A multi-modular combined high-power dc load and resistance module

Abstract

The multi-module combined high-power DC load and resistance module comprises a cabinet box, a control panel, a DC load and a cooling system; the DC load is installed on a support frame of the cabinet box; the DC load is composed of multiple resistance modules; the multiple resistance modules are combined in parallel; each path is arranged by multiple resistance modules in series; a multi-path series-parallel high-power DC load combination is formed; and the multiple resistance modules are vertically layered and installed on the support frame of the cabinet box according to the heat generation; the multi-position load power of the whole high-power DC load is determined by selective connection of the resistance modules in each path; and multi-position adjustment of the high-power load is realized.

Description

Technical Field

[0001] This utility model relates to the structure of a DC load, and more particularly to a high-power DC load with multiple modular combinations and its resistor module structure, belonging to the field of DC load technology. Background Technology

[0002] High-power DC loads refer to DC load devices with a power rating of 1000W or higher, primarily used for testing and simulating high-performance power supplies. High-power DC loads are mainly used for testing in high-power applications, such as testing high-power motors in industrial production and verifying the performance of battery chargers. They can simulate high-power load conditions, ensuring the stability and safety of equipment under high loads.

[0003] The application principle of high-power DC loads is based on the resistor principle. By adding an adjustable resistive load to the circuit, actual load conditions are simulated to perform load tests on the power supply or battery under test.

[0004] The power of existing high-power DC loads is getting larger and larger, but high-power DC loads will generate a lot of heat during operation, causing the resistor to heat up; therefore, heat dissipation is required for high-power DC loads during operation.

[0005] Currently, high-power DC loads are cooled using centralized cooling, where all DC power loads are cooled by a single heatsink. However, in practical applications, this method has been found to have uneven heat dissipation, leading to localized overheating. This is especially true with the introduction of distributed DC loads; if the traditional centralized cooling method is still used, localized burn-out is likely to occur. Therefore, it is necessary to improve this approach.

[0006] The search revealed no identical technical reports, only technical literature in related fields. The most similar articles are as follows: 1. Patent document CN109100661A discloses a high-power DC electronic load, comprising: multiple independent power units electrically connected in parallel, each independent power unit consisting of a main control module and a power module connected together; the main control modules of each independent power unit are connected via a data bus; and the control terminals of the power modules of each independent power unit are electrically connected to a shared control bus. While this electronic load allows multiple independent power units to be connected in parallel to form a high-power electronic load, or to be used independently according to power requirements, thus enabling free combination to form various forms of electronic loads, there is still no good solution for heat dissipation and cooling of the load; therefore, the aforementioned problems persist.

[0007] 2. Patent document CN221946080U discloses a molten salt-cooled high-power energy storage test load, including several energy-consuming resistor devices for load testing of the device under test. Each energy-consuming resistor device includes a resistor tank and several resistor components fixedly installed within the resistor tank. The resistor components are connected to the output terminal of the device under test. One end of the resistor tank is connected to a cold salt tank for storing solid molten salt, and the other end is connected to a hot salt tank for storing liquid molten salt. A power generation and energy storage device for converting heat energy into electrical energy is installed on the hot salt tank. Although this resistive load uses liquid molten salt for heat dissipation, which has excellent heat dissipation properties, it still employs a centralized heat dissipation solution, thus the aforementioned problems persist.

[0008] 3. Patent document CN107800306A discloses a high-power AC / DC drive rectifier cabinet based on heat pipe cooling technology, including a cabinet body, heat pipe power modules, support plates, AC and DC busbars, support frames, cooling fans, insulating partitions, shunts, AC busbar fixing frames, current transformers, fast fuses, resistors, capacitors, capacitor insulation boards, and resistor insulation boards. Support beams are installed on both sides of the cabinet body for support and fixation. The cabinet body is divided into front and rear sections: the front section is the rectifier module working area, the upper rear section is the fan exhaust cooling area, and the lower rear section is the AC and DC busbar area. This patent adopts a distributed module design, with each module using heat pipes for heat dissipation. However, this heat dissipation method presents problems for truly high-power applications, especially since the heat dissipation of the heat pipes often suffers from unevenness, thus the aforementioned problems remain unresolved.

[0009] Analysis of existing patented technologies reveals that heat dissipation and cooling remain pressing issues for ultra-high power DC loads; therefore, further research and improvement are needed. Utility Model Content

[0010] The technical problem to be solved by this utility model is: how to effectively combine modules and cool down the load in a high-power DC load, so as to effectively prevent the load from being burned out by local heat.

[0011] To address the above problems, the technical solution proposed by this utility model is as follows: A multi-modular high-power DC load includes a cabinet-type enclosure, a control panel, a DC load, and a cooling system. The DC load is mounted on a support frame of the cabinet-type enclosure. The DC load is characterized by being composed of multiple resistor modules connected in parallel in multiple circuits. Each circuit is further composed of multiple resistor modules connected in series, forming a multi-circuit series-parallel high-power DC load combination. Furthermore, the resistor modules are vertically layered on the support frame of the cabinet-type enclosure according to their heat generation capacity, and the overall high-power DC load's multi-level power output is determined by selectively connecting the resistor modules in each circuit, thus enabling multi-level adjustment of the high-power load.

[0012] Furthermore, the multiple resistor modules are divided into multiple single-channel DC loads, and each single-channel DC load is composed of multiple resistor modules to form multiple speed ranges.

[0013] Furthermore, the multiple speed settings are any speed settings between 10kW and 1000kW, with the smallest speed setting being 10kW and the smallest adjustment step being 10kW.

[0014] The resistor module is a module assembly composed of multiple long strip-shaped resistors. The multiple long strip-shaped resistors are arranged in an orderly manner inside a module box, and both ends of each long strip-shaped resistor extend out of the module box. They are connected in series and parallel to the contactor assembly and negative busbar of the control panel through connecting copper busbars and cables for each range.

[0015] Furthermore, the module housing contains cooling water, and the elongated resistor is installed in the cooling sleeve inside the module housing by locking nuts and sealing rings, so that the elongated resistor is isolated from the cooling water inside the module housing, and the cooling water dissipates heat from the outer sleeve of the elongated resistor, thus forming a water-cooled resistor module.

[0016] The module housing has a cooling water inlet and an outlet on one side. Cooling water enters from the inlet and flows out from the outlet.

[0017] Furthermore, the module housing is a rectangular housing that matches the elongated resistor. The inlet and outlet are both located on one side of the parallel side along the length of the elongated resistor, and the inlet and outlet are respectively located at both ends of the same side.

[0018] Furthermore, the water inlet and outlet of the module housing are connected vertically via cooling water pipes, and the water inlet of the upper module housing is connected to the water outlet of the lower module housing, forming a multi-layer module housing with cooling water connected from bottom to top.

[0019] Furthermore, the multiple resistor modules are vertically layered on the support frame of the cabinet-type enclosure according to their heat generation, with the resistor module generating the most heat at the bottom and the subsequent resistor modules arranged upwards in descending order of heat generation, with the resistor module generating the least heat at the top. Cooling water first enters the module enclosure of the bottom resistor module through its inlet, then flows out from its outlet and into the inlet of the module enclosure above it, until it reaches the inlet of the top module enclosure. The outlet pipe of the top resistor module enclosure is connected to the water tank of the circulating water cooling system, forming a circulating water cooling system.

[0020] Furthermore, the cooling water is connected to the cooling water pipe from the inlet via a flange.

[0021] Furthermore, the bottommost cooling water pipe and the topmost outlet pipe are each connected to a cooling water circulation system; the cooling water circulation system is located in a cooling water circulation tank next to the cabinet-type enclosure.

[0022] Beneficial effects: This utility model adopts a modular combination to form a DC load, and each resistor module is cooled through an independent module box. This not only allows for arbitrary module combination to realize multi-level load application, but also effectively combines electronic module cooling and heat dissipation, avoiding uneven heat dissipation of electronic modules. Attached Figure Description

[0023] Figure 1 This is a three-dimensional schematic diagram of the present invention; Figure 2 This is a front view of the present invention; Figure 3 This is a top view of the present invention; Figure 4 This is a schematic diagram of the resistor module of this utility model; Figure 5 This is a schematic diagram of the resistor module assembly structure of this utility model; Figure 6 This is a partial structural schematic diagram of the resistor module of this utility model; Figure 7 This is a cross-sectional view of the internal structure of the resistor module of this utility model.

[0024] In the diagram: 1. Cabinet-type enclosure; 2. Control panel; 3. DC load; 4. Cooling system; 5. Support frame; 6. Resistor module; 7. Long strip resistor; 8. Module enclosure; 801. Upper module enclosure; 802. Lower module enclosure; 9. Cable or busbar; 10. Resistor outer casing; 11. Water inlet; 12. Water outlet; 13. Guide plate; 14. Cooling water pipe; 15. Flange; 16. Connecting busbar; 17. Cooling cavity; 18. Guide hole. Detailed Implementation

[0025] The present invention will be further described below with reference to the accompanying drawings: like Figure 1 , 2 As shown in Figure 3, a multi-modal high-power DC load includes a cabinet-type enclosure 1, a control panel 2, a DC load 3, and a cooling system 4. The DC load 3 is mounted on a support frame 5 of the cabinet-type enclosure 1. The DC load 3 is composed of multiple resistor modules 6, which are connected in parallel in multiple circuits. Each circuit is further composed of multiple resistor modules 6 arranged in series to form a multi-circuit series-parallel high-power DC load combination. The multiple resistor modules 6 are vertically layered on the support frame 5 of the cabinet-type enclosure according to their heat generation, with the resistor module 6 generating the most heat at the bottom and the resistor module 6 generating the least heat at the top. By selectively connecting the resistor modules 6 in each circuit, the overall high-power DC load power is determined at multiple levels, thus achieving multi-level adjustment of the high-power load.

[0026] Furthermore, the multiple resistor modules 3 are divided into multiple single-channel DC loads, and each load is composed of multiple resistor modules 3 connected in series, forming multiple speed ranges through arbitrary combinations of resistor modules 3.

[0027] Furthermore, the multiple speed ranges are any speed range between 10kW and 1000kW, with the minimum speed range being 10kW and the minimum adjustment step being 10kW. Preferably, the total load design capacity is 3MW, DC900V voltage, and it is divided into 3 independent 1MW loads. The 3 loads can work independently or in combination.

[0028] As attached Figure 4 , 5 As shown in Figures 6 and 7, the resistor module 6 is a module assembly composed of multiple long strip resistors 7. The multiple long strip resistors 7 are arranged in an orderly manner inside a module housing 8, and the wires at both ends of each long strip resistor 7 extend out of the module housing 8. The long strip resistors 7 are electrically connected to each other through a connecting busbar 16, and then connected to the control device of the control panel through wires or busbars 9.

[0029] Furthermore, the module housing 8 contains cooling water, and the elongated resistor 7 is wrapped in a sealed outer jacket 10, which is inserted into the module housing 8, thus isolating the elongated resistor 7 from the cooling water inside the module housing 8. The cooling water dissipates heat from the outer jacket 10 of the elongated resistor 7, forming a water-cooled resistor module. Each resistor module 6 has its elongated resistor 7 sealed and placed inside the resistor outer sleeve 10 of the module housing 8. A water-cooled cavity 17 is located between the resistor outer sleeve 10 and the inner wall of the module housing 8. Cooling water flows within the water-cooled cavity 17, carrying away the heat from the elongated resistor 7 inside the resistor outer sleeve 10. Furthermore, guide plates 18 are evenly distributed within the water-cooled cavity 17, with turbulence holes 19 on them. The guide plates 18 further divide each module housing 8's water-cooled cavity 17 into multiple compartments, and the cooling water flows turbulently within the water-cooled cavity 17 through the turbulence holes 19, exiting from the inlet 11 to the outlet 12. Preferably, the guide plates 19 are perforated plates with evenly distributed holes, which further enhances the turbulence effect of the cooling water flow.

[0030] The module housing 8 is provided with cooling water inlets 11 and 12 on one side. Cooling water enters from the inlet 11 of each module housing 8 and flows out from the outlet 12.

[0031] Furthermore, the module housing 8 is a rectangular housing that matches the elongated resistor. The water inlet 11 and the water outlet 12 of the module housing 8 are both located on one side of the parallel side of the elongated resistor 7 along its length, and the water inlet 11 and the water outlet 12 are respectively located at both ends of the same side, forming a structure where water enters from one end and exits from the other end. A guide plate 13 is provided inside the module housing 8 to ensure that the incoming cooling water flows in a predetermined order, ensuring that the elongated resistor 7 inside the module housing 8 receives uniform heat dissipation.

[0032] Furthermore, the water inlet 11 and water outlet 12 of the module box 8 are connected vertically via 14, and the water inlet of the upper module box 801 of the upper layer is connected to the water outlet of the lower module box 802 of the lower layer, forming a multi-layer module box 8 with cooling water connected from bottom to top.

[0033] Furthermore, the multiple resistor modules 6 are vertically layered on the support frame 5 of the cabinet-type housing 1 according to their heat generation, with the resistor module 8 having the highest heat generation placed at the bottom. The subsequent resistor modules 8 are arranged upwards in descending order of heat generation, with the resistor module 8 having the lowest heat generation placed at the top. Cooling water first enters the housing of the bottom resistor module through its inlet, then flows out from its outlet and into the inlet of the next module, until it reaches the inlet of the top module. The outlet pipe of the top resistor module is connected to the water tank of the circulating water cooling system, and the outlet of the circulating water cooling system is connected to the inlet of the bottom module, forming a circulating water cooling system.

[0034] Furthermore, the cooling water is connected from the inlet to the cooling water pipe via flange 15.

[0035] Furthermore, the bottommost cooling water pipe and the topmost outlet pipe are respectively connected to the outlet pipe of a cooling water circulation system and the inlet pipe of a water tank; the cooling water circulation system is located in a cooling water circulation tank next to the cabinet-type enclosure.

[0036] The beneficial technical effects of this utility model are as follows: By adopting a modular combination to construct the DC load, and cooling each resistor module through an independent module enclosure, this approach not only allows for arbitrary module combinations and multi-level load applications, but also effectively integrates electronic module cooling and heat dissipation, avoiding uneven heat dissipation. This offers several advantages: 1. This utility model adopts a modular combination to form a DC load, and each module is independently cooled, so that the heat dissipation of the entire load is distributed. Through reasonable module combination, it can effectively ensure uniform heat dissipation of all modules. 2. The module of this utility model is divided into 3 independent loads, which can work independently or in combination; each independent load has a power of 1MW, with eight levels: 10kW, 20kW, 20kW, 50kW, 100kW, 200kW, 200kW, and 400kW. By reasonably matching these levels, they can be combined to form any level between 10kW and 1000kW, with a minimum level of 10kW and a minimum adjustment step of 10kW; this can basically meet the needs of various DC loads. 3. The combined control mode of the resistor module of this utility model is divided into two control modes: local manual control and user remote control (providing communication interface and communication scheme). It can adapt to the needs of various places. In particular, the use of setting the input and output lines on the same side greatly facilitates the connection of manual control. This has the characteristics of simplicity and practicality for customers who do not frequently need to change DC loads. 4. This utility model modularizes the high-power DC load and then installs them into independent water-cooled boxes. All the independent water-cooled boxes are connected in series by cooling water pipes, so that the cooling water flows through each independent water-cooled box according to the determined rules. This can effectively control the cooling of each resistor module and achieve good cooling effect for various selection methods of high-power DC load. 5. According to the heat output of each module, they are arranged vertically from bottom to top on the support frame inside the overall resistor box cabinet. They are then connected in series from bottom to top through water inlet pipes. This allows the cooling water to flow through the module with the highest heat output first, and then through each subsequent resistor module in decreasing order. This effectively matches the heat output with the cooling capacity, ensuring that each resistor module receives good and uniform heat dissipation and effectively reducing the phenomenon of uneven local heat dissipation. 6. This utility model divides the overall load into multiple resistor modules, and arranges the independent cooling water tanks of each resistor module in layers from bottom to top on the independent cooling water tank rack of the overall load cabinet according to their heat generation. All the independent cooling water tanks are connected in series by cooling water pipes according to their heat generation. Then, the inlet and outlet of the series-connected independent cooling water tanks are connected to the outlet and return of the cooling water pump station of the circulating water cooling system, forming an overall series cooling loop. This cooling method can effectively match the cooling water flow to the different heat generation of each independent cooling tank, so that each resistor module can receive appropriate cooling and effectively balance the cooling needs of each module.

[0037] It should be noted that the above-listed embodiments are merely a clear and complete description of the technical solution of this utility model in conjunction with the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this utility model, not all of them. Furthermore, terms such as "upper," "lower," "front," "rear," and "middle" used in this specification are only for clarity of description and not intended to limit the scope of implementation of this utility model. Changes or adjustments to their relative relationships, without substantially altering the technical content, should also be considered within the scope of implementation of this utility model. Simultaneously, the structures, proportions, sizes, etc., depicted in the accompanying drawings are only used to complement the content disclosed in the specification for those skilled in the art to understand and read, and are not intended to limit the implementation conditions of this utility model. Therefore, they have no substantial technical significance. Any modifications to the structure, changes in proportions, or adjustments to the size, without affecting the effects and purposes achieved by this utility model, should still fall within the scope of the technical content disclosed in this utility model. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this utility model.

Claims

1. A high-power DC load with multiple modular components, comprising a cabinet-type enclosure, a control panel, a DC load, and a cooling system; the DC load is mounted on a support frame of the cabinet-type enclosure; characterized in that: The DC load is composed of multiple resistor modules, which are connected in parallel in multiple paths. Each path is composed of multiple resistor modules arranged in series, forming a multi-path series-parallel high-power DC load combination. The multiple resistor modules are vertically layered on the support frame of the cabinet according to their heat generation. By selectively connecting the resistor modules in each path, the overall high-power DC load power is determined at multiple levels, realizing the adjustment of the high-power load at multiple levels.

2. The high-power DC load with multi-modular combination according to claim 1, characterized in that: The multiple resistor modules are divided into multiple single-channel DC loads, and each single-channel DC load is further composed of multiple resistor modules to form multiple speed ranges.

3. The high-power DC load with multi-modular combination according to claim 1, characterized in that: The multiple speed settings are any speed settings between 10kW and 1000kW, with the smallest speed setting being 10kW and the smallest adjustment step being 10kW.

4. A resistor module for a high-power DC load with multiple modular combinations as described in claim 1, characterized in that: The resistor module is a module assembly composed of multiple long strip-shaped resistors. The multiple long strip-shaped resistors are arranged in an orderly manner inside a module box, and both ends of each long strip-shaped resistor extend out of the module box. They are connected in series and parallel to the contactor assembly and negative busbar of the control panel through connecting copper busbars and cables for each range.

5. The resistor module for a high-power DC load with multiple modular combinations according to claim 4, characterized in that: The module housing contains cooling water. The elongated resistor is installed inside the cooling sleeve within the module housing by locking nuts and sealing rings, thus isolating the elongated resistor from the cooling water inside the module housing. The cooling water dissipates heat from the outer sleeve of the elongated resistor, forming a water-cooled resistor module.

6. The resistor module for a high-power DC load with multiple modular combinations according to claim 4, characterized in that: The module housing has a cooling water inlet and an outlet on one side. Cooling water enters from the inlet and flows out from the outlet.

7. The resistor module for a high-power DC load with multiple modular combinations according to claim 6, characterized in that: The module housing is a rectangular housing that matches the elongated resistor. The inlet and outlet are both located on one side of the parallel side along the length of the elongated resistor, and the inlet and outlet are respectively located at both ends of the same side.

8. The resistor module for a high-power DC load with multiple modular combinations according to claim 6, characterized in that: The water inlet and outlet of the module box are connected by cooling water pipes, and the water inlet of the upper module box is connected to the water outlet of the lower module box, forming a multi-layer module box with cooling water connected from bottom to top.

9. The resistor module for a high-power DC load with multiple modular combinations according to claim 6, characterized in that: The multiple resistor modules are vertically layered on the support frame of the cabinet-type enclosure, arranged from bottom to top according to their heat generation. The resistor module with the highest heat generation is placed at the bottom, and the subsequent resistor modules are arranged upwards in descending order of heat generation, with the resistor module with the lowest heat generation at the top. Cooling water first enters the module enclosure of the bottom resistor module through its inlet, then flows out from its outlet and into the inlet of the module enclosure above it, until it reaches the inlet of the top module enclosure. The outlet pipe of the top resistor module enclosure is connected to the water tank of the circulating water cooling system, forming a circulating water cooling system.

10. The resistor module for a high-power DC load with multiple modular combinations according to claim 9, characterized in that: The cooling water is connected to the cooling water pipe through a flange from the inlet; the bottom cooling water pipe and the top outlet pipe are respectively connected to a cooling water circulation system; the cooling water circulation system is set in a cooling water circulation tank next to the cabinet body.

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