Energy Efficient Cooling of Switch Cabinets Using Optimized Internal Settings

Abstract

The miniaturization progressing of electronic components-used in switch cabinets for manufacturingincreases the packaging density as well as the volumetric dissipation power of the electrical components. As a result, high air temperatures inside the switch cabinets, an overheating and, with that, a reduction in the component life time may result. For this reason, switch cabinets must be cooled actively very often. The commercial CFD code FloTHERM is used to obtain the influence of the packing density of the electrical components, the geometry of the wiring system and the inner air flow on the temperature and the velocity distribution inside a switch cabinet of given size. Based on CFD calculations, measures for optimizing the internal setting of switch cabinets are presented in order to be able to use cooling capacity provided by active cooling devices (e.g. air/air heat exchangers, airconditioning units) as energy efficiently as possible for the avoidance of hotspot areas (areas of a high inside air temperature). For the validation of the CFD model, as well as the verification of the suggested optimizations, experimental data are used. The experimental data are obtained from measurements of temperatures and flow velocities, carried out at a test equipment for switch cabinets in the laboratory. To reproduce the thermal situation inside the tested switch cabinet, empty housings of electronic components are fitted with resistance heaters and installed in the switch cabinet. By a single pulse-width modulated voltage, applied to each resistance heater, a variable distributed overall dissipation power is adjustable. Different steady-state operating conditions of the switch cabinet with natural and forced convection with and without cooled air are investigated. Theoretical results for optimized internal settings of switch cabinets show potential for the conservation of cooling energy up to 23 % compared to the not optimized initial state.

A method for testing partial discharge characteristics of switch cabinet based on improved particle swarm algorithm

“…If the minimum value meets the accuracy requirements or the maximum iteration count is reached, we output the optimal value. If the conditions are not met, we return to Step 2 to continue the iterative computation [7].…”

“…As technology continues to advance, the capabilities and features of high-voltage switchgear are evolving to meet the growing demands of the power industry. Modern switch cabinets are becoming increasingly intelligent, incorporating digital control systems and communication interfaces that facilitate remote monitoring and control [7,8]. This evolution enables more precise and efficient grid management, accommodating the integration of renewable energy sources and emerging smart grid technologies.…”

Fast thermodynamic simulation of electrical control cabinets via thermal resistor networks

“…programmable logic controllers, measurement instrumentation and power supplies. The temperature and flow field of the air inside industrial low-voltage control cabinets can be resolved precisely by means of a fine-grid Computational Fluid Dynamics (CFD) simulation without applying thermo-electric coupling [6,7]. Due to its complexity and computational expense, fine-grid CFD is not eligible for a widespread and automated utilization in the pre-production design process of control cabinets.…”

Modeling of the surface-to-surface radiation exchange using a Monte Carlo method

“…This leads to high temperatures inside of switch cabinets and with that to a reduction of component life time, which endangers the functionality of the whole switch cabinet. That is why most switch cabinets must be equipped with active cooling devices [1]. In order to improve the design process of the cooling devices, reliable simulation models for the temperature distribution are required.…”