Full-liquid-cooled modular energy storage converter having load break function

Abstract

The present application relates to the technical field of energy storage converters. Provided is a full-liquid-cooled modular energy storage converter having a load break function, comprising: a cabinet body; a power module disposed within the cabinet body; a functional assembly disposed within the cabinet body, the functional assembly and the power module being disposed opposite to one another; a liquid-cooling plate disposed on the power module, the liquid-cooling plate being used for cooling the power module; a partition plate disposed within the cabinet body, the partition plate being connected to the liquid-cooling plate, and the partition plate and the liquid-cooling plate dividing the space within the cabinet body into a first air passage and a second air passage; a heat radiation plate disposed in the second air passage and connected to the power module; a first fan disposed within the first air passage, the first fan being used for blowing air to the power module and blowing an airflow into the second air passage; a second fan disposed within the second air passage, the second fan being used for extracting air from the functional assembly and blowing an airflow into the first air passage; and a direct-current isolation switch device disposed in the cabinet body, the direct-current isolation switch device being used for direct-current isolation and direct-current protection.

Description

Fully liquid-cooled modular energy storage converter with on-load breaking function

[0001] This application claims priority to the Chinese patent application filed with the State Intellectual Property Office of China on September 19, 2023, with application number "202311206081.6" and application name "Fully liquid-cooled modular energy storage converter with load disconnecting function", the entire contents of which are incorporated by reference into this application. Technical Field

[0002] The present application relates to the technical field of energy storage converters, and in particular to a fully liquid-cooled modular energy storage converter with an on-load disconnecting function. Background Art

[0003] In related technologies, energy storage converters, when integrated into the system, are combined with AC circuit breakers and DC high-voltage switch boxes in the integrated cabinet. The energy storage integrated system can provide reliable protection and isolation measures in terms of AC / DC short-circuit protection and overload protection.

[0004] In actual use, the DC high-voltage switchgear is being gradually eliminated when integrating energy storage converters into energy storage systems for design optimization, space requirements, and cost considerations. When controlling battery charging and discharging using energy storage converters, battery-side anomalies, such as excessively high or low battery voltage, can lead to substandard insulation, thermal runaway, excessive voltage imbalance, and communication loss.

[0005] Therefore, after the DC high-voltage switch box is removed, how to ensure reliable protection and isolation of the DC side of the energy storage integrated system when the above-mentioned problems occur, especially in emergencies such as battery thermal runaway, communication loss, and uncontrolled energy storage inverter, has become a technical problem that needs to be solved urgently.

[0006] Application Contents

[0007] The present application aims to at least solve the technical problem of existing technologies or related technologies in that after the DC high-voltage switch box is eliminated, when an abnormality occurs on the battery side, the DC side of the energy storage integrated system can still be reliably protected and isolated.

[0008] To this end, the present application proposes a fully liquid-cooled modular energy storage converter with on-load breaking function.

[0009] In view of this, the present application proposes a fully liquid-cooled modular energy storage converter with on-load disconnection function, comprising: a cabinet; a power module, arranged in the cabinet; a functional component, arranged in the cabinet, and the functional component and the power module are arranged relative to each other; the functional component includes a DC power unit, arranged in the cabinet, the DC power unit is used to control the DC side on and off and provide DC overcurrent protection; the DC power unit includes a DC fuse; a liquid cooling plate, arranged in the power module, the liquid cooling plate is used to cool the power module; a partition, arranged in the cabinet, the partition is connected to the liquid cooling plate The partition and the liquid cooling plate divide the space inside the cabinet into a first air duct and a second air duct; the heat radiation plate is arranged in the second air duct and is connected to the power module; the first fan is arranged in the first air duct, and the first fan is used to blow air to the power module and blow the airflow into the second air duct; the second fan is arranged in the second air duct, and the second fan is used to exhaust air from the functional components and blow air into the first air duct; the DC isolating switch device is arranged in the cabinet, the DC isolating switch device is connected to the DC fuse, and the DC isolating switch device is used for DC isolation and DC protection.

[0010] The fully liquid-cooled modular energy storage converter with on-load disconnection function provided in this application includes a cabinet, a power module, a functional component, a liquid cooling plate, a partition, a heat radiation plate, a first fan, a second fan and a DC isolating switch device. Specifically, the power module is arranged in the cabinet. The power module is the core component of the fully liquid-cooled modular energy storage converter with on-load disconnection function. It can control the voltage and frequency of the power system, and has the ability to charge and discharge, and can effectively store and release electrical energy. The functional component includes a DC power unit, which is arranged in the cabinet. The DC power unit is used to control the DC side on and off and provide DC overcurrent protection; the DC power unit includes a DC fuse, which is used for overcurrent and short-circuit protection and can be quickly disconnected in the event of a fuse overload. The liquid cooling plate is arranged in the power module, and the liquid cooling plate can cool the power module in a liquid cooling manner. A partition is also arranged in the cabinet, which is connected to the liquid cooling plate, thereby dividing the space in the cabinet into a first air duct and a second air duct, so that air can circulate in the first air duct and the second air duct of the cabinet. A heat radiation plate is also provided in the cabinet. The heat radiation plate is provided in the second air duct and is connected to the power module. The heat radiation plate can absorb the heat of the power module and radiate the heat to other spaces in the cabinet to improve the cooling effect of the power module. A first fan and a second fan are provided in the first air duct and the second air duct respectively. The first fan is provided in the first air duct and is used to blow air to the power module. Since a heat sink is provided on the liquid cooling plate, the heat sink can conduct the low temperature on the liquid cooling plate to the first air duct. When the first fan blows air toward the power module, it can blow the cold air flow conducted from the liquid cooling plate into the second air duct. The second fan is provided in the second air duct and is used to extract air from the functional components, remove the heat from the functional components, and blow air into the first air duct, thereby causing the air flow to circulate in the first and second air ducts of the cabinet. A DC isolating switch device is provided in the cabinet. The DC isolating switch device is connected to the DC fuse. The DC isolating switch device is used for DC isolation and DC protection.

[0011] Specifically, the first fan and the second fan form an air cooling system for a fully liquid-cooled modular energy storage converter with an on-load disconnect function. Since the partition is connected to the liquid cooling plate, the space inside the cabinet is separated to form a first air duct and a second air duct. When the air cooling system is running, the air inside the cabinet can form a cooling circuit that circulates up and down. The cold air can be blown to the lower layer of the cabinet through the first fan and the heat sink on the liquid cooling plate. The second fan arranged in the second air duct can remove the heat from the functional components by exhausting air. The first fan and the second fan, one blowing air and the other exhausting air, maintain the operating environment temperature of the air inside the energy storage converter as a whole.

[0012] The fully liquid-cooled modular energy storage converter with on-load disconnect function provided by the present application divides the space in the cabinet into a first air duct and a second air duct by arranging a partition in the cabinet, and the partition is connected to the liquid cooling plate to divide the space in the cabinet into a first air duct and a second air duct, forming an internal air circulation cooling circuit. The present application adopts a liquid cooling plate and a first fan and a second fan to achieve mixed cooling of liquid cooling and air cooling. Through the mutual cooperation of the liquid cooling plate and the first fan and the second fan, it can be ensured that the power density per unit volume is sufficiently high, and the cost can be controlled, which is conducive to improving application reliability and reducing maintenance complexity. By arranging a partition in the cabinet, and connecting the partition to the liquid cooling plate to divide the space in the cabinet into a first air duct and a second air duct, forming an internal air circulation cooling circuit, the cooling method and thermal management layout are optimized. The interior of the cabinet of the fully liquid-cooled modular energy storage converter with on-load disconnect function can be maintained within the set temperature range, and the internal components work under suitable environmental conditions, effectively avoiding power reduction caused by temperature changes.

[0013] The present application maximizes the use effect of the liquid cooling part through the liquid cooling circuit formed by the liquid cooling plate, the heat sink on the liquid cooling plate and the first and second fans in the cabinet, so that the temperature inside the fully liquid-cooled modular energy storage converter with load disconnection function is maintained at the set operating environment temperature, the internal components are kept working in the best environmental conditions, and the power capacity is kept from being reduced due to temperature changes. The air duct inside the cabinet is optimized by setting partitions, so that the air circulation inside the cabinet is smoother, the air flow efficiency is improved, the internal ambient temperature is effectively reduced, and the internal components are kept working efficiently. In addition, the fully liquid-cooled modular energy storage converter with load disconnection function provided by the present application has a compact structure, small size, low cost, two independent upper and lower air ducts, so that heat does not accumulate locally, and the air contact surface is increased by the heat sink to enhance the cooling effect.

[0014] The present application provides a new, small-volume, fully liquid-cooled modular energy storage converter with an on-load disconnect function, which can directly disconnect the battery pack from the fully liquid-cooled modular energy storage converter with an on-load disconnect function under full load. While completely isolating the fully liquid-cooled modular energy storage converter with an on-load disconnect function from the battery pack, it also has the ability to disconnect on-load, solving the problem that DC contactors and DC disconnect switches do not have the ability to disconnect on-load, while avoiding the use of circuit breakers and electric operating mechanisms on the DC side, which are relatively space-consuming, large-volume, and high-cost devices. By adding a DC disconnect switch device with an on-load disconnect function, the energy storage integrated system can have the function of high-voltage DC isolation on the DC side regardless of whether a DC high-voltage switch box is present, and has a remote disconnect function. When an abnormality occurs on the battery side, especially in emergencies such as battery thermal runaway, communication loss, and uncontrolled full-liquid-cooled modular energy storage inverter with load disconnection function, the connection between the battery pack and the full-liquid-cooled modular energy storage inverter with load disconnection function can be quickly and remotely disconnected, regardless of whether the energy storage inverter is under full load or other load conditions, making the system design more flexible, the cost solution more optimized, and the control more convenient and rapid.

[0015] In addition, the fully liquid-cooled modular energy storage converter with on-load disconnection function in the above technical solution provided by this application may also have the following additional technical features:

[0016] In some technical solutions, optionally, the DC isolation switch device includes: a switch device, which is arranged in a cabinet and connected to a DC fuse; an operating handle, which is connected to the switch device and is used to control the opening or closing of the switch device; and a remote disconnect component, which is arranged in the cabinet and is used for remote control to achieve DC isolation and DC protection.

[0017] In this technical solution, the DC isolation switch device optionally includes a switch device, an operating handle, and a remote disconnect assembly. Specifically, the operating handle is connected to the switch device to control its opening or closing to achieve DC isolation and DC protection. The remote disconnect assembly can remotely and quickly disconnect the battery pack from the fully liquid-cooled modular energy storage inverter with on-load disconnection function to achieve DC isolation and DC protection.

[0018] Specifically, the remote shutdown function applies a voltage signal to the trip shunt of the switchgear, causing it to trip and disconnect from the DC fuse. The switchgear is the mechanical component of the DC disconnector. Its closing and opening connects the battery side to the fully liquid-cooled modular energy storage converter with on-load disconnect capability. The operating handle is an external manual operating mechanism that can be used to manually close and open the switchgear.

[0019] In practical applications, the switching device may be in the form of a circuit breaker and an electric operating mechanism, that is, the switching device includes a circuit breaker and an electric operating mechanism to achieve DC isolation and DC protection.

[0020] In some technical solutions, optionally, in the height direction of the fully liquid-cooled modular energy storage converter with load disconnecting function, the first air duct is located above the second air duct, the first fan is located above the power module, and the air outlet of the first fan is facing the power module; the air inlet of the second fan is facing the functional component.

[0021] In this technical solution, in the height direction of the fully liquid-cooled modular energy storage converter with a load-breaking function, the first air duct is located above the second air duct, and the first fan and the second fan are operated simultaneously, so that the airflow can circulate in the first air duct and the second air duct to form a circulating cooling loop. Specifically, the first fan is located above the power module, and the air outlet of the first fan is directed toward the power module. When the first fan is working, the cold air flow can be blown to the second air duct through the first fan and the heat sink on the liquid-cooled plate. The air inlet of the second fan is directed toward the functional component, and the second fan can take away the heat of the functional component by exhausting air. The first fan and the second fan, one blowing air and the other exhausting air, jointly maintain the air operating environment temperature inside the fully liquid-cooled modular energy storage converter with a load-breaking function.

[0022] In some technical solutions, optionally, the power module includes: a power component, arranged in the first air duct; a reactor component, arranged in the second air duct, and the reactor component is located between the liquid cooling plate and the heat radiation plate; wherein the liquid cooling plate is located between the power component and the reactor component.

[0023] In this technical solution, the power module includes a power component and a reactor component. Specifically, the power component is arranged in the first air duct, the reactor component is arranged in the second air duct, and a liquid cooling plate is located between the power component and the reactor component. One side of the liquid cooling plate is connected to the power component, and the other side of the liquid cooling plate is connected to the reactor component. The liquid cooling plate can liquid cool the power component and the reactor component. The reactor component is located between the liquid cooling plate and the heat radiation plate. The heat radiation plate can absorb heat from the reactor component and radiate it to other spaces within the cabinet, thereby improving the cooling effect on the reactor component and allowing the reactor component to operate in a suitable temperature environment.

[0024] In some technical solutions, optionally, the fully liquid-cooled modular energy storage converter with on-load disconnecting function also includes: a DC support unit, which is arranged in the cabinet and connected to the power component, and the DC support unit is used to provide DC side energy for equipment power conversion.

[0025] In this technical solution, the fully liquid-cooled modular energy storage converter with on-load disconnect capability also includes a DC support unit. Specifically, the DC support unit is installed in the cabinet and connected to the power components to provide DC-side energy for equipment power conversion.

[0026] In some technical solutions, the DC support unit optionally includes: a support capacitor disposed within the cabinet, the support capacitor being used to provide DC-side energy; and a laminated busbar, the laminated busbar being used to connect the support capacitor and the power components. The DC support unit also includes a fixing structure for fixing the connection.

[0027] In this technical solution, the DC support unit includes support capacitors and a laminated busbar. The support capacitors are installed in the cabinet and fixed to the sheet metal components with bottom bolts. The positive, midpoint, and negative poles of the support capacitors are connected in parallel via the laminated busbar and lead to terminals U+, U-, and U0, which are connected to the power components respectively.

[0028] In some technical solutions, optionally, the DC power unit further includes: a DC contactor, disposed in the cabinet and connected to the DC fuse; a DC current sensor, connected to the DC fuse, and located between the DC fuse and the laminated busbar.

[0029] In this technical solution, the DC power unit includes a DC contactor, a DC fuse, and a DC current sensor. Specifically, the DC contactor is connected to the cabinet and is used to interrupt the DC current. When the DC current is interrupted, its arc does not extinguish briefly like when the AC current passes through zero. Therefore, a special arc extinguishing device is designed inside the DC contactor. The DC fuse is connected to the DC contactor and is used for overcurrent and short-circuit protection. The DC fuse can be quickly disconnected in the event of a fuse overload. The DC current sensor is connected to the DC fuse and is used to detect the DC current. The DC current sensor is located between the DC fuse and the laminated busbar.

[0030] The DC current sensor is fixed to the copper busbar between the DC fuse and the laminated busbar. The copper busbar connects the DC contactor, DC fuse, DC current sensor, and external DC plug connector into a unified whole. The DC busbar, DC contactor, DC fuse, and DC plug connector form a complete DC output circuit, and each component is fixed together with bolts.

[0031] In some technical solutions, optionally, the functional components include: an AC power unit, which is arranged in a cabinet and connected to the power module, and the AC power unit is used to control the on and off of the AC side and provide AC overcurrent protection.

[0032] In this technical solution, the functional components include an AC power unit. Specifically, the AC power unit is disposed in a cabinet, connected to the power module, and used to control the on / off of the AC side and provide AC overcurrent protection.

[0033] The AC power unit is connected to the reactor assembly through a flexible connection, and is connected to an external AC plug connector through a flexible connection.

[0034] In some technical solutions, optionally, the AC power unit includes: an AC relay, which is arranged in a cabinet; and an AC fuse, which is connected to the AC relay.

[0035] In this technical solution, the AC power unit includes an AC relay and an AC fuse. Specifically, the AC relay is connected to the cabinet and controls the switching operation of the fully liquid-cooled modular energy storage converter with on-load disconnect function. When an abnormal situation occurs, it can quickly disconnect the circuit and protect the equipment from damage. The AC fuse is connected to the AC relay and provides overcurrent and short-circuit protection. When a short circuit or overload occurs in the circuit, the AC fuse can quickly disconnect the circuit, preventing further current increase and protecting the equipment in the circuit from damage.

[0036] Specifically, various structural modules such as the AC relay, the AC fuse, and the externally connected AC plug connector are connected into a unified whole through on-board welding of the circuit board.

[0037] In some technical solutions, optionally, the fully liquid-cooled modular energy storage converter with on-load disconnecting function also includes: a filtering unit, the filtering unit includes a filtering capacitor, and the filtering unit is used to filter out harmonics; a control unit, which is used to collect voltage, current and temperature information, and combine with preset software algorithms to realize grid-connected, charging and discharging, and grid-connected and off-grid functions.

[0038] In this technical solution, the fully liquid-cooled modular energy storage converter with on-load disconnect functionality also includes a filter unit and a control unit. Specifically, the filter unit consists of filter capacitors mounted on a circuit board. The filter unit filters out harmonics generated by the switching devices during operation, smoothing the voltage and current waveforms output by the fully liquid-cooled modular energy storage converter with on-load disconnect functionality.

[0039] The control unit serves as the core control actuator of the fully liquid-cooled modular energy storage converter with on-load disconnection function. It is used to sample voltage, current, temperature and other information. Combined with relevant software algorithms, it realizes grid connection, charging and discharging, grid connection and off-grid functions, and performs digital quantity control and reading, external communication and other functions.

[0040] Additional aspects and advantages of the present application will become apparent in the following description or may be learned through practice of the present application. BRIEF DESCRIPTION OF THE DRAWINGS

[0041] The above and / or additional aspects and advantages of the present application will become apparent and easily understood from the description of the embodiments in conjunction with the following drawings, in which:

[0042] FIG1 shows a schematic structural diagram of a fully liquid-cooled modular energy storage converter with an on-load breaking function according to an embodiment of the present application;

[0043] FIG2 shows a schematic structural diagram of a fully liquid-cooled modular energy storage converter with an on-load breaking function according to another embodiment of the present application;

[0044] FIG3 shows a schematic structural diagram of a fully liquid-cooled modular energy storage converter with an on-load breaking function according to another embodiment of the present application;

[0045] FIG4 shows a schematic structural diagram of a fully liquid-cooled modular energy storage converter with an on-load breaking function according to another embodiment of the present application;

[0046] FIG5 shows a schematic structural diagram of a fully liquid-cooled modular energy storage converter with an on-load breaking function according to another embodiment of the present application;

[0047] FIG6 shows a schematic structural diagram of a fully liquid-cooled modular energy storage converter with an on-load breaking function according to another embodiment of the present application;

[0048] FIG7 shows a schematic structural diagram of a fully liquid-cooled modular energy storage converter with an on-load breaking function according to another embodiment of the present application;

[0049] FIG8 shows a schematic structural diagram of a fully liquid-cooled modular energy storage converter with an on-load breaking function according to another embodiment of the present application;

[0050] FIG9 shows a schematic structural diagram of a fully liquid-cooled modular energy storage converter with an on-load breaking function according to another embodiment of the present application;

[0051] FIG10 shows a schematic structural diagram of a fully liquid-cooled modular energy storage converter with an on-load breaking function according to another embodiment of the present application.

[0052] The corresponding relationship between the reference numerals and component names in Figures 1 to 10 is as follows:

[0053] 100 Fully liquid-cooled modular energy storage converter with on-load disconnect function, 110 cabinet, 112 partition, 114 first air duct, 116 second air duct, 120 power module, 121 liquid cooling plate, 122 power component, 123 reactor component, 124 heat radiation plate, 126 heat sink, 128 functional component, 130 DC support unit, 131 support capacitor, 132 laminated busbar, 133 fixed structure, 140 DC power unit, 141 DC contactor, 142 DC fuse, 143 3 AC relay, 144 AC fuse, 145 DC current sensor, 146 AC power unit, 151 AC plug connector, 152 DC plug connector, 153 signal interface, 154 indicator light, 156 coolant inlet and outlet, 157 exhaust valve, 160 first fan, 161 air outlet, 162 second fan, 164 air inlet, 170 control unit, 180 filter unit, 190 DC isolation switch device, 191 switch device, 192 remote disconnect assembly, 193 operating handle. DETAILED DESCRIPTION

[0054] In order to more clearly understand the above-mentioned objects, features and advantages of the present application, the present application is further described in detail below in conjunction with the accompanying drawings and specific embodiments. It should be noted that the embodiments of the present application and the features therein can be combined with each other in the absence of conflict.

[0055] In the following description, many specific details are set forth to facilitate a full understanding of the present application. However, the present application may also be implemented in other ways different from those described herein. Therefore, the scope of protection of the present application is not limited to the specific embodiments disclosed below.

[0056] 1 to 10 , the fully liquid-cooled modular energy storage converter 100 with an on-load disconnecting function provided in an embodiment of the present application will be described in detail through specific embodiments and application scenarios.

[0057] The present application proposes a fully liquid-cooled modular energy storage converter 100 with an on-load disconnection function, as shown in Figures 1, 2, 3, 4, 5, 6, 7, 8, 9 and 10. The fully liquid-cooled modular energy storage converter 100 with an on-load disconnection function includes: a cabinet 110; a power module 120, which is arranged in the cabinet 110; a functional component 128, which is arranged in the cabinet 110, and the functional component 128 is arranged opposite to the power module 120; the functional component 128 includes a DC power unit 140, which is arranged in the cabinet 110, and the DC power unit 140 is used to control the on-off of the DC side and provide DC overcurrent protection; the DC power unit 140 includes a DC fuse 142; a liquid-cooled The plate 121 is provided in the power module 120, and the liquid cooling plate 121 is used to cool the power module 120; the partition 112 is provided in the cabinet 110, and the partition 112 is connected to the liquid cooling plate 121. The partition 112 and the liquid cooling plate 121 divide the space in the cabinet 110 into a first air duct 114 and a second air duct 116; the heat radiation plate 124 is provided in the second air duct 116 and is connected to the power module 120; the first fan 160 is provided in the first air duct 114, and the first fan 160 is used to blow air to the power module 120 and blow the airflow into the second air duct 116; the second fan 162 is provided in the second air duct 116, and the second fan 162 is used to radiate the functional components 128. DC isolating switch device 190 is provided in cabinet 110, and DC isolating switch device 190 is connected to DC fuse 142, and DC isolating switch device 190 is used for DC isolation and DC protection.

[0058] The fully liquid-cooled modular energy storage converter 100 with on-load disconnection function provided in the present application includes a cabinet 110, a power module 120, a functional component 128, a liquid cooling plate 121, a partition 112, a heat radiation plate 124, a first fan 160, a second fan 162 and a DC isolation switch device 190. Specifically, the power module 120 is arranged in the cabinet 110. The power module 120 is the core component of the fully liquid-cooled modular energy storage converter 100 with on-load disconnection function. It can control the voltage and frequency of the power system, and has the ability to charge and discharge, and can effectively store and release electrical energy. The functional component 128 includes a DC power unit 140, which is arranged in the cabinet 110. The DC power unit 140 is used to control the on-off of the DC side and provide DC overcurrent protection; the DC power unit 140 includes a DC fuse 142. The DC fuse 142 is used for overcurrent and short-circuit protection and can be quickly disconnected when the fuse is overloaded. A liquid cooling plate 121 is provided within the power module 120 and can cool the power module 120 using liquid cooling. A partition 112 is also provided within the cabinet 110 and is connected to the liquid cooling plate 121, thereby separating the space within the cabinet 110 into a first air duct 114 and a second air duct 116, allowing air to circulate within the first and second air ducts 114, 116 of the cabinet 110. A heat radiating plate 124 is also provided within the cabinet 110 and is located within the second air duct 116. The heat radiating plate 124 is connected to the power module 120 and can absorb heat from the power module 120 and radiate it to other spaces within the cabinet 110, thereby enhancing the cooling effect on the power module 120. A first fan 160 and a second fan 162 are provided within the first and second air ducts 114, 116, respectively. The first fan 160 is arranged in the first air duct 114, and is used to blow air to the power module 120. Since the liquid cooling plate 121 is provided with a heat sink 126, the heat sink 126 can conduct the low temperature on the liquid cooling plate 121 to the first air duct 114. When the first fan 160 blows air toward the power module, the cold air flow conducted by the liquid cooling plate 121 can be blown into the second air duct 116. The second fan 162 is arranged in the second air duct 116, and is used to exhaust air from the functional component 128, take away the heat of the functional component 128, and blow air into the first air duct 114, so that the air flow circulates in the first air duct 114 and the second air duct 116 of the cabinet 110. The black arrows in Figure 2 indicate the direction of the air flow circulating in the first air duct 114 and the second air duct 116 of the cabinet 110. The DC isolating switch device 190 is disposed in the cabinet 110 . The DC isolating switch device 190 is connected to the DC fuse 142 . The DC isolating switch device 190 is used for DC isolation and DC protection.

[0059] Specifically, the first fan 160 and the second fan 162 form an air cooling system for a fully liquid-cooled modular energy storage converter 100 with a load-breaking function. Since the partition 112 is connected to the liquid-cooling plate 121, the space inside the cabinet 110 is separated into a first air duct 114 and a second air duct 116. When the air cooling system is in operation, the air inside the cabinet 110 can form a cooling circuit that circulates up and down. Through the first fan 160 and the heat sink 126 on the liquid-cooling plate 121, cold air can be blown to the lower layer of the cabinet 110. The second fan 162 set in the second air duct 116 can remove the heat from the functional component 128 by exhausting air. The first fan 160 and the second fan 162, one blowing air and the other exhausting air, maintain the operating environment temperature of the air inside the energy storage converter as a whole.

[0060] The fully liquid-cooled modular energy storage converter 100 with on-load disconnection function provided in the present application is provided with a partition 112 in the cabinet 110. The partition 112 is connected to the liquid cooling plate 121 to divide the space in the cabinet 110 into a first air duct 114 and a second air duct 116, forming an internal air circulation cooling circuit. The present application adopts the liquid cooling plate 121 and the first fan 160 and the second fan 162 to achieve mixed cooling of liquid cooling and air cooling. Through the mutual cooperation of the liquid cooling plate 121 and the first fan 160 and the second fan 162, it is possible to ensure that the power density per unit volume is sufficiently high and to control the cost, which is conducive to improving application reliability and reducing maintenance complexity. By arranging a partition 112 in the cabinet 110, the partition 112 is connected to the liquid cooling plate 121 to divide the space inside the cabinet 110 into a first air duct 114 and a second air duct 116, forming an internal air circulation cooling circuit, optimizing the cooling method and thermal management layout, and the interior of the cabinet 110 of the fully liquid-cooled modular energy storage inverter 100 with load disconnecting function can be maintained within the set temperature range, and the internal components operate under suitable environmental conditions, effectively avoiding power reduction due to temperature changes.

[0061] By adding a DC isolating switch device 190 with an on-load disconnect function to a fully liquid-cooled modular energy storage converter 100 with an on-load disconnect function, the present application enables the energy storage integrated system to have high-voltage DC isolation on the DC side, regardless of whether a DC high-voltage switch box is present, and also has a remote disconnect function. In the event of a system abnormality, regardless of whether the energy storage converter is under full load or other load conditions, the connection between the battery pack and the fully liquid-cooled modular energy storage converter 100 with an on-load disconnect function can be quickly and remotely disconnected, thereby making the system design more flexible, the cost solution more optimized, and the control more convenient and rapid.

[0062] In actual applications, the fully liquid-cooled modular energy storage converter 100 with on-load breaking function can also fix each component on the liquid cooling plate 121 and adopt full liquid cooling to achieve cooling, or use an air-water exchanger as an alternative way to dissipate heat from internal components.

[0063] In actual applications, the fully liquid-cooled modular energy storage converter 100 with on-load disconnect functionality consists of seven components: a power module 120, a DC support unit 130, a DC power unit 140, an AC power unit 146, a filter unit 180, a control unit 170, and an external interface. When a first fan 160, located on the upper layer of the cabinet 110, is in operation, it blows cold air from the heat sink 126 of the liquid cooling plate 121 to the lower layer of the cabinet 110. A second fan 162, located on the lower layer of the cabinet 110, removes heat from components such as the heating element, switching power supply, AC relay 143, AC fuse 144, DC fuse 142, and DC contactor 141 through exhaust. The first fan 160 and the second fan 162, one for blowing air and one for exhausting air, maintain the overall operating temperature of the air inside the energy storage converter.

[0064] As shown in Figure 1, the external interfaces of the fully liquid-cooled modular energy storage converter 100 with on-load disconnect functionality include a signal interface 153 and a coolant inlet and outlet 156. The coolant inlet and outlet 156 connects to the liquid cooling plate 121, allowing coolant to flow in and out of the plate. An indicator light 154 is provided on the cabinet 110 to indicate the operating status of the fully liquid-cooled modular energy storage converter 100 with on-load disconnect functionality.

[0065] As shown in FIG7 and FIG8 , the fully liquid-cooled modular energy storage converter 100 with the on-load breaking function further includes an exhaust valve 157 , which is mainly used for exhausting gas.

[0066] In some embodiments, optionally, as shown in Figure 3, the DC isolation switch device 190 includes: a switch device 191, which is arranged in the cabinet 110, and the switch device 191 is connected to the DC fuse 142; an operating handle 193, which is connected to the switch device 110 and is used to control the opening or closing of the switch device 191; a remote disconnect component 192, which is arranged in the cabinet 110 and is used for remote control to achieve DC isolation and DC protection.

[0067] In this embodiment, the DC isolation switch device 190 optionally includes a switch device 191, an operating handle 193, and a remote disconnect assembly 192. Specifically, the operating handle 193 is connected to the switch device 191 and is used to control the opening or closing of the switch device 191 to achieve DC isolation and DC protection. The remote disconnect assembly 192 can remotely and quickly disconnect the battery pack from the fully liquid-cooled modular energy storage converter 100 with on-load disconnection function to achieve DC isolation and DC protection.

[0068] Specifically, the remote shutdown function applies a voltage signal to the trip shunt of switchgear 191, causing it to trip and disconnect, disconnecting switchgear 191 from DC fuse 142. Switchgear 191 is the mechanical component of DC isolation switch device 190. Its closing and opening establishes a connection between the battery side and fully liquid-cooled modular energy storage converter 100 with on-load disconnect capability. Operating handle 193 is an external manual operating mechanism that allows manual closing and opening of switchgear 191.

[0069] In some embodiments, optionally, as shown in Figure 2, in the height direction of the fully liquid-cooled modular energy storage converter 100 with load disconnecting function, the first air duct 114 is located above the second air duct 116, the first fan 160 is located above the power module 120, and the air outlet 161 of the first fan 160 is facing the power module 120; the air inlet 164 of the second fan 162 is facing the functional component 128.

[0070] In this embodiment, in the height direction of the fully liquid-cooled modular energy storage converter 100 with an on-load disconnect function, the first air duct 114 is located above the second air duct 116. The first fan 160 and the second fan 162 operate simultaneously, allowing airflow to circulate within the first air duct 114 and the second air duct 116, forming a circulating cooling loop. Specifically, the first fan 160 is located above the power module 120, and the air outlet 161 of the first fan 160 is oriented toward the power module 120. When the first fan 160 is operating, the cold airflow is blown into the second air duct 116 through the first fan 160 and the heat sink 126 on the liquid cooling plate 121. The air inlet 164 of the second fan 162 faces the functional component 128. The second fan 162 can take away the heat of the functional component 128 by exhausting air. The first fan 160 and the second fan 162, one blowing air and the other exhausting air, jointly maintain the air operating environment temperature inside the fully liquid-cooled modular energy storage converter 100 with load breaking function.

[0071] In some embodiments, optionally, as shown in Figure 2, the power module 120 includes: a power component 122, arranged in the first air duct 114; a reactor component 123, arranged in the second air duct 116, and the reactor component 123 is located between the liquid cooling plate 121 and the heat radiation plate 124; wherein, the liquid cooling plate 121 is located between the power component 122 and the reactor component 123.

[0072] In this embodiment, power module 120 includes a power assembly 122 and a reactor assembly 123. Specifically, power assembly 122 is disposed in first air duct 114, reactor assembly 123 is disposed in second air duct 116, and liquid cooling plate 121 is located between power assembly 122 and reactor assembly 123. One side of liquid cooling plate 121 is connected to power assembly 122, and the other side of liquid cooling plate 121 is connected to reactor assembly 123. Liquid cooling plate 121 can provide liquid cooling for power assembly 122 and reactor assembly 123. Reactor assembly 123 is located between liquid cooling plate 121 and heat radiation plate 124. Heat radiation plate 124 absorbs heat from reactor assembly 123 and radiates it to other spaces within cabinet 110, thereby improving the cooling effect on reactor assembly 123 and enabling reactor assembly 123 to operate in a suitable temperature environment.

[0073] In some embodiments, optionally, as shown in Figure 2, the fully liquid-cooled modular energy storage converter 100 with on-load disconnection function further includes: a DC support unit 130, which is arranged in the cabinet 110 and connected to the power component 122, and the DC support unit 130 is used to provide DC side energy for equipment power conversion.

[0074] In this embodiment, the fully liquid-cooled modular energy storage converter 100 with on-load disconnect functionality also includes a DC support unit 130. Specifically, the DC support unit 130 is disposed within the cabinet 110 and connected to the power assembly 122. The DC support unit 130 is used to provide DC-side energy for device power conversion. The DC support unit 130 also includes a fixing structure 133 for securing the connection.

[0075] In some embodiments, optionally, as shown in Figure 2, the DC support unit 130 includes: a support capacitor 131, which is arranged in the cabinet 110, and the support capacitor 131 is used to provide DC side energy; a laminated busbar 132, and the laminated busbar 132 is used to connect the support capacitor 131 and the power component 122.

[0076] In this embodiment, the DC support unit 130 includes a support capacitor 131 and a laminated busbar 132. The support capacitor 131 is disposed within the cabinet 110 and is fixed to the sheet metal components using bottom bolts. The positive, midpoint, and negative electrodes of the support capacitor 131 are connected in parallel via the laminated busbar 132 and lead to terminals U+, U-, and U0, which are respectively connected to the power components 122.

[0077] In some embodiments, optionally, as shown in Figures 2 and 4, the DC power unit 140 also includes: a DC contactor 141, which is arranged in the cabinet 110 and connected to the DC fuse 142; a DC current sensor 145, which is connected to the DC fuse 142, and the DC current sensor 145 is located between the DC fuse 142 and the laminated busbar 132.

[0078] In this embodiment, the DC power unit 140 includes a DC contactor 141, a DC fuse 142, and a DC current sensor 145. Specifically, the DC contactor 141 is connected to the cabinet 110 and is used to interrupt the DC current. When the DC current is interrupted, its arc is not extinguished briefly like when the AC current passes through zero. Therefore, a special arc extinguishing device is designed inside the DC contactor 141. The DC fuse 142 is connected to the DC contactor 141 and is used for overcurrent and short-circuit protection. The DC fuse 142 can be quickly disconnected in the event of a fuse overload. The DC current sensor 145 is connected to the DC fuse 142 and is used to detect the DC current. The DC current sensor 145 is located between the DC fuse 142 and the laminated busbar 132.

[0079] The DC current sensor 145 is fixed to the copper busbar between the DC fuse 142 and the laminated busbar 132. The copper busbar connects the DC contactor 141, DC fuse 142, DC current sensor 145, and the external DC plug connector 152 into a unified whole. The DC copper busbar, DC contactor 141, DC fuse 142, and DC plug connector 152 form a complete DC output circuit, and each component is fixed together with bolts.

[0080] In actual applications, the DC plug connector 152 of the fully liquid-cooled modular energy storage converter 100 with an on-load disconnection function can be replaced by a heavy-duty terminal.

[0081] In some embodiments, optionally, as shown in FIG5 , the functional component 128 includes: an AC power unit 146 , which is disposed in the cabinet 110 and connected to the power module 120 . The AC power unit 146 is used to control the on / off of the AC side and provide AC overcurrent protection.

[0082] In this embodiment, the functional component 128 includes an AC power unit 146. Specifically, the AC power unit 146 is disposed in the cabinet 110 and connected to the power module 120. The AC power unit 146 is used to control the on / off of the AC side and provide AC overcurrent protection.

[0083] In actual applications, the AC power unit 146 is connected to the reactor assembly 123 through a flexible connection, and is connected to the external AC plug connector 151 through a flexible connection.

[0084] In actual applications, the power component 122 and the reactor component 123 are respectively distributed on the upper and lower sides of the liquid cooling plate 121, fixed into a whole by screws, and then fixed as a whole to the side of the fully liquid-cooled modular energy storage converter 100 with load breaking function. The other side of the reactor component 123 is in full contact with the heat radiation plate 124. The power component 122 is connected to the input of the reactor component 123 through a soft connection, and the output of the reactor component 123 is also connected to the AC power unit 146 through a soft connection.

[0085] In some embodiments, optionally, as shown in FIG. 5 , the AC power unit 146 includes: an AC relay 143 disposed in the cabinet 110 ; and an AC fuse 144 connected to the AC relay 143 .

[0086] In this embodiment, AC power unit 146 includes an AC relay 143 and an AC fuse 144. Specifically, AC relay 143 is connected to cabinet 110 and can control the switching operation of fully liquid-cooled modular energy storage converter 100 with load disconnect function. When an abnormal situation occurs, it can quickly disconnect the circuit and protect the equipment from damage. AC fuse 144 is connected to AC relay 143 and is used for overcurrent and short-circuit protection. When a fault such as a short circuit or overload occurs in the circuit, AC fuse 144 can quickly disconnect the circuit to prevent further increase in current and protect the equipment in the circuit from damage.

[0087] Specifically, the AC relay 143 , the AC fuse 144 , the externally connected AC plug connector 151 and other structural modules are connected to form a unified whole through on-board welding of the circuit board.

[0088] In actual applications, the AC power unit 146 can also use an isolating switch plus a contactor to control the on / off of the AC side and provide AC overcurrent protection, or use a contactor to control the on / off of the AC side and provide AC overcurrent protection.

[0089] In actual applications, the AC plug connector 151 of the fully liquid-cooled modular energy storage converter 100 with an on-load disconnecting function can be replaced by a heavy-duty terminal.

[0090] In some embodiments, optionally, as shown in FIG4 , the fully liquid-cooled modular energy storage converter 100 with an on-load disconnection function further includes: a filter unit 180, the filter unit 180 includes a filter capacitor, and the filter unit 180 is used to filter out harmonics; a control unit 170, which is used to collect voltage, current, and temperature information, and to realize grid-connected, charging and discharging, and grid-connected and off-grid functions in combination with a preset software algorithm.

[0091] In this embodiment, the fully liquid-cooled modular energy storage converter 100 with on-load disconnect functionality further includes a filter unit 180 and a control unit 170. Specifically, the filter unit 180 comprises filter capacitors mounted on a circuit board. The switching devices generate harmonics when in operation, and the filter unit 180 is used to filter out these harmonics, thereby smoothing the voltage and current waveforms output by the fully liquid-cooled modular energy storage converter 100 with on-load disconnect functionality.

[0092] The control unit 170 serves as the core control actuator of the fully liquid-cooled modular energy storage converter 100 with on-load disconnection function. It is used to sample voltage, current, temperature and other information, and combined with relevant software algorithms to realize grid connection, charging and discharging, grid connection and off-grid functions, and perform digital quantity control and reading, external communication and other functions.

[0093] The present application utilizes a liquid cooling circuit formed by the liquid cooling plate 121, the heat sink 126 on the liquid cooling plate 121, and the first and second fans 160 and 162 within the cabinet 110 to maximize the use of the liquid cooling portion, maintaining the temperature within the fully liquid-cooled modular energy storage converter 100 with a load disconnect function at a set operating ambient temperature, keeping the internal components operating in optimal environmental conditions, and preventing power reduction due to temperature changes. The partition 112 is provided to optimize the air duct within the cabinet 110, making the air circulation within the cabinet 110 smoother, improving air flow efficiency, effectively reducing the internal ambient temperature, and maintaining efficient operation of the internal components. Furthermore, the fully liquid-cooled modular energy storage converter 100 with a load disconnect function provided by the present application has a compact structure, small size, and low cost; two independent upper and lower air ducts prevent heat from accumulating locally; and the heat sink 126 increases the air contact surface, thereby enhancing the cooling effect.

[0094] By adding a DC isolating switch device 190 with on-load disconnect functionality, this application enables the energy storage integrated system to provide high-voltage DC isolation on the DC side, regardless of whether a DC high-voltage switch box is present, and also provides a remote disconnect function. In the event of a system anomaly, the battery pack can be quickly and remotely disconnected from the fully liquid-cooled modular energy storage inverter 100 with on-load disconnect functionality, regardless of whether the energy storage inverter is operating at full load or in other load states. This makes system design more flexible, cost-effective, and control more convenient and rapid.

[0095] In this application, the term "plurality" refers to two or more, unless otherwise specified. Terms such as "installed," "connected," "connected," and "fixed" should be interpreted broadly. For example, "connected" can mean fixed, removable, or integrally connected; and "connected" can mean directly or indirectly through an intermediary. Those skilled in the art will understand the specific meanings of these terms in this application based on the specific circumstances.

[0096] Throughout this specification, terms such as "one embodiment," "some embodiments," and "specific embodiments" mean that the specific features, structures, materials, or characteristics described in conjunction with that embodiment or example are included in at least one embodiment or example of the present application. In this specification, schematic representations of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples.

[0097] The above description is merely a preferred embodiment of the present application and is not intended to limit the present application. Various modifications and variations are possible for those skilled in the art. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of the present application shall be included within the scope of protection of the present application.

Claims

1. A fully liquid-cooled modular energy storage converter with load breaking function, wherein: include: Cabinet; A power module is arranged in the cabinet; A functional component is arranged in the cabinet, and the functional component is arranged opposite to the power module; the functional component includes a DC power unit, which is arranged in the cabinet, and the DC power unit is used to control the on-off of the DC side and provide DC overcurrent protection; the DC power unit includes a DC fuse; A liquid cooling plate, arranged on the power module, and used for cooling the power module; A partition plate is disposed in the cabinet, the partition plate is connected to the liquid cooling plate, and the partition plate and the liquid cooling plate separate the space in the cabinet into a first air duct and a second air duct; A heat radiation plate, disposed in the second air duct and connected to the power module; A first fan is disposed in the first air duct, and the first fan is used to blow air to the power module and blow the airflow into the second air duct; a second fan, disposed in the second air duct, the second fan being used to extract air from the functional components and blow air into the first air duct; A DC isolating switch device is arranged in the cabinet, the DC isolating switch device is connected to the DC fuse, and the DC isolating switch device is used for DC isolation and DC protection.

2. The fully liquid-cooled modular energy storage converter with on-load breaking function according to claim 1, wherein: The DC isolating switch device comprises: A switch device, arranged in the cabinet, wherein the switch device is connected to the DC fuse; An operating handle, connected to the switch device, and used to control the switch device to be turned on or off; The remote disconnecting component is arranged in the cabinet and is used for remote control to realize DC isolation and DC protection.

3. The fully liquid-cooled modular energy storage converter with on-load breaking function according to claim 1, wherein: In the height direction of the fully liquid-cooled modular energy storage converter with an on-load disconnection function, the first air duct is located above the second air duct, the first fan is located above the power module, and the air outlet of the first fan faces the power module; The air inlet of the second fan faces the functional component.

4. The fully liquid-cooled modular energy storage converter with on-load breaking function according to claim 1, wherein: The power module comprises: A power component, arranged in the first air duct; A reactor assembly, arranged in the second air duct, wherein the reactor assembly is located between the liquid cooling plate and the heat radiation plate; Wherein, the liquid cooling plate is located between the power component and the reactor component.

5. The fully liquid-cooled modular energy storage converter with on-load breaking function according to claim 4, wherein: Also includes: A DC support unit is arranged in the cabinet and connected to the power component. The DC support unit is used to provide DC side energy for equipment power conversion.

6. The fully liquid-cooled modular energy storage converter with on-load breaking function according to claim 5, wherein: The DC support unit comprises: A supporting capacitor is arranged in the cabinet, and the supporting capacitor is used to provide DC side energy; A laminated busbar, wherein the laminated busbar is used to connect the supporting capacitor and the power component.

7. The fully liquid-cooled modular energy storage converter with on-load breaking function according to claim 6, wherein: The DC power unit also includes: A DC contactor is disposed in the cabinet and connected to the DC fuse; A DC current sensor is connected to the DC fuse, and the DC current sensor is located between the DC fuse and the laminated busbar.

8. The fully liquid-cooled modular energy storage converter with on-load breaking function according to any one of claims 1 to 7, wherein: The functional components also include: An AC power unit is disposed in the cabinet and connected to the power module. The AC power unit is used to control the on / off of the AC side and provide AC overcurrent protection.

9. The fully liquid-cooled modular energy storage converter with on-load breaking function according to claim 8, wherein: The AC power unit comprises: An AC relay is arranged in the cabinet; An AC fuse is connected to the AC relay.

10. The fully liquid-cooled modular energy storage converter with on-load breaking function according to any one of claims 1 to 7, wherein: Also includes: A filter unit, the filter unit comprising a filter capacitor, and the filter unit is used to filter out harmonics; The control unit is used to collect voltage, current and temperature information, and combine with preset software algorithms to realize grid-connected, charging and discharging, and grid-connected and off-grid functions.

Images