Intelligent charging seat

Abstract

The invention discloses an intelligent charging seat. The intelligent charging seat comprises a panel, and a direct current part, an alternating current part, a grounding part, a motor lock part and a CCU part which are connected behind the panel, an integrated circuit board in the panel is in direct insertion connection with the signal sockets and the CCU parts of all the modules through a plurality of signal adapter plugs; the direct-current part and the alternating-current part are provided with connector structures, and PCBA boards directly connected with signal sockets of the direct-current part and the alternating-current part are electrically connected with a high-voltage interlocking assembly, a signal jack and a temperature monitoring assembly. The temperature monitoring assembly adopts a patch temperature sensor and a heat-conducting fin structure, and the grounding part is of a cable-free integrated structure; and the CCU part is communicated with a vehicle control part MCU through a communication cable, and monitors and adjusts the operation of each part of the charging seat in real time. According to the invention, charging is effectively controlled, monitored and adjusted, intelligence, automation and user experience are improved, operation is safe, the number of cables is small, the structure is simplified, the product size is small, and assembling is convenient.

Description

Technical Field

[0001] This invention relates to the field of charging docks, and particularly to smart charging docks. Background Technology

[0002] The development of new energy electric vehicles is currently rapid. Electric vehicles often use high-power charging sockets, but these sockets have several drawbacks: First, current charging sockets are passive devices without electrical regulation, charging control, or communication functions. They simply provide plug-in charging and discharging, unable to monitor or adjust the charging and discharging status. This results in low levels of intelligence and automation, leading to a poor user experience. Second, current charging sockets have low temperature monitoring accuracy, with actual temperature detection exhibiting deviations and lags, posing a risk of monitoring failure. It is difficult to monitor the socket's real-time temperature within a safe range, causing the power terminal temperature to rise rapidly, potentially leading to failure or combustion of the socket itself or connected electronic components and cables. Third, the transmission cables for low-voltage signals and temperature detection signals, as well as the grounding... The cables require complex wiring structures and numerous sealing components (such as multiple sets of adapter caps, adapter terminals, cable seals, cable end caps, sealing caps, and sealing rings). The assembly process is complex and has low automation efficiency, making installation difficult and time-consuming. Furthermore, the large number of cables in the overall product occupies a significant portion of the vehicle's space, resulting in a large product size and higher costs. Fourthly, the complex grounding structure occupies considerable space, further increasing the product's size. Fifthly, the equipment has a low degree of modularity and low automation in assembly. Maintenance and replacement of parts require complete disassembly and reassembly, leading to a large maintenance workload. Moreover, the numerous parts are prone to damage, resulting in frequent and prolonged equipment downtime. Summary of the Invention

[0003] To address one or more of the above problems, the present invention provides a smart charging dock.

[0004] According to one aspect of the present invention, the smart charging dock includes: a panel and a DC part, an AC part, a grounding part, a motor lock part, and a CCU part connected to the panel;

[0005] The front panel has a DC socket and an AC socket on one side and an integrated cavity for fixing the integrated circuit board on the other side. Multiple signal adapter plugs connected to the integrated circuit board are exposed on the panel and directly connected to the signal sockets of the DC section, AC section and motor lock section.

[0006] The DC and AC sections have connector structures with exposed DC and AC sockets. The signal sockets of both sections are soldered to corresponding PCBA boards. The PCBA boards are electrically connected to high-voltage interlock components, signal sockets, and temperature monitoring components.

[0007] The surface-mount temperature sensor of the temperature monitoring component is soldered onto a DC or AC PCBA board. Its heat-conducting sheet is integrally injection molded into a DC or AC shell. The lower end of the heat-conducting sheet is connected to a DC or AC socket and the upper end is attached to the surface-mount temperature sensor.

[0008] The grounding part includes a transition copper busbar that is integrally injection molded into the DC shell and the AC shell respectively. The inner ends of the two transition copper busbars are wrapped with grounding sockets and the outer ends are connected to the two branches of the grounding copper busbar. The end of the grounding copper busbar is sleeved with a panel.

[0009] The input terminal of the CCU is electrically connected to the integrated circuit board, and the output terminal is connected to the vehicle control unit MCU via a communication cable. The CCU sends feedback signals to the MCU and receives instructions from the MCU, and monitors and adjusts the operation of various components of the charging dock in real time.

[0010] In some embodiments, the DC section includes a DC plug section and a DC socket section that are plugged in from the front and back. The commutation housing of the DC plug section is equipped with an interlocking pin of the high-voltage interlock assembly in the middle. The mounting housing of the DC socket section is threaded to a panel and its inner cavity is connected to a DC PCBA board. After the interlocking spring of the high-voltage interlock assembly is welded to the PCBA board, the signal socket is fitted with the front mounting housing and welded to the PCBA board. When plugged in, the interlocking pin is inserted into the interlocking spring to form a high-voltage interlock circuit.

[0011] The AC section includes an AC plug section and an AC socket section that are plugged in at the front and back. The high-voltage interlocking structure between the AC plug section and the AC socket section is the same as that of the DC section. The signal socket is fitted with a front mounting plate and soldered onto a PCBA board.

[0012] In some implementations, multiple signal jacks are connected to the mounting housing and the socket housing via bushings. The middle section of the signal jack passes through the PCBA board with an equal diameter. One end of the surface-mount copper busbar is soldered to the rear end of the signal jack, and the other end of the surface-mount copper busbar is soldered to the PCBA board, thereby achieving wireless low-voltage signal output.

[0013] In some embodiments, the front wall of the plug housing is integrally connected with multiple axial primary locking holes. The front end of the primary locking hole is provided with multiple elastic locking plates in a circumferential array. Several AC terminals are inserted through the primary locking holes with equal diameters and are locked in one step by the elastic locking plates. The secondary locking block is inserted into the inner cavity of the plug housing and its axial secondary locking hole is interference-fitted with the elastic locking plates so that the AC terminals are locked in a secondary way.

[0014] In some embodiments, the upper end of the plug housing has an integrally provided axial slide in the middle of the lock housing and an integrally provided locking platform at the rear end of the lower wall, and an outer C-shaped slide is provided at the rear end of the axial slide.

[0015] The locking connector has a pressure contact end at the front end and a secondary locking buckle at the rear end. The locking connector has an inner slider at the lower middle of the rear end. The locking connector has inner C-shaped slides at both ends that cooperate with the outer C-shaped slides. The locking connector has a push block at the upper end.

[0016] The rear mounting plate has a primary locking buckle. When force is applied to push the block, the front end of the contact end presses against the primary locking buckle to achieve the primary locking of the connector. The secondary locking buckle enters the locking platform to achieve the secondary locking of the connector.

[0017] In some embodiments, the grounding socket's connecting tube is connected to the grounding shaft hole via riveting; the DC section's transition copper busbar has a three-dimensional bending structure; and the AC section's transition copper busbar has a planar bending structure. The inner end of the transition copper busbar is exposed outside the grounding shaft hole and sleeved onto the grounding socket; the outer end is fitted against the branch arm of the grounding copper busbar and connected to the housing via screws.

[0018] The grounding part also includes a conductive grounding bushing, with the outer end of the grounding copper busbar attached to the grounding bushing. The grounding bushing is connected to the grounding hole of the panel, the panel is mounted on the body sheet metal, and the grounding bushing contacts the body sheet metal.

[0019] In some embodiments, the heat-conducting sheet is integrally injection molded to the rear housing or rear mounting plate, and an ultra-thin wall layer or adhesive connection is provided between the upper end of the heat-conducting sheet and the temperature detection groove of the rear housing or rear mounting plate. The lower end of the heat-conducting sheet protrudes and is sleeved with a DC or AC socket. The gap between the patch temperature sensor and the temperature detection groove is bonded together by thermally conductive silicone.

[0020] In some embodiments, the signal socket has a rectangular array of multi-hole bases with several output shaft holes. The middle section of the connecting pin is integrally injection molded to the output shaft hole. The rear end of the connecting pin extends out of the multi-hole base. The multi-hole base is fixedly connected to the through hole of the housing and welded to the PCBA board.

[0021] The signal adapter is a single injection-molded connector with multiple input pins arranged in a rectangular array inside the panel.

[0022] In some embodiments, the CCU module includes an outer housing behind the threaded connection panel and a PCBA assembly disposed in the inner cavity of the outer housing. The input and output terminals of the PCBA assembly are electrically connected to a signal input module and an output connector. The signal input module extends out of the lower connection port of the outer housing and enters the integrated cavity through an adapter that is electrically connected to the integrated circuit board. The output connector is plugged into the upper connection port of the outer housing and is connected to the MCU via a communication cable. The communication cable is a CAN protocol bus.

[0023] In some implementations, the device also includes a charging cover opening / closing module and an LED light module, wherein the motor and induction switch of the charging cover opening / closing module and the LED light module are all electrically connected to the integrated circuit board.

[0024] The charging cover is hinged to one side of the front panel. The charging cover can be rotated to close the socket or rotated to expose the socket. Attached Figure Description

[0025] Figure 1 This is a three-dimensional schematic diagram (a) of an embodiment of the smart charging dock of the present invention;

[0026] Figure 2 for Figure 1 The image shows a 3D exploded view of the smart charging dock.

[0027] Figure 3 for Figure 1 A three-dimensional schematic diagram (II) of the smart charging dock shown;

[0028] Figure 4 for Figure 3 A 3D schematic diagram of the panel shown;

[0029] Figure 5 for Figure 3 A three-dimensional schematic diagram of the DC section is shown.

[0030] Figure 6 for Figure 5 A three-dimensional schematic diagram of the DC plug section shown;

[0031] Figure 7 for Figure 5 A three-dimensional schematic diagram of the DC socket section is shown;

[0032] Figure 8 for Figure 7 A cross-sectional schematic diagram of the temperature detection component shown.

[0033] Figure 9 for Figure 3 A three-dimensional schematic diagram of the AC unit is shown.

[0034] Figure 10 for Figure 9 A three-dimensional schematic diagram of the AC socket section shown;

[0035] Figure 11 for Figure 9 A three-dimensional schematic diagram of the AC plug shown;

[0036] Figure 12 for Figure 11 A cross-sectional view of the AC plug section shown.

[0037] Figure 13 for Figure 3 A three-dimensional schematic diagram of the grounding part is shown;

[0038] Figure 14 for Figure 3 A three-dimensional schematic diagram of the CCU section shown;

[0039] Panel 1, DC socket 101, AC socket 102, integrated cavity 103, adapter 104, plastic cover 105, integrated circuit board 10, signal adapter plug 11;

[0040] DC section 2, DC housing 20, commutation housing 201, front housing 202, rear housing 203, protective cover 204, DC plug section 21, DC socket section 22, DC cable 23.

[0041] AC section 3, AC housing 30, plug housing 300, primary locking hole 3001, locking platform 3002, lock housing 3003, axial slide 3004, outer C-shaped slide 3005, front mounting plate 301, rear mounting plate 302, AC plug section 31, AC terminal 310, AC socket section 32, locking member 33, secondary locking buckle 331, pressure contact end 332, inner slider 333, inner C-shaped slide 334, push block 335, secondary locking block 34;

[0042] Temperature monitoring component 4, temperature detection slot 40, patch temperature sensor 41, thermal conductive sheet 42, thermal conductive silicone 43;

[0043] Grounding part 5, transition copper busbar 50, grounding copper busbar 51, grounding bushing 52;

[0044] Motor lock part 6;

[0045] CCU unit 7, outer shell 71, bottom cover 711, upper cover 712, PCBA assembly 72, output pin 721, signal input module 73, output connector 74, output shell 741, output socket body 742, sliding locking structure 743, first sealing ring 75.

[0046] PCBA board 8, surface mount copper busbar 81;

[0047] High-voltage interlock assembly 9;

[0048] Signal socket 12, multi-hole socket 120, connecting pin 121;

[0049] Signal jack 13, grounding jack 14. Detailed Implementation

[0050] The invention will now be described in further detail with reference to the accompanying drawings. It should be noted that the terms "front," "rear," "left," "right," "up," and "down" used in the following description refer to directions in the accompanying drawings, while the terms "inner" and "outer" refer to directions toward or away from the geometric center of a specific component, respectively.

[0051] Figures 1 to 14 A smart charging dock according to an embodiment of the present invention is schematically shown. As shown, the smart charging dock includes: a panel 1 and a DC part 2, an AC part 3, a grounding part 5, a motor lock part 6, and a CCU part 7 connected to the panel 1;

[0052] The front side of the panel 1 is provided with a DC socket 101 and an AC socket 102, and the other side is provided with an integrated cavity 103 for fixing the integrated circuit board 10. Multiple signal adapter plugs 11 connected to the integrated circuit board 10 are exposed on the panel 1 and directly connected to the signal sockets 12 of the DC part 2, AC part 3 and motor lock part 6. The integrated circuit board 10 collects the operating status signals of each component and transmits them to the CCU part 7.

[0053] The DC section 2 and AC section 3 have connector structures with exposed DC sockets 101 and AC sockets 102. Corresponding PCBA boards 8 are soldered to the inner ends of the signal sockets 12 of both sections. The PCBA boards 8 are electrically connected to the high-voltage interlock assembly 9, signal sockets 13, and temperature monitoring components 4. Preferably, the DC section 2 has exposed DC sockets 101, and the DC signal socket 12 has a DC PCBA board 8 soldered to its inner end. The DC PCBA board 8 is electrically connected to the high-voltage interlock assembly 9, multiple DC signal sockets 13, and multiple DC socket temperature monitoring components 4. The AC section 3 has exposed AC sockets 102, and the AC signal socket 12 has an AC PCBA board 8 soldered to its inner end. The AC PCBA board 8 is electrically connected to the high-voltage interlock assembly 9, multiple AC signal sockets 13, and multiple AC socket temperature monitoring components 4.

[0054] The surface-mount temperature sensor 41 of the temperature monitoring component 4 is soldered to a DC or AC PCBA board 8, and its heat-conducting sheet 42 is integrally injection molded into a DC shell 20 or an AC shell 30. The lower end of the heat-conducting sheet 42 is sleeved with a DC or AC socket and the upper end is attached to the surface-mount temperature sensor 41.

[0055] The grounding part 5 includes a transition copper busbar 50 integrally injection molded in the DC housing 20 and the AC housing 30 respectively. The inner ends of the two transition copper busbars 50 are covered with grounding sockets 14 and the outer ends are connected to the two branches of the grounding copper busbar 51. The end of the grounding copper busbar 51 is sleeved with a panel 1.

[0056] The input terminal of the CCU unit 7 is electrically connected to the integrated circuit board 10, and the output terminal is connected to the vehicle control unit MCU via a communication cable. The CCU unit 7 feeds back signals to the MCU and receives instructions from the MCU, and monitors and adjusts the operation of each component of the charging dock in real time.

[0057] The intelligent charging dock features control structures in its DC section 2, AC section 3, and motor lock 6. Various signal sources are integrated into the integrated circuit board 10 via signal sockets 12 and signal adapters 11 (wireless connector structure), and then further integrated into the CCU section 7. The CCU section 7 transmits data to the MCU via fewer communication cables. The DC section 2 and AC section 3 incorporate novel temperature monitoring and charging status confirmation structures. The novel grounding section 5 is highly integrated and structurally simple. Its advantages are: First, the charging dock incorporates an MCU and integrated circuit board 10, which provides electrical control functions. It processes various signals, including charging and temperature monitoring signals, and communicates with the vehicle to provide real-time charging status feedback and execute vehicle commands, effectively controlling and monitoring charging adjustments, significantly improving the charging dock's intelligence and automation, and enhancing the user experience. Second, the novel temperature monitoring structure integrates a heat-conducting sheet 41, which is integrally injection-molded into the housing. The PCBA board 8 with the soldered surface temperature sensor 42 is then attached to the heat-conducting sheet. This structure offers high measurement accuracy, fast response speed, and easy installation. The convenient features further improve the accuracy of temperature detection, reduce data lag, and ensure safe and stable operation. Moreover, the structure is simple, with fewer related parts, simple assembly process, less labor time, and high assembly efficiency. Thirdly, the signal socket 12 and signal adapter plug 11 with wireless bundle connector structure reduce the overall wiring harness, occupy less space, and significantly reduce product size. At the same time, the simple structure and fewer parts reduce assembly difficulty and significantly reduce costs. Fourthly, the DC section 2 and AC section 3 adopt the connector direct plug-in structure, which facilitates modular assembly and realizes intelligent assembly. The structure is simple, reduces assembly time, and has high assembly efficiency. In addition, it is equipped with a high-voltage interlock component 9 to ensure safe and reliable connection of the connector structure module. Fifthly, the grounding section 5 is highly integrated, and the adapter copper busbar 50 is integrally injection molded into the housing. After on-site assembly, the panel directly contacts the body sheet metal to realize the grounding function without the need for cables and on-site assembly. Compared with the cable structure, there is no need for part through holes and sealing, and no need for grounding before assembly. The assembly is simple, less labor time, and more efficient, while further reducing the number of cables.

[0058] Furthermore, the DC section 2 includes a DC plug section 21 and a DC socket section 22 that are connected to the front and rear. The interlocking pin of the high voltage interlocking assembly 9 is installed in the middle of the commutation shell 201 of the DC plug section 21. The mounting shell of the DC socket section 22 is threaded to the panel 1 and the inner cavity is connected to the DC PCBA board 8. After the interlocking spring of the high voltage interlocking assembly 9 is welded to the PCBA board 8, the signal socket 12 is fitted through the front mounting shell 202 and welded to the PCBA board 8. When plugged in, the interlocking pin is inserted into the interlocking spring to form a high voltage interlocking circuit.

[0059] The AC section 3 includes an AC plug section 31 and an AC socket section 32 that are connected front and rear. The plug housing 300 of the AC plug section 31 contains an interlocking spring of the high-voltage interlock assembly 9. The socket housing of the AC socket section 32 is threadedly connected to the panel 1 and its inner cavity is connected to the AC PCBA board 8. After the interlocking pins of the high-voltage interlock assembly 9 are soldered to the PCBA board 8, the signal socket 12 is fitted with the front mounting plate 301 and soldered to the PCBA board 8, forming a high-voltage interlock circuit during mating. Its beneficial effect is that this high-voltage interlock assembly enables a safe and reliable connection of the connector structure modules.

[0060] Preferably, two DC cables 23 are symmetrically installed inside the commutation housing 201 of the DC plug section 21; the DC cables 23 are any one of aluminum wire, copper wire and aluminum busbar, and the connecting lugs are copper wire lugs;

[0061] The mounting shell of the DC socket part 22 is threadedly connected to the panel 1 and its inner bushing is connected to multiple plug-in components. The plug-in components include a DC plug-in, a ground plug-in 14 and a signal plug-in 13. The mounting shell is formed by connecting a front mounting shell 202 and a rear mounting shell 203. The threaded component passes through the rear ear plate of the rear mounting shell 203 and the front ear plate of the front mounting shell 202 and is connected to the fixing screw hole of the panel 1.

[0062] When the DC plug part 21 and the DC socket part 22 are assembled together, the rear housing 203 of the mounting housing 202 is sleeved onto the commutation housing 201, and the rear end of the DC socket is attached to the connecting lug of the DC cable 23 and fixedly connected by screws.

[0063] The rear port of the commutator housing 201 is hinged to a protective cover 204. Rotating the protective cover 204 opens or closes it. The protective cover 204 and the rear housing 203 are fixed together by a common screw. Its advantages are: the two parts of the DC section 2 plug-in structure can be assembled on different assembly lines. One production line assembles the socket section, and the other assembles the plug section. The two modules can be assembled symmetrically, achieving intelligent assembly. The structure is simple, assembly time is reduced, and assembly efficiency is high.

[0064] Preferably, a plurality of AC terminals 310 for connecting power wires at the rear end are installed inside the plug housing 300 of the AC plug section 31.

[0065] The socket housing of the AC socket section 32 is connected to multiple socket components by a bushing. The socket components include a DC socket, a grounding socket 14 and a signal socket 13. The socket housing is formed by connecting a front mounting plate 301 and a rear mounting plate 302. Threaded parts pass through the rear ear plate of the rear mounting plate 302 and the front ear plate of the front mounting plate 301 are connected to the fixing screw holes of the front panel 1.

[0066] When the AC plug part 31 and the AC socket part 32 are assembled together, the rear mounting plate 302 of the plug shell 300 is fitted onto the plug shell 300. The beneficial effects are: the two parts of the AC part 3's mating structure can be assembled on different assembly lines; one production line assembles the socket part, and another production line assembles the plug part. The two modules can be assembled symmetrically, achieving intelligent assembly, a simple structure, reduced assembly time, and high assembly efficiency.

[0067] Furthermore, multiple signal jacks 13 are connected to the mounting housing and socket housing via bushings. The middle section of each signal jack 13 passes through a PCBA board 8 of equal diameter. One end of a surface-mount copper busbar 81 is soldered to the rear end of the signal jack 13, and the other end of the surface-mount copper busbar 81 is soldered to the PCBA board 8, thus achieving wireless low-voltage signal output. Its advantages are: firstly, this structure eliminates the need for various low-voltage cables, copper busbars, and seals used for signal output, thus occupying less space, simplifying the assembly structure, reducing labor time, and increasing assembly efficiency, while also reducing assembly costs and component costs; secondly, this connection structure provides a robust connection and high signal transmission accuracy.

[0068] Furthermore, the front wall of the plug housing 300 is integrally connected with several axial primary locking holes 3001. Each primary locking hole 3001 has a circumferential array of elastic locking plates at its front end. Several AC terminals 310, with equal diameters at their front ends, pass through the primary locking holes 3001 and are locked in place by the elastic locking plates. A secondary locking block 34 inserts into the inner cavity of the plug housing 300, and its axial secondary locking holes are interference-fitted with the elastic locking plates, thus locking the AC terminals 310 in a secondary manner. The advantages are: the power terminals adopt a secondary locking structure, resulting in a secure overall installation and a long service life.

[0069] Furthermore, the upper end of the plug housing 300 has an integrally provided axial slide 3004 in the middle of the lock housing 3003 and an integrally provided locking platform 3002 at the rear end of the lower wall. The axial slide 3004 has a locking hole in the middle and an outer C-shaped slide 3005 at its rear end.

[0070] The locking member 33 has a pressure contact end 332 at the front end and a triangular tooth-shaped secondary locking buckle 331 at the rear end. The locking member 33 has an inner slider 333 at the lower middle of the rear end. The locking member 33 has an inner C-shaped slide 334 at both ends that slide and engage with the outer C-shaped slide 3005. The locking member 33 has a push block 335 at the upper end.

[0071] The rear mounting plate 302 has a primary locking buckle at its rear end. Applying force to the push block 335 causes the pressure contact end 332 to press against the primary locking buckle, achieving primary locking of the connector. The secondary locking buckle 331 then engages with the locking platform 3002, achieving secondary locking of the connector. The advantages are: firstly, the two modules of the AC section 2 adopt a secondary locking structure, ensuring a tight overall assembly connection; secondly, this locking structure offers high motion precision and ease of operation.

[0072] Furthermore, the grounding socket 14's connecting tube is connected to the grounding shaft hole via riveting, making the adapter copper busbar 50 and the grounding terminal 52 rigidly connected as a whole. The adapter copper busbar 50 of the DC section 2 has a three-dimensional bending structure, while the adapter copper busbar 50 of the AC section 3 has a planar bending structure. Both are integrally injection molded onto the rear mounting shell 203 of the DC shell 20 and the rear mounting plate 302 of the AC shell 30. The inner connection end of the adapter copper busbar 50 is exposed at the grounding shaft hole and sleeved with the grounding socket 14, while the outer connection end is attached to the branch arm of the grounding copper busbar 51 and connected to the shell via screws.

[0073] The grounding part 5 also includes a conductive grounding bushing 52. The outer end of the grounding copper busbar 51 is attached to the grounding bushing 52. The grounding bushing 52 is sleeved on the grounding hole of the panel 1. The panel 1 is mounted on the body sheet metal. The grounding bushing 52 contacts the body sheet metal. The grounding terminal, the adapter copper busbar 50, the grounding copper busbar 51, the grounding bushing 52, and the body sheet metal are connected to achieve the grounding function. Its advantages are: during assembly, only threaded parts are needed to connect the adapter copper busbar and the grounding copper busbar, and the grounding copper busbar and the grounding bushing, respectively, to complete the internal assembly of the product. During on-site assembly, the grounding bushing directly contacts the body sheet metal, thus achieving the grounding function. No cables or on-site assembly are required. Compared with cable structures, there is no need for part through holes or sealing settings, and no need for grounding before assembly. Assembly is simple, less time-consuming, and more efficient.

[0074] Furthermore, the heat-conducting sheet 42 is integrally injection molded to connect to the rear housing 203 or the rear mounting plate 302, and an ultra-thin wall layer or a bonded connection is provided between the upper end of the heat-conducting sheet 42 and the temperature detection groove 40 of the rear housing 203 or the rear mounting plate 302. The lower end of the heat-conducting sheet 42 protrudes and is sleeved to a DC or AC socket. The front end of the surface-mount temperature sensor 41 enters the temperature detection groove 40 and is bonded to the surface-mount temperature sensor 40 by thermally conductive silicone 43. The beneficial effects are: firstly, the temperature detection groove 40 facilitates the entry of the surface-mount temperature sensor 3, improving the assembly speed; secondly, the heat-conducting sheet 42 and the surface-mount temperature sensor 41 achieve precise matching through the temperature detection groove 40 and full connection through the thermally conductive silicone 43, with a small or even zero gap between them, greatly reducing the difference between the real-time temperature of the power terminal and the actual temperature of the temperature sensor, resulting in high detection accuracy.

[0075] Furthermore, the signal socket 12 includes a multi-hole base 120 and a plurality of connecting pins 121. The multi-hole base 120 is arranged in a rectangular array with a plurality of output shaft holes. The middle section of the connecting pin 121 is integrally injection molded to the output shaft hole. The rear end of the connecting pin 121 extends out of the multi-hole base 120 and its front end is located inside the output shaft hole. The multi-hole base 120 is fixedly connected to the through hole of the housing and soldered to the PCBA board 8. A sealing ring is also provided at each through hole.

[0076] The signal adapter plug 11 is a single injection-molded assembly of multiple input pins arranged in a rectangular array within the panel 1. When plugged in, the input pins are directly inserted into the multi-hole socket 120 and tightly fitted against the connecting pins 121; a sealing ring seals the connection gap. Its advantages are: firstly, this design reduces assembly steps, improves component precision, facilitates plugging applications, enables modular product processing, and ensures high component yield and assembly efficiency; secondly, the robust connection structure ensures stable and reliable signal transmission; and thirdly, the end-face sealing ring prevents interference from foreign objects at the signal transmission connection point, achieving precise transmission.

[0077] Furthermore, an adapter 104 is provided on one side of the integrated cavity 103 of the panel 1, and a plastic cover 105 is glued to the outer port of the integrated cavity 103, and the positioning connection hole of the integrated circuit board 10 and the vertical positioning post inside the integrated cavity 103 are interference-fitted.

[0078] The CCU module 7 includes an outer housing 71 behind the threaded connection panel 1 and a PCBA assembly 72 located inside the outer housing 71. The input and output ends of the PCBA assembly 72 are electrically connected to a signal input module 73 and an output connector 74. The signal input module 73 extends out of the lower port of the outer housing 71 and enters the adapter 104 to be electrically connected to the integrated circuit board 10. The output connector 74 is plugged into the upper port of the outer housing 71 and is connected to the MCU via a communication cable. The communication cable is a CAN protocol bus.

[0079] The connecting lugs of the lower bottom cover 711 of the outer shell 71, the connecting lugs of the upper cover 712, and the screw holes of the panel 1 are fixedly connected by threaded parts; the lower bottom cover 711 is provided with a rectangular lower connection port, and the upper cover 712 has an elliptical tubular upper connection port on one side of the recessed platform; the two ends of the PCBA assembly 72 are directly opposite the lower connection port and the upper connection port.

[0080] The output connector 74 includes an output housing 741 and an output socket body 742 installed inside the output housing 741. The output socket body 742 is tightly inserted into the output pin 721 of the PCBA assembly 72. The output housing 741 is interference-fitted to the upper connector and the two are fixedly connected by a sliding locking structure 743.

[0081] The signal input module is a plug-in module with several plug holes. At the adapter, the output pins connected to the integrated circuit board are directly plugged into the plug holes. The advantages of this CCU unit 7 are: First, this setup requires only one or two external communication cables, with fewer and simpler cables, a simple overall structure, modular assembly, quick and efficient assembly, and low cost; Second, this setup mainly adopts signal integration structure and direct plug-in adapter structure, with fewer cables, avoiding electromagnetic interference, high signal transmission accuracy, reliable signal connection, stable charging, and high safety; Third, the modular structure of this setup facilitates maintenance, with fewer parts, a lower probability of damage, and less equipment downtime; Fourth, the CCU module 02 can reduce the computational load of the vehicle MCU, improve the overall system operating speed, and ensure high signal transmission immediacy.

[0082] The stepped groove at the edge of the lower connector is also fixedly connected to the first sealing ring 75, which fits into the adapter 104 of the sealing panel.

[0083] Furthermore, it also includes a charging cover opening and closing module and a three-color LED light module. The motor and induction switch of the charging cover opening and closing module and the three-color LED light module are all electrically connected to the integrated circuit board 10.

[0084] The charging cover is hinged to one side of the front end of panel 1, and the charging cover can be rotated to close or expose the two ports. Its advantages are: this design further enhances the automation and intelligence of the charging dock, improving the user experience.

[0085] A control system for any of the above-mentioned smart charging docks includes:

[0086] The vehicle control unit (MCU) is a high-performance on-board processor. The vehicle control unit issues commands according to the set program to control the charging process of the charging dock and makes logical decisions based on the signals fed back by the CCU 7 during charging, and issues new adjustment commands.

[0087] CCU 7, the output of CCU 7 is connected to the vehicle control unit MCU via CAN communication cable. CCU 7 will feed back the collected signals to the MCU and receive the MCU's instructions, and monitor and adjust the operation of each module in real time.

[0088] Integrated circuit board 10 is electrically connected to the signal output section of each module, transmits the operating status signal of each module to CCU section 7, and transmits the relay command of CCU section 7 to the signal output section of the corresponding module.

[0089] The control circuit of DC unit 2 includes a multi-channel temperature sensor real-time temperature detection circuit, a vehicle communication interaction unit and a control guidance detection unit of DC unit 2. The control guidance detection unit can detect the CC1 charging pile end connection confirmation signal and the CC2 vehicle end charging connection confirmation signal, detect the connection status, provide real-time feedback on status and faults, and execute the CC1 and CC2 state switching according to normal instructions.

[0090] The control circuit of AC unit 3 includes a real-time temperature detection circuit with temperature sensors for multiple AC terminals and a control guidance detection unit of AC unit 3. The control guidance detection unit includes a CP wave detection unit and a CC connection confirmation detection circuit. The CP wave detection unit realizes connection status detection and charging current detection; the CC connection confirmation detection circuit realizes connection status detection and cable current carrying capacity detection.

[0091] The control circuit of the motor lock part 6 drives the AC charging port electronic lock of the AC part 3, which locks when the vehicle is locked and unlocks when the vehicle is unlocked.

[0092] The inductive switch circuit detects the pressed state of the charging cover inductive switch to control the opening and closing state of the charging cover.

[0093] The charging cover opening and closing module can open the charging cover after the charging cover sensor switch is pressed once, and close the charging cover motor when pressed again and the charging gun head is not connected; moreover, it controls the opening and closing of the charging cover according to the vehicle CAN communication.

[0094] The LED light module uses multiple LEDs at the charging port to display different colors depending on the charging status.

[0095] The beneficial effects of this control system are: First, fewer and simpler cables, simpler overall structure, modular assembly, quick and efficient assembly, low cost, avoidance of electromagnetic interference, high signal transmission accuracy, stable and safe charging; Second, the CCU module 02 can reduce the computational load of the vehicle MCU, improve the overall system operating speed, and ensure high signal transmission immediacy; Third, it enhances the intelligence and smartness of the charging dock operation.

[0096] Preferably, the opening and closing motor of the charging cover opening and closing module is a brushed DC motor driver with fault reporting function, such as the DRV8872 model, which adopts an H-bridge motor driver built with built-in MOS, a wide operating voltage range of 6.8V to 45V, a typical value of 565mΩ RDS(on)(HS+LS), a maximum peak current drive capability of 3.6A, and a pulse width modulation (PWM) control interface.

[0097] The inductive switch uses an inductive inductive switch, with the LDC1612 sampling chip collecting the sensing status. The induction coil and the LDC1612 sampling chip are not located inside the CCU; they communicate with the control board's MCU via I2C. The advantages of this design are: it further improves the stability, reliability, and intelligence of the charging dock.

[0098] The above are merely some embodiments of the present invention. For those skilled in the art, various modifications and improvements can be made without departing from the inventive concept of the present invention, and all such modifications and improvements fall within the scope of protection of the present invention.

Claims

1. A smart charging dock, characterized in that, Includes: panel (1) and DC section (2), AC section (3), grounding section (5), motor lock section (6), and CCU section (7) connected to panel (1); The panel (1) has a DC socket (101) and an AC socket (102) on one side of the front and an integrated cavity (103) for fixing the integrated circuit board (10) on the other side. Multiple signal adapter plugs (11) connected to the integrated circuit board (10) are exposed on the panel (1) and directly connected to the signal socket (12) of the DC part (2), AC part (3) and motor lock part (6). The DC section (2) and AC section (3) have connector structures and the plug components expose the DC socket (101) and AC socket (102). The signal sockets (12) of both are welded to the corresponding PCBA boards (8). The PCBA boards (8) are electrically connected to the high voltage interlock assembly (9), the signal socket (13) and the temperature monitoring assembly (4). The surface-mount temperature sensor (41) of the temperature monitoring component (4) is soldered to a DC or AC PCBA board (8), and its heat-conducting sheet (42) is integrally injection molded into a DC shell (20) or an AC shell (30). The lower end of the heat-conducting sheet (42) is sleeved with a DC or AC socket and the upper end is attached to the surface-mount temperature sensor (41). The grounding part (5) includes a transition copper busbar (50) integrally injection molded in the DC shell (20) and the AC shell (30), respectively. The inner ends of the two transition copper busbars (50) are wrapped with grounding sockets (14) and the outer ends are connected to the two arms of the grounding copper busbar (51). The end of the grounding copper busbar (51) is sleeved with a panel (1). The input terminal of the CCU (7) is electrically connected to the integrated circuit board (10), and the output terminal is connected to the vehicle control unit (MCU) via a communication cable. The CCU (7) feeds back signals to the MCU and receives instructions from the MCU, and monitors and adjusts the operation of each component of the charging dock in real time.

2. The smart charging dock according to claim 1, characterized in that, The DC section (2) includes a DC plug section (21) and a DC socket section (22) that are plugged in at the front and back. The interlocking pin of the high voltage interlock assembly (9) is installed in the middle of the commutation shell (201) of the DC plug section (21). The mounting shell of the DC socket section (22) is threaded to the panel (1) and the inner cavity is connected to the DC PCBA board (8). After the interlocking spring of the high voltage interlock assembly (9) is welded to the PCBA board (8), the signal socket (12) is fitted through the front mounting shell (202) and welded to the PCBA board (8). When plugged in, the interlocking pin is inserted into the interlocking spring to form a high voltage interlock circuit. The AC section (3) includes an AC plug section (31) and an AC socket section (32) that are plugged in at the front and back. The high-voltage interlock structure between the AC plug section (31) and the AC socket section (32) is the same as that of the DC section (2). The signal socket (12) is fitted with a front mounting plate (301) and soldered onto a PCBA board (8).

3. The smart charging dock according to claim 2, characterized in that, Multiple signal jacks (13) are connected to the mounting housing and the socket housing. The middle section of the signal jack (13) is fitted with a PCBA board (8) of equal diameter. One end of the patch copper busbar (81) is welded to the rear end of the signal jack (13), and the other end of the patch copper busbar (81) is welded to the PCBA board (8) to realize the wireless beam low voltage signal output.

4. The smart charging dock according to claim 2, characterized in that, The front wall of the plug housing (300) is integrally connected with multiple axial primary locking holes (3001). The front end of the primary locking hole (3001) is provided with multiple elastic locking plates in a circumferential array. The front ends of several AC terminals (310) pass through the primary locking hole (3001) with equal diameter and are locked by the elastic locking plates in one step. The secondary locking block (34) is inserted into the inner cavity of the plug housing (300) and its axial secondary locking hole is interference-fitted with the elastic locking plate so that the AC terminals (310) are locked in a second step.

5. The smart charging dock according to claim 4, characterized in that, The upper end of the plug housing (300) has an integrally provided axial slide (3004) in the middle of the lock housing (3003) and an integrally provided locking platform (3002) at the rear end of the lower wall. The rear end of the axial slide (3004) has an outer C-shaped slide (3005). The locking connector (33) has a pressure contact end (332) at the front end and a secondary locking buckle (331) at the rear end. The locking connector (33) has an inner slider (333) at the lower middle of the rear end. The locking connector (33) has inner C-shaped slides (334) at both ends that cooperate with the outer C-shaped slides (3005). The locking connector (33) has a push block (335) at the upper end. The rear mounting plate (302) is provided with a primary locking buckle. When force is applied to push the block (335), the front end of the pressure contact end (332) presses the primary locking buckle to realize the primary locking of the connector. The secondary locking buckle (331) enters the locking platform (3002) to realize the secondary locking of the connector.

6. The smart charging dock according to claim 1, characterized in that, The grounding socket (14) is connected to the grounding shaft hole by riveting. The DC section (2) has a three-dimensional bending structure for the connecting copper busbar (50), and the AC section (3) has a planar bending structure for the connecting copper busbar (50). The inner end of the connecting copper busbar (50) is exposed to the grounding shaft hole and connected to the grounding socket (14). The outer end is attached to the branch arm of the grounding copper busbar (51) and connected to the housing by screws. The grounding part (5) also includes a conductive grounding bushing (52), the outer end of the grounding copper busbar (51) is attached to the grounding bushing (52), the grounding bushing (52) is sleeved on the grounding hole of the panel (1), the panel (1) is mounted on the body sheet metal, and the grounding bushing (52) contacts the body sheet metal.

7. The smart charging dock according to claim 1, characterized in that, The heat-conducting sheet (42) is integrally injection molded and connected to the rear housing (203) or the rear mounting plate (302). An ultra-thin wall layer or a bonding connection is provided between the upper end of the heat-conducting sheet (42) and the temperature detection groove (40) of the rear housing (203) or the rear mounting plate (302). The lower end of the heat-conducting sheet (42) protrudes and is sleeved with a DC or AC socket. The gap between the patch temperature sensor (41) and the temperature detection groove (40) is bonded together by thermally conductive silicone (43).

8. The smart charging dock according to claim 2, characterized in that, The signal socket (12) has a rectangular array of multi-hole base (120) with several output shaft holes. The middle section of the connecting pin (121) is integrally injection molded and connected to the output shaft hole. The rear end of the connecting pin (121) extends out of the multi-hole base (120). The multi-hole base (120) is fixedly connected to the through hole of the housing and welded to the PCBA board (8). The signal adapter plug (11) is a set of multiple input pins that are integrally injection molded and connected to the panel (1) in a rectangular array.

9. The smart charging dock according to claim 3, characterized in that, The CCU module (7) includes an outer shell (71) behind the threaded connection panel (1) and a PCBA assembly (72) located inside the outer shell (71). The input and output ends of the PCBA assembly (72) are electrically connected to a signal input module (73) and an output connector (74). The signal input module (73) extends out of the lower port of the outer shell (71) and enters the adapter (104) of the integrated cavity (103) and is electrically connected to the integrated circuit board (10). The output connector (74) is plugged into the upper port of the outer shell (71) and is connected to the MCU through a communication cable. The communication cable is a CAN protocol bus.

10. The smart charging dock according to claim 7, characterized in that, It also includes a charging cover opening and closing module and an LED light module, wherein the motor and induction switch of the charging cover opening and closing module and the LED light module are all electrically connected to the integrated circuit board (10); The charging cover is connected to the front side of the hinged panel (1). The charging cover can be rotated to close the socket or rotated to expose the socket.

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