Active filter device

Abstract

Provided is an active filter device, comprising a shell (1), a first group of electrical components (11), a second group of electrical components (12), and a third group of electrical components (13) are arranged in sequence along a first direction inside the shell (1). A fan (32) is arranged between the first group of electrical components (11) and the third group of electrical components (13) to form an air flow that sequentially flows through the first group of electrical components (11), the second group of electrical components (12), and the third group of electrical components (13), wherein the second group of electrical components (12) is arranged more adjacent to the fan than the first group of electrical components (11). The first group of electrical components (11) comprises a plurality of capacitors (21), the second group of electrical components (12) comprises a plurality of power devices (31), and the third group of electrical components (13) comprises a plurality of inductors (41).

Description

Technical Field

[0001] This disclosure relates to the electrical field, specifically the design of an active filter device. Background Technology

[0002] Currently, most mainstream power electronic device units (such as active filter devices) adopt a single-end cooling mode, that is, the cooling fan is placed at the front or rear of the unit. The core disadvantage of single-end cooling is that it cannot achieve balanced cooling of all components in the entire chain, which can easily lead to local overheating of the system, reduced cooling efficiency, and decreased reliability.

[0003] Furthermore, some power electronic devices require integrated design. However, the highly integrated structure of traditional integrated designs results in extremely strong interrelationships between components; modifications to one part can have far-reaching consequences, making functional expansion or adjustment difficult. If a component fails, it is often difficult to repair or replace it individually, potentially leading to overall failure and increased maintenance costs. Simultaneously, precise matching of parameters is required upfront, resulting in high design complexity, high R&D thresholds and costs, and limited room for customized adjustments before mass production. In traditional active power filter designs, not only are there numerous components, complex assembly processes, and difficult maintenance, but they are also often large in size and have a low power density limit. Utility Model Content

[0004] Therefore, this disclosure aims to solve the aforementioned problems of existing active filter devices, with the purpose of improving heat dissipation of electrical components within the active filter device and improving the internal layout.

[0005] The active filter according to this disclosure includes a housing (1) in which a first group of electrical components (11), a second group of electrical components (12), and a third group of electrical components (13) are arranged sequentially along a first direction. A fan (32) is disposed between the first group of electrical components (11) and the third group of electrical components (13) to form an airflow that flows sequentially through the first group of electrical components (11), the second group of electrical components (12), and the third group of electrical components (13), wherein the second group of electrical components (12) is arranged closer to the fan than the first group of electrical components (11). The first group of electrical components (11) includes a plurality of capacitors (21), the second group of electrical components (12) includes a plurality of power devices (31), and the third group of electrical components (13) includes a plurality of inductors (41). The active filter according to this disclosure may also have one or more of the following features individually or in combination.

[0006] For example, according to one embodiment of this disclosure, the first group of electrical components includes a plurality of capacitors, the second group of electrical components includes a plurality of power devices, and the third group of electrical components includes a plurality of inductors.

[0007] For example, according to one embodiment of this disclosure, the plurality of capacitors are integrated in a capacitor module, the plurality of power devices and the fan are integrated in a power module, and the plurality of inductors are integrated in an inductor module, wherein the capacitor module, the power module and the inductor module can be independently disassembled and installed.

[0008] For example, according to one embodiment of this disclosure, the fans are configured as a plurality of fans arranged along a second direction perpendicular to the first direction.

[0009] For example, according to one embodiment of this disclosure, the power module includes a heat sink disposed upstream of a fan, and the power device is attached to the heat sink.

[0010] For example, according to one embodiment of this disclosure, the power module further includes an upper plate and a lower plate spaced apart in a height direction perpendicular to the first direction and the second direction. The power device, heat sink and fan are sequentially fixed above the upper plate along the first direction. A baffle is provided between the upper plate and the lower plate to prevent airflow from flowing back from the second group of electrical components to the first group of electrical components from between the upper plate and the lower plate.

[0011] For example, according to one embodiment of this disclosure, a separate control module and a busbar module are further provided downstream of the third group of electrical components. The control module is used to control the operation of the active filter, and the busbar module is used to connect to an external power supply.

[0012] For example, according to one embodiment of this disclosure, the capacitor module, the power module, the inductor module, the control module, and the busbar module are each provided with a connection portion and are electrically connected to each other through direct connection of the connection portions.

[0013] For example, according to one embodiment of this disclosure, the active filter includes a fuse disposed outside the housing of the active filter.

[0014] For example, according to one embodiment of this disclosure, the fuse includes a first terminal electrically connected to a terminal block on an active filter and a second terminal electrically connected to an external power source. A terminal block and an insulating pad protruding from the housing are provided on the outer surface of the housing. The first terminal is electrically connected to the terminal block by a screw, and the second terminal is fixed to the insulating pad by a screw to space the second terminal from the housing.

[0015] For example, according to one embodiment of this disclosure, the active filter further includes a protective cover that is mounted to the housing and covers the fuse. Attached Figure Description

[0016] The above and other features and advantages of this disclosure will become more apparent from the following detailed description of exemplary embodiments taken in conjunction with the accompanying drawings, which are for illustrative purposes only and are not intended to limit the scope of this disclosure in any way. The following drawings are not intentionally drawn to scale with actual dimensions; their focus is on illustrating the gist of this disclosure. In the figures:

[0017] Figure 1 A perspective view of the arrangement of an active filter device according to an embodiment of the present disclosure is shown, wherein a cover plate is hidden to show the internal arrangement.

[0018] Figure 2 A perspective view of the arrangement of an active filter device according to an embodiment of the present disclosure is shown, wherein a cover plate and a housing body are concealed to show the structure of the internal modules.

[0019] Figure 3 A perspective view showing the coordination between the internal modules of an active filter according to an embodiment of the present disclosure is provided.

[0020] Figure 4 An exploded perspective view of an active filter device according to an embodiment of the present disclosure is shown.

[0021] Figure 5 A partial exploded perspective view shows the mounting structure of the fuse of an active filter device according to an embodiment of the present disclosure.

[0022] In each figure, identical or similar parts are represented by the same reference numerals.

[0023] List of reference numerals

[0024] 100 Active Filter Device

[0025] 1. Shell

[0026] 11 First group of electrical components

[0027] 12 Second group of electrical components

[0028] 13 Third group of electrical components

[0029] 14. Main body of the shell

[0030] 15 Cover plate

[0031] 16 Front-end board

[0032] 17. Backend board

[0033] 2 Capacitor Module

[0034] 21 Capacitor

[0035] 3 Power Modules

[0036] 31 Power Devices

[0037] 32 fans

[0038] 33 Radiator

[0039] 34 board

[0040] 35 Lower plate

[0041] 36 baffles

[0042] 4 Inductor Module

[0043] 41 Inductors

[0044] 5. Control Module

[0045] 6 busbar modules

[0046] 7. Fuse

[0047] 71 First terminal

[0048] 72 Second Terminal

[0049] 81 Connecting part

[0050] 82 terminal blocks

[0051] 83 Insulating pads

[0052] 84 Protective Shield Detailed Implementation

[0053] To make the objectives, technical solutions, and advantages of the embodiments of this disclosure clearer, the technical solutions of the embodiments of this disclosure will be clearly and completely described below with reference to the accompanying drawings.

[0054] Unless otherwise defined, the technical or scientific terms used herein shall have the ordinary meaning as understood by one of ordinary skill in the art to which this disclosure pertains. The use of terms such as “a,” “an,” or “the” in this patent application specification and claims does not indicate a limitation of quantity, but rather indicates the presence of at least one. Terms such as “comprising” or “including” mean that an element or object preceding the word encompasses the elements or objects listed following the word and their equivalents, without excluding other elements or objects.

[0055] In this disclosure, the first direction refers to the direction in which the first group of electrical components, the second group of electrical components, and the third group of electrical components are arranged in sequence; the second direction refers to the direction in which the multiple fans are arranged perpendicular to the first direction; and the height direction refers to the direction perpendicular to both the first and second directions. Furthermore, in this disclosure, the airflow direction generated by the upstream and downstream sequential fans is also specified.

[0056] According to one aspect of this disclosure, an active filter device 100 is proposed, such as... Figure 1 and Figure 4 As shown, the device includes a housing 1. The housing 1 may include, for example, a housing body 14, a cover plate 15, a front end plate 16, and a rear end plate 17. The housing body 14, cover plate 15, front end plate 16, and rear end plate 17 can form a complete cuboid housing. Multiple through holes may be provided on the front end plate 16 and the rear end plate 17 to allow airflow.

[0057] Electrical components such as capacitor 21, power device 31, and inductor 41 are installed inside the housing 1. These electrical components generate heat and rise in temperature during the operation of the active filter 100. This temperature rise will affect the normal operation of these electrical components and thus affect the function of the active filter 100. Therefore, a heat dissipation system is needed to effectively dissipate heat from these electrical components.

[0058] According to embodiments of this disclosure, such as Figure 1 and Figure 2 As shown, the active filter device 100 includes a fan 32 for generating airflow to dissipate heat from these electrical components. For example, the fan 32 is disposed within the housing 1, and specifically disposed in the central region of the housing 1 along a first direction D1, rather than at either end of the housing 1.

[0059] Specifically, the interior of the housing 1 may be provided with a first group of electrical components 11, a second group of electrical components 12, and a third group of electrical components 13, which are arranged sequentially along a first direction D1. For example, the first group of electrical components 11 includes a plurality of capacitors 21. For example, the second group of electrical components 12 includes a plurality of power devices 31. For example, the third group of electrical components 13 includes a plurality of inductors 41.

[0060] A fan 32 is positioned between the first group of electrical components 11 and the third group of electrical components 13 to form an airflow along a first direction D1. This airflow sequentially passes through the first group of electrical components 11, the second group of electrical components 12, and the third group of electrical components 13, thereby dissipating heat from each group of electrical components. Specifically, the first group of electrical components upstream of the fan (which may be components with high heat dissipation requirements, such as capacitor 21) can be specifically protected; the second group of electrical components closest to the fan (which may be components with the highest heat dissipation requirements, such as power devices) can be efficiently cooled; and the third group of electrical components downstream of the fan (which may be components with relatively low heat dissipation requirements, such as inductors) can be cooled collaboratively. This single-heat dissipation system arrangement is simple, occupies little space, and is beneficial for significantly increasing the power density of the active filter. According to the arrangement of this disclosure, the heat dissipation capacity of the airflow is redistributed, particularly according to the required degree of heat dissipation.

[0061] This results in overall system-level gains, leading to an orderly temperature distribution. The directional airflow generated by the suction mode connects the heat dissipation paths of the three core components in series, avoiding localized hot spots caused by turbulent hot and cold airflow. Furthermore, the energy-efficient and space-optimized design, with the fan positioned in the middle of the suction channel, reduces airflow resistance and improves heat dissipation efficiency. Simultaneously, the cold air path is highly compatible with the device layout, eliminating the need for additional complex air ducts and saving space for product miniaturization and integration. The arrangement disclosed herein is also suitable for high-load scenarios. During high-power operation, this design can ensure that all components operate within a safe temperature range through staged cooling.

[0062] Furthermore, according to embodiments of this disclosure, such as Figure 1 and Figure 2 As shown, multiple capacitors 21, multiple power devices 31, and multiple inductors 4 can be arranged in a second direction D2 perpendicular to the first direction D1 to achieve a compact spatial arrangement. In order to dissipate heat from all electrical components, multiple fans 32 are provided, which are arranged in the second direction D2 so that airflow can substantially cover all the space inside the housing 1 along the second direction D2.

[0063] To enhance heat dissipation for the power device 31, multiple heat sinks 33 can be installed near the second group of electrical components 12, such as... Figure 2 and Figure 3 As shown, for example, the heat sink 33 may be positioned upstream of the fan 32. The heat sink 33 may include, for example, a plurality of spaced-apart fins to increase the contact area with the airflow. The power device 31 may be positioned close to the heat sink 33 to exchange heat with the heat sink 33, thereby increasing the heat dissipation effect.

[0064] According to embodiments of this disclosure, the arrangement within the active filter device 100 is also optimized. Specifically, as... Figure 3 He Ru Figure 4 As shown, multiple capacitors 21 can be integrated into a capacitor module 2; multiple power devices 31, fans 32 and heat sinks 33 can be integrated into a power module 3; and multiple inductors 41 can be integrated into an inductor module 4.

[0065] In addition, such as Figure 3 He Ru Figure 4 As shown, the active filter device 100 may also include an independent control module 5 and a busbar module 6. The control module 5 and busbar module 6 may be located downstream of the third group of electrical components 13. The control module 5 is used, for example, to control the operation of the active filter device, and the busbar module 6 is used, for example, to connect to an external power supply.

[0066] Capacitor module 2, power module 3, inductor module 4, control module 5, and busbar module 6 can be independently disassembled and installed. By encapsulating the main internal components of the active filter 100 into individual modules, the device size, assembly difficulty, and labor time are significantly reduced, while maintaining module maintainability and power density are improved. Simultaneously, some modules are fully interchangeable, reducing production management complexity. Power density is a key indicator of an active filter device; higher power density provides a competitive advantage in the market and attracts customers. Modular design, by breaking the system down into functionally independent modules, not only enables flexible combination and replacement of modules, facilitating rapid upgrades or functional expansion as needed, but also significantly reduces maintenance costs—if a module fails, only the corresponding part needs replacement, without replacing the entire system. Furthermore, modules can be developed in parallel and reused in batches, shortening the R&D cycle and reducing costs through large-scale production, making it particularly suitable for complex systems requiring customization and multi-scenario adaptation.

[0067] Furthermore, standardized interfaces can be used for individual modules to further facilitate flexible combination and replacement. Specifically, such as... Figure 3 The capacitor module 2, power module 3, inductor module 4, control module 5, and busbar module 6 shown can each be provided with a connection part 81. The connection part 81 may be, for example, a protrusion with a through hole or a lug that mates with the protrusion, allowing the connection parts 81 on two different modules to be connected together using screws. Direct connection of the connection parts 81 enables electrical connection between different modules. For example, as... Figure 3 and Figure 4 As shown, capacitor module 2 is connected to power module 3, power module 3 is connected to inductor module 4, and inductor module 4 is connected to busbar module 6.

[0068] According to embodiments of this disclosure, such as Figure 2 and Figure 3As shown, the power module 3 may further include an upper plate 34 and a lower plate 35 spaced apart in a height direction perpendicular to the first direction D1 and the second direction D2. The power device 31, heat sink 33, and fan 32 may be directly or indirectly fixed above the upper plate along the first direction D1. A baffle is provided between the upper plate 34 and the lower plate 35 to prevent airflow from flowing back from the second group of electrical components 12 to the first group of electrical components 11 through the space between the upper and lower plates. This prevents airflow disturbance and thus avoids affecting heat dissipation efficiency.

[0069] like Figure 1 and Figure 5 As shown, the active filter device 100 may further include a fuse 7 for protecting the active filter device 100. Existing active filter devices typically use fuses built into the PCB, meaning the fuse is placed inside the active filter device. This arrangement occupies internal space and is inconvenient for fuse maintenance and replacement. Therefore, according to embodiments of this disclosure, the fuse 7 can be disposed on the exterior of the housing 1 of the active filter device 100, for example, on the outer surface of the rear end plate 17 near the busbar module 6, to facilitate fuse maintenance and replacement, thus solving the problem of needing to open the cover to replace the fuse.

[0070] Specifically, the fuse 7 may include a first terminal 71 electrically connected to a terminal block 82 on the active filter device 100 and a second terminal 72 electrically connected to an external power supply. A terminal block 82, for example, connected to a busbar module 6, is provided on the outer surface of the housing 1 (e.g., the outer surface of the rear end plate 17). The first terminal 71 is electrically connected to the terminal block 82 by screws and thus connected to the busbar module 6. An insulating pad 83 protruding from the housing 1 may also be provided on the outer surface of the housing 1 (e.g., the outer surface of the rear end plate 17), that is, the insulating pad 83 has a certain thickness in the direction protruding from the outer surface of the housing. Thus, the second terminal 72 can be fixed to the insulating pad 83 by screws to space the second terminal 72 from the housing 1, providing a sufficient safety distance to prevent short circuits.

[0071] like Figure 5 As shown, three fuses 7 can be provided, for example, to correspond to three-phase power. Correspondingly, three terminals 82 can be provided, and three threaded holes are provided on a large insulating pad 83.

[0072] Furthermore, such as Figure 5 As shown, the active filter device 100 may also include a protective cover 84, which can be mounted to the housing and cover the fuse 7 to provide protection.

[0073] Certain features, structures, or characteristics in one or more embodiments of this disclosure may be appropriately combined.

[0074] The foregoing description is illustrative of the present disclosure and should not be construed as limiting it. While several exemplary embodiments of the present disclosure have been described, those skilled in the art will readily understand that many modifications may be made to the exemplary embodiments without departing from the novel teachings and advantages of the present disclosure. Therefore, all such modifications are intended to be included within the scope of the present disclosure as defined in the claims. It should be understood that the foregoing description is illustrative of the present disclosure and should not be construed as limiting it to the specific embodiments disclosed, and modifications to the disclosed embodiments and other embodiments are intended to be included within the scope of this disclosure.

Claims

1. An active filter device (100), characterized in that, Includes a housing (1), inside which are arranged a first group of electrical components (11), a second group of electrical components (12), and a third group of electrical components (13) arranged sequentially along a first direction. A fan (32) is provided between the first group of electrical components (11) and the third group of electrical components (13) to form an airflow that flows sequentially through the first group of electrical components (11), the second group of electrical components (12), and the third group of electrical components (13), wherein the second group of electrical components (12) is arranged closer to the fan than the first group of electrical components (11). The first group of electrical components (11) includes multiple capacitors (21), the second group of electrical components (12) includes multiple power devices (31), and the third group of electrical components (13) includes multiple inductors (41).

2. The active filter device (100) according to claim 1, characterized in that, The multiple capacitors (21) are integrated into a capacitor module (2), the multiple power devices (31) and the fan (32) are integrated into a power module (3), and the multiple inductors (41) are integrated into an inductor module (4). The capacitor module (2), the power module (3) and the inductor module (4) can be disassembled and installed independently of each other.

3. The active filter device (100) according to claim 2, characterized in that, The fans (32) are configured as a plurality of fans arranged along a second direction perpendicular to the first direction.

4. The active filter device (100) according to claim 3, characterized in that, The power module (3) includes a heat sink (33) disposed upstream of the fan (32), and the power device (31) is attached to the heat sink (33).

5. The active filter device (100) according to claim 4, characterized in that, The power module (3) further includes an upper plate (34) and a lower plate (35) spaced apart in a height direction perpendicular to the first direction and the second direction. The power device, heat sink and fan (32) are fixed above the upper plate (34) in sequence along the first direction. A baffle (36) is provided between the upper plate (34) and the lower plate (35) to prevent airflow from flowing back from the second group of electrical components to the first group of electrical components from between the upper plate (34) and the lower plate (35).

6. The active filter device (100) according to claim 2, characterized in that, Downstream of the third group of electrical components, there is also an independent control module (5) and a busbar module (6). The control module (5) is used to control the operation of the active filter device (100), and the busbar module (6) is used to connect to an external power supply.

7. The active filter device (100) according to claim 6, characterized in that, The capacitor module (2), the power module (3), the inductor module (4), the control module (5), and the busbar module (6) are each provided with a connection part (81) and are electrically connected to each other through the direct connection of the connection parts (81).

8. The active filter device (100) according to claim 1, characterized in that, The active filter device includes a fuse (7), which is disposed outside the housing (1) of the active filter device.

9. The active filter device (100) according to claim 8, characterized in that, The fuse (7) includes a first terminal (71) electrically connected to a terminal (82) on an active filter (100) and a second terminal (72) electrically connected to an external power source. The outer surface of the housing (1) is provided with wiring terminals and insulating pads protruding from the housing (1). The first terminal (71) is electrically connected to the wiring terminal by a screw, and the second terminal (72) is fixed to the insulating pad by a screw to separate the second terminal from the housing (1).

10. The active filter device (100) according to claim 9, characterized in that, The active filter also includes a protective cover (84), which is installed on the housing (1) and covers the fuse (7).

Images