Patent Application
20100302728
The invention relates to an inverter or other electronically controlled power source for transforming electrical energy of predefined voltage and/or current. Further, the invention relates to a method for setting up and operating an inverter or other electronically controlled power source.
Inverter and other electronically controlled power sources for transforming electrical energy of predefined voltage and/or current are generally known. Such inverters are generally known and used to provide electrical energy of predefined voltage and/or current. To give one example, such inverters are used to transform electrical DC-energy provided by a solar generator into a basically sinusoidal current signal for feeding into a public or private grid. E.g. a 60 Hz signal for the public grid in the United States or a 50 Hz signal for the public European grid.
For transforming the electrical energy at least some power loss within the inverter is unavoidable. In particular such power loss appears at semiconductor switching elements such as IGBTs and also at chokes. To avoid malfunction of the inverter, in particular of the lossy components at which the power loss basically appears, cooling is necessary to avoid exceeding of a certain temperature.
Additionally, the inverter might not only suffer from heat generated by the electronic or electrical components but also by the sun. In particular if the inverter is used in connection with a solar generator, a high level of radiation of the sun is expected. This results in a dilemma for the designer of the inverter. I.e. the inverter could be isolated against heating of the sun but on the other hand an isolation might also make dissipating of heat more difficult.
However, it is also one general demand for an inverter to be sealed against water and dust and the like to protect the inverter. From the German utility model DE 20 2004 009 926 U1 an inverter is known comprising two chambers. These two chambers are separated by one wall that comprises the lossy components. One chamber comprises a cooling aggregate and each lossy component or a heat sink of it is attached directly to the separating wall and facing the chamber of the cooling aggregate.
However, such a common wall providing the lossy components might conduct heat from a lossy component to its heat sink, but it also conducts heat in the reverse direction, i.e. from the chamber comprising the cooling aggregate to the chamber comprising the other electronic components, which are not considered to be lossy but still may not get too hot. Also, the success of cooling basically depends on the efficiency of the cooling aggregate. Therefore, the success also depends on the energy provided for the cooling aggregate. Such an inverter does also not solve the dilemma of protection of the inverter against the heat of the sun and simultaneously still being able of dissipating heat generated within the inverter.
Accordingly it is at least one object of the invention to provide an inverter which reduces at least one of the above problems and to provide a method of setting up and/or operating such an inverter. In particular, it is one object of the invention to improve the capabilities of an inverter regarding dissipating of heat and protection against heat. A further object of the present invention is to improve the efficiency of the inverter regarding the dissipating of generated heat and protection against heat from outside.
To achieve these and other objects the invention proposes an inverter or other electronically controlled power source for transforming electrical energy into electrical energy of predetermined voltage and/or current comprising: an inner housing for housing the main circuitry of the inverter, and a cover connected to the inner housing, covering at least part of the inner housing, defining at least one cover channel between the inner housing and the cover for air to flow through that channel for cooling of the inverter, whereby the cover channel is adapted to facilitate natural convection of the air.
Accordingly, the invention proposes an inverter having an inner housing for housing the main circuitry of the inverter. Of course, if another electronically controlled power source is used, the inner housing comprises the main circuitry of that other power source. Such main circuitry usually comprises of one main circuit board having the most or even all electronic components attached, either directly or by means of further smaller circuit boards. Only special parts of the inverter that are necessarily or at least usually located outside might not be housed in the inner housing, such as an operating panel or a display. Also, a choke which is used for filtering our smoothing the generated current or other component dissipating high amount of energy might not be inside this inner housing.
A cover is connected to this inner housing, covering at least part of the inner housing, defining at least one cover channel between the inner housing and the cover. Such cover channel is designed as an air channel for air to flow through this channel to cool the inverter, provided that the air is cooler than the inverter. The channel is provided such, that natural convection of the air is facilitated.
Natural convection of air takes place according to warmer air ascending in an environment of cooler air. The force of such natural convection is, compared to an airflow generated by a fan or a vent, usually weak. The channel to facilitate natural convection must therefore comprise a relatively large cross sectional area. Of course, such channel must be of generally vertical orientation to let the warmer airflow upwards.
The vertical orientation of the channel is provided when the inverter is in use and accordingly, this vertical orientation assumes that the inverter is arranged in a normal upright operational position. Such an upright operational position is usually indicated at the inverter. In particular, any printing or even signs indicate an upright position, including any letters, numbers or signs displayed in a display of the inverter.
According to a further aspect of the present invention the cover is adapted to protect the inner housing against sunlight, in particular against direct radiation of sunlight. Accordingly, the cover is designed and attached to the inner housing such, that the sunrays do not or only in a very small measure reach the inner housing. I.e. it is only necessary, that the cover basically provides a shade for the inner housing but the cover does not necessarily have to enclose the inner housing completely. However, it must be noted, that the protection against the sun should be provided for a complete day and thus the change of the direction of the sun over the daytime must be taken into account.
According to one embodiment the cover comprises an outside having a light color, in particular white or silver. Such light color enhances the protection of the cover against radiation of sun light. The color can be provided in several ways such as a painting or a coating. In particular when the color is silver, it can be the natural color of a metal such as aluminium forming the cover.
Advantageously, the cover covers at least two sides of the inner housing preferably at least three sides and in particular five of six sides of the inner housing. The number of sides of the housing to be covered depends on many aspects as the shape and size of the inner housing, the shape and size of the cover and also on the intended use and location of use of the inverter. Considering an inner housing having a basically cuboid like shape and thus six sides, at least two, usually three sides would be reached by the sun during a (cloudless) day. These sides should be covered by the cover. In particular, three vertically arranged sides of such inner housing should be covered, also resulting in at least one vertical covered channel. If such cover covering three vertically arranged sides of the inner housing also touches two edges of these three sides, three separately covered channels may result, each corresponding to one side. However, it is preferred that the cover touches the inner housing only as far as necessary for attaching the cover at the inner housing, to avoid any unnecessary heat bridges.
According to one aspect the invention, the cover covers five of six sides of the inner housing i.e. only the back side of the inner housing is not covered by the cover.
A further advantage of such cover is to provide a possibility of an independent appearance. Generally the appearance of the inverter is dependent on the cover rather than the inner housing and any small changes in variations of the inverter might change the appearance of the inner housing, but the cover and thus the appearance of the inverter may remain unchanged.
For protection against the sun, in particular against direct radiation of the sun, the cover would not transmit but reflect the sun. However, at least some heating of the cover when exposed to the sun is expected. The heated cover will as a result heat the air in the cover channel and thus will result in natural convection of the air in the cover channel or it will enhanced it. As a further result there will be an air stream in upward direction, sucking in cooler air at a bottom and this will enhance cooling of the inverter. In other words, heating of the cover by the sun will result in a cooling effect.
According to a further invention a choke or other component dissipating high amount of energy of the inverter is positioned in the cover channel such, that air in the cover channel transports heat from the choke or corresponding component and heat of the choke or corresponding component enhances convection of air in the channel. Accordingly, a choke or corresponding component is positioned outside the inner housing in the cover channel and is exposed to an airflow in this channel. The air will flow along the choke or corresponding component resulting in cooling the choke or corresponding component respectively and heating the air. Since the air gets warmer, natural convection and thus the flow of air in an upward direction is enhanced, improving the cooling of the inverter and the choke or corresponding component. Further embodiments and advantages described for a choke apply also to an other component dissipating high amount of energy.
According to one aspect of the invention the choke or other component dissipating a high amount of energy is positioned at the top or at the bottom of the inner housing and thus is arranged in a top area of the cover channel or a bottom area of the cover channel respectively. If two or more chokes are used, at least one could be arranged in the top area and at least one other could be arranged in the bottom area.
According to one aspect of the invention, the cover channel comprises an input opening for air to enter the cover channel and an output opening for air to exit the cover channel and whereby the input opening is arranged at the bottom of the inverter and the output opening is arranged at the top of the inverter. Such top arrangement and bottom arrangement is to be understood with respect to an inverter being arranged in a normal upright operational position. If a choke is positioned in a bottom area, this would preferably be close to the input opening and if a choke is arranged in the top area this could preferably be close to the output opening. If a choke is arranged close to the input opening, it will be subjected to cool air entering the cover channel resulting in a good cooling result of the choke. On the other hand, if the choke is arranged close to the output opening the air heated by the choke will subsequently exit the cover channel and thus cannot heat the inverter.
According to a further aspect the inverter comprises at least one heat sink for cooling power components of the inverter, whereby the heat sink is attached to the inner housing basically providing a space between the heat sink and the inner housing.
Such a heat sink usually consists of a base with one or more flat surfaces and an array of comb or fin-like protrusions to increase the heat sink's surface area contacting the air. Contrary to known systems the base does not provide one wall of the inner housing nor is the base and in particular such a flat surface directly connected to a wall having a large contact area. Instead, the invention proposes to leave a space such as a gap between the heat sink and the inner housing, in particular between the base or base plate of the heat sink and a wall of the inner housing. This way, it is avoided that heat in the heat sink is conducted back to such wall of the inner housing and thus back to the inner housing. Accordingly this avoids any reversely directed flow of heat back into the housing. This aspect shall improve the cooling properties of the inverter with respect to the heat sink. This aspect may improve the heating properties of an inverter independently to the aspect of providing a cover to further provide a cover channel. However, both of these general features may be combined having synergetic effects.
According to one aspect of the invention the inner housing is sealed against the environment to prevent the circuitry of the inverter against dust and/or water. This way, a good protection can protect the circuitry of the inverter by means of a sealed inner housing, whereby good cooling properties can still be achieved.
According to a further embodiment power components which need external cooling, e.g. semiconductor switches such as IGBTs, or other components dissipating a high amount of energy extend through the casing of the inner housing against the heat sink and/or are sealed against the inner housing. Accordingly, such power components may be attached to the same circuit board as all other components which do not need cooling. But these power components extend through the casing of the inner housing, in particular through a wail of inner housing, extend through the space or gap between the inner housing and the heat sink and finally are attached against the heat sink e.g. at a base or base plate of it. This way the power components are mounted at the heat sink for conducting heat generated in the power components to the heat sink but the inner housing remains sealed and a distance between the inner housing and the heat sink does also remain.
Advantageously the heat sink comprises a base plate having one or a plurality of power components attached to that base plate, whereby the base plate comprises protrusions extending towards the power components so as to provide a base for each attached power component. Such protrusion can extend at least partly through a gap or space between the base plate and the inner housing. This way even flat components electrically connected within the inner housing can be attached to the base plate and a gap or space can still be provided between the base plate and the inner housing. According to one embodiment, at least one of such protrusions can extend through the gap or space into the housing for being attached to a component that needs cooling, whereby the protrusion is sealed against the wall of the inner housing. Therefore, the protrusion can conduct heat of that component to the base plate of the heat sink, whereas conducting heat from the base plate back to the inner housing is avoided due to the gap or space between the base plate.
As proposed according to one aspect the heat sink may be attached to the inner housing by means of distance pieces. E.g. the heat sink might be screwed at four corners of the heat sink through such distance pieces and into the inner housing. Such distance pieces might be provided as cylinders of a material that does not conduct heat very well, such as a plastic material, or a ceramic material or resin or such alike. The distance pieces may also take the form of two bars holding the heat sink at two sides.
It is also to be noted, that at least one main circuit board in the inner housing does not necessarily need to be attached to a wall of the inner housing facing towards the heat sink, but there might also be provided a gap between such circuit board and the wall of the inner housing, to have a further distance providing a further heat protection of the circuit board.
In a further embodiment the inverter comprises a heat sink channel accommodating the heat sink for guiding air long the heat sink for cooling this way, providing an air stream along the heat sink is facilitated. If the heat sink comprises a plurality of fin-like protrusions, the heat sink channel is oriented in the same direction as the fin-like protrusions are.
According to one embodiment an airflow along the heat sink is enhanced by means of at least one vent for blowing air through the heat sink channel along the heat sink and in particular also through the space or gap between the inner housing and the heat sink. This way, the heat sink channel ensures a certain direction of an airflow whereas the vent provides for or increases the velocity of such air stream. As the heat sink is basically not attached with the large surface of a base of it to the inner housing, this surface of the base can also be used for dissipating heat by means of an air stream. Therefore, the vent not only blows the air along the finlike protrusions but also along such surface facing the inner housing and thus facing the space or gap between them.
According to a further aspect it is proposed to provide the output opening of the cover channel adjacent to an output opening of the heat sink channel. This way, the hot air coming out of both output openings may be directed in the same direction. Even though the cover channel and the heat sink channel are basically independent of each other the arrangement of both openings next to each other might result in a suction effect from the one channel to the other one. In particular, if the heat sink channel is provided with at least one a vent whereas the cover channel is not provided with a vent the air of the heat sink channel might flow with a higher velocity and thus the cover channel might be subjected to a suction effect resulting from the higher velocity of the heat sink channel.
The invention also provides for a method for setting up and operating an inverter or other electronically controlled power source for transforming electrical energy into electrical energy of predetermined voltage and/or current, having an inner housing for housing the main circuitry of the inverter and a cover, covering at least part of the inner housing, defining at least one cover channel between the inner housing and the cover comprising the steps:
Additionally, the method comprises the step:
Accordingly, one step is to arrange the inverter in a fixed position and thus in an upright position. For protection against radiation of the sun the inverter is positioned such, that the cover basically faces the direction to the sun at daytime, taking into account, that the direction of the sun will change of approximately 180° during the daytime. The term “facing the direction of the sun” basically refers to a direction in the horizontal plane, and is not meant to refer to an inclination. As a result of providing an upright position of the inverter the cover channel should also be arranged in a basically vertical manner. The operating of the inverter with respect to transforming the electrical energy into electrical energy of predefined voltage and/or current is performed as generally known. However, it should be taken care, that any openings of the cover channel and/or the heat sink channel are kept open to prevent the air to flow in the corresponding channel and out of the corresponding channel.
Of course, the inverter might be installed in a location where it is not or only partly subjected to radiation of the sun. This can be in a shaded place or an inside place.
According to one aspect a solar system is proposed for providing electrical energy of predefined voltage and/or current comprising at least one solar generator outputting electrical energy as a DC-signal and at least one inverter according to at least on aspect of the present invention for transforming the DC-signal of the solar generator into an AC-signal of predefined frequency for feeding into an isolated grid or a public grid. A solar generator, comprising of one or a plurality of photovoltaic cells is usually installed in an area of increased sun radiation and thus an inverter coupled to this solar generator is also subjected to this increased sun radiation. To avoid overheating of the inverter, such solar system is provided with an inventive inverter, in particular an inverter comprising a cover to protect the inverter against sun radiation. Such solar systems, in particular if they are of large size, are provided in rural areas or even deserts. Such solar systems are more likely to be exposed to dust or other influences of the environment such as water. The reliability of such systems may be improved by using an inverter having good cooling properties including good properties for protection against the sun, whereas at the same time at least the main part of the inverter is effectively sealed against dust and water and such alike.
Preferred embodiments of the invention are described with reference to the accompanying figures, wherein
According to the back view of
The inner housing 22 is sealed against the environment and a pressure compensation adapter 32 is provided to fulfil a pressure equalisation if necessary. Accordingly, all electrical connections 10 (cf.
The electronic components 26 are basically arranged on a main circuit board 36, that is arranged in a plane parallel to a back wall 38 of the inner housing 22 but comprising a gap 40 between the main circuit board 36 at the back wall 38. Many of the components 26 do not produce considerable heat and are arranged at the main circuit board 36 facing to the inside of the inner housing 22. Some of these components 26 are arranged on smaller circuit boards 27, which are attached or connected to the main circuit board 36. It is to be noted, that the electronic components 26, including the smaller circuit boards 27 are only shown in a schematic way and the components, the number of the components, the certain arrangement and so on may vary with respect to different inverters. However, the used electronic components and thus any possible variations are not of importance for the present invention.
The heat sink channel 30 is basically defined by the heat sink plate 12 and/or a device such as a wall to which the inverter 1 is attached and a support frame 13. The support frame 13 is attached to the inner housing 22 at the back wall 38 and does support the heat sink 14. The heat sink 14 comprises one base plate 42 and a plurality of fin-like means 44 for enlarging the surface of the heat sink 14. At the base plate 42 there are provided protrusions 46, on which the heat sink 14 is attached to the support frame 13 by means of screws 48.
The protrusions 46 function as distance pieces integrally formed with the heat sink 14, to provide a gap 50 between the base plate 42 of the heat sink 14 and the support frame 13. Accordingly, a gap 50 is provided between the heat sink 14 and the inner housing 22. According to an other embodiment, there are further fin-like means at the base plate protruding into the gap, to further increase the surface of the heat sink.
According to
A cover 2 is at two sides attached to the support frame 13 at attachment lash 56 further involving support means 58. Because the cover 2 almost touches edges 60 of the inner housing 22, the cover channel 28 is basically subdivided in a front and two side cover channels 28a-c. A cover channel 28 and also the sub channels 28a-c according to
The cross sectional view according to
The cover 2, as seen in
A bottom opening 70 for air to enter the cover channel 28 is basically positioned next to the bottoms skirt 66, facing in a downward direction.
When operating the inverter 1 air in the cover channel 28 will be heated in particular by means of the chokes 54 and by means of the cover 2 when being heated by the sun. Accordingly, the heated air will flow upwards according to natural convection and as a result cooler air from the outside will flow into the bottom opening 70 and thus cool the inner housing 22 and the cover 2 of the inverter, while gradually being heated in the cover channel. The heated air flowing upwards will exit the cover channel 28 at the top opening 68. For cooling the power components and thus cooling the heat sink 14, the vents 18 will blow air along the heat sinks 14, in particular along the fin-like means 44 and through the gap 50 along the base plate 42. This air will be heated by the heat sink and will be flowing in the heat sink channel. This hot air will exit the heat sink channel 30 in an area close to the top opening 68 of the cover channel 28. In this area, the air of the cover channel 28 and the air of the heat sink channel 30 will come together. Because of the vents 18 the air in the heat sink channel usually has a larger velocity than the air in the cover channel 2, the air exiting the heat sink channel 30 might provide a suction effect on the air in the cover channel 22 and thus might accelerate the air flow in the cover channel 28.
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/EP07/62956 | 11/28/2007 | WO | 00 | 5/27/2010 |
