular design. The specific solution is as follows: Enclosure: The enclosure is made of Q235 carbon steel with powder coating and bending. The interior of the enclosure is divided into a primary device module area, a secondary control module area, and a composite heat dissipation system area. The areas are connected by cables or copper busbars with reserved ports. Each area does not interfere with the others and supports independent disassembly and replacement. The cover plate adopts a plug-in structure with plug-in holes for limiting the position at the enclosure. The cover plate is designed with a snap-fit, which directly and seamlessly connects to the enclosure, forming a flat top with no protruding structure. It is only fixed from the back with two fasteners, thereby reducing disassembly time.

[0005] The primary component module consists of a molded case circuit breaker, a main positive relay, a pre-charge relay, a shunt, and a primary fuse. The components are connected by copper busbars, which shortens the wiring path and reduces heat concentration caused by messy wiring. Each component can be disassembled individually or as a whole. Installation only requires fixing the components to the sheet metal mounting plate on the outside of the enclosure, and then fixing the whole assembly to the enclosure. This effectively avoids the disadvantage of being difficult to operate due to the small space of the enclosure and improves the efficiency of component installation and maintenance.

[0006] Composite heat dissipation system: For the IES switch, the component that generates the most heat inside the enclosure and is the core component of the entire enclosure, in order to avoid excessive heat generation during operation, which could cause the tube to burst and lead to a short circuit, it is designed as a separate component. Two sets of IES switches are installed inside a high-voltage box and are integrated and mounted on an aluminum alloy heat sink. An external air duct is formed and equipped with an axial flow fan for local heat dissipation. This effectively reduces the possibility of thermal runaway caused by insufficient space inside the enclosure, and also reduces the malfunction of other components due to excessively high ambient temperature.

[0007] The modular design of the high-voltage box for the energy storage system proposed in this utility model has the following advantages: 1. Highly efficient space utilization: The integrated structural design allows for layered layout of high and low voltage wiring harnesses, reducing wiring space by 20%; 2. Improve maintenance efficiency: Through structural optimization and functional integration, significantly improve equipment performance and maintenance efficiency, and shorten maintenance time by 30%; 3. Improved heat dissipation performance: The independent air duct design of the heat dissipation system effectively avoids airflow interference, making the high-voltage box more stable, reliable and efficient in operation. At the same time, the physical isolation design between the heat dissipation system and the electrical module avoids heat cross-interference and reduces space conflicts, achieving efficient utilization of three-dimensional space. Attached Figure Description

[0008] Figure 1 This is a schematic diagram of the present invention; Figure 2 This is a schematic diagram of the modular design of functional units; Figure 3 This is a schematic diagram of an integrated heat dissipation system. Figure 4 This is an exploded view of the module; Figure 5 This is a schematic diagram of the airflow direction in the air duct.

[0009] Reference numerals: 1-Enclosure; 2-Primary device module; 3-Secondary control module; 4-TMU module; 5-Primary terminal; 6-Secondary terminal; 7-Secondary control terminal assembly; 8-Composite heat dissipation system; 9-Main positive relay; 10-Pre-charge relay; 11-Molded case circuit breaker; 12-Functional unit module mounting plate; 13-Molded case circuit breaker rocker arm; 14-Molded case circuit breaker handle; 15-Insulation detection module; 16-Shunt unit; 17-Fuse; 18-Aluminum alloy heat sink; 19-IES switch; 20-Heat sink bracket; 21-Axial flow fan; 22-TMU mounting plate. Detailed Implementation

[0010] The advantages of this utility model are further illustrated below with reference to the accompanying drawings and specific embodiments.

[0011] Exemplary embodiments will now be described in detail, examples of which are illustrated in the accompanying drawings. When the following description relates to the drawings, unless otherwise indicated, the same numerals in different drawings denote the same or similar elements. The embodiments described in the following exemplary embodiments do not represent all embodiments consistent with this disclosure. Rather, they are merely examples of apparatuses and methods consistent with some aspects of this disclosure as detailed in the appended claims.

[0012] The terminology used in this disclosure is for the purpose of describing particular embodiments only and is not intended to be limiting of the disclosure. The singular forms “a,” “the,” and “the” as used in this disclosure and the appended claims are also intended to include the plural forms unless the context clearly indicates otherwise. It should also be understood that the term “and / or” as used herein refers to and includes any and all possible combinations of one or more of the associated listed items.

[0013] It should be understood that although the terms first, second, third, etc., may be used in this disclosure to describe various information, such information should not be limited to these terms. These terms are used only to distinguish information of the same type from one another. For example, without departing from the scope of this disclosure, first information may also be referred to as second information, and similarly, second information may also be referred to as first information. Depending on the context, the word "if" as used herein may be interpreted as "when," "when," or "in response to determination."

[0014] In the description of this utility model, unless otherwise specified and limited, it should be noted that the terms "installation", "connection" and "linking" should be interpreted broadly. For example, they can refer to mechanical or electrical connections, or internal connections between two components. They can be direct connections or indirect connections through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms according to the specific circumstances.

[0015] In the following description, the use of suffixes such as "module," "part," or "unit" to denote elements is solely for the purpose of illustrating this invention and has no specific meaning in itself. Therefore, "module" and "part" can be used interchangeably.

[0016] Example 1: The enclosure (1) is made of 2mm thick Q235 carbon steel, bent and powder coated, with internal functional areas. In the primary device module (2) area, the molded case circuit breaker (11) is fixed to the functional unit module mounting plate (12) by 4 sets of M4 bolts. The molded case circuit breaker rocker arm (13) extends to the front of the enclosure. The molded case circuit breaker handle (14) can be connected to an extension rod to achieve remote control, adapting to different installation scenarios. The main positive relay (9) and the precharge relay (10) are arranged in a staggered layout with a spacing of 30mm and an adjustable range of ±5mm. A maintenance window is reserved to avoid arc interference. The secondary control module (3) area integrates the TMU module (4) and the primary terminal (5), and quick wiring is achieved through plug-in wiring harness.

[0017] Example 2: The core of the composite heat dissipation system (8) is an aluminum alloy heat sink (18) with dimensions of 300×200×15mm (tolerance ±1mm). 35 heat dissipation fins with a height of 12mm are machined on the surface, with a fin spacing of 2.5mm. The spacing can be extended to 2-4mm to accommodate different heat dissipation needs. Two sets of IES switches (19) are fixed to the central area of ​​the aluminum alloy heat sink with rivet nuts. A 5N·m installation torque is applied to the contact surface to ensure a tight fit. The axial flow fan (21) is a DC24V / 0.5A model. It uses a tapered S-shaped air duct with an inlet cross-sectional area to outlet cross-sectional area ratio of 1:0.8 to form a directional airflow. Filters are installed at the air outlets to effectively block the intake of large dust particles.

[0018] Example 3: Standardized Modular Interface Design A standardized plug-in interface is set between the primary device module (2) area and the secondary control module (3) area of ​​the enclosure (1), including: Primary electrical interface: adopts a copper busbar quick-connect structure (contact resistance ≤0.1mΩ), supporting the overall plugging and unplugging of the primary device module (2); Secondary signal interface: integrates a 24-pin plug, with built-in CAN bus and RS485 dual communication protocols, realizing plug-and-play functionality. Each primary device module (2) has a reserved test port on the back, supporting external portable testing instruments to independently measure parameters such as the opening and closing time of the molded case circuit breaker (11), the pull-in voltage of the main positive relay (9) and the pre-charge relay (10), without the need to disassemble the module.

[0019] Example 4: Modular heat dissipation hierarchical control. Three sets of NTC sensors are arranged on the surface of the aluminum alloy heat sink (18) to monitor the temperature of the IES switch (19) respectively. The temperature of the IES switch is monitored in real time, and an alarm is triggered when the temperature reaches the set value.

Claims

1. A high-voltage box for an energy storage system based on modular design, characterized in that, include: The portable, detachable enclosure (1) is formed by bending Q235 carbon steel. The interior is divided into a primary device module (2) area, a secondary control module (3) area, and a composite heat dissipation system (8) area. Each area is physically isolated by a detachable cover plate. The primary device module includes a molded case circuit breaker (11), a main positive relay (9), a precharge relay (10), a shunt (16), and a fuse (17). Each device is connected by an L-shaped copper busbar with topology optimization to form a modular circuit, which is integrated into a detachable functional unit module mounting plate (1). 2) The composite heat dissipation system (8) includes a combination of two sets of IES switches (19) and aluminum alloy heat dissipation plates (18). The aluminum alloy heat dissipation plates (18) are fixed to the side wall of the box by heat dissipation plate brackets (20) and the surface is provided with staggered heat dissipation fins. The height of the heat dissipation fins is 12±0.5mm and the spacing is 2.5±0.2mm. It is equipped with an independent air duct and an axial flow fan (21). The air duct adopts a gradually narrowing S-shaped flow guide structure. The ratio of the inlet cross-sectional area to the outlet cross-sectional area of ​​the air duct is 1:0.8, forming forced convection.

2. The high-voltage box of an energy storage system based on modular design according to claim 1, characterized in that: The front panel of the portable detachable case (1) is equipped with a quick-release mechanism, including a top plug-in buckle and a bottom rotating limit pin. The back of the case is equipped with a fixing interface. The front of the panel is mainly equipped with a primary terminal (5) and a secondary terminal (6).

3. The high-voltage box of an energy storage system based on modular design according to claim 1, characterized in that: The primary device module (2) area adopts a layered layout. The molded case circuit breaker (11) is remotely tripped through the molded case circuit breaker rocker (13). The fuse (17) and the shunt (16) are arranged vertically and orthogonally. The copper busbar connection path length is ≤150mm.

4. The high-voltage box of an energy storage system based on modular design according to claim 1, characterized in that: The composite heat dissipation system (8) adopts an S-shaped flow guide structure for its air duct. The wind speed of the axial fan (21) is adjustable from 0.5 to 3 m / s. The aluminum alloy heat sink (18) has a fin array on its surface with a fin spacing of 2.5 mm ± 0.2 mm.

5. The high-voltage box of an energy storage system based on modular design according to claim 1, characterized in that: The axial flow fan (21) has a temperature-speed linkage control module. When the surface temperature of the IES switch (19) is ≥60℃, it automatically switches to high-speed mode and the speed is not less than 2500rpm.

6. The high-voltage box of an energy storage system based on modular design according to claim 1, characterized in that: The contact surface between the aluminum alloy heat sink (18) and the IES switch (19) is padded with a 1mm thick thermal grease pad.

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