A mobile high-power light storage inverter integrated machine

Abstract

The application relates to the technical field of new energy storage equipment, and discloses a mobile high-power light storage inverter integrated machine which solves the problems of poor mobility, insufficient power and energy storage, poor heat dissipation and heat insulation and the like of existing equipment. The machine comprises a main body rack, a 12KW inverter, a square lithium iron phosphate battery PACK, a BMS protection plate and a mobile caster with a brake, the main body rack is a heat insulation structure with upper and lower compartments, the upper inverter compartment is provided with the inverter, and the lower energy storage compartment is provided with the battery PACK, the battery is fixed through a side beam pressing strip and is insulated through an epoxy plate. The rack is provided with multiple cover plates for sealing and protection, the left cover plate is integrated with a circuit breaker, a socket and the like, and the right cover plate is provided with wiring terminals and a BMS heat dissipation fan. The application has high integration, is flexible to move, can meet the high-power demand of families and small businesses, has long battery cycle life, is safe and protected in an all-round way, is convenient to operate and maintains, and realizes efficient collaborative power supply of commercial power, photovoltaic power and energy storage.

Description

Technical Field

[0001] This utility model provides an integrated photovoltaic-storage-inverter unit, and particularly relates to a mobile high-power integrated photovoltaic-storage-inverter unit. Background Technology

[0002] With the development of new energy technologies, photovoltaic-energy storage inverter equipment is being used more and more widely in industrial, commercial, and emergency fields. Currently, photovoltaic-energy storage equipment on the market generally suffers from the following technical defects: Poor mobility: Traditional photovoltaic storage equipment is mostly fixed installation and lacks convenient moving mechanisms, making it difficult to meet the needs of outdoor construction, temporary power supply and other scenarios. For example, when enterprises are working outdoors, they need to configure additional hoisting equipment, which results in high transportation costs and low efficiency.

[0003] Low integration: Inverters, battery packs, control systems and other components are scattered, requiring complex wiring and debugging on site, resulting in long installation cycles and high maintenance difficulty, which does not meet the needs of rapid deployment.

[0004] Insufficient heat dissipation: High-power equipment generates a lot of heat when running. Existing equipment mostly uses a single heat dissipation method, and there is a lack of effective heat insulation measures between the inverter compartment and the energy storage compartment, which can easily lead to excessive battery temperature difference (the temperature difference of some equipment can reach more than 15°C), affecting the battery cycle life (usually less than 4,000 cycles).

[0005] Safety needs improvement: the insulation between the battery pack and the rack is inadequate, and the high-voltage terminals lack protective structures, posing a risk of electric shock; at the same time, dust easily accumulates in the air inlet of the cooling fan, affecting heat dissipation efficiency and causing equipment failure.

[0006] Inconvenient operation and maintenance: key components are difficult to disassemble and assemble, troubleshooting requires professional personnel, and there is a lack of intuitive operation status display and parameter adjustment interface.

[0007] Therefore, developing a highly integrated, portable, efficient, safe, and reliable mobile high-power photovoltaic-storage-inverter is key to solving the aforementioned technical challenges. Utility Model Content

[0008] To address the shortcomings of existing technologies, the purpose of this utility model is to provide a mobile high-power photovoltaic-storage inverter integrated machine, achieving the following technical objectives: ① improving the mobility of the equipment; ② increasing the integration of components and simplifying the installation and commissioning process; ③ optimizing heat dissipation and insulation design to extend battery life; ④ enhancing electrical safety protection; and ⑤ reducing the difficulty of operation and maintenance.

[0009] To solve the above-mentioned technical problems, this utility model provides the following technical solution: a mobile high-power photovoltaic-storage inverter integrated machine, including a main frame, a 12KW inverter, a battery pack, a BMS protection board and mobile casters; The main frame is a split-compartment heat-insulated structure, with the upper part forming an inverter compartment and the lower part forming an energy storage compartment; the 12KW inverter is installed in the inverter compartment of the main frame to realize the AC-DC conversion between mains power, photovoltaic power and battery; The battery pack is a square lithium iron phosphate battery pack, which is installed in the energy storage compartment of the main frame for storing electrical energy. The BMS protection board is fixed inside the inverter compartment of the main frame and is electrically connected to the 12KW inverter and battery pack respectively, and is used to control the charging and discharging circuit and realize the protection function; the casters are installed at the bottom of the main frame. The main frame is also provided with a top cover, a bottom cover, a rear cover, a left cover, and a right cover. The top cover is detachably attached to the top of the inverter compartment, the bottom cover is fixed to the bottom of the energy storage compartment, the rear cover fits against the rear of the main frame and covers the rear ends of the inverter compartment and the energy storage compartment, the left cover is fixed to the left side of the main frame and is set corresponding to the left end of the inverter compartment and the energy storage compartment, and the right cover is fixed to the right side of the main frame and is set corresponding to the right end of the inverter compartment and the energy storage compartment. An AC circuit breaker and a mechanical push-button switch are installed on the left cover plate. The mechanical push-button switch is electrically connected to the battery pack and the 12KW inverter respectively. One end of the AC circuit breaker is electrically connected to the 12KW inverter, and the other end is used to connect the mains input and the load output. The right cover plate is equipped with an AC terminal block and a PV input terminal block. The AC terminal block is electrically connected to the AC circuit breaker, and the PV input terminal block is electrically connected to the BMS protection board.

[0010] Preferably, a heat insulation layer is provided between the inverter compartment and the energy storage compartment of the main frame; an inverter base is also fixed inside the inverter compartment, the inverter base is set to fit against the bottom of the inverter compartment of the main frame, and the 12KW inverter is fixedly installed on the inverter base.

[0011] Preferably, a side beam strip is fixed on the inner wall of the energy storage compartment of the main frame, the side beam strip is set along the outer periphery of the battery PACK and abuts against the side of the battery PACK; an epoxy board is provided between the battery PACK and the inner wall of the energy storage compartment of the main frame, the epoxy board completely covers the outer surface of the battery PACK and is insulated from the battery PACK and the main frame respectively.

[0012] Preferably, a BMS cooling fan is installed on the inner side of the right cover plate of the main frame, corresponding to the position of the BMS protection board. The BMS cooling fan is electrically connected to the BMS protection board, with its air inlet facing the BMS protection board and its air outlet passing through the right cover plate and facing outward. A right filter cover is detachably installed on the right cover plate at the position corresponding to the air inlet of the BMS cooling fan.

[0013] Preferably, the movable casters are swivel casters with braking mechanisms, and there are 4 of them, which are symmetrically fixed at the four corners of the bottom of the main frame.

[0014] Preferably, a long light strip is fixed to the inner surface of the lower cover plate, and the long light strip is electrically connected to the BMS protection board; an inverter screen button assembly is installed on the front of the 12KW inverter, and the inverter screen button assembly is electrically connected to the 12KW inverter for displaying the device's operating status and adjusting parameters.

[0015] Preferably, a universal AC output socket is also installed on the left cover plate, which is electrically connected to the AC circuit breaker; the AC wiring terminals and PV input terminals on the right cover plate are covered with right end caps, and wiring markings are printed on the right end caps.

[0016] Preferably, a decorative cover is also installed on the main frame. The decorative cover is located between the upper cover and the lower cover plate and is fixedly connected to the edge of the upper cover and the edge of the lower cover plate, respectively.

[0017] One or more technical solutions provided in this application embodiment have at least the following technical effects or advantages compared with the prior art: A. Improved mobility: The equipment features braked swivel casters, allowing a single person to move it, increasing transport efficiency by over 60% and meeting the flexible deployment needs of various outdoor scenarios.

[0018] B. High integration: The inverter, energy storage, control and protection systems are integrated into one design, eliminating the need for complex wiring on site. It can be used immediately after opening the box, and the installation time is reduced to 1 / 5 of that of traditional equipment.

[0019] C. Optimized heat dissipation and insulation: The compartmentalized heat insulation structure, combined with the BMS cooling fan, keeps the battery temperature difference within 5°C, and the system cycle life can reach more than 6,000 cycles (70% SOH), increasing the service life by 20%; the right filter cover design facilitates dust cleaning and ensures continuous and efficient heat dissipation.

[0020] D. Comprehensive safety protection: epoxy board insulation, terminal right end cover protection, and BMS multiple protection triple protection reduce the risk of electric shock by 90%; the fully enclosed cover design achieves a dustproof and waterproof rating of IP54.

[0021] E. Reduced maintenance costs: Modular disassembly and assembly design reduces component replacement time by 50%, and the screen display and button components enable visualized maintenance, reducing reliance on professional personnel.

[0022] Other advantages, objectives and features of this invention will be set forth in part in the description which follows, and in part will be apparent to those skilled in the art from the following examination or study, or may be taught from the practice of this invention. Attached Figure Description

[0023] Figure 1 This is an exploded view of the overall structure of a mobile high-power photovoltaic-storage-inverter integrated machine according to this utility model; Figure 2 This is a schematic diagram of the main frame compartment structure of a mobile high-power photovoltaic-storage-inverter integrated machine according to the present invention. Figure 3 This is a layout diagram of the left cover plate assembly of a mobile high-power photovoltaic-storage-inverter integrated machine according to this utility model.

[0024] As shown in the figure: 1. 12kW inverter; 2. Top cover; 3. Decorative cover; 4. BMS cooling fan; 5. Battery pack; 6. Side beam trim; 7. Epoxy board; 8. Long strip light; 9. Bottom cover; 10. Rear cover; 11. Casters; 12. AC / DC circuit breaker; 13. Universal AC output socket; 14. Mechanical push-button switch; 15. AC terminal block; 16. PV input terminal block; 17. Inverter base; 18. Inverter display button assembly; 19. Right end cover of terminal block; 20. Right filter cover; 21. Main unit frame; 22. BMS protection board; 23. Right cover; 24. Left cover. Detailed Implementation

[0025] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0026] It should be noted that the terms "vertical," "horizontal," "up," "down," "left," "right," and similar expressions used in this article are for illustrative purposes only and do not represent the only possible implementation.

[0027] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains; the terminology used herein in the description of this invention is for the purpose of describing particular embodiments only and is not intended to limit the invention; the term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0028] like Figure 1 and Figure 2 As shown, the main frame 21 is welded from Q235 steel plate with a thickness of 3mm. A 5mm thick aluminum silicate insulation cotton is laid between the inverter compartment and the energy storage compartment. The inverter base 17 is made of aluminum alloy and is fixed to the bottom of the inverter compartment with four M8 bolts. The 12KW inverter 1 is connected to the base with a positioning pin to ensure installation accuracy. The battery PACK5 uses 3.2V / 200Ah lithium iron phosphate battery cells, which are arranged in a 16-series 8-parallel configuration to form a 51.2V / 1600Ah battery pack. It is clamped and fixed to the inner wall of the energy storage compartment by the side beam pressure strip 6 (stainless steel material, cross-sectional size 20×10mm). The outside of the battery pack is wrapped with a 0.2mm thick epoxy board 7 to achieve an insulation strength of ≥1000V. MS protection board 22, model JK-BMS-51.2V160A, is connected to the inverter's DC input terminal and the positive and negative terminals of the battery pack via wires. The control wiring harness uses shielded wires to reduce interference. AC circuit breaker 12 is model DZ47-63 with a rated current of 63A. One end is connected to the inverter's AC output terminal via a copper busbar, and the other end is connected to universal AC output socket 13 (10A / 250V) and AC terminal block 15 (TC-603 type). PV input terminal 16 uses an MC4 interface and is connected to the BMS photovoltaic charging terminal via a photovoltaic cable, supporting a maximum DC input of 1500V.

[0029] like Figure 2 and Figure 3 As shown, the MS cooling fan 4 is a 12V / 0.5A axial fan with an airflow of ≥80CFM. A louver is opened on the right cover plate 23 at the air outlet, and a removable nylon filter cover 20 is installed at the air inlet. The long light strip 8 is a 12V / 24W LED flexible light strip, arranged along the inner edge of the lower cover plate 9, and controlled by a rocker switch. The inverter screen display button assembly 18 adopts a 7-inch touch screen, which supports the display of parameters such as voltage, current, and SOC, and has functions such as charging and discharging current adjustment and operating mode switching. The casters 11 are 4-inch polyurethane universal wheels with a load capacity of ≥500kg / each, and are equipped with a foot-operated braking mechanism.

[0030] All covers are made of cold-rolled steel plate with powder coating. The top cover 2 is connected to the frame by 6 clips for easy and quick disassembly. The rear cover 10 has heat dissipation holes with a spacing of 30mm and a diameter of 5mm, and is covered with a dustproof mesh. The right end cover 19 of the terminal is made of ABS plastic injection molding, with AC / PV wiring markings silk-screened on the inside, and is fixed to the right cover 23 by 2 self-tapping screws. The decorative cover 3 is made of PVC and is bonded to the edges of the upper and lower cover plates with double-sided adhesive to improve the overall appearance of the equipment.

[0031] Under ambient temperature of 25℃, after 2 hours of full-load operation, the inverter chamber temperature is ≤45℃, the energy storage chamber temperature is ≤35℃, and the temperature difference between individual battery cells is ≤3℃. During the movement test, the resistance to pushing the equipment on a cement floor is ≤50N, and there is no sliding displacement after the braking mechanism is locked. During the insulation test, the insulation resistance between the frame and the battery pack is ≥500MΩ. After 100 consecutive charge-discharge cycles, the battery capacity retention rate is ≥98%.

[0032] In actual use, this device requires the use of a photovoltaic array as the photovoltaic energy input source. A standard AC power plug is used to connect to the AC terminal block for mains power access. A photovoltaic cable with an MC4 connector is used to reliably connect the PV input terminal to the photovoltaic array output terminal. A remote monitoring module is configured and connected to the BMS protection board via an RS485 communication interface to achieve remote data acquisition and management of equipment operation. An Allen wrench is used to disassemble and assemble the bolts securing each cover plate. Insulating tape is used to insulate temporarily exposed wire joints. Thermally conductive silicone pads are filled between the inverter and the inverter base to enhance heat dissipation. Waterproof sealing rings are used to strengthen the sealing performance at the joints between each cover plate and the main frame. Nylon cable ties are used to secure the internal components of the equipment. The wiring harness is neatly fixed, and the voltage and current parameters of each electrical node are checked regularly using a multimeter. The main frame is made of Q235 cold-rolled steel plate with electrostatic powder coating and epoxy resin powder coating to improve corrosion resistance. The copper core wires connecting each electrical component are RVV multi-strand flexible wires with a cross-sectional area of ​​not less than 4 square millimeters. The insulating sleeve wrapped around the control wiring harness is made of high-temperature resistant polytetrafluoroethylene. The buffer pads at the contact points between the battery PACK and the side beam pressure strip are made of EVA foam. The filter screen of the right filter cover is made of polyester fiber and is cleaned regularly with compressed air to ensure unobstructed heat dissipation. During equipment movement, steering and displacement can be achieved by using a traction rod and casters. During daily maintenance, a brush is used to clean the dust and impurities inside the inverter compartment and energy storage compartment.

[0033] Specifically, during the installation and deployment phase of this device, expansion bolts are used to secure the main frame to the ground foundation in the fixed usage environment. Before connecting the wires, a wire lug crimping tool is used to crimp the ends of the copper core wires, and an insulation tester is used to pre-test the circuit insulation performance. When connecting the photovoltaic array, the output terminals of multiple photovoltaic modules are aggregated through a photovoltaic combiner box before being connected to the PV input terminal. Before connecting to the mains power, a leakage current protection switch must be installed as upstream protection. During use, the load device is connected to a universal AC output socket via an industrial plug, and the data collected by the BMS protection board is uploaded to the cloud monitoring platform using a GPRS wireless communication module. To enable remote operation and maintenance, during routine maintenance, a compressed air spray gun is used to clean the dust from the right filter cover and the dustproof screen of the rear cover. When replacing the battery pack, a Phillips screwdriver set is used to remove the fixing screws of the side beam pressure strip. The battery pack is regularly balanced using a battery equalizer to ensure the consistency of individual cell voltages. Before the equipment is idle for a long time, the main power supply and the mains power and photovoltaic input must be turned off by mechanical button switch. Before restarting, the current of each circuit must be checked with a clamp meter to ensure that it is normal. When used in a humid environment, a rubber insulating mat should be laid at the bottom of the main frame to enhance insulation protection. Insulating gloves must be worn and an insulating wrench must be used throughout the wiring operation to prevent the risk of electric shock.

[0034] Although the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art can make various modifications and alterations without departing from the spirit and scope of the present invention. Therefore, the scope of protection of the present invention should be determined by the claims.

Claims

1. A mobile high-power photovoltaic-storage-inverter integrated machine, characterized in that: Includes main frame (21), 12KW inverter (1), battery PACK (5), BMS protection board (22) and casters (11); The main frame (21) is a split-compartment heat insulation structure, with the upper part forming an inverter compartment and the lower part forming an energy storage compartment; the 12KW inverter (1) is installed in the inverter compartment of the main frame (21) to realize the AC / DC conversion between mains power, photovoltaic and battery; The battery PACK (5) is a square lithium iron phosphate battery PACK, which is installed in the energy storage compartment of the main frame (21) for storing electrical energy; The BMS protection board (22) is fixed in the inverter compartment of the main frame (21) and is electrically connected to the 12KW inverter (1) and the battery PACK (5) respectively, for controlling the charging and discharging circuit and realizing the protection function; the movable casters (11) are installed at the bottom of the main frame (21); The main frame (21) is also provided with an upper cover (2), a lower cover (9), a rear cover (10), a left cover (24) and a right cover (23). The upper cover (2) is detachably covered on the top of the inverter compartment, the lower cover (9) is fixed to the bottom of the energy storage compartment, the rear cover (10) fits against the rear of the main frame (21) and covers the rear ends of the inverter compartment and the energy storage compartment, the left cover (24) is fixed on the left side of the main frame (21) and is set at the left end of the inverter compartment and the energy storage compartment, and the right cover (23) is fixed on the right side of the main frame (21) and is set at the right end of the inverter compartment and the energy storage compartment. An AC circuit breaker (12) and a mechanical push-button switch (14) are installed on the left cover plate (24). The mechanical push-button switch (14) is electrically connected to the battery PACK (5) and the 12KW inverter (1) respectively. One end of the AC circuit breaker (12) is electrically connected to the 12KW inverter (1), and the other end is used to connect the mains input and the load output. The right cover plate (23) is equipped with an AC terminal (15) and a PV input terminal (16). The AC terminal (15) is electrically connected to the AC circuit breaker (12), and the PV input terminal (16) is electrically connected to the BMS protection board (22).

2. The mobile high-power photovoltaic-storage-inverter integrated machine according to claim 1, characterized in that: A heat insulation layer is provided between the inverter compartment and the energy storage compartment of the main frame (21); an inverter base (17) is also fixed inside the inverter compartment. The inverter base (17) is set in close contact with the bottom of the inverter compartment of the main frame (21), and the 12KW inverter (1) is fixedly installed on the inverter base (17).

3. The mobile high-power photovoltaic-storage-inverter integrated machine according to claim 1, characterized in that: A side beam strip (6) is fixed on the inner wall of the energy storage compartment of the main frame (21). The side beam strip (6) is set along the outer periphery of the battery PACK (5) and abuts against the side of the battery PACK (5). An epoxy board (7) is provided between the battery PACK (5) and the inner wall of the energy storage compartment of the main frame (21). The epoxy board (7) completely covers the outer surface of the battery PACK (5) and is insulated from the battery PACK (5) and the main frame (21) respectively.

4. The mobile high-power photovoltaic-storage-inverter integrated machine according to claim 1, characterized in that: A BMS cooling fan (4) is installed on the inner side of the right cover plate (23) of the main frame (21) at the position corresponding to the BMS protection plate (22). The BMS cooling fan (4) is electrically connected to the BMS protection plate (22), with its air inlet facing the BMS protection plate (22) and its air outlet passing through the right cover plate (23) and facing outward. A right filter cover (20) is detachably installed on the right cover plate (23) at the position corresponding to the air inlet of the BMS cooling fan (4).

5. The mobile high-power photovoltaic-storage-inverter integrated machine according to claim 1, characterized in that: The movable casters (11) are omnidirectional casters with braking mechanisms, and there are 4 of them, which are symmetrically fixed at the four corners of the bottom of the main frame (21).

6. The mobile high-power photovoltaic-storage-inverter integrated machine according to claim 1, characterized in that: A long light strip (8) is fixed on the inner surface of the lower cover plate (9), and the long light strip (8) is electrically connected to the BMS protection board (22); an inverter screen button assembly (18) is installed on the front of the 12KW inverter (1), and the inverter screen button assembly (18) is electrically connected to the 12KW inverter (1) for displaying the device's operating status and adjustment parameters.

7. The mobile high-power photovoltaic-storage-inverter integrated machine according to claim 1, characterized in that: The left cover plate (24) is also equipped with a universal AC output socket (13), which is electrically connected to the AC circuit breaker (12); the AC wiring terminal (15) and PV input terminal (16) on the right cover plate (23) are covered with a terminal right end cover (19), and the terminal right end cover (19) is silkscreened with wiring markings.

8. The mobile high-power photovoltaic-storage-inverter integrated machine according to claim 1, characterized in that: A decorative cover (3) is also installed on the main frame (21). The decorative cover (3) is located between the upper cover (2) and the lower cover (9) and is fixedly connected to the edge of the upper cover (2) and the edge of the lower cover (9) respectively.

Images