Parallel main cabinet type direct current charging pile system

Abstract

The invention provides a parallel main cabinet type direct current charging pile system, which comprises a main control unit, at least one power distribution matrix unit, at least one main cabinet and a plurality of charging terminals, and is characterized in that each main cabinet is internally provided with a plurality of pluggable power supply modules, and each charging terminal is provided with at least one charging gun; the switching control logic of the power distribution matrix unit supports any power scheduling across a main cabinet, across a charging terminal and across a charging gun; each power distribution matrix unit is constructed as an M * N full-connection switch matrix, and the power distribution matrix unit dynamically switches the output power of any one power supply module to any one charging gun. The main control unit dynamically dispatches the output ports of the SCU to be connected in parallel according to the number of the charging gun, automatic superposition of power of multiple main cabinets is achieved, the megawatt charging requirements of electric heavy trucks, buses and the like are met, any power module is supported to be correspondingly connected with the charging gun of any number, and the physical boundary among the main cabinets, the charging terminals and the charging gun is broken.

Description

Technical Field

[0001] This invention relates to the field of charging cabinet technology, specifically to a parallel main cabinet type DC charging pile system. Background Technology

[0002] With the rapid development of the new energy vehicle industry, high-power electric vehicles such as electric heavy trucks, buses, and logistics vehicles have placed higher demands on DC fast charging infrastructure. Existing DC charging piles generally adopt a "one machine, one gun" or "fixed power distribution" architecture, meaning that each charging terminal corresponds to a fixed number of power modules, which cannot dynamically adjust the output power according to the real-time charging needs of the vehicle.

[0003] To improve charging efficiency, some manufacturers have launched modular charging piles, which supply power to a single charging gun through multiple power modules connected in parallel. However, such systems typically have the following drawbacks: First, their scalability is limited. When the maximum power of a single cabinet (e.g., 480kW) cannot meet the megawatt-level charging demand, it is difficult to achieve power expansion by simply stacking equipment. Second, power scheduling is rigid. The relationship between power modules and charging guns is mostly fixed, making it impossible to flexibly switch the power of any module to any charging terminal. This results in a resource mismatch phenomenon where "some guns have excessive power and some guns have insufficient power" when multiple vehicles are charging simultaneously. Summary of the Invention

[0004] To address the shortcomings of existing technologies, the present invention aims to provide a parallel main cabinet type DC charging pile system to solve the problems of limited scalability and rigid power scheduling in the existing modular charging pile charging power distribution system.

[0005] To solve the above-mentioned technical problems, the present invention is implemented through the following solution:

[0006] The present invention provides a parallel main cabinet type DC charging pile system, including a main control unit, at least one power distribution matrix unit, at least one main cabinet and multiple charging terminals. Each main cabinet is provided with multiple pluggable power modules, and each charging terminal is provided with at least one charging gun.

[0007] The power distribution matrix unit is used to switch the output power of the power modules in each main cabinet to each charging gun, and is uniformly scheduled by the main control unit. The switching control logic of the power distribution matrix unit supports arbitrary power scheduling across main cabinets, charging terminals, and charging guns.

[0008] The main control unit dynamically generates power switching commands based on the real-time power requirements of each charging terminal, the health status of the power module, and the load balancing strategy to achieve optimal power allocation.

[0009] Each of the power allocation matrix units is constructed as an M×N fully connected switch matrix, where M is the total number of power modules in one of the main cabinets in the system, and N is the total number of charging guns in all the charging terminals. The power allocation matrix unit dynamically switches the output power of any power module to any charging gun.

[0010] When the parallel main cabinet type DC charging pile system includes multiple main cabinets, the output terminals of the power modules in each main cabinet are processed by their respective power distribution matrix units, and the power output lines with corresponding serial numbers in the power distribution matrix units are connected in parallel on one side of the charging gun, so that the power modules on multiple main cabinets can jointly provide superimposed power to the same charging gun.

[0011] Preferably, the power distribution matrix unit has a centralized structure, and all power modules in the multiple main cabinets share the same power distribution matrix unit.

[0012] Preferably, each of the main cabinets is independently equipped with one of the power distribution matrix units.

[0013] Preferably, when the parallel main cabinet type DC charging pile system includes two main cabinets, the power output lines of the two main cabinets through the power distribution matrix unit are connected in parallel according to the charging gun numbers, and the parallel connection order is allowed to be staggered or non-sequence corresponding.

[0014] Preferably, the matrix topology of the power allocation matrix unit is selected from one or more combinations of full matrix, ring matrix, and fixed group matrix.

[0015] Preferably, the switching actuator in the power distribution matrix unit is a switching device, which includes one or more of relays, DC contactors, IGBT modules, and MOSFET solid-state switches.

[0016] Preferably, when the parallel main cabinet type DC charging pile system includes three or more main cabinets, the charging terminal is divided into megawatt-level high-power charging terminal and conventional charging terminal;

[0017] The output ports of the specified numbered power distribution matrix units are connected in parallel to the megawatt-level high-power charging terminal, and the output ports of the remaining power distribution matrix units are respectively connected to the conventional charging terminal. The output ports of the power distribution matrix units corresponding to the conventional charging terminal are independently connected among the multiple main cabinets.

[0018] Preferably, the number of power modules is not limited, and the rated power of a single power module is 30kW, 40kW or higher, and it supports AC-DC, DC-DC, unidirectional or bidirectional energy conversion topologies.

[0019] Compared with the prior art, the beneficial effects of the present invention are:

[0020] This invention achieves automatic power aggregation across multiple main cabinets by connecting the output ports of the power distribution matrix unit (SCU) in parallel according to the charging gun numbers. The total power increases linearly with the number of main cabinets, without requiring changes to the control architecture or wiring logic, easily meeting the megawatt-level charging needs of electric heavy trucks, buses, etc., and possessing engineering scalability. Each main cabinet's power distribution matrix unit (SCU) constructs an M×N fully connected matrix, supporting any power module to connect to any number of charging guns. The main control unit dynamically schedules based on global information, breaking down the physical boundaries between main cabinets, charging terminals, and charging guns. All modules constitute a shared power resource pool, allocated on demand. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of a single power distribution matrix unit in a parallel main cabinet type DC charging pile system of the present invention.

[0022] Figure 2 This is a schematic diagram of a parallel main cabinet type DC charging pile system of the present invention, which includes two main cabinets.

[0023] Figure 3 This is a schematic diagram of a parallel main cabinet type DC charging pile system of the present invention, which includes three or more main cabinets.

[0024] Figure 4 This is a control principle diagram of a parallel main cabinet type DC charging pile system according to the present invention.

[0025] Figure 5 This is a schematic diagram of a centralized structure for the power distribution matrix unit in a parallel main cabinet type DC charging pile system according to the present invention. Detailed Implementation

[0026] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings, so that the advantages and features of the present invention can be more easily understood by those skilled in the art, thereby making a clearer and more definite definition of the scope of protection of the present invention. Obviously, the embodiments described in this invention are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0027] Furthermore, 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.

[0028] Example 1: The specific structure of the present invention is as follows:

[0029] like Figure 1 , Figure 2 and Figure 4 As shown, a parallel main cabinet type DC charging pile system includes a main control unit, at least one power distribution matrix unit (SCU), at least one main cabinet, and multiple charging terminals. Each main cabinet contains multiple pluggable power modules, and each charging terminal contains at least one charging gun. The power distribution matrix unit (SCU) is used to switch the output power of the power modules in each main cabinet to each charging gun, and is uniformly scheduled by the main control unit. The switching control logic of the power distribution matrix unit (SCU) supports arbitrary power scheduling across main cabinets, charging terminals, and charging guns. The main control unit dynamically generates power switching commands based on the real-time power demand of each charging terminal, the health status of the power modules, and the load balancing strategy to achieve optimal power allocation. The power distribution matrix unit (SCU) is constructed as an M×N fully connected switching matrix, where M is the total number of power modules in one of the main cabinets in the system, and N is the total number of charging guns in all the charging terminals. The power distribution matrix unit (SCU) dynamically switches the output power of any power module to any charging gun. When the parallel main cabinet DC charging pile system includes multiple main cabinets, the output terminals of the power modules in each main cabinet are processed by their respective power distribution matrix units (SCUs). The power output lines with corresponding serial numbers in the power distribution matrix units (SCUs) are then connected in parallel on one side of the charging gun, allowing the power modules on multiple main cabinets to jointly provide superimposed power to the same charging gun.

[0030] In this embodiment, when the system contains multiple main cabinets: the main control unit sends switching commands to the power distribution matrix unit (SCU) of the relevant main cabinet, for example: main cabinet #1: power module #1 → charging gun #3; main cabinet #2: power module #2 → charging gun #3;

[0031] Each main cabinet's power distribution matrix unit (SCU) schedules its internal power modules; the output ports with the same serial number in all main cabinets' power distribution matrix units (SCU) are connected in parallel on the charging gun side according to the charging gun number, such as power distribution matrix unit SCU output ports ①, ②, ...;

[0032] For example: If all three main cabinets supply power to charging gun #1, then the "output port ①" line of the power distribution matrix unit SCU on each main cabinet is connected in parallel to charging gun #1; the output current of the power modules of multiple main cabinets converges in charging gun #1 to achieve linear power superposition, such as 3×480kW = 1.44MW.

[0033] In summary, this invention achieves automatic power aggregation across multiple main cabinets by connecting the output ports of the power distribution matrix unit (SCU) in parallel according to the charging gun numbers. The total power increases linearly with the number of main cabinets, without requiring changes to the control architecture or wiring logic, easily meeting the megawatt-level charging needs of electric heavy trucks, buses, etc., and possessing engineering scalability. Each main cabinet's power distribution matrix unit (SCU) constructs an M×N fully connected matrix, supporting any power module to connect to any number of charging guns. The main control unit dynamically schedules based on global information, breaking down the physical boundaries between the main cabinets, charging terminals, and charging guns. All modules constitute a shared power resource pool, allocated on demand.

[0034] Furthermore, the matrix topology of the power allocation matrix unit (SCU) is selected from one or more combinations of full matrix, ring matrix, and fixed group matrix.

[0035] In this embodiment, a hybrid topology coexistence is supported through a design of "one or more combinations"; for example, a full-matrix scheduling (MCS) is activated during the daytime when heavy trucks are charging intensively; at night, when only passenger vehicles are charging, a group mode is switched to save energy and reduce consumption; or within the same station, area A uses a full-matrix service for logistics vehicles, and area B uses a ring matrix service for ride-hailing vehicles. The parallel main cabinet type DC charging pile system has scene adaptive capabilities, meeting the full spectrum of needs from dedicated stations to integrated hubs.

[0036] Furthermore, the switching actuator in the power distribution matrix unit (SCU) is a switching device, which includes one or more of relays, DC contactors, IGBT modules, and MOSFET solid-state switches.

[0037] In this embodiment, different types of switching devices are used to adapt to different application scenarios.

[0038] Among them, relays are low in cost and have good isolation properties, making them suitable for low-power, low-frequency switching scenarios.

[0039] The DC contactor is a heavy-duty relay designed for high DC current. It features an arc-extinguishing structure, high voltage resistance, high current capacity, and high reliability, making it suitable for mainstream high-power charging piles such as 480kW cabinets.

[0040] IGBT modules are expensive, require driver circuits, and have conduction losses. They are suitable for high dynamic response, bidirectional charge-discharge V2G, and megawatt-level systems.

[0041] MOSFET solid-state switches are highly efficient, small in size, and noiseless, making them suitable for small and medium power terminals, auxiliary circuits, and liquid-cooled gun front-ends.

[0042] Furthermore, the number of power modules is unlimited, and the rated power of a single power module is 30kW, 40kW or higher, and it supports AC-DC, DC-DC, unidirectional or bidirectional energy conversion topologies.

[0043] In this embodiment, by setting an unlimited number of power modules with selectable power, on-demand configuration and flexible capacity expansion are achieved; the mixed use of new and old modules is supported, extending the equipment life cycle, significantly reducing the initial investment threshold and long-term operation and maintenance costs, and improving asset utilization. It supports bidirectional energy conversion and DC-DC topology, providing a hardware foundation for accessing diverse energy sources; the system can simultaneously include unidirectional and bidirectional modules, balancing current economic efficiency with future functionality, upgrading the charging pile from a "simple electrical device" to a "flexible energy node."

[0044] Example 2: This example is a further specific embodiment of Example 1.

[0045] like Figure 2 As shown, each main cabinet is independently equipped with a power distribution matrix unit (SCU), which is a distributed power distribution matrix unit (SCU) architecture. Its advantages are as follows:

[0046] In terms of scalability, the distributed power distribution matrix unit (SCU) relies on a modular design, making it easy to add or remove main cabinets as needed.

[0047] In terms of control complexity, the distributed power allocation matrix unit (SCU) relies on multi-node collaborative communication, which places higher demands on system synchronization and protocol consistency.

[0048] In terms of system redundancy, the distributed power distribution matrix unit (SCU) is more robust—when a single main cabinet or its power distribution matrix unit (SCU) fails, only the local charging terminals are affected, while the rest can still operate normally.

[0049] In terms of wiring complexity, the distributed power distribution matrix unit (SCU) has simple local wiring in the main cabinet, but additional handling is required for parallel coordination between the outputs of multiple power distribution matrix units (SCU).

[0050] The Distributed Power Distribution Matrix Unit (SCU) solution is more suitable for scenarios with stringent requirements for high reliability and high availability, such as large charging stations and public transportation hubs.

[0051] Example 3: This example is a second, more specific embodiment of Example 1. The differences between this example and Example 2 are as follows:

[0052] like Figure 5 As shown, the power distribution matrix unit (SCU) is further described as a centralized structure, in which all power modules in the multiple main cabinets share the same power distribution matrix unit (SCU), which is a centralized power distribution matrix unit (SCU) architecture.

[0053] The centralized power distribution matrix unit (SCU) architecture proposed in this embodiment and the distributed power distribution matrix unit (SCU) architecture proposed in Embodiment 2 each have their own advantages and are suitable for different application scenarios. The two complement each other and together constitute a complete technical system.

[0054] In terms of expansion flexibility, the centralized power distribution matrix unit (SCU) enables new main cabinets to be "plug and play" through a unified access interface, and the expansion process is equally simple and efficient.

[0055] In terms of control complexity, centralized power distribution matrix units (SCUs) have a clear advantage. Since the entire system only needs to manage one SCU, the main control unit does not need to coordinate scheduling instructions between multiple SCUs, resulting in simpler control logic and faster response.

[0056] Regarding system redundancy, the centralized power distribution matrix unit (SCU) has a single point of failure risk. Once the power distribution matrix unit (SCU) fails, it may cause the entire station to shut down. However, this risk can be effectively mitigated by introducing redundant paths or hot backup design within the centralized power distribution matrix unit (SCU).

[0057] In terms of wiring complexity, although the centralized power distribution matrix unit (SCU) requires the power modules of each main cabinet to be brought together to the central power distribution matrix unit (SCU), resulting in a longer wiring distance, the overall electrical topology is clear and easy to maintain and troubleshoot.

[0058] The centralized power distribution matrix unit (SCU) solution is more suitable for small and medium-sized power plants, cost-sensitive projects, or applications that seek simplified control.

[0059] Example 4: This example is a further optimization based on Example 2:

[0060] like Figure 2 As shown, further, when the parallel main cabinet type DC charging pile system includes two main cabinets, the power output lines of the two main cabinets through the power distribution matrix unit SCU are connected in parallel one-to-one according to the charging gun number, and the parallel connection order is allowed to be staggered or non-sequence corresponding.

[0061] During system initialization or operation, the main control unit records, through a configuration table or automatic identification mechanism, which power distribution matrix unit (SCU) output ports are actually connected in parallel for each charging gun. When generating power switching commands, the main control unit sends commands to the actual physical ports of the corresponding power distribution matrix unit (SCU) based on this mapping relationship. For example, if charging gun #1 is composed of output port ③ of power distribution matrix unit SCU on main cabinet #1 and output port ⑦ of power distribution matrix unit SCU on main cabinet #2 connected in parallel, then when scheduling charging gun #1, it is necessary to simultaneously control the output ports ③ of power distribution matrix unit SCU on main cabinet #1 and ⑦ of power distribution matrix unit SCU on main cabinet #2 to be turned on. Therefore, although the physical wiring is not "sequence number corresponding", the logical scheduling can still accurately realize the power superposition of multiple main cabinets.

[0062] Traditional solutions have several drawbacks: Parallel connection of multiple main cabinets requires strict adherence to the rule that "output port ① of the power distribution matrix unit SCU on main cabinet #1 corresponds to output port ① of the power distribution matrix unit SCU on main cabinet #2, output port ② of the power distribution matrix unit SCU on main cabinet #1 corresponds to output port ② of the power distribution matrix unit SCU on main cabinet #2…", otherwise, power cannot be correctly superimposed, potentially leading to short circuits or control malfunctions. On-site wiring requires high standardization, has a low tolerance for error, and requires rework if incorrectly connected. Furthermore, incompatibility between different devices is difficult, hindering system expansion or hybrid deployment.

[0063] This technical solution addresses the following issues: it decouples physical wiring from logical functions by defining port mapping relationships in software; it allows for "interleaved or non-sequence-corresponding connections," returning wiring freedom to the project implementer; the main control unit dynamically adapts to the actual connection topology, ensuring scheduling accuracy, significantly reducing installation, debugging, and maintenance costs, and improving the system's adaptability in complex field environments.

[0064] Furthermore, traditional solutions have drawbacks: if an SCU output port is damaged, it usually requires downtime for maintenance or replacement of the entire cabinet; if the port definitions of a new main cabinet are inconsistent with the original system, it cannot be integrated into the existing system.

[0065] This solution utilizes a non-sequenced parallel connection and software mapping mechanism to flexibly bind the charging gun to any available port; it enables "soft repair of hardware faults" and "plug-and-play for heterogeneous devices," enhancing system robustness and lifecycle management capabilities, and extending equipment service life.

[0066] Example 5: This example is a further optimization based on Example 2:

[0067] like Figure 3 As shown, further, when the parallel main cabinet type DC charging pile system includes three or more main cabinets, the charging terminal is divided into megawatt-level high-power charging terminal MCS and conventional charging terminal CCS.

[0068] The output ports of multiple power distribution matrix units (SCUs) with specified numbers are connected in parallel to the megawatt-level high-power charging terminal (MCS). The output ports of the remaining power distribution matrix units (SCUs) are respectively connected to the conventional charging terminal (CCS). The output ports of the power distribution matrix units (SCUs) corresponding to the conventional charging terminal (CCS) are independently connected among the multiple main cabinets.

[0069] Megawatt-level high-power charging terminals (MCS) are used in electric heavy trucks, mining trucks, buses, etc., requiring continuous high-power charging at the megawatt level; conventional charging terminals (CCS) are used in passenger cars or light commercial vehicles, with typical power requirements of 60–240kW.

[0070] Specifically, the output ports ① of the power distribution matrix unit SCU on main cabinet #1, main cabinet #2, and main cabinet #3 are all connected to MCS charging gun #1, enabling joint power supply from the three cabinet power modules, with a total power of up to 1.44MW (3×480kW); or, the output ports ② of the power distribution matrix unit SCU on main cabinet #1, main cabinet #2, and main cabinet #3 are all connected to the charging gun #1 of the megawatt-level high-power charging terminal MCS, enabling joint power supply from the three cabinet power modules, with a total power of up to 1.44MW (3×480kW).

[0071] The remaining output ports, such as 3#–12#, are connected to their respective conventional charging terminals (CCS) and are not connected in parallel across main cabinets. That is: output port ③ of the power distribution matrix unit (SCU) on main cabinet 1# → charging gun #1 of the conventional charging terminal (CCS); output port ③ of the power distribution matrix unit (SCU) on main cabinet 2# → charging gun #2 of the conventional charging terminal (CCS); output port ③ of the power distribution matrix unit (SCU) on main cabinet 3# → charging gun #3 of the conventional charging terminal (CCS). The CCS channels of each main cabinet are independent of each other and do not affect each other.

[0072] It solves the problem that homogeneous architecture cannot adapt to heterogeneous vehicles, and further optimizes engineering implementation costs and operation and maintenance safety. It is particularly suitable for complex charging scenarios that need to serve multiple electric vehicle models at the same time, such as bus stations, logistics parks, and highway heavy truck service areas.

[0073] The above description is only a preferred embodiment of the present invention and does not limit the patent scope of the present invention. Any equivalent structural or procedural transformations made based on the content of the present invention specification and drawings, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of the present invention.

Claims

1. A parallel main cabinet type DC charging pile system, characterized in that, It includes a main control unit, at least one power distribution matrix unit (SCU), at least one main cabinet and multiple charging terminals. Each main cabinet is equipped with multiple pluggable power modules, and each charging terminal is equipped with at least one charging gun. The power distribution matrix unit (SCU) is used to switch the output power of the power modules in each main cabinet to each charging gun, and is uniformly scheduled by the main control unit. The switching control logic of the power distribution matrix unit (SCU) supports arbitrary power scheduling across main cabinets, charging terminals, and charging guns. The main control unit dynamically generates power switching commands based on the real-time power requirements of each charging terminal, the health status of the power module, and the load balancing strategy to achieve optimal power allocation. Each of the power distribution matrix units (SCUs) is constructed as an M×N fully connected switching matrix, where M is the total number of power modules in one of the main cabinets in the system, and N is the total number of charging guns in all the charging terminals. The power distribution matrix unit (SCU) dynamically switches the output power of any power module to any charging gun. When the parallel main cabinet type DC charging pile system includes multiple main cabinets, the output terminals of the power modules in each main cabinet are processed by their respective power distribution matrix units (SCUs). The power output lines with corresponding serial numbers in the power distribution matrix units (SCUs) are connected in parallel on one side of the charging gun, so that the power modules on multiple main cabinets can jointly provide superimposed power to the same charging gun.

2. The parallel main cabinet type DC charging pile system as described in claim 1, characterized in that, The power distribution matrix unit (SCU) has a centralized structure, and all power modules in multiple main cabinets share the same power distribution matrix unit (SCU).

3. The parallel main cabinet type DC charging pile system as described in claim 1, characterized in that, Each of the main cabinets is independently equipped with a power distribution matrix unit (SCU).

4. The parallel main cabinet type DC charging pile system as described in claim 2, characterized in that, When the parallel main cabinet type DC charging pile system includes two main cabinets, the power output lines of the two main cabinets through the power distribution matrix unit (SCU) are connected in parallel one by one according to the charging gun number, and the parallel connection order is allowed to be staggered or non-serial number corresponding connection.

5. The parallel main cabinet type DC charging pile system as described in claim 1, characterized in that, The matrix topology of the power distribution matrix unit (SCU) is selected from one or more combinations of full matrix, ring matrix, and fixed group matrix.

6. The parallel main cabinet type DC charging pile system as described in claim 1, characterized in that, The switching actuator in the power distribution matrix unit (SCU) is a switching device, which includes one or more of relays, DC contactors, IGBT modules, and MOSFET solid-state switches.

7. The parallel main cabinet type DC charging pile system as described in claim 3, characterized in that, When the parallel main cabinet type DC charging pile system includes three or more main cabinets, the charging terminal is divided into megawatt-level high-power charging terminal (MCS) and conventional charging terminal (CCS). The output ports of the multiple power distribution matrix units (SCUs) with designated numbers are connected in parallel to the megawatt-level high-power charging terminal (MCS). The output ports of the remaining power distribution matrix units (SCUs) are respectively connected to the conventional charging terminal (CCS). The output ports of the power distribution matrix units (SCUs) corresponding to the conventional charging terminal (CCS) are independently connected among the multiple main cabinets.

8. The parallel main cabinet type DC charging pile system as described in claim 1, characterized in that, The number of power modules is unlimited, and the rated power of a single power module is 30kW, 40kW or higher, and it supports AC-DC, DC-DC, unidirectional or bidirectional energy conversion topologies.

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