Rapid and safe super capacitor charging and discharging control circuit and method thereof

Abstract

The invention discloses a rapid and safe super capacitor charging and discharging control circuit and a method thereof, and relates to the technical field of circuit protection. Comprising a power taking device, a Boost plate, a pre-charging plate, a first pre-charging relay K1, a second pre-charging relay K2, a bypass relay K3, a bleeder relay K4, a first pre-charging resistor R1, a second pre-charging resistor R2, a bleeder resistor R3, a first diode D1, a second diode D2, a third diode D3, a super capacitor and an electric device. According to the invention, the temperature of the first pre-charging resistor R1 and the second pre-charging resistor R2, the temperature and the current of the power taking equipment and the voltage rising speed of the super capacitor can be monitored in real time, and the most reasonable closing point of the second-stage relay can be found, so that the quick charging of the super capacitor is realized; if the power supply system is suddenly powered off, the pre-charging operation can still be continued according to the current voltage on the super capacitor after the power supply system is powered on again.

Description

Technical Field

[0001] The present invention relates to the technical field of circuit protection, and in particular to a fast and safe supercapacitor charge and discharge control circuit and method thereof. Background Art

[0002] In WPS (wireless power supply technology) power-consuming equipment, such as semiconductor stockers (automated wafer storage systems), RGV carts (unmanned transport robot systems) and AMHS (automatic material handling systems), when the rated power of the power-taking equipment is lower than the instantaneous output power of the load, the current on the power-taking equipment will surge instantly, which may damage the power-taking equipment. Therefore, by adding supercapacitors as support capacitors to meet the peak power at the load end, the calculation formula is:

[0003]

[0004] C: is the supercapacitor capacity, in F; U0: is the initial voltage on the capacitor, in V; U1: is the current voltage on the capacitor, in V; PP: is the peak power of the electrical equipment, in W; t: is the duration of the peak power of the electrical equipment, in S.

[0005] During actual operation, the supercapacitor supports the peak power of the electrical equipment, and the capacitor voltage will drop from U0 to U1; then, during the low-power period of the electrical equipment, after the power obtained by the power-taking device meets the power of the equipment, the excess power will be provided to charge the supercapacitor.

[0006] However, the following defects or problems still exist in combination with the existing technology: First, in the existing supercapacitor charging and discharging control circuit, when the supercapacitor is in the charging process or charging is completed, if the input is disconnected at this time, an external UPS (uninterruptible power supply) is usually used to supply power to the control unit to ensure that the voltage on the supercapacitor drops to a safe voltage range after the system is powered off. This solution increases the cost and the complexity of the system. Second, the communication between the power supply unit and the pre-charging unit is not established, and effective protection measures cannot be implemented in time when facing abnormal input conditions. Summary of the Invention

[0007] The purpose of the present invention is to solve the shortcomings of the prior art and to propose a fast and safe supercapacitor charge and discharge control circuit and method.

[0008] In order to achieve the above object, the present invention adopts the following technical solutions:

[0009] A fast and safe supercapacitor charge and discharge control circuit includes a power supply device, a boost board, a pre-charge board, a pre-charge relay K1, a pre-charge relay K2, a bypass relay K3, a discharge relay K4, a pre-charge resistor R1, a pre-charge resistor R2, a discharge resistor R3, a diode D1, a diode D2, a diode D3, a supercapacitor, and an electrical device;

[0010] The power taking device is electrically connected to the Boost board, one end of the pre-filling relay K1, the pre-filling relay K2, and the bypass relay K3 are all electrically connected to the Boost board, the other end of the pre-filling relay K1 is electrically connected to one end of the pre-filling resistor R1, and the other end of the pre-filling relay K2 is electrically connected to one end of the pre-filling resistor R2;

[0011] The other ends of the pre-charging resistor R1, pre-charging resistor R2, and bypass relay K3 are all electrically connected to the positive electrode of diode D1, the negative electrode of diode D1 and one end of discharge relay K4 are all electrically connected to the supercapacitor, the other end of discharge relay K4 is electrically connected to one end of discharge resistor R3, and the other end of discharge resistor R3 is grounded;

[0012] The power taking device, the Boost board, and the super capacitor are all electrically connected to the pre-charging board, and the super capacitor is electrically connected to the power consuming device.

[0013] Preferably, the pre-charge board includes a pre-charge control module, the Boost board is electrically connected to the pre-charge control module, the pre-charge control module and the Boost board communicate via a 485 bus, and the pre-charge control module is used to detect the input and output voltages of the Boost board;

[0014] The power taking device is electrically connected to the pre-charge control module, and the pre-charge control module is further used to detect the temperature and current of the power taking device;

[0015] The supercapacitor is electrically connected to a pre-charge control module, and the pre-charge control module is further used to detect the input and output voltages of the supercapacitor.

[0016] Preferably, the pre-charging board also includes an auxiliary power supply, which is electrically connected to the pre-charging control module, the positive pole of the diode D2 is electrically connected to the Boost board, the negative pole of the diode D2 is electrically connected to the auxiliary power supply, the positive pole of the diode D3 is electrically connected to the supercapacitor, and the negative pole of the diode D3 is electrically connected to the auxiliary power supply.

[0017] Preferably, the pre-charging resistor R1, the pre-charging resistor R2, and the bleeder resistor R3 are all aluminum shell resistors, and the pre-charging resistor R1, the pre-charging resistor R2, and the bleeder resistor R3 are all electrically connected to an NTC thermistor, and the NTC thermistor is used to detect the temperature of the pre-charging resistor R1, the pre-charging resistor R2, and the bleeder resistor R3.

[0018] A fast and safe supercapacitor charge and discharge control method is provided, which is based on a fast and safe supercapacitor charge and discharge control circuit and includes the following steps:

[0019] S1: When the power supply cabinet is powered on, the electrical appliance will provide the power it obtains to the BOOST board.

[0020] S2, after the BOOST board is powered on, it supplies power to the pre-charge board. At the same time, the BOOST board performs a self-test. If the self-test is normal, it sends a READY signal to the pre-charge board through the 485 bus.

[0021] S3. After the pre-charging board is powered on, it performs a self-test to detect its input and output voltages, the temperature and current of the power supply device, the temperature of the pre-charging resistor R1, the pre-charging resistor R2, the discharge resistor R3, and the working status of the pre-charging relay K1, the pre-charging relay K2, the bypass relay K3, and the discharge relay K4. After the self-test is completed and the READY signal is received, the pre-charging relay K1 is closed to charge the supercapacitor through the pre-charging resistor R1.

[0022] S4: When the first-stage charging speed is lower than the set threshold V / S, the pre-charge relay K2 is closed to charge the supercapacitor through two-stage pre-charging.

[0023] S5. When the voltage of the supercapacitor reaches 95% of the input voltage, the bypass relay K3 is closed.

[0024] S6. If the circuit system suddenly loses power during the charging process of the supercapacitor, the BOOST board will have no input, stop working, and stop sending the READY signal to the pre-charging board;

[0025] After the pre-charging board does not receive the REDAY signal, the pre-charging relay K1, the pre-charging relay K2, and the bypass relay K3 are disconnected, and the discharge relay K4 is closed synchronously.

[0026] Preferably, in step S4, during the entire charging process, the pre-charging board monitors the temperature of the pre-charging resistor R1 and the pre-charging resistor R2 as well as the temperature and current of the power-taking equipment in real time. If an abnormality occurs, the pre-charging relay K1 and the pre-charging relay K2 are disconnected at any time, and the discharge relay K4 is closed synchronously.

[0027] Preferably, in step S5, the pre-charging board monitors the peak current and temperature of the electrical device in real time. If the peak current and temperature exceed the protection threshold, the pre-charging relay K1, the pre-charging relay K2, and the bypass relay K3 are disconnected, and the discharge relay K4 is closed synchronously.

[0028] Preferably, in step S6, the power supply of the pre-charge board is provided by the BOOST board and the super capacitor, so that after the BOOST is powered off, the pre-charge board can continue to work.

[0029] Preferably, in step S6, the minimum operating voltage of the pre-charging board is 36V. Therefore, after the voltage of the supercapacitor drops to 36V, the entire pre-charging board is powered off, and pre-charging is restarted after the BOOST board is powered on.

[0030] Preferably, in step S6, if the voltage of the supercapacitor is greater than 36V, when the BOOST board is powered on again and the pre-charging board receives the READY signal again, the bypass relay K3 is first disconnected, and then the pre-charging relay K1 is closed to perform the power-on pre-charging operation again.

[0031] The beneficial effects of the present invention are:

[0032] 1. In the present invention, the temperature of the pre-charging resistor R1 and the pre-charging resistor R2, the temperature and current of the power-taking device, and the voltage rise rate on the supercapacitor can be monitored in real time, and the most reasonable closing point of the second-stage relay can be found to achieve rapid charging of the supercapacitor.

[0033] 2. In the present invention, if the power supply system is suddenly powered off, after the power supply system is powered on again, the pre-charging operation can still be continued according to the current voltage on the supercapacitor.

[0034] 3. In the present invention, the method of bidirectionally powering the pre-charging board through the BOOST board and the supercapacitor is that after a normal or abnormal power outage of the system, the pre-charging board will discharge the voltage on the supercapacitor to a safe voltage below 36V within a specified time. At this time, the voltage on the supercapacitor drops to a safe voltage range to ensure the personal safety of the operator. BRIEF DESCRIPTION OF THE DRAWINGS

[0035] Figure 1 The figure is a circuit diagram of a fast and safe supercapacitor charge and discharge control circuit of the present invention. DETAILED DESCRIPTION

[0036] The technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, rather than all the embodiments.

[0037] Example 1:

[0038] As attached Figure 1 As shown, a fast and safe supercapacitor charge and discharge control circuit includes a power supply device, a boost board, a pre-charge board, a pre-charge relay K1, a pre-charge relay K2, a bypass relay K3, a discharge relay K4, a pre-charge resistor R1, a pre-charge resistor R2, a discharge resistor R3, a diode D1, a diode D2, a diode D3, a supercapacitor, and an electrical device;

[0039] The power supply device is electrically connected to the Boost board. One end of the pre-charge relay K1, the pre-charge relay K2, and the bypass relay K3 are all electrically connected to the Boost board. The other end of the pre-charge relay K1 is electrically connected to one end of the pre-charge resistor R1. The other end of the pre-charge relay K2 is electrically connected to one end of the pre-charge resistor R2.

[0040] The other end of the pre-charge resistor R1, the pre-charge resistor R2, and the bypass relay K3 are all electrically connected to the positive electrode of the diode D1. The negative electrode of the diode D1 and one end of the discharge relay K4 are all electrically connected to the supercapacitor. The other end of the discharge relay K4 is electrically connected to one end of the discharge resistor R3. The other end of the discharge resistor R3 is grounded.

[0041] The power taking device, the Boost board, and the supercapacitor are all electrically connected to the pre-charging board, and the supercapacitor is electrically connected to the power consuming device.

[0042] The pre-charge board includes a pre-charge control module, the Boost board is electrically connected to the pre-charge control module, the pre-charge control module and the Boost board communicate via a 485 bus, and the pre-charge control module is used to detect the input and output voltages of the Boost board;

[0043] The power taking device is electrically connected to the pre-charge control module, and the pre-charge control module is also used to detect the temperature and current of the power taking device;

[0044] The supercapacitor is electrically connected to the pre-charge control module, and the pre-charge control module is also used to detect the input and output voltages of the supercapacitor.

[0045] The pre-charge board also includes an auxiliary power supply, which is electrically connected to the pre-charge control module. The positive pole of diode two D2 is electrically connected to the Boost board, the negative pole of diode two D2 is electrically connected to the auxiliary power supply, the positive pole of diode three D3 is electrically connected to the supercapacitor, and the negative pole of diode three D3 is electrically connected to the auxiliary power supply.

[0046] The pre-charge resistor R1, the pre-charge resistor R2, and the bleeder resistor R3 are all aluminum-shell resistors. The pre-charge resistor R1, the pre-charge resistor R2, and the bleeder resistor R3 are all electrically connected to an NTC thermistor, which is used to detect the temperature of the pre-charge resistor R1, the pre-charge resistor R2, and the bleeder resistor R3.

[0047] Example 2:

[0048] A fast and safe supercapacitor charge and discharge control method is provided, which is based on a fast and safe supercapacitor charge and discharge control circuit and includes the following steps:

[0049] S1: When the power supply cabinet is powered on, the electrical appliance will provide the power it obtains to the BOOST board.

[0050] S2, after the BOOST board is powered on, it supplies power to the pre-charge board. At the same time, the BOOST board performs a self-test. If the self-test is normal, it sends a READY signal to the pre-charge board through the 485 bus.

[0051] S3. After the pre-charging board is powered on, it performs a self-test to detect its input and output voltages, the temperature and current of the power supply device, the temperature of the pre-charging resistor R1, the pre-charging resistor R2, the discharge resistor R3, and the working status of the pre-charging relay K1, the pre-charging relay K2, the bypass relay K3, and the discharge relay K4. After the self-test is completed and the READY signal is received, the pre-charging relay K1 is closed to charge the supercapacitor through the pre-charging resistor R1.

[0052] S4. When the first-stage charging speed is lower than the set threshold V / S (the threshold is adjustable), the pre-charge relay K2 is closed to charge the supercapacitor through two-stage pre-charging. During the entire charging process, the pre-charging board monitors the temperature of the pre-charging resistor R1 and the pre-charging resistor R2, as well as the temperature and current of the power supply device in real time. If any abnormality occurs, the pre-charging relay K1 and the pre-charging relay K2 are disconnected at any time, and the discharge relay K4 is closed synchronously.

[0053] In the above technical solution, the temperature of the pre-charging resistor R1, the pre-charging resistor R2, the temperature and current of the power-taking equipment, and the voltage rise rate on the supercapacitor can be monitored in real time, and the most reasonable closing point of the second-stage relay can be found to achieve rapid charging of the supercapacitor.

[0054] S5. When the voltage of the supercapacitor reaches 95% of the input voltage, the bypass relay K3 is closed. The pre-charging board monitors the peak current and temperature of the power supply in real time. If the protection threshold is exceeded, the pre-charging relay K1, pre-charging relay K2, and bypass relay K3 are disconnected, and the discharge relay K4 is closed simultaneously.

[0055] S6. If the circuit system suddenly loses power during the charging process of the supercapacitor, the BOOST board will have no input, stop working, and stop sending the READY signal to the pre-charging board;

[0056] The pre-charge board is powered by the BOOST board and the supercapacitor, so the pre-charge board can continue to work after the BOOST power is cut off.

[0057] When the pre-charge board does not receive the REDAY signal, the pre-charge relay K1, pre-charge relay K2, and bypass relay K3 are disconnected, and the discharge relay K4 is closed synchronously;

[0058] The minimum operating voltage of the pre-charging board is 36V. Therefore, when the voltage of the supercapacitor drops to 36V, the entire pre-charging board is powered off and waits for the BOOST board to be powered on before re-pre-charging. If the voltage of the supercapacitor is greater than 36V, when the BOOST board is powered on again and the pre-charging board receives the READY signal again, the bypass relay K3 is first opened, and then the pre-charging relay K1 is closed, and the power-on pre-charging operation is restarted.

[0059] In the above technical solution, if the power supply system is suddenly powered off, after the power supply system is powered on again, the pre-charging operation can still be continued according to the current voltage on the supercapacitor.

[0060] It is worth mentioning that by using the BOOST board and supercapacitor to bidirectionally power the pre-charge board, after a normal or abnormal power outage in the system, the pre-charge board will discharge the voltage on the supercapacitor to below the safe voltage of 36V within the specified time. At this time, the voltage on the supercapacitor drops to the safe voltage range to ensure the personal safety of the operator.

[0061] It is worth mentioning that this solution is not recommended when the rated power of the power-taking device cannot meet the peak power of the power-consuming device; if the peak power of the power-consuming device far exceeds the rated power of the power-taking device, or the rated power of the power-taking device does not meet the rated power of the power-consuming device.

[0062] The above description is only a preferred specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any technician familiar with the technical field, within the technical scope disclosed by the present invention, who makes equivalent replacements or changes based on the technical solution and inventive concept of the present invention, should be covered by the scope of protection of the present invention.

Claims

1. A fast and safe supercapacitor charge and discharge control circuit, characterized in that: Including power supply equipment, Boost board, pre-charge board, pre-charge relay 1 K1, pre-charge relay 2 K2, bypass relay K3, discharge relay K4, pre-charge resistor 1 R1, pre-charge resistor 2 R2, discharge resistor R3, diode 1 D1, diode 2 D2, diode 3 D3, super capacitor and power-consuming equipment; The power taking device is electrically connected to the Boost board, one end of the pre-filling relay K1, the pre-filling relay K2, and the bypass relay K3 are all electrically connected to the Boost board, the other end of the pre-filling relay K1 is electrically connected to one end of the pre-filling resistor R1, and the other end of the pre-filling relay K2 is electrically connected to one end of the pre-filling resistor R2; The other ends of the pre-charging resistor R1, pre-charging resistor R2, and bypass relay K3 are all electrically connected to the positive electrode of diode D1, the negative electrode of diode D1 and one end of discharge relay K4 are all electrically connected to the supercapacitor, the other end of discharge relay K4 is electrically connected to one end of discharge resistor R3, and the other end of discharge resistor R3 is grounded; The power taking device, the Boost board, and the super capacitor are all electrically connected to the pre-charging board, and the super capacitor is electrically connected to the power consuming device.

2. A fast and safe supercapacitor charge and discharge control circuit according to claim 1, characterized in that: The pre-charge board includes a pre-charge control module, the Boost board is electrically connected to the pre-charge control module, the pre-charge control module and the Boost board communicate via a 485 bus, and the pre-charge control module is used to detect the input and output voltages of the Boost board; The power taking device is electrically connected to the pre-charge control module, and the pre-charge control module is further used to detect the temperature and current of the power taking device; The supercapacitor is electrically connected to a pre-charge control module, and the pre-charge control module is further used to detect the input and output voltages of the supercapacitor.

3. A fast and safe supercapacitor charge and discharge control circuit according to claim 2, characterized in that: The pre-charge board also includes an auxiliary power supply, which is electrically connected to the pre-charge control module. The positive electrode of the diode 2 D2 is electrically connected to the Boost board, the negative electrode of the diode 2 D2 is electrically connected to the auxiliary power supply, the positive electrode of the diode 3 D3 is electrically connected to the supercapacitor, and the negative electrode of the diode 3 D3 is electrically connected to the auxiliary power supply.

4. A fast and safe supercapacitor charge and discharge control circuit and method thereof according to claim 3, characterized in that: The pre-charging resistor R1, the pre-charging resistor R2, and the bleeder resistor R3 are all aluminum shell resistors. The pre-charging resistor R1, the pre-charging resistor R2, and the bleeder resistor R3 are all electrically connected to an NTC thermistor, and the NTC thermistor is used to detect the temperature of the pre-charging resistor R1, the pre-charging resistor R2, and the bleeder resistor R3.

5. A fast and safe supercapacitor charge and discharge control method, the method is implemented based on the fast and safe supercapacitor charge and discharge control circuit of claim 4, characterized in that: The following steps are involved: S1: When the power supply cabinet is powered on, the electrical appliance will provide the power it obtains to the BOOST board. S2, after the BOOST board is powered on, it supplies power to the pre-charge board. At the same time, the BOOST board performs a self-test. If the self-test is normal, it sends a READY signal to the pre-charge board through the 485 bus. S3. After the pre-charging board is powered on, it performs a self-test to detect its input and output voltages, the temperature and current of the power supply device, the temperature of the pre-charging resistor R1, the pre-charging resistor R2, the discharge resistor R3, and the working status of the pre-charging relay K1, the pre-charging relay K2, the bypass relay K3, and the discharge relay K4. After the self-test is completed and the READY signal is received, the pre-charging relay K1 is closed to charge the supercapacitor through the pre-charging resistor R1. S4: When the first-stage charging speed is lower than the set threshold V / S, the pre-charge relay K2 is closed to charge the supercapacitor through two-stage pre-charging. S5. When the voltage of the supercapacitor reaches 95% of the input voltage, the bypass relay K3 is closed. S6. If the circuit system suddenly loses power during the charging process of the supercapacitor, the BOOST board will have no input, stop working, and stop sending the READY signal to the pre-charging board; After the pre-charging board does not receive the REDAY signal, the pre-charging relay K1, the pre-charging relay K2, and the bypass relay K3 are disconnected, and the discharge relay K4 is closed synchronously.

6. A fast and safe supercapacitor charge and discharge control method according to claim 1, characterized in that: In step S4, during the entire charging process, the pre-charging board monitors the temperature of the pre-charging resistor R1 and the pre-charging resistor R2 as well as the temperature and current of the power-taking device in real time. If any abnormality occurs, the pre-charging relay K1 and the pre-charging relay K2 are disconnected at any time, and the discharge relay K4 is closed synchronously.

7. A fast and safe supercapacitor charge and discharge control method according to claim 1, characterized in that: In step S5, the pre-charging board monitors the peak current and temperature of the electrical device in real time. If the peak current and temperature exceed the protection threshold, the pre-charging relay K1, the pre-charging relay K2, and the bypass relay K3 are disconnected, and the discharge relay K4 is closed synchronously.

8. A fast and safe supercapacitor charge and discharge control method according to claim 1, characterized in that: In step S6, the power supply of the pre-charge board is provided by the BOOST board and the super capacitor, so the pre-charge board can continue to work after the BOOST is powered off.

9. A fast and safe supercapacitor charge and discharge control method according to claim 8, characterized in that: In step S6, the minimum operating voltage of the pre-charging board is 36V. Therefore, after the voltage of the supercapacitor drops to 36V, the entire pre-charging board is powered off and waits for the BOOST board to be powered before re-charging.

10. A fast and safe supercapacitor charge and discharge control method according to claim 9, characterized in that: In step S6, if the voltage of the supercapacitor is greater than 36V, when the BOOST board is powered on again and the pre-charging board receives the READY signal again, the bypass relay K3 is first disconnected, and then the pre-charging relay K1 is closed to perform the power-on pre-charging operation again.

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