Rectifier power module for internal combustion locomotive traction system

Abstract

The present disclosure relates to the technical field of structural arrangement of power modules in traction converter systems, and relates in particular to a rectifier power module for an internal combustion engine traction system. The disclosure addresses the technical problem of numerous specifications and models of rectifier power modules in existing internal combustion locomotives, which hinders the overall modular and standardized design of converters. The rectifier power module comprises a water-cooled baseplate, a left composite busbar, a right composite busbar, a left frame, and a right frame. All diodes are evenly arranged on two sides of the water-cooled baseplate. A resistor in a traction system grounding circuit is disposed on the left side of the water-cooled baseplate, and a resistor in an auxiliary system grounding circuit and a resistor in a traction system discharge circuit are disposed on the right side of the water-cooled baseplate. The left frame is located on the left side of the left composite busbar, and the right frame is located on the right side of the right composite busbar. Interfaces S1 and S2 are disposed on plates on the front sides of the left and right composite busbars, respectively. Interfaces S6, S7, and S8 are disposed on the front side of the right frame. Three-phase high-voltage input interfaces S3, S4, and S5 are connected to plates on the rear sides of the left and right composite busbars.

Description

A rectifier power module for a diesel locomotive traction system

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This disclosure is based on the Chinese patent application with application number 202311792098.4 and application date of December 25, 2023, and claims the priority of the Chinese patent application. The entire content of the Chinese patent application is hereby incorporated into this disclosure by introduction. Technical Field

[0003] The present disclosure relates to the technical field of structural arrangement of power modules in a traction converter system, and in particular to a rectifier power module for an internal combustion engine traction system. Background Art

[0004] With the rapid development of rail transit technology, high-power devices are widely used in converters. Converters are moving towards miniaturization, lightweighting, modularization, and high reliability. Energy-saving and environmentally friendly hybrid locomotives are the platform for future hybrid vehicles, electric-electric shunting vehicles, rescue vehicles, and tunnel engineering vehicles. They can effectively reduce diesel engine emissions and noise, while also being energy-efficient and environmentally friendly. To better meet the needs of railway transportation, ensure system reliability, and reduce operating and maintenance costs, power units, as the core components of the entire converter, are also developing towards high frequency, miniaturization, intelligence, and high reliability. Currently, the diesel locomotive rectifier power modules used in the power units of rail transit vehicle converter systems come in a wide variety of specifications and models, with poor interchangeability. This hinders the modularization and standardization of the converter's overall design. Furthermore, the wide variety of power module designs results in low product reuse, high design costs, and large inventory holdings. This makes component reliability difficult to ensure, resulting in high operating and maintenance costs. The wide variety of module structures and poor versatility complicate converter structural design, further complicating overall traction system stability.

[0005] Summary of the Invention

[0006] In order to overcome the technical defects of existing internal combustion locomotive rectifier power modules, such as a wide variety of specifications and models, poor interchangeability, being unfavorable for the overall modularization and standardization design of the converter, and difficulty in ensuring the overall stability of the traction system, the present disclosure provides a rectifier power module for an internal combustion engine traction system.

[0007] The present disclosure provides a rectifier power module for an internal combustion engine traction system, the rectifier power module including a three-phase uncontrolled rectifier circuit, a traction system grounding loop, a traction system discharge loop, and an auxiliary system grounding loop. The three-phase uncontrolled rectifier circuit includes three AC output bridge arms composed of a diode D11, a diode D12, a diode D13, a diode D21, a diode D22, and a diode D23. The three AC output bridge arms are respectively connected to three-phase high-voltage input interfaces S3 (U), S4 (V), and S5 (W); the traction system grounding loop is composed of a resistor GRe1 and a resistor GRe2. The traction system grounding loop realizes the traction system. The 1 / 2 grounding detection function of the system is realized. The traction system discharge circuit is composed of resistors DR1 to DR6. The traction system discharge circuit realizes the discharge function of the supporting capacitor voltage after the traction system is shut down. The auxiliary system grounding circuit includes a resistor ADR. The auxiliary system grounding circuit realizes the detection function of the auxiliary system grounding. The positive and negative interfaces of the DC bus of the rectifier power module are S1 and S2 respectively. The 1 / 2 output interface of the traction system grounding circuit is S6. The interfaces configured to connect the two ends of the resistor ADR in the auxiliary system grounding circuit are S7 and S8 respectively; the rectifier power module also includes a water-cooled base plate, a left composite busbar, and a right composite busbar. The diodes in the three-phase uncontrolled rectifier circuit are distributed on both sides of the water-cooled base plate, the resistors in the traction system grounding loop are set on the left side of the water-cooled base plate, the resistors in the auxiliary system grounding loop and the resistors in the traction system discharge loop are set on the right side of the water-cooled base plate, and all resistors are arranged near the diodes according to the layout of the flow channel on the water-cooled base plate. The two ends of the three AC output bridge arms, the two ends of the traction system grounding loop, and the two ends of the traction system discharge loop are respectively connected to the left composite busbar and the right composite busbar on both sides of the water-cooled base plate. The left frame is located on the left side of the left composite busbar, and the right frame is located on the right side of the right composite busbar. The frame and the right frame are fixedly connected to the left and right side walls of the water-cooled baseplate respectively. The plates on the front sides of the left and right composite busbars are respectively connected to the front sides of the water-cooled baseplate through insulating support seats. Interface S1 is arranged on the plate on the front side of the left composite busbar, and interface S2 is arranged on the plate on the front side of the right composite busbar. Interface S6, interface S7 and interface S8 are connected to the front side of the right frame through insulating support terminals. The three-phase high-voltage input interfaces S3 (U), S4 (V), and S5 (W) are respectively connected to the plates on the rear sides of the left and right composite busbars through high-voltage connectors. The water connector of the water-cooled baseplate is arranged on the front right side of the rectifier power module as a whole.

[0008] This paper presents a rectifier power module for a diesel engine traction system. By analyzing the main circuit functions of a diesel locomotive traction system and aligning it with the axle power, electrical parameters, and environmental requirements of mainline diesel locomotives, the rectifier power module is streamlined and designed using a modular, component-based structure. The rectifier power module utilizes a double-sided diode structure to integrate the three-phase uncontrolled rectifier circuit, traction system grounding circuit, traction system discharge circuit, and auxiliary system grounding circuit of the traction rheological system, achieving the AC-DC conversion requirements of the traction system. Through reasonable layout, the volume of the traction converter cabinet is reduced and the structural layout is more reasonable; the discharge circuit and grounding circuit power devices are integrated into the power device components with water cooling technology, which reduces the power loss and flow demand of the vehicle system; through circuit integration design and low-inductance composite busbar design application, the system circuit stray inductance is reduced and the system reliability is improved; the general interchangeability, simplification and standardization of components are proposed. Technical requirements for design are put forward to reduce spare parts, realize the optimization of component product types, specifications and models, and reduce design costs; optimize component product structure, promote the rational layout of the overall structure of the converter system, flexibly adapt to changes in customer needs, and quickly respond to market customer needs to meet the development of miniaturization, lightweight, modularization and high reliability of converter devices.

[0009] The technical solution provided by the present disclosure has the following advantages compared with the existing technology:

[0010] 1) By analyzing the main circuit functions of the diesel locomotive traction system and meeting the requirements of the diesel locomotive's axle power, electrical parameters, and environment, a modular structure is used to simplify the design of the traction rectifier power module, thereby improving component and system reliability, reducing quality losses, and lowering design costs;

[0011] 2) The traction system grounding circuit, traction system discharge circuit, and auxiliary system grounding circuit are integrated into the power module, which is compatible with the traction system electrical functions, control and protection functions, and interface requirements, and reduces the size of the converter;

[0012] 3) The discharge circuit and grounding circuit power devices are integrated into the IGBT component water cooling technology, reducing system power loss and flow requirements;

[0013] 4) By optimizing the product structure of traction power modules, the overall structure of the converter system can be rationally arranged, facilitating the miniaturization and lightweight design of the converter.

[0014] 5) Modular design of the rectifier power module reduces the backlog of rectifier power modules of various specifications, models, and types. The rectifier power module disclosed in the present invention is universal and interchangeable, reducing repair and maintenance costs;

[0015] 6) Improve component reliability, reduce product quality and cost losses, and enhance overall system reliability through research on component standard reliability;

[0016] 7) Fewer product types, shorter development cycles, flexible adaptation to changes in customer needs, and rapid response to market customer demands. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments consistent with the present disclosure and, together with the description, serve to explain the principles of the present disclosure.

[0018] In order to more clearly illustrate the embodiments of the present disclosure or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, for ordinary technicians in this field, other drawings can be obtained based on these drawings without any creative work.

[0019] FIG1 is a circuit diagram of a rectifier power module of an internal combustion engine traction system according to an embodiment of the present disclosure;

[0020] FIG2 is a main circuit topology structure of a rectifier power module of an internal combustion engine traction system connected to a traction converter system according to an embodiment of the present disclosure;

[0021] FIG3 is a front structural diagram of a rectifier power module of an internal combustion engine traction system according to an embodiment of the present disclosure;

[0022] FIG4 is a rear view schematic diagram of a rectifier power module of an internal combustion engine traction system according to an embodiment of the present disclosure;

[0023] FIG5 is an exploded view of the structure of a rectifier power module of an internal combustion engine traction system according to an embodiment of the present disclosure;

[0024] FIG6 is a schematic diagram of the left and right sides of a rectifier power module of an internal combustion engine traction system according to an embodiment of the present disclosure.

[0025] In the figure: 1. Water-cooled base plate; 2. Left composite busbar; 3. Right composite busbar; 4. Left frame; 5. Right frame; 6. Insulation support seat; 7. Insulation support terminal; 8. High-voltage connector; 9. Water joint. DETAILED DESCRIPTION

[0026] In order to more clearly understand the above-mentioned objectives, features and advantages of the present disclosure, the scheme of the present disclosure will be further described below. It should be noted that the embodiments of the present disclosure and the features therein can be combined with each other in the absence of conflict.

[0027] In the following description, many specific details are set forth to facilitate a full understanding of the present disclosure, but the present disclosure may also be implemented in other ways different from those described herein; it is obvious that the embodiments in the specification are only part of the embodiments of the present disclosure, rather than all of the embodiments.

[0028] The specific embodiments of the present disclosure are described in detail below with reference to the accompanying drawings.

[0029] According to the integrated requirements of the rail transit power conversion system, the main function of the rectifier power module is to perform pulse rectification on the three-phase AC power input by the generator to form an intermediate DC voltage for use in the traction inverter circuit and auxiliary circuit; at the same time, the rectifier power module highly integrates the traction system discharge circuit and grounding circuit into the power module, realizing the AC-DC functional conversion requirements of the traction system.

[0030] The traction converter system uses a rack-controlled method, powered by a diesel generator and a traction charger. It converts three-phase AC voltage into DC power through AC-DC conversion for use by the traction and auxiliary systems. The specific circuit diagram is shown in Figure 1. The main function of the traction rectifier power module is to pulse-rectify the three-phase AC input from the internal combustion engine generator to form an intermediate DC voltage for use by the traction and auxiliary systems. The present disclosure integrates the three-phase uncontrolled rectifier circuit, traction system grounding circuit, traction system discharge circuit, and auxiliary system grounding circuit in the main circuit topology of the traction converter system into the rectifier power module. The circuit structure is shown in Figure 2, and its specific mechanical structure has been integrated into the design, as shown in Figures 2-6.

[0031] As shown in FIG1 , in the system main circuit topology, the switching devices D11 and D21 , D12 and D22 , and D13 and D23 respectively form three AC output bridge arms S3 (U), S4 (V), and S5 (W).

[0032] According to the system main circuit type requirements, the rated input operating voltage of the traction rectifier power module is 560V~1400V / 3P, 620V~1406V / 3P and 850V~2100V / 3P. The maximum bus voltage of the diesel locomotive main circuit is DC 2800V, and the operating voltage range is DC 800V~1800V, DC 1200V~1800V and DC 850V~2800V.

[0033] According to the system main circuit requirements, this rectifier power module is suitable for systems with a wheel power of less than 1500kW. The maximum rated input operating current of the traction rectifier power module is 670A, and the maximum rated output current is 891A. After conversion, the maximum bus voltage can reach 2800V.

[0034] Among them, the current and voltage parameters of the diesel locomotive rectifier power module are shown in Table 1.

[0035] Table 1 Current and voltage parameters of diesel locomotive rectifier power module

[0036] Comprehensive consideration was given to the main circuit of the diesel locomotive traction system, the system's application environment, electrical performance, mechanical performance, and repair and maintenance requirements. The diesel locomotive traction rectifier power module was designed based on its operating conditions, technical requirements, and volume requirements. The module was then designed with electrical specifications including an input voltage of AC 560V to 2100V / 3P, a maximum input current of 670V, an output voltage range of DC 800V to 2800V, and a maximum output current of 891A. Specific technical parameters are shown in Table 2.

[0037] Table 2 Technical parameter table of diesel locomotive rectifier power module

[0038] In one embodiment, as shown in Figures 1 to 6, a rectifier power module for an internal combustion engine traction system is disclosed. The rectifier power module includes a three-phase uncontrolled rectifier circuit, a traction system grounding loop, a traction system discharge loop, and an auxiliary system grounding loop. The three-phase uncontrolled rectifier circuit includes three AC output bridge arms consisting of a diode D11, a diode D12, a diode D13, a diode D21, a diode D22, and a diode D23. The three AC output bridge arms are respectively connected to three-phase high-voltage input interfaces S3 (U), S4 (V), and S5 (W); the traction system grounding loop is composed of a resistor GRe1 and a resistor GRe2. The traction system grounding loop implements a 1 / 2 grounding detection function of the traction system. The traction system discharge circuit is composed of resistors DR1 to DR6. The traction system discharge circuit realizes the discharge function of the supporting capacitor voltage after the traction system is shut down. The auxiliary system grounding circuit includes a resistor ADR. The auxiliary system grounding circuit realizes the detection function of the auxiliary system grounding. The positive and negative interfaces of the DC bus of the rectifier power module are S1 and S2 respectively, and the 1 / 2 output interface of the traction system grounding circuit is S6. The interfaces configured to connect the two ends of the resistor ADR in the auxiliary system grounding circuit are S7 and S8 respectively; the rectifier power module also includes a water-cooled base plate 1, a left composite busbar 2, a right composite busbar 3, a left frame 4 and a right frame 5. The diodes in the three-phase uncontrolled rectifier circuit are evenly distributed to the water-cooled base plate. On both sides of the board 1, the resistors in the traction system grounding loop are set on the left side of the water-cooled base plate 1, and the resistors in the auxiliary system grounding loop and the resistors in the traction system discharge loop are set on the right side of the water-cooled base plate 1. All resistors are arranged according to the layout of the flow channel on the water-cooled base plate 1. The two ends of the three AC output bridge arms, the two ends of the traction system grounding loop, and the two ends of the traction system discharge loop are respectively connected to the left composite busbar 2 and the right composite busbar 3 on both sides of the water-cooled base plate 1. The left frame 4 is located on the left side of the left composite busbar 2, and the right frame 5 is located on the right side of the right composite busbar 3. The left frame 4 and the right frame 5 are fixedly connected to the left and right side walls of the water-cooled base plate 1 respectively. The left composite busbar 2 and the right composite busbar 3 are on the front side. The plate bodies are respectively connected to the front sides of the water-cooled base plates 1 through insulating support seats 6. A movable nut is embedded in the insulating support seats 6. The provision of the insulating support seats 6 can not only achieve reliable electrical connection, but also facilitate heat dissipation and the realization of a stacked structure. The interface S1 is provided on the plate body on the front side of the left composite busbar 2, and the interface S2 is provided on the plate body on the front side of the right composite busbar 3. The interfaces S6, S7 and S8 are connected to the front side of the right frame 5 through insulating support terminals 7. The three-phase high-voltage input interfaces S3 (U), S4 (V) and S5 (W) are respectively connected to the plate bodies on the rear sides of the left composite busbar 2 and the right composite busbar 3 through high-voltage connectors 8. The water connector 9 of the water-cooled base plate 1 is provided on the front right side of the overall rectifier power module.

[0039] The high-voltage connector 8 is provided to enable quick installation of the power module. The present disclosure achieves an integrated design of the power module through a reasonable layout, reduces the volume of the traction converter cabinet, reduces the power loss and flow requirements of the vehicle system, reduces the stray inductance of the system loop, and improves system reliability. The left frame 4 and the right frame 5 clamp and fix the left composite busbar 2, the water-cooled base plate 1, the right composite busbar 3, as well as the three-phase uncontrolled rectifier circuit, the traction system grounding loop, the traction system discharge loop, and the auxiliary system grounding loop, and finally connect them to other connection components such as the insulating support seat 6, the insulating support terminal 7, the high-voltage connector 8, and the water joint 9 to form the rectifier power module as a whole.

[0040] The above description is merely a specific embodiment of the present disclosure, which enables those skilled in the art to understand or implement the present disclosure. Although detailed descriptions have been made with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or replace some or all of the technical features therein with equivalents; and such modifications or replacements do not deviate from the essence of the corresponding technical solutions within the scope of the technical solutions of the embodiments, and they should all be covered by the scope of protection of the claims.

Claims

1. A rectifier power module for an internal combustion engine traction system. The rectifier power module includes a three-phase uncontrolled rectifier circuit, a traction system grounding loop, a traction system discharge loop, and an auxiliary system grounding loop. The three-phase uncontrolled rectifier circuit includes three AC output bridge arms composed of diodes D11, D12, D13, D21, D22, and D23. Three-phase high-voltage input interfaces S3, S4, and S5 are respectively connected to the three AC output bridge arms; the traction system grounding loop is composed of resistors GRe1 and GRe2, and the traction system grounding loop realizes the 1 / 2 grounding detection function of the traction system. The traction system discharge loop is composed of resistors DR1 to DR6, and the traction system discharge loop realizes the discharge function of the support capacitor voltage after the traction system stops. The auxiliary system grounding loop includes resistor ADR, and the auxiliary system grounding loop realizes the detection function of the auxiliary system grounding. The positive and negative interfaces of the DC bus of the rectifier power module are S1 and S2 respectively, the 1 / 2 output interface of the traction system grounding loop is S6, and the interfaces configured to connect both ends of resistor ADR in the auxiliary system grounding loop are S7 and S8 respectively; among them, The rectifier power module further includes a water-cooled substrate (1), a left composite busbar (2), a right composite busbar (3), a left frame (4), and a right frame (5). The diodes in the three-phase uncontrolled rectifier circuit are evenly distributed on both sides of the water-cooled substrate (1). The resistor in the traction system grounding loop is arranged on the left side of the water-cooled substrate (1). The resistors in the auxiliary system grounding loop and the traction system discharge loop are arranged on the right side of the water-cooled substrate (1). All the resistors are arranged near the diodes according to the layout of the flow channels on the water-cooled substrate (1). The two ends of the three AC output bridge arms, the two ends of the traction system grounding loop, and the two ends of the traction system discharge loop are respectively connected to the left composite busbar (2) and the right composite busbar (3) located on both sides of the water-cooled substrate (1). The left frame (4) is located on the left side of the left composite busbar (2), and the right frame (5) is located on the right side of the right composite busbar (3). The left frame (4) and the right frame (5) are respectively fixedly connected to the left and right side walls of the water-cooled substrate (1). The front plates of the left composite busbar (2) and the right composite busbar (3) are respectively connected to the front side of the water-cooled substrate (1) through insulating support seats (6). The interface S1 is arranged on the front plate of the left composite busbar (2). The interface S2 is arranged on the front plate of the right composite busbar (3). The interfaces S6, S7, and S8 are connected to the front side of the right frame (5) through insulating support terminals (7). The three-phase high-voltage input interfaces S3, S4, and S5 are respectively connected to the rear plates of the left composite busbar (2) and the right composite busbar (3) through high-voltage connectors (8). The water joint (9) of the water-cooled substrate (1) is arranged at the front right of the whole rectifier power module.

Images