Power conversion system, energy storage system and electrical device

Abstract

Power conversion system (PCS) applied to an energy storage system, wherein a housing (101) of the PCS is provided with an output compartment and a power conversion control compartment; wherein the output compartment has multiple output connection terminals arranged on a front panel of the housing (101), and the power conversion control compartment includes a destination printed circuit board (PCB) (107) and a power board (102), multiple inductors (106) and an AC output board (104), each connected to the destination printed circuit board (107).

Description

TECHNICAL AREA

[0001] The present application relates to the field of energy storage technologies and in particular to a power conversion system (PCS), an energy storage system and an electrical device. GENERAL STATE OF THE ART

[0002] A PCS uses a bidirectional DC / AC converter to achieve bidirectional conversion between DC battery power and mains AC power, and is designed to support switching between grid-connected and off-grid operation, thereby meeting various requirements such as grid frequency regulation, voltage regulation, and power distribution.

[0003] According to the current state of the art, the PCS is consequently very small due to the limited size of an energy storage system and the fact that cells occupy most of the space within the energy storage system. Furthermore, a copper busbar in the PCS occupies a significant amount of space, leading to difficulties in arranging other functional boards within the PCS. SUMMARY

[0004] Accordingly, a PCS, an energy storage system and an electrical device are provided.

[0005] Following a first aspect, a PCS (Power Supply Unit) for use in an energy storage system is provided. The PCS enclosure includes an output compartment and a power conversion control compartment. The output compartment has several output connection terminals located on the front panel of the enclosure. The power conversion control compartment contains a destination circuit board and a power board, several inductors, and an AC output board, each connected to the destination circuit board.

[0006] In some embodiments, the target circuit board is located above the multiple inductors and is electrically connected to all of the multiple inductors; and the AC output circuit board is located above the target circuit board and is electrically connected to the target circuit board by multiple copper columns.

[0007] In some embodiments, the output compartment has an upper compartment and a lower compartment, wherein the upper compartment of the output compartment contains several high-voltage output devices and the lower compartment of the output compartment is connected to a lower compartment of the power conversion control compartment; several first ventilation openings are provided in the front panel of the housing at positions corresponding to the lower compartment of the output compartment; and several second ventilation openings are provided in a rear panel of the housing at positions corresponding to the lower compartment of the power conversion control compartment; wherein the first multiple ventilation openings and the multiple second ventilation openings are arranged to dissipate heat from the lower compartment of the output compartment and the lower compartment of the power conversion control compartment; wherein the multiple inductors are located inside the lower compartment of the power conversion control compartment.

[0008] In some embodiments, the lower compartment of the output compartment and the lower compartment of the power conversion control compartment, which are interconnected, form an outside air duct, and a first cooling fan group is arranged in the lower compartment of the output compartment.

[0009] In some embodiments, a heat sink is further arranged in the lower space of the power conversion control compartment, with the power board being located above the heat sink and electrically connected to the target circuit board.

[0010] In some embodiments, the PCS further comprises several current-sensing Hall sensors located on the AC output board, wherein the power board is electrically connected to the several current-sensing Hall sensors, and the current-sensing Hall sensors are electrically connected to several DC output terminals of the target circuit board.

[0011] In some embodiments, the PCS further comprises a control board, wherein the control board is located in the current conversion control compartment; and the multiple current-sensing Hall sensors are each electrically connected to the control board and transmit multiple detected current data elements to the control board, and the control board is configured to protect the PCS according to the multiple current data elements.

[0012] In some embodiments, the control board is configured to perform the following steps: calculating a chopped wave power output from the power board according to the current data detected by the current-sensing Hall sensors; and determining, according to the chopped wave power output from the power board, whether there is an anomaly in a group of insulated-gate bipolar transistors (an IGBT group) corresponding to the current-sensing Hall sensors.

[0013] In some embodiments, the target circuit board has multiple inductor connection points; wherein the multiple inductor connection points are each electrically connected to the corresponding inductors.

[0014] In some embodiments, the target circuit board further has multiple input connection points; wherein the multiple input connection points are each connected to an output connection point of the power board and are further connected to the corresponding inductor connection point by a printed circuit on the target circuit board.

[0015] In some embodiments, the target circuit board further has multiple output connection points; wherein the multiple output connection points are each connected to an input connection point of the AC output board and are further connected by a printed circuit on the target circuit board to the corresponding inductor connection point.

[0016] In some embodiments, the PCS further comprises a second cooling fan assembly, wherein the second cooling fan assembly is located on the rear panel and at a position corresponding to an upper compartment of the power conversion control compartment; wherein several third ventilation openings are provided in the front panel and at positions corresponding to the upper compartment of the power conversion control compartment, and the several third ventilation openings and the second cooling fan assembly are arranged to form a cooling air duct in the upper compartment of the power conversion control compartment.

[0017] In some embodiments, the present application provides, according to a second aspect, an energy storage system comprising a battery set, a management subsystem, a thermal management system and the PCS according to one of the preceding embodiments.

[0018] In some embodiments, according to a third aspect, the present application provides an electrical device comprising the PCS according to one of the preceding embodiments. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] To further illustrate the technical solutions of the embodiments of the present application, the accompanying drawings used in the description of these embodiments are briefly presented below. It is obvious that the accompanying drawings represent only some embodiments of the present application in the following description, and that other drawings can be derived from the provided drawings without any creative effort by a person skilled in the art. Fig. Figure 1 is a schematic diagram of a PCS according to an embodiment of the present application. Fig. Figure 2 is a schematic diagram of an existing PCS according to an embodiment of the present application. Fig. Figure 3 is a schematic diagram of a target circuit board according to an embodiment of the present application. Reference symbol:

[0020] 101: Housing; 102: Power board; 103: Copper column; 104: AC output board; 105: Second cooling fan group; 106: Inductor; 107: Destination board; 108: IGBT group; 109: Heat sink; 110: First cooling fan group; 201: Copper busbar; 301: Copper column connection point; 302: Copper connecting wire; 303: Inductor connection point. DETAILED DESCRIPTION

[0021] To facilitate understanding of the present application, a more comprehensive description is given below with reference to the corresponding accompanying drawings. The drawings depict preferred embodiments of the present application. However, the present application can be implemented in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided to facilitate a more thorough and comprehensive understanding of the content disclosed in the present application.

[0022] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as generally understood by those skilled in the technical field of the present invention. The terms used herein in the description of the present application serve only to describe specific embodiments and are not intended to limit the present application. The term "and / or" used herein includes any and all combinations of one or more of the points mentioned.

[0023] If the expressions "comprise," "exhibit," and "contain" described here are used, another component may be added, provided that no explicitly limiting expressions such as "only" or "consisting of" are used. Unless otherwise stated, an expression in a singular form may also include the plural form and cannot be understood as "single" in terms of quantity.

[0024] Although terms such as "first" and "second" are used here to describe different elements, it should be understood that these elements are not limited to these terms. The terms are merely used to distinguish one element from another. For example, a first element may be referred to as a second element, and likewise a second element may be referred to as a first element, without altering the scope of this application.

[0025] Unless expressly specified and limited otherwise, the terms "connected" and "connection" in this application are to be understood in a broad sense, encompassing, for example, a direct connection, an indirect connection through an intermediary, communication within two elements, or an interaction between two elements. Individuals skilled in the art may understand certain meanings of the above terms in this application depending on the specific situation.

[0026] As a key component of an energy storage system, the PCS faces design challenges due to space constraints. The PCS achieves energy exchange between a battery and the grid through bidirectional DC / AC conversion technology and is capable of seamless switching between grid-connected and off-grid operation. Since the interior of the energy storage system is primarily occupied by cells, the space available for mounting the PCS is severely limited, resulting in a highly compact arrangement of its internal components. These spatial limitations place higher demands on heat dissipation design, maintenance accessibility, and reliability. Furthermore, the copper busbar within the PCS occupies a significant amount of space, complicating the placement of other functional boards.

[0027] With reference to Fig. 2 is Fig. 2 as a comparative embodiment of the present application, a schematic diagram of a PCS.

[0028] In some embodiments, the PCS is like in Fig. Figure 2 shows an inductor 106 connected to a power board 102 and an AC output board 104 via copper busbars 201. Because the shape and connection position of the copper busbar 201 must correspond to the positions of output connection points of the inductor 106, the copper busbar 201 occupies a considerable amount of space. For example, the copper busbar 201 connecting the inductor 106 and the AC output board 104 occupies most of the space above the inductor 106. Consequently, other functional boards cannot be arranged in this space and can only be stacked above or below the AC output board 104, or occupy an output slot position between the AC output board 104 and a front panel (not shown), resulting in an excessively dense arrangement of multiple PCS functional boards.And due to the insufficient space in a power conversion control compartment and a larger number of function boards that need to be arranged in the power conversion control compartment, the function boards in the power conversion control compartment may protrude into the output compartment, resulting in an interlocking of the output compartment and the power conversion control compartment and thereby causing the problem of high-voltage and low-voltage devices in the output compartment and the power conversion control compartment interfering with each other.

[0029] Still referring to Fig. Inductor 106 and power board 102 are also connected by a copper busbar 201. Since the shape and connection position of the copper busbar 201 must correspond to the positions of the input connection points of the inductor 106, and the copper busbar 201 requires a specific routing path and mounting redundancy, it occupies vertical and longitudinal space between the inductor 106 and the power board 102. This necessitates either increasing the length of the PCS housing 101 or stacking the devices more densely. However, a denser stacking of devices can also prevent effective heat dissipation. An additional cooling fan can significantly reduce ventilation efficiency due to obstruction by the copper busbar 201.

[0030] In some embodiments, the present application provides a PCS. With reference to Fig. 1 and Fig. 2. The PCS has a housing 101. The housing 101 is equipped with an output compartment and a power conversion control compartment.

[0031] The output compartment has several output connection terminals formed on a front panel of the housing 101. The power conversion control compartment contains a power board 102, several inductors 106, an AC output board 104, and a destination circuit board consisting of a printed circuit board (PCB) 107. The destination circuit board 107 is connected to the power board 102, the several inductors 106, and the AC output board 104.

[0032] For example, the output compartment is a high-voltage compartment and the power conversion control compartment is a low-voltage compartment. By using the destination circuit board 107 instead of the copper busbar 201, the power board 102, the multiple inductors 106, the AC output board 104, and the destination circuit board 107 can be stacked in this way, preventing the power conversion control compartment from displacing the output compartment space and thus forming a separate arrangement where the high-voltage and low-voltage compartments of the output compartment and the power conversion control compartment are separate.

[0033] For example, the output compartment may contain a DC-side high-voltage component, an AC-side high-voltage component, a reactive power compensation board, a DC lightning protection and fuse protection board, a high-voltage switch and circuit breaker assembly, a power semiconductor device, and the like. The DC-side high-voltage component includes a DC busbar, a DC decoupling capacitor, a DC filter choke, and the like. The DC busbar may be a low-resistance copper or aluminum bar coated with multiple insulating layers, such as epoxy coatings, and is configured to connect a battery cluster to the PCS and carry a DC voltage in the range of 1000 V to 1500 V. In a three-stage topology, voltage balancing control must be achieved between the stages.The DC smoothing capacitor can be a film capacitor, which can improve high ripple current capability, or an electrolytic capacitor, which is suitable for cost-effective solutions and can suppress voltage fluctuations on the DC side, absorb high-frequency harmonics, and provide transient current buffering during the switching of an insulated-gate bipolar transistor (IGBT). The DC filter choke can be wound with an iron-silicon-aluminum core. The inductance value of the DC filter choke is set according to the power requirements. The AC-side high-voltage component includes an inverter power unit, a step-up transformer, and similar components. The inverter power unit can have a two-stage, three-stage, or multi-stage topological structure.The step-up transformer can be a power-to-frequency transformer, a high-frequency transformer, or similar device, and increases the voltage of a low-voltage AC power output by the PCS to meet a grid connection requirement. The power semiconductor device can be an IGBT module, a metal-oxide-semiconductor field-effect transistor (MOSFET) module, or similar. The IGBT module can include an IGBT chip, a drive circuit, a heat sink, and similar components, potentially employing a multi-stage packaging structure. The MOSFET module has a voltage rating exceeding 1700 V and supports higher switching frequencies, reducing losses by 30% compared to an IGBT and thus being better suited to the high-frequency requirements of energy storage systems.The reactive power compensation board is designed to dynamically adjust reactive power and optimize the grid-side power factor, making it suitable for dynamic reactive power compensation in high-voltage applications and improving power transmission efficiency. The DC lightning protection and fuse protection board is designed to protect internal high-voltage compartment circuitry from damage caused by overvoltage or short circuits. The high-voltage switch and circuit breaker assembly includes an AC circuit breaker, such as a U / V / W phase-type breaker, a DC disconnect switch, and similar devices to provide on / off control and fault isolation of a high-voltage circuit.

[0034] As an example, several insulating layers such as epoxy resin coatings are stacked, which can carry direct current voltages such as 1000 V, 1300 V and 1500 V.

[0035] It should be noted that the PCS proposed in the present application is applied here to an energy storage system. The energy storage system is further equipped with a battery pack, a battery management system for managing the battery pack, a fire protection system, and the like.

[0036] As an example, the battery pack is located in a battery compartment of the energy storage system. The arrangement and number of battery packs can be determined according to specific requirements. The battery pack can store power from the grid during off-peak hours and supply power to an external electrical device during peak hours to provide peak load coverage and trough filling, thus meeting seasonal regional power demands. The Power Supply Unit (PSU) is located in a device compartment. The PSU is electrically connected to the battery pack and configured to set an output voltage, frequency, number of phases, and other electrical parameters when power is supplied from the battery pack to the external device, ensuring the battery pack provides sufficient power. The battery management system is configured to manage the battery pack.Specifically, the battery management system may include a control cabinet. The control cabinet is located in the device compartment. The control cabinet is electrically connected to the battery pack to manage the charging and discharging processes, such as monitoring the battery pack's charging and discharging voltage. The battery management system may also include a temperature sensor, located on the battery pack, to monitor its temperature and thereby ensure its safe and reliable operation. The fire protection system is designed to initiate appropriate fire suppression measures upon fire detection. It is understood that the specific location of the fire protection system can be determined according to the actual requirements.To ensure the safe operation of a micro energy storage system, the fire protection system can also be located in the battery compartment, or a fire protection system can be located in both the device compartment and the battery compartment.

[0037] As an example, the fire protection system can include devices such as a temperature sensor, a smoke detector, an automatic fire extinguisher, and a control unit. The control unit is connected to each of the temperature, smoke, and automatic fire extinguishers, allowing it to determine whether a fire has occurred based on the temperature detected by the temperature sensor and the smoke detected by the smoke detector. If a fire is detected, the control unit activates the automatic fire extinguisher, causing it to automatically discharge an extinguishing agent and thus extinguishing the fire. A partition between the battery compartment and the device compartment can be made of fire-resistant materials.If a fire has broken out in the battery compartment or the device compartment, the spread of the fire can be effectively blocked and the fire is limited to the battery compartment or the device compartment, thereby effectively reducing device losses, lowering the fire hazard and gaining valuable time for rescue.

[0038] Optionally, the energy storage system may also include a monitoring system. The monitoring system may include at least one audible and visual alarm, a gas discharge indicator, a ventilation mechanism, and a pressure relief mechanism. The audible and visual alarm may be located outside the energy storage system. In the event of an emergency, such as a fire, within the energy storage system, the audible and visual alarm may emit a warning signal in the form of sound and / or light to alert personnel so that timely intervention is possible. The gas discharge indicator may also be located outside the energy storage system. The battery pack may generate a certain amount of hydrogen during charging and discharging.When the hydrogen concentration in the energy storage system reaches a certain level, the gas discharge indicator can emit a warning signal, such as an audible tone and / or a visual alert, to notify personnel that hydrogen must be vented from the energy storage system, thus ensuring the safe operation of the system. The venting mechanism can be configured to perform this hydrogen venting. The venting mechanism may include an exhaust fan. When hydrogen venting is required, the exhaust fan is activated manually or automatically.

[0039] Specifically, the target circuit board 107 is located with reference to Fig. The AC output board 104 is located above the target circuit board 107 and is electrically connected to the target circuit board 107 via several copper columns 103.

[0040] Specifically, the multiple inductors 106, the target circuit board 107 and the AC output board 104 are still referred to as Fig. 1 are arranged in a stacked manner and connected to each other by several copper columns 103. Compared to the technical solution of connecting the several inductors 106 and the AC output board 104 using the copper busbar 201, a considerable amount of space is saved.

[0041] With reference to Fig. The target circuit board 107 has several inductor connection points 303, several input connection points, and several output connection points. The positions of the several inductor connection points 303 correspond to connection positions of the several inductors 106. Each inductor connection point 303 is electrically connected to a wiring position of the corresponding inductor 106.

[0042] Each input terminal point of the target circuit board 107 is connected to an output terminal point of the power board 102 by a copper column 103 and further connected to the corresponding inductor terminal point 303 by a printed circuit on the target circuit board 107.

[0043] Each output terminal point of the target circuit board 107 is connected to an input terminal point of the AC output board 104 by a copper column 103 and to the corresponding inductor terminal point 303 by the printed circuit on the target circuit board 107.

[0044] As an example, with reference to Fig. 3 several inductor connection points 303 are formed on the target circuit board 107 and each inductor connection point 303 is electrically connected to an input connection point and an output connection point corresponding to the respective inductor 106.

[0045] Still referring to Fig. 3 the target circuit board 107 further has several copper column connection points 301 and the copper column connection points 301 form electrical connections with the inductors 106 by means of a circuit arrangement on the target circuit board 107, whereby the target circuit board 107 can act as a replacement for the copper busbar 201.

[0046] Still referring to Fig. Furthermore, several connecting copper wires 302 are printed onto the target circuit board 107. Here, the connecting copper wires 302 on the target circuit board 107 are used to connect the inductors 106 to the copper columns 103, thereby fulfilling the requirements for high conductivity and stability of the PCS and also preventing the risk of overheating caused by an electrical connection due to the use of a different conductive material.

[0047] Still with reference to Fig. 1 and Fig. 3 The arrangement positions of the multiple inductor connection points 303, the multiple input connection points and the multiple output connection points of the target circuit board 107 correspond to the positions of the multiple inductors 106, the output connection points of the power board 102 and the input connection points of the AC output board 104, respectively, which ensures that the electrical connections between the AC output board 104, the target circuit board 107 and the stacked multiple inductors 106 are still formed by a copper medium, thus eliminating the need to define a complex shape for the copper busbar 201 and requiring only that the copper columns 103 complete the connections between the AC output board 104, the target circuit board 107 and the stacked multiple inductors 106.The connection to the power board 102 via the copper column 103 ensures the stability of the electrical connection and also reduces the volume of the occupied space.

[0048] Specifically, the starting compartment has an upper room and a lower room.

[0049] Specifically, the upper compartment of the output chamber contains several high-voltage output devices.

[0050] It should be noted that, according to current technology, functional boards such as the power board 102 and the AC output board 104 tend to protrude significantly into the output compartment due to the fact that the copper busbar 201 occupies most of the space in the power conversion control compartment and the size requirements of the PCS. The mixed arrangement of the high-voltage and low-voltage compartments can significantly increase system complexity, leading to problems such as efficiency losses, increased failure rates, and safety risks, thus creating considerable systemic hazards.

[0051] In some embodiments, the output compartment has an upper and a lower compartment. The upper compartment contains several high-voltage output devices, and the lower compartment is connected to a lower compartment of the power conversion control compartment. Several first ventilation openings are provided in the front panel of the housing 101 at positions corresponding to the lower compartment of the output compartment. Several second ventilation openings are provided in a rear panel of the housing 101 at positions corresponding to the lower compartment of the power conversion control compartment. The multiple first and second ventilation openings are configured to dissipate heat from the lower compartment of the output compartment and the lower compartment of the power conversion control compartment.

[0052] In some embodiments, the multiple inductors are located inside the lower compartment of the power conversion control compartment.

[0053] With reference to Fig. 1 In some embodiments, the multiple inductors 106 are located inside the lower space of the power conversion control compartment.

[0054] Specifically, the lower compartment of the output compartment and the lower compartment of the power conversion control compartment, which are interconnected, form an outside air duct, and a first cooling fan group 110 is arranged in the lower compartment of the output compartment.

[0055] In this way, the target circuit board 107 is used instead of the copper busbar 201, which prevents the copper busbar 201 from obstructing the cooling airflow. The arrangement of the multiple inductors 106 in the lower compartment of the power conversion control compartment improves the heat dissipation capability for the multiple inductors 106.

[0056] It should be noted that the inductor 106 in the PCS performs the functions of current filtering and energy storage. However, when an alternating current flows through the inductor 106, copper losses (i.e., conductor resistance losses) and core losses (i.e., eddy current losses) occur in the magnetic core, leading to a temperature increase in the device. If the inductor 106 cannot be effectively cooled, its losses can increase significantly, thereby reducing the overall power conversion efficiency of the PCS. Therefore, in the present application, the inductor 106 is located in the external air duct, thus ensuring efficient heat dissipation for the inductor 106.

[0057] Specifically, it is still referring to Fig. 1 in the lower space in the power conversion control compartment a heat sink 109 is also provided.

[0058] The power board 102 is located above the heat sink 109 and forms an electrical connection with the target circuit board 107 via the copper column 103.

[0059] It should be noted that several power devices, such as an IGBT and a MOSFET, arranged on the power board 102, can generate a significant amount of heat during power conversion. Therefore, in this embodiment, the power board 102 is mounted on the heat sink 109. This improves heat dissipation for the power board 102 through the heat sink 109, and the heat sink 109 is positioned in the lower air duct in direct contact with the outside cooling air. This ensures efficient heat dissipation from the heat sink 109 and further enhances the heat dissipation effect on the power board 102.

[0060] The heat sink 109 employs a finned structure to increase the heat dissipation area, and the heat dissipation performance can be optimized by adjusting parameters such as fin height, thickness, and width. The first cooling fan group 110 can interact with the heat sink 109 to generate forced convection, thereby achieving a balanced temperature distribution. The heat sink 109 can be made of a thermally conductive metal such as aluminum or copper, and the finned structure allows for an increase in the surface area of ​​the heat dissipation area.

[0061] Since no copper busbar is used in the PCS, a lower air duct can be formed at the position of the multiple inductors 106 in the embodiments of the present application, wherein the lower air duct is in direct contact with the outside air, so that the cooling air flowing into the outside air duct does not pass through other components, thereby ensuring a cooling effect of the heat sink on multiple IGBT groups and also ensuring a cooling effect of the heat sink 106 on the multiple inductors 106.

[0062] The multiple inductors 106 can be arranged in parallel or in an offset manner. For inductors 106 arranged in parallel, their long axes should be parallel to the direction of a forced airflow to reduce airflow resistance and increase flow velocity. This configuration allows the airflow to form a laminar flow along a surface of the inductor 106, thereby improving convective heat transfer capability. When finned inductors 106 are used and arranged parallel along their axes, wind velocity losses can be reduced by 15% to 20%.When an offset arrangement is used for optimization, the multiple inductors 106 are arranged in a group with an offset arrangement of 45° to 60°, which improves the turbulence effect by destroying an airflow boundary layer, thereby increasing a heat transfer coefficient by 8% to 12%.

[0063] Optionally, a temperature sensing device can be arranged near the inductor, with both the temperature sensing device and the first cooling fan group 110 being connected to a control board. The control board can dynamically adjust the speed of the first cooling fan group 110 depending on the real-time temperature of the inductor 106.

[0064] Specifically, the PCS points out, with reference to Fig. 1 also a second cooling fan group 1052.

[0065] The second cooling fan group 105 is located at a position corresponding to the upper space of the power conversion control compartment on the rear panel; in the front panel, several third ventilation openings are formed at positions corresponding to the upper space of the power conversion control compartment, and the several third ventilation openings are arranged to form a cooling air duct in the upper space of the power conversion control compartment.

[0066] Since no copper busbar is used in this application, the cooling air in the cooling air duct cannot be blocked in the upper space. Due to the larger space available for arranging the functional boards, the gaps between the multiple functional boards are also larger, which is more favorable for the circulation of the cooling air.

[0067] In this way, the target circuit board 107 is used instead of the copper busbar 201, preventing the copper busbar 201 from obstructing the cooling airflow. The stacked design and the use of copper columns 103 to connect the power board 102, the AC output board 104, and the target circuit board 107 ensure sufficient spacing between these boards when they are stacked. This creates a cooling air duct in the upper compartment of the power conversion control compartment, effectively cooling the power board 102, the AC output board 104, and the target circuit board 107.

[0068] As an example, the PCS points out, with reference to Fig. 1. Furthermore, a power supply board, an auxiliary power supply board, and the like are included. The power supply board is configured to supply power to the functional boards, such as the control board and the power board 102. The auxiliary power supply board is configured to supply power to the first cooling fan group 110 and the second cooling fan group 105. Both the power supply board and the auxiliary power supply board are low-voltage boards and are located in the power conversion control compartment.

[0069] Specifically, the PCS still points out, with reference to Fig. 1 also several current-sensing Hall sensors (not shown).

[0070] The multiple current-sensing Hall sensors are located on the AC output board 104, the power board 102 is connected to one end of the multiple current-sensing Hall sensors by several copper columns 103, and the Hall sensors are connected by the copper columns 103 to several DC output terminals of the target circuit board 107.

[0071] Specifically, the PCS still points out, with reference to Fig. 1. Furthermore, a control board is located in the power conversion control compartment.

[0072] The multiple current-sensing Hall sensors are each electrically connected to the control board and transmit multiple detected current data elements to the control board, the control board being configured to protect the PCS according to the current data.

[0073] Here, the Hall sensor detects an output current from the power board 102, and the data is transmitted to the control board in real time. If the current exceeds a threshold, the control board can immediately trigger a protection mechanism, such as interrupting an IGBT drive signal, to prevent damage to the device due to an overload. The Hall effect enables current sensing via a magnetic field, eliminating the need for a direct connection to a main circuit and thus preventing additional losses and insulation risks associated with sampling resistors.

[0074] Furthermore, with reference to Fig. 1. An output signal from the current-sensing Hall sensor is directly connected to the target circuit board 107 via a copper bus 103, thus reducing the transmission of noise over a long distance. Since, according to the prior art, the copper bus 201 is required to form connections between the inductor 106, the power board 102, and the AC output board 104, whose shapes and traces are fixed, and since the cooling airflow is obstructed by the several function boards, it is extremely difficult to arrange an additional copper bus 201 to acquire the current data. Because the copper bus 201 occupies most of the space in the PCS in question, the control board must be positioned in the output compartment far from the power board 102 and is not directly connected to the AC output board 104.

[0075] In some embodiments, the control board is specifically configured to perform the following steps: Calculating, for each current-sensing Hall sensor, a chopped wave power output by the power board 102 according to the current data detected by the current-sensing Hall sensor; and Determining, for each current-sensing Hall sensor, according to the chopped wave power output by the power board 102, whether there is an anomaly in the IGBT group 108 corresponding to the current-sensing Hall sensor.

[0076] If the control board is still referring to Fig. For example, if it is determined that an anomaly exists in a specific IGBT group 108, the control board can disconnect the abnormal IGBT group 108 from the corresponding DC and AC power supplies. Generally, an IGBT group 108 is equivalent to a battery pack, and the energy storage system can continue to operate normally after disconnecting the abnormal IGBT group 108 from its corresponding DC and AC power supplies.

[0077] Optionally, the PCS also features an inductor-capacitor filter module (LC filter module), and the LC filter module includes multiple filter capacitors and filter inductors. The filter inductor and filter capacitor can filter out dual-frequency currents and ripple fluctuations from the battery. Furthermore, the filter inductor and filter capacitor are devices with low failure rates and long service life, and are less susceptible to interference. However, the filter inductor has a relatively large mass, and the mounting distance between multiple filter inductors cannot be excessively close.

[0078] In one possible implementation, one side of the LC filter module is connected to an AC / DC conversion module and the other side is connected to a battery high-voltage box.

[0079] Optionally, the front panel of the housing 101 is equipped with a positive PCS AC power connector, a negative PCS AC power connector, a 15V low voltage test connector, a positive battery high voltage box connector, a negative battery high voltage box connector, a data network connector, a secondary control cable interface, a communication indicator, a bypass contactor on / off switch, a fiber optic communication interface, a high voltage test connector, and the like.

[0080] The positive and negative PCS AC terminals are internally connected to the positive and negative terminals of the bypass contactor, respectively, and externally in series with a positive and negative PCS AC terminal of another cascaded high-voltage energy storage converter. The positive and negative PCS AC terminals are configured to connect individual voltages of the DC / AC power conversion module in series, thus enabling connection to a medium-high voltage. The 15V low-voltage test terminal is connected to a power management control board (PMC board), and before high voltage is applied to the device, the external device supplies power to the board, allowing the device status to be observed and read on the board.The PCM board is powered on under low-voltage conditions to test and read the module's operational performance. The high-voltage test terminal is connected to an energy storage capacitor bank. Before powering on the device, a DC energy storage capacitor bank can be powered on via an external voltage power supply, and the DC / AC conversion module is powered on via the high-voltage test terminal to verify its performance. The bypass contactor's on / off switch serves as the bypass contactor's operating interface and is configured to implement a self-bypass function for the module, automatically interrupting the bypass in the event of a bypass failure. This requires manual resetting after module repair.The fiber optic communication interface is part of the PMC board interface. Once connected to a fiber optic cable, it uploads a PMC signal to a control cabinet backend via an optical signal or sends a backend control command to the PMC board. Energy storage batteries of a battery cluster are connected in series and via a bus, and finally connected to the positive and negative terminals of the battery high-voltage box. The data transmission network connection can upload data monitored by the high-voltage box to the control cabinet backend via an RS-485 cable for remote control of the device. The battery high-voltage box is used to monitor parameters such as voltage, current, and temperature of the energy storage system, and this information is transmitted to the control system.By monitoring the parameters, abnormal conditions in the system can be detected immediately and appropriate measures taken. The secondary control cable interface is connected to the energy storage battery. If an abnormal current or voltage occurs in the system, the circuit can be interrupted in a timely manner to protect the safety of the energy storage system and other electrical devices. The communication indicator is electrically connected to the battery high-voltage box and is configured to display device status information monitored by the battery high-voltage box and to observe the device's operating status. Generally, red indicates a fault, while green indicates normal operation.

[0081] Specifically, the housing 101 can comprise a structural frame, a front panel, a right panel, a left panel, a rear ventilation panel, a top cover panel, and the like. The structural frame can be formed by welding standard profiles and is designed to support internal components, thus ensuring the structural strength of the device. The frame is provided with a lifting interface. The lifting interface includes a lifting mechanism. The frame, front panel, right panel, left panel, rear ventilation panel, top cover panel, and the like are all made of metal materials, forming a protective enclosure for the device.

[0082] With reference to Fig.1 In some embodiments, the control board further includes a signal transmission unit (not shown). The signal transmission unit can be connected to an alarm device of the energy storage system in a wired or wireless manner. When the control board determines that an anomaly exists in a particular IGBT group 108, the signal transmission unit can be controlled to transmit an indicator signal, indicating the presence of the anomaly in the IGBT group 108, to the alarm device to facilitate the repair and replacement of the abnormal IGBT group 108 by personnel.

[0083] In some embodiments, if an anomaly is present in a particular IGBT group 108, the control board can isolate the battery pack corresponding to the abnormal IGBT group 108 from a normal battery pack, whereby the power of the abnormal battery pack can be transferred through the control board to the normal battery pack.

[0084] In the PCS above, the target circuit board 107 is used instead of the copper busbar 201 for the connection, thereby reducing the space occupied by the connection via the copper busbar 201 and also facilitating a stacked design in the PCS, thus ensuring a separation of the high-voltage and low-voltage compartments and further reducing the size of the PCS through the stacked design.

[0085] The absence of the blockage by the copper busbar 201 facilitates the formation of the cooling air channel, thereby reducing the size of the PCS and also facilitating heat dissipation for the PCS.

[0086] In one exemplary embodiment, an energy storage system is provided which includes a battery set, a management subsystem, a thermal management system and the PCS according to one of the preceding embodiments.

[0087] In one exemplary embodiment, an electrical device is provided. The electrical device includes the PCS according to one of the preceding embodiments.

[0088] It should be noted that the above embodiments are for illustrative purposes only and are not intended to limit the present application.

[0089] The description details several embodiments in succession. Each embodiment focuses on differences from other embodiments, and identical or similar parts in the embodiments may relate to one another.

[0090] The present application relates to the field of energy storage technologies and, in particular, to a power conversion system (PCS), an energy storage system, and an electrical device. The PCS is applied to an energy storage system and comprises a housing. The housing includes an output compartment and a power conversion control compartment. The output compartment has several output connection terminals formed on a front panel of the housing. The power conversion control compartment contains a power board, several inductors, an AC output board, and a destination printed circuit board (PCB). The destination PCB is connected to the power board, the several inductors, and the AC output board, respectively.

Claims

[1] Power conversion system (PCS) applied to an energy storage system, wherein a housing (101) of the PCS is provided with an output compartment and a power conversion control compartment; wherein the output compartment has multiple output connection terminals arranged on a front panel of the housing (101), and the power conversion control compartment includes a destination printed circuit board (PCB) (107) and a power board (102), multiple inductors (106) and an AC output board (104), each connected to the destination printed circuit board (107). [2] PCS according to claim 1, wherein the target circuit board (107) is located above the multiple inductors (106) and is electrically connected to all of the multiple inductors (106); and the AC output board (104) is located above the target circuit board (107) and is electrically connected to the target circuit board (107) by multiple copper columns (103). [3] PCS according to claim 1 or 2, wherein the output compartment has an upper compartment and a lower compartment, the upper compartment of the output compartment containing several high-voltage output devices and the lower compartment of the output compartment being connected to a lower compartment of the power conversion control compartment; several first ventilation openings are provided in the front panel of the housing (101) at positions corresponding to the lower compartment of the output compartment; and several second ventilation openings are provided in a rear panel of the housing (101) at positions corresponding to the lower compartment of the power conversion control compartment; wherein the several first ventilation openings and the several second ventilation openings are arranged to dissipate heat from the lower compartment of the output compartment and the lower compartment of the power conversion control compartment;wherein the multiple inductors (106) are located inside the lower compartment of the power conversion control compartment.; [4] PCS according to claim 3, wherein the lower compartment of the output compartment and the lower compartment of the power conversion control compartment, which are interconnected, form an outside air duct, and a first cooling fan group (110) is arranged in the lower compartment of the output compartment. [5] PCS according to claim 3, wherein a heat sink (109) is further arranged in the lower space of the power conversion control compartment, and the power board (102) is located above the heat sink (109) and is electrically connected to the target circuit board (107). [6] PCS according to any one of claims 1 to 5, further comprising several current-sensing Hall sensors located on the AC output board (104), wherein the power board (102) is electrically connected to the several current-sensing Hall sensors, and the current-sensing Hall sensors are electrically connected to several DC output terminals of the target circuit board (107). [7] PCS according to claim 6, wherein the PCS further comprises a control board, the control board being located in the power conversion control compartment; and the multiple current-sensing Hall sensors are each electrically connected to the control board and transmit multiple detected current data elements to the control board, and the control board is configured to protect the PCS according to the multiple current data elements. [8] PCS according to claim 7, wherein the control board is configured to perform the following steps: Calculating a chopped wave power output by the power board (102) according to the current data detected by the current-sampling Hall sensors; and Determine, based on the chopped wave power output by the power board (102), whether there is an anomaly in a group of insulated gate bipolar transistors (an IGBT group) corresponding to the current-sensing Hall sensors. [9] PCS according to any one of claims 1 to 8, wherein the target circuit board (107) has multiple inductor connection points (303); wherein the multiple inductor connection points (303) are each electrically connected to the corresponding inductor (106). [10] PCS according to claim 9, wherein the target circuit board (107) further comprises several input connection points, wherein the several input connection points are each connected to an output connection point of the power board (102) and are further connected by a printed circuit on the target circuit board (107) to the corresponding inductor connection point (303). [11] PCS according to claim 9 or 10, wherein the target circuit board (107) further comprises multiple output connection points; wherein the multiple output connection points are each connected to an input connection point of the AC output board (104) and are further connected by a printed circuit on the target circuit board (107) to the corresponding inductor connection point (303). [12] PCS according to one of claims 3 to 5, further comprising a second cooling fan group (105), wherein the second cooling fan group (105) is located on the rear panel and at a position corresponding to an upper compartment of the power conversion control compartment, wherein several third ventilation openings are provided in the front panel and at positions corresponding to the upper compartment of the power conversion control compartment, and the several third ventilation openings and the second cooling fan group (105) are arranged to form a cooling air duct in the upper compartment of the power conversion control compartment. [13] PCS according to any one of claims 1 to 12, wherein the multiple inductors (106) are arranged in parallel or in a group with an arrangement offset by 45° to 60°. [14] Energy storage system comprising a set of batteries; an administrative subsystem; a heat management system; and the PCS according to any one of claims 1 to 13. [15] Electrical device comprising the PCS according to any one of claims 1 to 13.

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