地铁列车大功率高频辅助变流器散热系统的设计及优化试验验证
易滔1赵清良1别必龙2刘海涛3饶沛南1周帅1张云瀚1宋森1耿志东1杨浩1
Design and Optimization Experimental Verification of Heat Dissipation System for High-power High-frequency Auxiliary Converters in Metro Trains
YI Tao1ZHAO Qingliang1BIE Bilong2LIU Haitao3RAO Peinan1ZHOU Shuai1ZHANG Yunhan1SONG Sen1GENG Zhidong1YANG Hao1
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作者信息:1.株洲中车时代电气股份有限公司， 412001， 株洲
2.宁波市轨道交通集团有限公司智慧运营分公司， 315111， 宁波
3.中车株洲电力机车研究所有限公司， 412001， 株洲
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Affiliation:1.Zhuzhou CRRC Times Electric Co., Ltd., 412001, Zhuzhou, China
2.Smart Operation Branch of Ningbo Rail Transit Group Co., Ltd., 315111, Ningbo, China
3.CRRC Zhuzhou Institute Co., Ltd., 412001, Zhuzhou, China
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关键词:
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Key words:
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DOI:10.16037/j.1007-869x.2024.01.027
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中图分类号/CLCN:U270.38+1
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栏目/Col:研究报告
摘要:
［目的］地铁列车大功率辅助变流器高度集成化后，散热要求越来越高，为此有必要提出散热系统新设计方案。［方法］通过系统的损耗计算、风机选型、散热风道布局等一系列正向设计，结合仿真来验证热设计的合理性。［结果及结论］仿真表明，在单台辅助变流器故障工况下，中间腔室流场分布不均，导致变压器温升较高，存在热失效风险。在此基础上对风道结构进行优化，仿真确认优化后风道的流场分布较均匀，变压器温升显著降低且在器件应用温度范围内，表明优化后散热系统满足应用需求。为验证理论设计的合理性，开展了样机的温升试验，对比仿真和样机试验结果，在单台/两台满载工况下，关键器件的温升和仿真温度差控制在5 ℃，均在选型的应用范围内，表明风道散热系统设计合理。通过正向优化设计提出了一种新型变流器散热系统及柜体结构，样机试验验证了仿真分析的有效性，大幅缩短了样机的开发周期，提高了市场响应速度，为大功率高频辅助变流器设计及优化提供方法及思路。
Abstracts:
［Objective］ With the high-degree integration of high-power auxiliary converters in metro trains, the demand for heat dissipation is rising significantly, necessitating the proposal of a new heat dissipation system design scheme. ［Method］ Through a series of forward designs involving power loss calculation, fan type selection, and heat dissipation duct layout, the rationality of the thermal design is validated by combining the simulation. ［Result & Conclusion］ Simulation results indicate that under the fault condition of a single auxiliary converter, uneven flow distribution in the intermediate chamber leads to elevated transformer temperature, posing a risk of thermal inefficiency. On this basis, the duct structure is optimized, and the simulation confirms a more uniform flow distribution in the duct, and a significant reduction in transformer temperature rise within the permissible operating temperature range, indicating that the optimized heat dissipation system meets application requirements. To validate the theoretical design, a prototype temperature rise test is conducted to compare the simulation and prototype test results. Under single and dual full-load working conditions, the temperature rise of key components and the temperature difference compared to the simulation are controlled within 5°C, both within the specified application range. This indicates the rationality of the duct heat dissipation system design. A new converter heat dissipation system and cabinet structure are proposed through forward optimization design, and prototype testing validates the effectiveness of the simulation analysis. This approach substantially shortens the prototype development cycle, enhances market responsiveness, and provides a methodology and direction for the design and optimization of high-power high-frequency auxiliary converters.
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