Intelligent charging pile

Abstract

The invention discloses an intelligent charging pile, and the pile comprises a central host system which comprises a multi-mode power module group, a triple-redundancy control unit, and a liquid cooling unit. The multi-mode power module group is used for realizing AC / DC (Alternating Current / Direct Current) conversion; the triple-redundancy control unit comprises a main PLC (Programmable Logic Controller), a standby PLC and an FPGA (Field Programmable Gate Array) coprocessor; the liquid cooling unit adopts a double-circulating-pump redundancy design and is used for ensuring the heat dissipation efficiency of the central host system; the intelligent auxiliary pile group comprises a plurality of auxiliary piles, and one auxiliary pile is provided with 1-3 charging terminals; each auxiliary pile comprises a local DC / DC module, an auxiliary controller, a hybrid cooling unit and a power divider; an intelligent charging gun; and a four-stage mixed heat dissipation scheme is adopted. The technical problem that the charging terminals of the whole station are paralyzed easily due to faults of a host and a control system is solved, the heat dissipation efficiency is improved, and the charging power of the charging gun is intelligently allocated and managed.

Description

Technical Field

[0001] The present invention relates to the technical field of smart charging stacks, and in particular to a smart charging stack. Background Art

[0002] A charging stack, or "flexible charging stack," is a centralized DC charging system that integrates multiple charging modules into a large power cluster to form a "power pool," which then intelligently allocates charging power based on the real-time needs of electric vehicles. Its core design concepts are "power sharing" and "flexible charging," aiming to address issues such as fixed power and poor compatibility in traditional charging piles. The charging stack centrally manages all charging modules within the charging station to form a shared power resource pool. When a vehicle is connected, the monitoring module obtains vehicle requirements (such as voltage and current) through the BMS (battery management system) and dynamically allocates the required power.

[0003] Currently, charging stacks have the following problems: all charging modules rely on the same host. Once the host or control system fails, the charging terminals of the entire station will be paralyzed; the dense concentration of modules leads to low heat dissipation efficiency, requiring the installation of an additional air-conditioning system, but contactor burnout still occurs frequently; multiple vehicles compete for power: for example, in a 120kW charging stack, a single vehicle can charge at full power, but if two vehicles charge at the same time, each vehicle only receives 60kW, doubling the charging time. Summary of the Invention

[0004] In order to overcome the above-mentioned shortcomings of the prior art, the present invention proposes an intelligent charging stack to solve the technical problem that failure of the host and control system can easily cause paralysis of the charging terminals of the entire station, improve the heat dissipation efficiency, and intelligently allocate and manage the charging power of the charging gun.

[0005] The technical solution adopted by the present invention to solve the technical problem is: an intelligent charging stack, comprising:

[0006] The central host system includes a multimodal power module group, a triple-redundant control unit, and a liquid cooling unit. The multimodal power module group is used to implement AC / DC conversion. The triple-redundant control unit includes a main PLC, a backup PLC, and an FPGA coprocessor. The main PLC is responsible for real-time power allocation calculations based on a dynamic allocation method. The backup PLC implements millisecond-level fault switching based on a three-level fault-tolerant architecture. The FPGA specifically performs hardware-level processing of protection logic. The liquid cooling unit uses a dual-circulation pump redundant design to ensure the heat dissipation efficiency of the central host system.

[0007] Smart secondary charging pile cluster: consists of several secondary charging piles, each of which is equipped with 1-3 charging terminals. Each secondary charging pile includes a local DC / DC module, a secondary controller, a hybrid cooling unit, and a power distributor. The local DC / DC module receives the DC bus of the host computer for fine voltage regulation, achieving a conversion efficiency of over 97%. The secondary controller can both execute host instructions and switch to local control within 50ms. The hybrid cooling unit combines phase change materials and eddy current air cooling technology to achieve pumpless heat dissipation and control the contact temperature rise within 15°C. The power distributor supports dynamic distribution of three guns on the pile, and the power switching time is less than 100ms.

[0008] Smart charging gun, as a charging terminal, includes a charging gun body protected by core protection components, a gun head control unit, and a safety monitoring system. The core protection component, a vacuum magnetic latching contactor, has a rated current of 300A and a transient withstand capability of 600A. The safety monitoring system includes a real-time contact temperature sampling device, an optical detection device for plugging and unplugging status, and a coolant flow monitoring device. The gun head control unit is connected to the corresponding secondary charging pile via the CAN bus.

[0009] The layered cooling system adopts a four-stage hybrid heat dissipation solution.

[0010] Furthermore, the dynamic allocation method specifically includes the following steps:

[0011] Obtain real-time capacity of the power grid;

[0012] Set the basic demand allocation power; set the power over limit; set the electric vehicle priority strategy, which is used to determine the high priority electric vehicle type according to the needs;

[0013] When charging, each vehicle is allocated power to ensure basic needs;

[0014] Further power allocation is carried out according to the following strategies; priority adjustment: increase power on the basis of basic demand allocation power according to the priority of low SOC > high priority electric vehicle > low battery temperature; power flexible adjustment: when a new vehicle is connected, the power of the high SOC vehicle is automatically reduced, and the minimum power is not lower than the basic demand allocation power; overload prevention: when the total demand power connected to the secondary pile is greater than the power limit, the power of each electric vehicle is allocated according to the basic demand allocation power.

[0015] Furthermore, the central host system also includes an overvoltage protection circuit, an overcurrent protection circuit, a short circuit protection circuit, and a leakage protection circuit.

[0016] Furthermore, the central host system also includes a bidirectional inverter module to support electric vehicles to feed power to the power grid.

[0017] Furthermore, the smart charging gun is provided with a color touch screen for human-computer interaction.

[0018] Furthermore, the four-level hybrid heat dissipation solution is specifically as follows:

[0019] The central host system cools the IGBT power module through a forced liquid cooling cycle, and automatically reduces power when the temperature exceeds 85°C; the intelligent sub-pile group uses graphene-enhanced phase change material to wrap the contactor and terminal blocks, triggering eddy current air cooling when the temperature reaches 75°C; the gun line level has built-in active liquid cooling pipes, and an alarm is issued when the flow rate is lower than 8L / min; the intelligent air duct system is activated when the temperature inside the cabinet where the central host system is placed exceeds 40°C.

[0020] Furthermore, the sub-controller adopts an ARM Cortex-A53 processor.

[0021] Furthermore, the three-level fault-tolerant architecture is specifically as follows:

[0022] When the central host system fails, the slave pile controller generates a new host within 200ms through a preset election mechanism; when a single slave pile fails, the system completes fault isolation and power redistribution within 500ms; a single gun failure only affects the charging terminal itself, while other charging terminals operate normally; this architecture builds a dual-channel control network through a fiber optic ring network and a CAN bus, forming a cascade control flow from the main PLC to the slave controller, and from the slave controller to the charging terminal, while the backup controller synchronizes the operating status in real time.

[0023] Compared with the prior art, the present invention has the following beneficial effects:

[0024] This invention breaks through the single-point failure bottleneck of current traditional charging stacks. Through triple redundant control, layered cooling technology, and dynamic power allocation algorithms, it completely solves the three major technical problems of host dependence, low heat dissipation efficiency, and power competition. The output voltage can be finely adjusted in 50V steps within the range of 200-1000V. The maximum output power of a single charging gun reaches 250kW, and the overall system efficiency exceeds 96.5%. The intelligent charging stack designed using this invention is particularly suitable for charging scenarios with high reliability requirements, such as highway service areas, bus hubs, and urban fast charging stations. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the following briefly introduces the drawings required for describing the embodiments.

[0026] Figure 1 This is a system architecture diagram of a smart charging stack according to an embodiment of the present invention.

[0027] Figure 2 This is a physical diagram of an intelligent charging pile according to an embodiment of the present invention. In the diagram: 1. Central host system; 2. Auxiliary pile; 3. Intelligent charging gun. DETAILED DESCRIPTION

[0028] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only some of the embodiments of the present invention, not all of them. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making any creative efforts shall fall within the scope of protection of the present invention.

[0029] In the description of the present invention, it should be noted that the terms "center", "up", "down", "left", "right", "vertical", "horizontal", "inside", "outside", etc., indicating directions or positional relationships, are based on the directions or positional relationships shown in the accompanying drawings. They are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific direction, be constructed and operated in a specific direction. Therefore, they cannot be understood as limiting the present invention.

[0030] In the description of the present invention, it should be noted that, unless otherwise clearly specified and limited, the terms "installed", "connected", and "connected" should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection, or it can be indirectly connected through an intermediate medium, or it can be internal communication between two components. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances. In addition, the technical features involved in the different embodiments of the present invention described below can be combined with each other as long as they do not conflict with each other.

[0031] like Figure 1 、 Figure 2 As shown, an embodiment of the present invention provides a smart charging stack, comprising:

[0032] Central host system 1 includes a multimodal power module group, a triple-redundant control unit, and a liquid cooling unit. The multimodal power module group is used to implement AC / DC conversion. The triple-redundant control unit includes a main PLC, a backup PLC, and an FPGA coprocessor. The main PLC is responsible for real-time power allocation calculations based on a dynamic allocation method. The backup PLC implements millisecond-level fault switching based on a three-level fault-tolerant architecture. The FPGA specifically performs hardware-level processing of protection logic. The liquid cooling unit uses a dual-circulation pump redundant design to ensure the heat dissipation efficiency of central host system 1. Central host system 1 also includes overvoltage protection circuits, overcurrent protection circuits, short-circuit protection circuits, and leakage protection circuits. Central host system 1 also includes a bidirectional inverter module to support electric vehicles feeding power into the grid.

[0033] The dynamic allocation method specifically includes the following steps:

[0034] Obtain real-time capacity of the power grid;

[0035] Set the basic demand allocation power; set the power over limit; set the electric vehicle priority strategy, which is used to determine the high priority electric vehicle type according to the needs;

[0036] When charging, each vehicle is allocated power to ensure basic needs;

[0037] Further power allocation is carried out according to the following strategies; priority adjustment: increase power on the basis of basic demand allocation power according to the priority of low SOC > high priority electric vehicle > low battery temperature; power flexible adjustment: when a new vehicle is connected, the power of the high SOC vehicle is automatically reduced, and the minimum power is not lower than the basic demand allocation power; overload prevention: when the total demand power connected to the auxiliary pile 2 is greater than the power limit, the power of each electric vehicle is allocated according to the basic demand allocation power.

[0038] The three-level fault-tolerant architecture is as follows:

[0039] When the central host system 1 fails, the slave pile controller generates a new host within 200ms through a preset election mechanism. When a single slave pile 2 fails, the system completes fault isolation and power redistribution within 500ms. A single gun failure only affects the charging terminal itself, while other charging terminals operate normally. This architecture builds a dual-channel control network through a fiber optic ring network and a CAN bus, forming a cascade control flow from the main PLC to the slave controller, and then from the slave controller to the charging terminal, while the standby controller synchronizes the operating status in real time.

[0040] Smart sub-pile group: includes several sub-pile 2s, each sub-pile 2 is equipped with 1-3 charging terminals; each sub-pile 2 includes a local DC / DC module, a sub-controller, a hybrid cooling unit, and a power distributor; the local DC / DC module receives the host DC bus for fine voltage adjustment to achieve a conversion efficiency of more than 97%; the sub-controller can both execute host instructions and switch local control within 50ms; the hybrid cooling unit combines phase change materials and eddy current air cooling technology to achieve pumpless heat dissipation and control the contact point temperature rise within 15°C; the power distributor supports dynamic distribution of three guns on this pile, and the power switching time is less than 100ms; the sub-controller uses an ARM Cortex-A53 processor.

[0041] Smart charging gun 3, smart charging gun 3 serves as a charging terminal, including a charging gun body protected by core protection elements, a gun head control unit, and a safety monitoring system; the core protection element vacuum magnetic holding contactor has a rated current of 300A and a transient withstand capability of 600A; the safety monitoring system includes a contact temperature real-time sampling device, an optical detection device for plug-in and unplug status, and a coolant flow monitoring device; the gun head control unit is connected to the corresponding sub-pile 2 through the CAN bus; the smart charging gun 3 is provided with a color touch screen for human-computer interaction.

[0042] The tiered cooling system adopts a four-stage hybrid heat dissipation solution. The four-stage hybrid heat dissipation solution is as follows:

[0043] The central host system 1 uses a forced liquid cooling cycle to cool the IGBT power modules, automatically reducing power when the temperature exceeds 85°C. The intelligent secondary piles utilize graphene-enhanced phase-change material to encapsulate the contactors and terminals, triggering eddy current cooling when the temperature reaches 75°C. Active liquid cooling pipes are built into the gun-line level, triggering an alarm when the flow rate falls below 8L / min. The intelligent air duct system activates when the internal temperature of the cabinet housing the central host system exceeds 40°C. Field tests have shown that this solution reduces energy consumption by 70% compared to traditional air conditioning and cooling, keeping system temperature rise within a range of 15-20°C.

[0044] The working principle of the embodiment of the present invention is as follows: In the embodiment of the present invention, electric energy transmission flows along the path of "power grid → central host system 1 (AC / DC conversion) → DC bus → auxiliary pile 2 (DC / DC voltage regulation) → charging gun → vehicle battery". The control flow adopts a layered architecture: the main controller sends instructions to the auxiliary controller through the optical fiber ring network, and the auxiliary controller manages the charging terminal via the CAN bus. At the same time, the status data of each node is transmitted back in real time. Key data collaboration includes: the real-time power demand provided by the vehicle BMS is algorithmically processed by the central host system 1 for dynamic power allocation; the gun head and contactor temperature data drive the cooling system regulation of the auxiliary pile 2; the grid status parameters guide the charging and discharging strategy of the energy storage unit; the fault code of each monitoring node triggers the protection action of the three redundant controllers.

[0045] The system's single-gun output covers a wide voltage range of 200-1000V, with a maximum power of 250kW. In terms of control accuracy, the output voltage deviation is less than ±0.5% of the full scale, the power distribution response time is less than 150ms, and the fault switching speed is at the 200ms level. Reliability indicators have been significantly improved: the host's mean time between failures (MTBF) is >50,000 hours, the contactor's mechanical life exceeds 1 million times, and the protection level reaches IP54 (host) / IP55 (gun head). The energy efficiency performance is outstanding, with a system peak efficiency of 96.7% and standby power consumption of less than 0.5kW. In terms of environmental adaptability, it can operate stably in the temperature range of -30℃ to +55℃, and the cooling system ensures continuous full-power output at an ambient temperature of 40℃.

[0046] This system eliminates the risk of single points of failure through a distributed architecture. The hybrid cooling solution reduces the temperature rise of the power module by 40%, and the intelligent power allocation algorithm shortens the average charging time by 35%, setting a reliability benchmark for the next generation of high-power charging infrastructure.

[0047] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any changes or substitutions that can be easily conceived by a person skilled in the art within the technical scope disclosed in the present invention should be included in the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be based on the scope of protection of the claims.

Claims

1. A smart charging stack, characterized in that: include: The central host system includes a multimodal power module group, a triple-redundant control unit, and a liquid cooling unit. The multimodal power module group is used to implement AC / DC conversion. The triple-redundant control unit includes a main PLC, a backup PLC, and an FPGA coprocessor. The main PLC is responsible for real-time power allocation calculations based on a dynamic allocation method. The backup PLC implements millisecond-level fault switching based on a three-level fault-tolerant architecture. The FPGA specifically performs hardware-level processing of protection logic. The liquid cooling unit uses a dual-circulation pump redundant design to ensure the heat dissipation efficiency of the central host system. Smart secondary charging pile cluster: consists of several secondary charging piles, each of which is equipped with 1-3 charging terminals. Each secondary charging pile includes a local DC / DC module, a secondary controller, a hybrid cooling unit, and a power distributor. The local DC / DC module receives the DC bus of the host computer for fine voltage regulation, achieving a conversion efficiency of over 97%. The secondary controller can both execute host instructions and switch to local control within 50ms. The hybrid cooling unit combines phase change materials and eddy current air cooling technology to achieve pumpless heat dissipation and control the contact temperature rise within 15°C. The power distributor supports dynamic distribution of three guns on the pile, and the power switching time is less than 100ms. Smart charging gun, as a charging terminal, includes a charging gun body protected by core protection components, a gun head control unit, and a safety monitoring system. The core protection component, a vacuum magnetic latching contactor, has a rated current of 300A and a transient withstand capability of 600A. The safety monitoring system includes a real-time contact temperature sampling device, an optical detection device for plugging and unplugging status, and a coolant flow monitoring device. The gun head control unit is connected to the corresponding secondary charging pile via the CAN bus. The layered cooling system adopts a four-stage hybrid heat dissipation solution.

2. The intelligent charging stack according to claim 1, characterized in that: The dynamic allocation method specifically comprises the following steps: Obtain real-time capacity of the power grid; Set the basic demand allocation power; set the power over limit; set the electric vehicle priority strategy, which is used to determine the high priority electric vehicle type according to needs; When charging, each vehicle is allocated power to ensure basic needs; Further power allocation is carried out according to the following strategies; priority adjustment: increase power on the basis of basic demand allocation power according to the priority of low SOC > high priority electric vehicle > low battery temperature; power flexible adjustment: when a new vehicle is connected, the power of the high SOC vehicle is automatically reduced, and the minimum power is not lower than the basic demand allocation power; overload prevention: when the total demand power connected to the secondary pile is greater than the power limit, the power of each electric vehicle is allocated according to the basic demand allocation power.

3. The intelligent charging stack according to claim 1, characterized in that: The central host system also includes an overvoltage protection circuit, an overcurrent protection circuit, a short circuit protection circuit, and a leakage protection circuit.

4. The intelligent charging stack according to claim 1, characterized in that: The central host system also includes a bidirectional inverter module to support electric vehicles feeding power into the grid.

5. The intelligent charging stack according to claim 1, characterized in that: The smart charging gun is provided with a color touch screen for human-computer interaction.

6. The intelligent charging stack according to claim 1, characterized in that: The four-level hybrid heat dissipation solution is as follows: The central host system cools the IGBT power module through a forced liquid cooling cycle, and automatically reduces power when the temperature exceeds 85°C; the intelligent sub-pile group uses graphene-enhanced phase change material to wrap the contactor and terminal blocks, triggering eddy current air cooling when the temperature reaches 75°C; the gun line level has built-in active liquid cooling pipes, and an alarm is issued when the flow rate is lower than 8L / min; the intelligent air duct system is activated when the temperature inside the cabinet where the central host system is placed exceeds 40°C.

7. The intelligent charging stack according to claim 1, characterized in that: The sub-controller uses an ARM Cortex-A53 processor.

8. The intelligent charging stack according to claim 1, characterized in that: The three-level fault-tolerant architecture is specifically: When the central host system fails, the secondary pile controller generates a new host within 200ms through a preset election mechanism; when a single secondary pile fails, the system completes fault isolation and power redistribution within 500ms; a single gun failure only affects the charging terminal itself, while other charging terminals operate normally; this architecture builds a dual-channel control network through a fiber optic ring network and a CAN bus, forming a cascade control flow from the main PLC to the secondary controller, and from the secondary controller to the charging terminal, while the backup controller synchronizes the operating status in real time.

Images