Charging module fault communication system and method

Abstract

The application discloses a charging module fault communication system and method, and belongs to the technical field of communication.The application sets a PFC circuit, a DC-DC circuit, a first control chip and a second control chip in the charging module fault communication system, the PFC circuit is used for controlling the current waveform input by the charging module, so that the current waveform is synchronous with the voltage waveform input by the charging module, the DC-DC circuit is used for transforming the voltage input by the charging module, when a fault occurs in a certain stage circuit of the charging module or an emergency situation occurs in input and output, the frequency information of PWM is acquired and corresponding circuit control is carried out through the first control chip and the second control chip, information intercommunication between power transformation links can be quickly realized, the circuit of the charging module is quickly protected and responded, and the fault processing capacity of the charging module is improved.

Description

Technical Field

[0001] This invention relates to the field of communication technology, and in particular to a charging module fault communication system and method. Background Technology

[0002] The charging module contains two power conversion stages. The first stage is the front-end AC-DC stage, which is generally implemented using PFC. The second stage is the back-end DC-DC stage, which is generally implemented using LLC circuits or full-bridge phase-shifting technology. The two power conversion stages need to transmit control and protection signals. When a circuit in a certain stage of the charging module fails or an emergency occurs in the input or output, a fast communication method is needed to enable information exchange between the two power conversion stages in order to achieve rapid protection response of the power conversion stages.

[0003] Existing communication methods utilize a high / low level signal via I / O ports. When a fault occurs in a power conversion stage, the I / O port's level is changed for rapid fault handling. However, this type of fault communication method cannot handle all fault types.

[0004] The above content is only used to help understand the technical solution of the present invention and does not represent an admission that the above content is prior art. Summary of the Invention

[0005] The main objective of this invention is to provide a charging module fault communication system and method, which aims to solve the technical problem of low efficiency in handling charging module faults in the prior art.

[0006] To achieve the above objectives, the present invention provides a charging module fault communication system, which includes: a PFC circuit, a DC-DC circuit, a first control chip, and a second control chip. The PFC circuit is connected to the first control chip, the DC-DC circuit is connected to the second control chip, and the PFC circuit and the DC-DC circuit are interconnected.

[0007] The PFC circuit is used to control the current waveform input to the charging module, so that the current waveform is synchronized with the voltage waveform input to the charging module.

[0008] The DC-DC circuit is used to transform the voltage input to the charging module;

[0009] The first control chip is used to acquire the frequency information of the PWM when a fault occurs, determine the fault type based on the frequency information of the PWM, and control the PFC circuit.

[0010] The second control chip is used to acquire the frequency information of the PWM when a fault occurs, determine the fault type based on the frequency information of the PWM, and control the DC-DC circuit.

[0011] Optionally, the frequency information includes: first frequency information;

[0012] When the frequency information is the first frequency information, the fault type is determined to be a power conversion fault;

[0013] The first control chip is further configured to acquire power conversion fault information of the PFC circuit, generate a corresponding first PWM waveform based on the power conversion fault information of the PFC circuit, and control the PFC circuit based on the first PWM waveform.

[0014] Optionally, the second control chip is further configured to acquire power conversion fault information of the DC-DC circuit, generate a corresponding second PWM waveform based on the power conversion fault information of the DC-DC circuit, and control the DC-DC circuit based on the second PWM waveform.

[0015] Optionally, the first PWM waveform includes a fault code and a PWM duty cycle;

[0016] The first control chip is also used to acquire power conversion fault information of the PFC circuit and generate a fault code based on the power conversion fault information;

[0017] The first control chip is also used to query a preset fault mapping table through the fault code to obtain the PWM duty cycle. The preset fault mapping table stores the relationship between fault codes, fault types and PWM duty cycles.

[0018] The first control chip is further configured to determine the PFC circuit fault type based on the fault code and the PWM duty cycle, and to shut down the PFC circuit based on the PFC circuit fault type;

[0019] The first control chip is further configured to send the PFC circuit fault type and the PWM duty cycle to the second control chip, so that the second control chip performs a protection action on the DC-DC circuit according to the PFC circuit fault type and the PWM duty cycle.

[0020] Optionally, the second PWM waveform includes a fault code and a PWM duty cycle;

[0021] The second control chip is also used to acquire power conversion fault information of the DC-DC circuit and generate a fault code based on the power conversion fault information;

[0022] The second control chip is also used to query a preset fault mapping table through the fault code to obtain the PWM duty cycle;

[0023] The second control chip is further configured to determine the DC-DC circuit fault type based on the fault code and the PWM duty cycle, and to shut down the DC-DC circuit based on the DC-DC circuit fault type;

[0024] The second control chip is further configured to send the DC-DC circuit fault type and the PWM duty cycle to the first control chip, so that the first control chip performs a protection action on the PFC circuit according to the DC-DC circuit fault type and the PWM duty cycle.

[0025] Optionally, the first control chip or the second control chip is further configured to store the fault code and send the fault code to a display device or a storage device.

[0026] Optionally, the frequency information further includes: second frequency information, wherein the first frequency information is different from the second frequency information; the charging module fault communication system further includes: a first sampling circuit and a second sampling circuit, wherein the first sampling circuit is connected to the first control chip, and the second sampling circuit is connected to the second control chip.

[0027] When the frequency information is the second frequency information, the fault type is determined to be a voltage fault;

[0028] The first sampling circuit is used to collect voltage fault information at the input terminal of the charging module and send the voltage fault information at the input terminal to the first control chip.

[0029] The second sampling circuit is used to collect voltage fault information at the output terminal of the charging module and send the voltage fault information at the output terminal to the second control chip.

[0030] The first control chip is also used to generate a corresponding third PWM waveform based on the voltage fault information at the input terminal, and to control the PFC circuit based on the third PWM waveform;

[0031] The second control chip is also used to generate a corresponding fourth PWM waveform based on the voltage fault information at the output terminal, and to control the DC-DC circuit based on the fourth PWM waveform.

[0032] Optionally, the first control chip is further configured to determine the voltage value and PWM duty cycle of the input terminal based on the voltage fault information of the input terminal, compare the voltage value and PWM duty cycle of the input terminal with a preset input terminal voltage value and a preset duty cycle, and control the PFC circuit to reduce the output power or shut down when the voltage value and PWM duty cycle of the input terminal are equal to the preset input terminal voltage value and the preset duty cycle.

[0033] Optionally, the first control chip is further configured to generate a third PWM waveform from the voltage value at the input terminal and the PWM duty cycle and send it to the second control chip, so that the second control chip compares the voltage value at the input terminal and the PWM duty cycle in the third PWM waveform with a preset input terminal voltage value and a preset duty cycle, and controls the DC-DC circuit to reduce its output power or shut down when the voltage value at the input terminal and the PWM duty cycle are equal to the preset input terminal voltage value and the preset duty cycle.

[0034] The second control chip is also used to determine the voltage value and PWM duty cycle of the output terminal based on the voltage fault information of the output terminal, compare the voltage value and PWM duty cycle of the output terminal with the preset output terminal voltage value and preset duty cycle, and control the DC-DC circuit to reduce the input power or shut down when the voltage value and PWM duty cycle of the output terminal are equal to the preset output terminal voltage value and preset duty cycle.

[0035] The second control chip is further configured to generate a fourth PWM waveform from the voltage value of the output terminal and the PWM duty cycle and send it to the first control chip, so that the first control chip compares the voltage value of the output terminal and the PWM duty cycle in the fourth PWM waveform with a preset output terminal voltage value and a preset duty cycle, and controls the PFC circuit to reduce the input power or shut down when the voltage value of the output terminal and the PWM duty cycle are equal to the preset output terminal voltage value and the preset duty cycle.

[0036] To achieve the above objectives, the present invention provides a charging module fault communication method, the method comprising the following steps:

[0037] The PFC circuit controls the current waveform input to the charging module, so that the current waveform is synchronized with the voltage waveform input to the charging module.

[0038] The DC-DC circuit transforms the voltage input to the charging module;

[0039] When a fault occurs, the first control chip acquires the frequency information of the PWM and determines the fault type based on the frequency information of the PWM, and then controls the PFC circuit.

[0040] When a fault occurs, the second control chip acquires the frequency information of the PWM and determines the fault type based on the frequency information of the PWM, and then controls the DC-DC circuit.

[0041] This invention establishes a PFC circuit, a DC-DC circuit, a first control chip, and a second control chip in a charging module fault communication system. The PFC circuit is connected to the first control chip, and the DC-DC circuit is connected to the second control chip. The PFC circuit and the DC-DC circuit are interconnected. The PFC circuit controls the current waveform input to the charging module, synchronizing the current waveform with the voltage waveform input to the charging module. The DC-DC circuit transforms the voltage input to the charging module. The first control chip acquires the PWM frequency information and determines the fault type based on the PWM frequency information when a fault occurs, then controls the PFC circuit. The second control chip acquires the PWM frequency information and determines the fault type based on the PWM frequency information when a fault occurs in a certain stage of the charging module circuit or an emergency situation occurs in the input / output. This enables rapid information exchange between power conversion stages, provides rapid protection response for the charging module circuit, and improves the fault handling capability of the charging module. Attached Figure Description

[0042] Figure 1 This is a schematic diagram of the first embodiment of the charging module fault communication system of the present invention;

[0043] Figure 2 This is a schematic diagram of the third embodiment of the charging module fault communication system of the present invention;

[0044] Figure 3 This is a flowchart illustrating the first embodiment of the charging module fault communication method of the present invention.

[0045] Explanation of icon numbers:

[0046] 10 PFC circuit 50 First sampling circuit 20 DC-DC circuit 60 Second sampling circuit 30 First control chip 70 Charging module input terminal 40 Second control chip 80 Charging module output end

[0047] The realization of the objective, functional features and advantages of the present invention will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0048] It should be understood that the specific embodiments described herein are for illustrative purposes only and are not intended to limit the scope of the invention.

[0049] Reference Figure 1 , Figure 1This is a structural diagram of the first embodiment of the charging module fault communication system of the present invention.

[0050] like Figure 1 As shown, the charging module fault communication system of the present invention includes: a PFC circuit 10, a DC-DC circuit 20, a first control chip 30, and a second control chip 40. The PFC circuit 10 is connected to the first control chip 30, the DC-DC circuit 20 is connected to the second control chip 40, and the PFC circuit 10 and the DC-DC circuit 20 are interconnected. The PFC circuit 10 is used to control the current waveform input to the charging module, so that the current waveform is synchronized with the voltage waveform input to the charging module. The DC-DC circuit 20 is used to transform the voltage input to the charging module. The first control chip 30 is used to acquire the frequency information of the PWM when a fault occurs, determine the fault type based on the frequency information of the PWM, and control the PFC circuit 10. The second control chip 40 is used to acquire the frequency information of the PWM when a fault occurs, determine the fault type based on the frequency information of the PWM, and control the DC-DC circuit 20.

[0051] It should be noted that the PFC (Power Factor Correction) circuit 10 and the DC-DC circuit 20 are interconnected. The PFC circuit 10 controls the current waveform input to the charging module, synchronizing the current waveform with the voltage waveform input to the charging module, thereby reducing the power loss during charging due to the exchange of power between current and voltage. The DC-DC circuit 20 transforms the voltage input to the charging module, improving the power conversion efficiency.

[0052] In this embodiment, the first control chip 30 is connected to the PFC circuit 10. When a circuit of the charging module fails, it can acquire the PWM (Pulse Width Modulation) frequency information of the failure, determine the fault type based on the PWM frequency information, and control the PFC circuit 10 according to the fault type to protect the PFC circuit 10. The second control chip 40 is connected to the DC-DC circuit 20. When a circuit of the charging module fails, it can acquire the PWM frequency information of the failure, determine the fault type based on the PWM frequency information, and control the DC-DC circuit 20 according to the fault type.

[0053] In practical implementation, different frequency information can correspond to different fault types. For example, frequency f1 corresponds to a fault in the power conversion stage, while frequency f2 corresponds to a fault in the input or output voltage. Fault types can include power conversion faults, such as those in PFC circuit 10 and DC-DC circuit 20. Power conversion faults in PFC circuit 10 can include PFC transformer overheating, PFC power switch overheating, PFC output overcurrent, PFC output overvoltage, PFC input duct overtemperature, and other faults in PFC circuit 10. Power conversion faults in DC-DC circuit 20 can include DC-DC inductor overheating, DC-DC power switch overheating, DC-DC output overcurrent, DC-DC output overvoltage, excessive DC-DC output error, and other faults in DC-DC circuit 20. Fault types may also include voltage faults such as sudden changes in the input voltage and output voltage of the charging module, as well as sudden changes in ambient temperature caused by factors such as blocked air ducts, or communication interface faults between power conversion circuits. The first control chip 30 and the second control chip 40 can quickly identify the PWM frequency information of the fault and determine the type of fault, and immediately execute protection actions to improve the protection efficiency of the PFC circuit 10 and DC-DC circuit in power conversion.

[0054] This embodiment sets up a PFC circuit, a DC-DC circuit, a first control chip, and a second control chip in the charging module fault communication system. The PFC circuit is connected to the first control chip, and the DC-DC circuit is connected to the second control chip. The PFC circuit and the DC-DC circuit are interconnected. The PFC circuit controls the current waveform input to the charging module, synchronizing the current waveform with the voltage waveform input to the charging module. The DC-DC circuit converts the voltage input to the charging module. The first control chip acquires the PWM frequency information and determines the fault type based on the PWM frequency information when a fault occurs, and then controls the PFC circuit. The second control chip acquires the PWM frequency information and determines the fault type based on the PWM frequency information when a fault occurs in a certain stage of the charging module circuit or an emergency situation occurs in the input / output. This allows for rapid information exchange between power conversion stages, enabling rapid protection response of the charging module circuit and improving the fault handling capability of the charging module.

[0055] Based on the first embodiment described above, a second embodiment of the charging module fault communication system of the present invention is proposed. Continuing as described... Figure 1As shown, the frequency information in this embodiment of the invention includes: first frequency information; when the frequency information is the first frequency information, the fault type is determined to be a power conversion fault; the first control chip 30 is also used to acquire the power conversion fault information of the PFC circuit 10, generate a corresponding first PWM waveform according to the power conversion fault information of the PFC circuit 10, and control the PFC circuit 10 according to the first PWM waveform.

[0056] It should be noted that the first frequency information is the PWM frequency information when a power conversion fault occurs, that is, the number of times the power conversion signal goes from high level to low level and back to high level per second. When the PWM frequency information is the first frequency information, it means that the number of times the power conversion signal goes from high level to low level and back to high level per second is greater than or less than the PWM frequency during normal power conversion, and the fault type can be determined to be a power conversion fault.

[0057] In this embodiment, when the PWM frequency information is the first frequency information, the fault type is determined to be a power conversion fault, which could be a fault in the PFC circuit 10 or the DC-DC circuit 20. The first control chip 30, connected to the PFC circuit 10, obtains the power conversion fault information of the PFC circuit 10 and generates a corresponding first PWM waveform based on the power conversion fault information of the PFC circuit 10. The PFC circuit 10 is then controlled using the first PWM waveform. The first PWM waveform is the corresponding PWM waveform generated based on the fault type of the PFC circuit 10. The first PWM waveform may include the PWM frequency information of the fault, the fault type, the fault code, and the PWM duty cycle, etc. The relevant information of the PFC circuit 10 fault can be obtained by reading the first PWM waveform, and the PFC circuit 10 can be controlled accordingly. The PWM duty cycle is the ratio between the high-level duration and the low-level duration. Different fault types correspond to different PWM duty cycles, and the fault information can be accurately determined based on the PWM duty cycle and the fault type information.

[0058] In this embodiment, the second control chip 40 is further configured to acquire power conversion fault information of the DC-DC circuit 20, generate a corresponding second PWM waveform based on the power conversion fault information of the DC-DC circuit 20, and control the DC-DC circuit 20 based on the second PWM waveform.

[0059] It should be understood that the second PWM waveform is a corresponding PWM waveform generated according to the fault type that occurred in the DC-DC circuit 20. The second PWM waveform may include the PWM frequency information of the faulty circuit, the fault type, the fault code, and the PWM duty cycle, etc.

[0060] In this embodiment, the first PWM waveform includes a fault code and a PWM duty cycle; the first control chip 30 is further configured to acquire power conversion fault information of the PFC circuit 10 and generate a fault code based on the power conversion fault information; the first control chip 30 is further configured to query a preset fault mapping table through the fault code to obtain the PWM duty cycle, the preset fault mapping table storing the relationship between fault codes, fault types, and PWM duty cycles; the first control chip 30 is further configured to determine the fault type of the PFC circuit 10 based on the fault code and the PWM duty cycle, and shut down the PFC circuit 10 based on the fault type; the first control chip 30 is further configured to send the fault type of the PFC circuit 10 and the PWM duty cycle to the second control chip 40, so that the second control chip 40 performs a protection action on the DC-DC circuit 20 based on the fault type of the PFC circuit 10 and the PWM duty cycle.

[0061] In practical implementation, the fault code is a fault code generated based on the power conversion fault information that indicates the type of fault. The encoding method of the fault code can be determined and updated by the equipment manufacturer. The first control chip 30 generates the corresponding fault code through the power conversion fault information of the PFC circuit 10. The preset fault mapping table is a table generated based on the mapping relationship between the power conversion fault type and the PWM duty cycle, and the corresponding fault code is obtained according to the power conversion fault type. As shown in Table 1, Table 1 shows the correspondence between fault codes, fault types, and PWM duty cycles in the preset fault mapping table. Among them, the fault types of PFC circuit 10 can be: PFC transformer overheating (PWM duty cycle 5%, fault code E001); PFC power switch overheating (PWM duty cycle 6%, fault code E002); PFC output overcurrent (fault code E003, PWM duty cycle 7%); PFC output overvoltage (fault code E004, PWM duty cycle 8%); and PFC input duct overtemperature (fault code E005, PWM duty cycle 9%). When other faults exist in the PFC circuit, the existing faults can be coded according to the fault code encoding method, and the corresponding PWM duty cycle can be determined. In the table, E0XX represents the fault codes of PFC circuit 10. E1YY represents the fault code for DC-DC circuit 20. Fault types for DC-DC circuit 20 include: DC-DC inductor overheating (fault code E101, PWM duty cycle 5%), DC-DC power switch overheating (fault code E102, PWM duty cycle 6%), DC-DC output overcurrent (fault code E103, PWM duty cycle 7%), DC-DC output overvoltage (fault code E104, PWM duty cycle 8%), DC-DC output excessive error (fault code E105, PWM duty cycle 9%), and other DC-DC circuit faults (fault code E1YY, PWM duty cycle Y%). The fault code and PWM duty cycle can be determined based on the specific fault type.

[0062] Table 1 Preset Fault Mapping Table

[0063] E001 PFC transformer overheating 5％ E002 PFC power switch overheating 6％ E003 PFC output overcurrent 7％ E004 PFC output overvoltage 8％ E005 PFC input air duct overheating 9％ E0XX Other faults in PFC circuit X％ E101 DC-DC inductor overheating 5％ E102 DC-DC power switching transistor overheating 6％ E103 DC-DC output overcurrent 7％ E104 DC-DC output overvoltage 8％ E105 DC-DC output error is too large 9％ E1YY Other faults in DC-DC circuits Y％

[0064] In this embodiment, the first PWM waveform includes a fault code and PWM duty cycle information. After the first control chip 30 generates the first PWM waveform based on the fault information of the PFC circuit 10, it can determine the fault code and duty cycle information through the first PWM waveform. Based on the fault code and PWM duty cycle information, it searches a preset fault mapping table to obtain the fault type of the PFC circuit 10, and shuts down the PFC circuit 10 according to the fault type, thereby achieving the purpose of protecting the PFC circuit 10. The first control chip 30 is also used to send the information of the PFC circuit 10 fault type and PWM duty cycle in the first PWM waveform to the second control chip 40. When the second control chip 40 receives the first PWM waveform sent by the first control chip 30, it reads the information of the PFC circuit 10 fault type and PWM duty cycle in the first PWM waveform and performs a protection action on the DC-DC circuit 20, such as shutting down the DC-DC circuit 20 or disconnecting the path between the DC-DC circuit 20 and the PFC circuit 10. For example, if the PFC transformer in the PFC circuit 10 overheats, the first control chip 30 generates an E001 fault code and a first PWM waveform. The first control chip 30 transmits the first PWM waveform to the second control chip 40 through an I / O interface or other physical layer. At the same time, the first control chip 30 determines the fault type of the PFC circuit 10 as PFC transformer overheating based on the first PWM waveform. The first control chip 30 can reduce the risk of PFC circuit 10 burning out or affecting other circuits by shutting down the PFC circuit 10 or reducing the operating speed of the PFC circuit 10. The second control chip 40 reads the first PWM waveform sent by the first control chip 30 and obtains the fault type, fault code, and PWM duty cycle of the PFC circuit 10 in the first PWM waveform. If the fault type of the PFC circuit 10 is found to be PFC transformer overheating, the second control chip 40 immediately performs a protection action on the DC-DC circuit 20, such as shutting down the DC-DC circuit 20 or disconnecting the loop between the DC-DC circuit 20 and the PFC circuit 10, thereby protecting the DC-DC circuit 20 from damage.

[0065] In this embodiment, the second PWM waveform includes a fault code and a PWM duty cycle; the second control chip 40 is further configured to acquire power conversion fault information of the DC-DC circuit 20 and generate a fault code based on the power conversion fault information; the second control chip 40 is further configured to query a preset fault mapping table through the fault code to obtain the PWM duty cycle; the second control chip 40 is further configured to determine the fault type of the DC-DC circuit 20 based on the fault code and the PWM duty cycle, and shut down the DC-DC circuit 20 based on the fault type; the second control chip 40 is further configured to send the fault type of the DC-DC circuit 20 and the PWM duty cycle to the first control chip 30, so that the first control chip 30 performs a protection action on the PFC circuit 10 based on the fault type of the DC-DC circuit 20 and the PWM duty cycle.

[0066] It should be noted that the second PWM waveform includes the fault code of the DC-DC circuit 20 and the PWM duty cycle information. The second control chip 40 generates the corresponding fault code based on the power conversion fault information of the DC-DC circuit 20. The preset fault mapping table is a table generated according to the mapping relationship between the power conversion fault type and the PWM duty cycle, and the corresponding fault code is obtained according to the power conversion fault type. As shown in Table 1, Table 1 contains the fault type and corresponding fault code when the DC-DC circuit fails. For example, if the fault type is DC-DC inductor overheating, the corresponding fault code is E101, and the PWM duty cycle is 5%. After the second control chip 40 generates the second PWM waveform based on the fault information of the DC-DC circuit 20, it can determine the fault code and duty cycle information through the second PWM waveform. Based on the fault code and PWM duty cycle information, it searches a preset fault mapping table to obtain the fault type of the DC-DC circuit 20, and shuts down the DC-DC circuit 20 according to the fault type, thereby achieving the purpose of protecting the DC-DC circuit 20. The second control chip 40 is also used to send the fault type and PWM duty cycle information of the DC-DC circuit 20 in the second PWM waveform to the first control chip 30. When the first control chip 30 receives the second PWM waveform sent by the second control chip 40, it reads the fault type and duty cycle information of the DC-DC circuit 20 in the second PWM waveform and performs protection actions on the PFC circuit 10, such as shutting down the PFC circuit 10 or disconnecting the path between the PFC circuit 10 and the DC-DC circuit 20. For example, if a DC-DC output overcurrent fault occurs in DC-DC circuit 20, the second control chip 40 generates an E103 fault code and a second PWM waveform. The second control chip 40 transmits the second PWM waveform to the first control chip 30 through an I / O interface or other physical layer. At the same time, the second control chip 40 determines the fault type of DC-DC circuit 20 as DC-DC output overcurrent based on the second PWM waveform. The second control chip 40 can reduce the risk of DC-DC circuit 20 burning out or affecting other circuits by shutting down DC-DC circuit 20 or reducing the magnitude and speed of the output current of DC-DC circuit 20. The first control chip 30 reads the second PWM waveform sent by the second control chip 40 and obtains the fault type, fault code, and PWM duty cycle of DC-DC circuit 20 in the second PWM waveform. If the fault type of DC-DC circuit 20 is determined to be DC-DC output overcurrent, the first control chip 30 immediately executes a protection action for PFC circuit 10, such as shutting down PFC circuit 10 or disconnecting the loop between PFC circuit 10 and DC-DC circuit 20, thereby protecting PFC circuit 10 from damage.

[0067] Furthermore, the first control chip 30 or the second control chip 40 is also used to store the fault code and send the fault code to the display device or storage device.

[0068] It should be understood that after the first control chip 30 and the second control chip 40 control and protect the corresponding circuits, the fault codes can be saved and sent to a display device for display or to a storage device for storage to facilitate subsequent tracing and retrieval. The display device can be a PC, browser, mobile terminal, or other display-enabled device, and the storage device can include RAM (Random Access Memory), ROM (Read-Only Memory), USB flash drive, or other storage devices. Saving the fault codes to the display device or storage device facilitates subsequent analysis of faults in the charging module's communication system.

[0069] In this embodiment, when the frequency information is the first frequency information, the fault type is determined to be a power conversion fault. The first control chip is further used to acquire the power conversion fault information of the PFC circuit, generate a corresponding first PWM waveform based on the power conversion fault information of the PFC circuit, and control the PFC circuit based on the first PWM waveform. The second control chip is further used to acquire the power conversion fault information of the DC-DC circuit, generate a corresponding second PWM waveform based on the power conversion fault information of the DC-DC circuit, and control the DC-DC circuit based on the second PWM waveform. By generating corresponding PWM waveforms through the first and second control chips and reading the PWM waveforms, protection actions for the PFC circuit and DC-DC circuit are executed, thereby improving the response speed of the charging module protection and enhancing the safety of charging new energy vehicles.

[0070] Reference Figure 2 , Figure 2 This is a schematic diagram of the third embodiment of the charging module fault communication system of the present invention.

[0071] Based on the first and second embodiments described above, as Figure 2As shown, in this embodiment of the invention, the frequency information further includes: second frequency information, the first frequency information being different from the second frequency information. The charging module fault communication system further includes: a first sampling circuit 50 and a second sampling circuit 60, the first sampling circuit 50 being connected to the first control chip 30, and the second sampling circuit 60 being connected to the second control chip 40. When the frequency information is the second frequency information, the fault type is determined to be a voltage fault. The first sampling circuit 50 is used to collect voltage fault information at the input terminal 70 of the charging module and send the voltage fault information at the input terminal to the first control chip 30. The second sampling circuit 60 is used to collect voltage fault information at the output terminal 80 of the charging module and send the voltage fault information at the output terminal to the second control chip 40. The first control chip 30 is also used to generate a corresponding third PWM waveform based on the voltage fault information at the input terminal and control the PFC circuit 10 based on the third PWM waveform. The second control chip 40 is also used to generate a corresponding fourth PWM waveform based on the voltage fault information at the output terminal and control the DC-DC circuit 20 based on the fourth PWM waveform.

[0072] It should be noted that the second frequency information is different from the first frequency information. The second frequency information is the PWM frequency information when a voltage fault occurs. When the PWM frequency information is the second frequency information, it means that the number of times the voltage transformation signal changes from high level to low level and back to high level per second is greater than or less than the PWM frequency during normal voltage transformation. It can be determined that the fault type is a voltage fault, which can include input voltage faults and output voltage faults, etc.

[0073] In this embodiment, when the PWM frequency information is the second frequency information, the fault type is determined to be a voltage fault. The first sampling circuit 50 is connected to the first control chip 30 and is used to collect the voltage fault information of the charging module input terminal 70 and send the voltage fault information of the input terminal to the first control chip 30, so that the first control chip 30 performs protection action on the PFC circuit 10 according to the voltage fault information of the charging module input terminal 70 collected by the first sampling circuit 50. The third PWM waveform is the corresponding PWM waveform generated according to the voltage fault information of the charging module input terminal 70. The third PWM waveform may include the PWM frequency information of the fault, the fault voltage value, and the PWM duty cycle, etc. The first control chip 30 can obtain the voltage fault information of the charging module input terminal 70 by reading the third PWM waveform and perform corresponding control on the PFC circuit 10.

[0074] In specific implementation, the fourth PWM waveform is a corresponding PWM waveform generated based on the voltage fault information of the charging module output terminal 80. The fourth PWM waveform may include the PWM frequency information of the fault, the fault voltage value, and the PWM duty cycle, etc. The second control chip 40 can obtain the voltage fault information of the charging module output terminal 80 by reading the fourth PWM waveform and perform corresponding control on the DC-DC circuit 20. The second sampling circuit 60 is connected to the second control chip 40 and is used to collect the voltage fault information of the charging module output terminal 80 and send the voltage fault information of the output terminal to the second control chip 40, so that the second control chip 40 performs protection actions on the DC-DC circuit 20 according to the voltage fault information of the charging module output terminal 80 collected by the second sampling circuit 60.

[0075] In this embodiment, the first control chip 30 is further configured to determine the input voltage value and PWM duty cycle based on the voltage fault information at the input terminal, compare the input voltage value and PWM duty cycle with a preset input voltage value and preset duty cycle, and control the PFC circuit 10 to reduce output power or shut down when the input voltage value and PWM duty cycle are equal to the preset input voltage value and preset duty cycle; the first control chip 30 is further configured to generate a third PWM waveform from the input voltage value and PWM duty cycle and send it to the second control chip 40, so that the second control chip 40 compares the input voltage value and PWM duty cycle in the third PWM waveform with the preset input voltage value and preset duty cycle, and controls the DC-DC circuit 20 to reduce output power or shut down when the input voltage value and PWM duty cycle are equal to the preset input voltage value and preset duty cycle.

[0076] The preset input voltage value and preset duty cycle are the maximum values ​​of the input voltages of different phases. When the voltage fault information at the input terminal determines that the input voltage value and PWM duty cycle are equal to the preset input voltage value and preset duty cycle, it indicates that the voltage and duty cycle are about to exceed the protection value, which may lead to risks such as circuit burnout, requiring the circuit to perform protection actions. As shown in Table 2, Table 2 is a mapping table of the relationship between preset input voltage values ​​and preset duty cycles. The input voltage can include phase A voltage, phase B voltage, and phase C voltage. The PWM duty cycle corresponding to a phase A voltage of 180V is 5%, the corresponding to a phase A voltage of 190V is 6%, the corresponding to a phase A voltage of 200V is 7%, the corresponding to a phase A voltage of 210V is 8%, the corresponding to a phase A voltage of 220V is 9%, and the corresponding to other phase A voltage values ​​is X%. The PWM duty cycle for phase B voltage 180V is X+1%, for phase B voltage 190V it is X+2%, for phase B voltage 200V it is X+3%, for phase B voltage 210V it is X+4%, for phase B voltage 220V it is X+5%, and the PWM duty cycle for other phase B voltage values ​​is X+Y%. The PWM duty cycle for phase C voltage 180V is X+Y+1%, for phase C voltage 190V it is X+Y+2%, for phase C voltage 200V it is X+Y+3%, for phase C voltage 210V it is X+Y+4%, for phase C voltage 220V it is X+Y+5%, and the PWM duty cycle for other phase C voltage values ​​is X+Y+Z. The third and fourth PWM waves can be correlated with external detection quantities such as input, output, and environment using methods such as duty cycle or frequency value. The corresponding values ​​can be determined by the equipment manufacturer.

[0077] The first control chip 30 generates a third PWM wave in real time from the input voltage value and duty cycle information in the voltage fault information of the charging module input terminal 70 collected by the first sampling circuit 50. This third PWM wave is then sent to the fourth control chip 40. Simultaneously, the first control chip compares the input voltage value and duty cycle information with preset input voltage values ​​and preset duty cycles. When the input voltage value and duty cycle equal the preset values ​​and duty cycles, it indicates that the input voltage and duty cycle have reached the set protection limits, requiring circuit protection. The first control chip 30 then controls the output power of the PFC circuit 10 to decrease or shut down, protecting the PFC circuit. For circuit safety, the second control chip 40 reads the received third PWM wave and obtains the input voltage value and PWM duty cycle of the charging module input terminal 70. It compares the input voltage value and PWM duty cycle with the preset input voltage value and preset PWM duty cycle. When the input voltage value and duty cycle are equal to the preset input voltage value and preset duty cycle, it means that the input voltage and duty cycle have reached the set protection limit and the circuit needs to be protected. Then, the second control chip 40 controls the output power of the DC-DC circuit 20 to decrease or shut down to avoid circuit damage caused by excessively high or low input phase voltage of the DC-DC circuit.

[0078] In specific implementations, for example, the duty cycle values ​​of the input voltage undervoltage protection point and overvoltage protection point set by the second control chip 40 are m% and n, respectively. When the second control chip 40 receives a signal from the first control chip 30 that the input voltage of any one phase reaches the undervoltage protection point m%, it immediately controls the output power of the DC-DC circuit 20 to decrease or shut down, so as to avoid overcurrent damage or protection of the PFC circuit 10 caused by excessive current due to low input voltage. When the second control chip 40 detects that the input voltage of any one phase reaches the overvoltage protection point n%, it immediately controls the DC-DC circuit 20 to shut down or protect, so as to avoid damage to circuit components due to overvoltage.

[0079] Table 2 Mapping Table of Preset Input Voltage Values ​​and Preset Duty Cycles

[0080] Phase A voltage 180V 5％ Phase A voltage 190V 6％ Phase A voltage 200V 7％ Phase A voltage 210V 8％ Phase A voltage 220V 9％ Phase A voltage other voltage values X％ Phase B voltage 180V X+1％ Phase B voltage 190V X+2％ Phase B voltage 200V X+3％ Phase B voltage 210V X+4％ Phase B voltage 220V X+5％ Other voltage values ​​for phase B X+Y% C-phase voltage 180V X+Y+1% C-phase voltage 190V X+Y+2% C-phase voltage 200V X+Y+3% C-phase voltage 210V X+Y+4% C-phase voltage 220V X+Y+5% Other voltage values ​​for phase C X+Y+Z%

[0081] In this embodiment, the second control chip 40 is further configured to determine the output voltage value and PWM duty cycle based on the voltage fault information at the output terminal, compare the output voltage value and PWM duty cycle with a preset output voltage value and preset duty cycle, and control the DC-DC circuit 20 to reduce input power or shut down when the output voltage value and PWM duty cycle are equal to the preset output voltage value and preset duty cycle; the second control chip 40 is further configured to generate a fourth PWM waveform from the output voltage value and PWM duty cycle and send it to the first control chip 30, so that the first control chip 30 compares the output voltage value and PWM duty cycle in the fourth PWM waveform with the preset output voltage value and preset duty cycle, and controls the PFC circuit 10 to reduce input power or shut down when the output voltage value and PWM duty cycle are equal to the preset output voltage value and preset duty cycle.

[0082] Specifically, when the second control chip 40 detects that the output voltage has reached the set output voltage undervoltage protection point or overvoltage protection point, it immediately controls the DC-DC circuit 20 to shut down or protect it, and sends the output voltage and other information to the first control chip 30, so that the first control chip 30 shuts down or protects the PFC circuit 10.

[0083] In practice, after the first control chip 30 or the second control chip 40 performs the corresponding circuit protection work, the input voltage value information collected by the first sampling circuit 50 or the output voltage value information collected by the second sampling circuit 60 is saved and sent to the display device for display or to the cloud storage for storage, so that users or staff can analyze and view the voltage fault of the charging module.

[0084] Furthermore, the communication interface in the charging module can also receive the PWM waveform between the first control chip 30 and the second control chip 40. The change information of the PWM waveform between the first control chip 30 and the second control chip 40 can determine whether the communication interface between them has malfunctioned. When the PWM waveform between the first control chip 30 and the second control chip 40 changes to a high level or a low level, it indicates a malfunction in the communication interface. The first control chip 30 or the second control chip 40 can immediately receive the fault information and protect the PFC circuit 10 and the DC-DC circuit 20. The first control chip 30 and the second control chip 40 can also exchange information for other power conversion circuit actions, processing quickly and ensuring the safety of all circuit components in the communication system of the charging module.

[0085] This embodiment further includes a first sampling circuit and a second sampling circuit in the charging module fault communication system. The first sampling circuit is connected to the first control chip, and the second sampling circuit is connected to the second control chip. When the frequency information is the second frequency information, the fault type is determined to be a voltage fault. The first sampling circuit is used to collect voltage fault information at the input terminal of the charging module and send the input terminal voltage fault information to the first control chip. The second sampling circuit is used to collect voltage fault information at the output terminal of the charging module and send the output terminal voltage fault information to the second control chip. The first control chip is also used to generate a corresponding third PWM waveform based on the input terminal voltage fault information and control the PFC circuit based on the third PWM waveform. The second control chip is also used to generate a corresponding fourth PWM waveform based on the voltage fault information at the output terminal, and to control the DC-DC circuit based on the fourth PWM waveform. It acquires voltage information at the input and output terminals through the first and second sampling circuits, and sends the voltage information to the first and second control chips. The first and second control chips compare the voltage information at the input and output terminals with a set voltage protection value. When the voltage values ​​at the input and output terminals reach the set voltage protection value, they can quickly control the output power of the PFC circuit and the DC-DC circuit to decrease, shut down, or perform other protection actions, ensuring that the components in the circuit are not damaged. The detected fault information during the charging module communication process is comprehensive, improving the circuit protection efficiency during charging.

[0086] Based on the above-mentioned charging module fault communication system, this embodiment of the invention provides a charging module fault communication method, referring to... Figure 3 , Figure 3 This is a flowchart illustrating the first embodiment of the charging module fault communication method of the present invention.

[0087] In this embodiment, the charging module fault communication method includes the following steps:

[0088] Step S10: The PFC circuit controls the current waveform input to the charging module to synchronize the current waveform with the voltage waveform input to the charging module.

[0089] It should be understood that the PFC (Power Factor Correction) circuit and the DC-DC circuit are interconnected. The PFC circuit is used to control the current waveform input to the charging module, so that the current waveform input to the charging module is synchronized with the voltage waveform input to the charging module, thereby reducing the loss of power exchange between current and voltage during charging.

[0090] Step S20: The DC-DC circuit transforms the voltage input to the charging module.

[0091] In practice, the DC-DC circuit transforms the voltage input to the charging module, improving the power conversion efficiency.

[0092] Step S30: When a fault occurs, the first control chip acquires the frequency information of the PWM and determines the fault type based on the frequency information of the PWM, and controls the PFC circuit.

[0093] In this embodiment, the first control chip is connected to the PFC circuit. When a circuit of the charging module fails, the chip can obtain the PWM (Pulse Width Modulation) frequency information of the fault, determine the fault type based on the PWM frequency information, and control the PFC circuit according to the fault type to protect the PFC circuit.

[0094] Step S40: When a fault occurs, the second control chip acquires the frequency information of the PWM, determines the fault type based on the frequency information of the PWM, and controls the DC-DC circuit.

[0095] In practice, the second control chip is connected to the DC-DC circuit. When a circuit of the charging module fails, the PWM frequency information of the failure can be obtained. The fault type can be determined based on the PWM frequency information, and the DC-DC circuit can be controlled according to the fault type.

[0096] It should be understood that different frequency information can correspond to different fault types. For example, frequency f1 corresponds to a fault in the power conversion stage, while frequency f2 corresponds to a fault in the input or output voltage. Fault types can include power conversion faults, such as power conversion faults in PFC circuits and power conversion faults in DC-DC circuits. Power conversion faults in PFC circuits can include PFC transformer overheating, PFC power switch overheating, PFC output overcurrent, PFC output overvoltage, PFC input duct overtemperature, and other PFC circuit faults. Power conversion faults in DC-DC circuits can include DC-DC inductor overheating, DC-DC power switch overheating, DC-DC output overcurrent, DC-DC output overvoltage, excessive DC-DC output error, and other DC-DC circuit faults. Fault types may also include voltage faults such as sudden changes in the input voltage and output voltage of the charging module, as well as sudden changes in ambient temperature caused by factors such as blocked air ducts, or communication interface faults between power conversion circuits. The first control chip 30 and the second control chip 40 can quickly identify the PWM frequency information of the fault and determine the type of fault, and immediately execute protection actions to improve the protection efficiency of the PFC circuit 10 and DC-DC circuit in power conversion.

[0097] This embodiment sets up a PFC circuit, a DC-DC circuit, a first control chip, and a second control chip in the charging module fault communication system. The PFC circuit is connected to the first control chip, and the DC-DC circuit is connected to the second control chip. The PFC circuit and the DC-DC circuit are interconnected. The PFC circuit controls the current waveform input to the charging module, synchronizing the current waveform with the voltage waveform input to the charging module. The DC-DC circuit converts the voltage input to the charging module. The first control chip acquires the PWM frequency information and determines the fault type based on the PWM frequency information when a fault occurs, and then controls the PFC circuit. The second control chip acquires the PWM frequency information and determines the fault type based on the PWM frequency information when a fault occurs in a certain stage of the charging module circuit or an emergency situation occurs in the input / output. This allows for rapid information exchange between power conversion stages, enabling rapid protection response of the charging module circuit and improving the fault handling capability of the charging module.

[0098] It should be understood that the above are merely illustrative examples and do not constitute any limitation on the technical solutions of the present invention. In specific applications, those skilled in the art can make settings as needed, and the present invention does not impose any restrictions on this.

[0099] It should be noted that the workflow described above is merely illustrative and does not limit the scope of protection of this invention. In practical applications, those skilled in the art can select some or all of the workflow to achieve the purpose of this embodiment according to actual needs, and no restrictions are imposed here.

[0100] In addition, for technical details not described in detail in this embodiment, please refer to the charging module fault communication method provided in any embodiment of the present invention, which will not be repeated here.

[0101] Furthermore, it should be noted that, in this document, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or system that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or system. Unless otherwise specified, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or system that includes that element.

[0102] The sequence numbers of the above embodiments of the present invention are for descriptive purposes only and do not represent the superiority or inferiority of the embodiments.

[0103] Through the above description of the embodiments, those skilled in the art can clearly understand that the methods of the above embodiments can be implemented by means of software plus necessary general-purpose hardware platforms. Of course, they can also be implemented by hardware, but in many cases the former is a better implementation method. Based on this understanding, the technical solution of the present invention, or the part that contributes to the prior art, can be embodied in the form of a software product. This computer software product is stored in a storage medium (such as read-only memory (ROM) / RAM, magnetic disk, optical disk) and includes several instructions to cause a terminal device (which may be a mobile phone, computer, server, or network device, etc.) to execute the methods described in the various embodiments of the present invention.

[0104] The above are merely preferred embodiments of the present invention and do not limit the scope of the patent. Any equivalent structural or procedural transformations made based on the description and drawings of the present invention, or direct or indirect applications in other related technical fields, are similarly included within the scope of patent protection of the present invention.

Claims

1. A charging module fault communication system, characterized in that, The charging module fault communication system includes: a PFC circuit, a DC-DC circuit, a first control chip, and a second control chip. The PFC circuit is connected to the first control chip, the DC-DC circuit is connected to the second control chip, and the PFC circuit and the DC-DC circuit are interconnected. The PFC circuit is used to control the current waveform input to the charging module, so that the current waveform is synchronized with the voltage waveform input to the charging module. The DC-DC circuit is used to transform the voltage input to the charging module; The first control chip is used to acquire the frequency information of the PWM when a fault occurs, determine the fault type based on the frequency information of the PWM, and control the PFC circuit. The second control chip is used to acquire the frequency information of the PWM when a fault occurs, determine the fault type based on the frequency information of the PWM, and control the DC-DC circuit. The frequency information includes: first frequency information; When the frequency information is the first frequency information, the fault type is determined to be a power conversion fault; The first control chip is further configured to acquire power conversion fault information of the PFC circuit, generate a corresponding first PWM waveform based on the power conversion fault information of the PFC circuit, and shut down the PFC circuit based on the fault type obtained by reading the first PWM waveform.

2. The charging module fault communication system of claim 1, wherein, The second control chip is also used to acquire power conversion fault information of the DC-DC circuit, generate a corresponding second PWM waveform based on the power conversion fault information of the DC-DC circuit, and shut down the DC-DC circuit based on the fault type obtained by reading the second PWM waveform.

3. The charging module fault communication system of claim 2, wherein, The first PWM waveform includes a fault code and the PWM duty cycle; The first control chip is also used to acquire power conversion fault information of the PFC circuit and generate a fault code based on the power conversion fault information; The first control chip is also used to query a preset fault mapping table through the fault code to obtain the PWM duty cycle. The preset fault mapping table stores the relationship between fault codes, fault types and PWM duty cycles. The first control chip is further configured to determine the PFC circuit fault type based on the fault code and the PWM duty cycle, and to shut down the PFC circuit based on the PFC circuit fault type; The first control chip is further configured to send the PFC circuit fault type and the PWM duty cycle to the second control chip, so that the second control chip performs a protection action on the DC-DC circuit according to the PFC circuit fault type and the PWM duty cycle.

4. The charging module fault communication system of claim 3, wherein, The second PWM waveform includes a fault code and the PWM duty cycle; The second control chip is also used to acquire power conversion fault information of the DC-DC circuit and generate a fault code based on the power conversion fault information; The second control chip is also used to query a preset fault mapping table through the fault code to obtain the PWM duty cycle; The second control chip is further configured to determine the DC-DC circuit fault type based on the fault code and the PWM duty cycle, and to shut down the DC-DC circuit based on the DC-DC circuit fault type; The second control chip is further configured to send the DC-DC circuit fault type and the PWM duty cycle to the first control chip, so that the first control chip performs a protection action on the PFC circuit according to the DC-DC circuit fault type and the PWM duty cycle.

5. The charging module fault communication system as described in claim 3 or 4, characterized in that, The first control chip or the second control chip is also used to store the fault code and send the fault code to the display device or storage device.

6. The charging module fault communication system as described in claim 1, characterized in that, The frequency information further includes: second frequency information, wherein the first frequency information is different from the second frequency information; the charging module fault communication system further includes: a first sampling circuit and a second sampling circuit, wherein the first sampling circuit is connected to the first control chip and the second sampling circuit is connected to the second control chip. When the frequency information is the second frequency information, the fault type is determined to be a voltage fault; The first sampling circuit is used to collect voltage fault information at the input terminal of the charging module and send the voltage fault information at the input terminal to the first control chip. The second sampling circuit is used to collect voltage fault information at the output terminal of the charging module and send the voltage fault information at the output terminal to the second control chip. The first control chip is also used to generate a corresponding third PWM waveform based on the voltage fault information at the input terminal, and to control the PFC circuit based on the third PWM waveform; The second control chip is also used to generate a corresponding fourth PWM waveform based on the voltage fault information at the output terminal, and to control the DC-DC circuit based on the fourth PWM waveform.

7. The charging module fault communication system as described in claim 6, characterized in that, The first control chip is further configured to determine the voltage value and PWM duty cycle of the input terminal based on the voltage fault information of the input terminal, compare the voltage value and PWM duty cycle of the input terminal with a preset input terminal voltage value and a preset duty cycle, and control the PFC circuit to reduce the output power or shut down when the voltage value and PWM duty cycle of the input terminal are equal to the preset input terminal voltage value and the preset duty cycle. The first control chip is further configured to generate a third PWM waveform from the voltage value at the input terminal and the PWM duty cycle and send it to the second control chip, so that the second control chip compares the voltage value at the input terminal and the PWM duty cycle in the third PWM waveform with a preset input terminal voltage value and a preset duty cycle, and controls the DC-DC circuit to reduce its output power or shut down when the voltage value at the input terminal and the PWM duty cycle are equal to the preset input terminal voltage value and the preset duty cycle.

8. The charging module fault communication system of claim 6, wherein, The second control chip is also used to determine the voltage value and PWM duty cycle of the output terminal based on the voltage fault information of the output terminal, compare the voltage value and PWM duty cycle of the output terminal with the preset output terminal voltage value and preset duty cycle, and control the DC-DC circuit to reduce the input power or shut down when the voltage value and PWM duty cycle of the output terminal are equal to the preset output terminal voltage value and preset duty cycle. The second control chip is further configured to generate a fourth PWM waveform from the voltage value of the output terminal and the PWM duty cycle and send it to the first control chip, so that the first control chip compares the voltage value of the output terminal and the PWM duty cycle in the fourth PWM waveform with a preset output terminal voltage value and a preset duty cycle, and controls the PFC circuit to reduce the input power or shut down when the voltage value of the output terminal and the PWM duty cycle are equal to the preset output terminal voltage value and the preset duty cycle.

9. A charging module fault communication method characterized by, The charging module fault communication method is applied to the charging module fault communication system according to any one of claims 1-8, wherein the charging module fault communication system includes: a PFC circuit, a DC-DC circuit, a first control chip, and a second control chip, and the method includes: The PFC circuit controls the current waveform input to the charging module, so that the current waveform is synchronized with the voltage waveform input to the charging module. The DC-DC circuit transforms the voltage input to the charging module; When a fault occurs, the first control chip acquires the frequency information of the PWM and determines the fault type based on the frequency information of the PWM, and then controls the PFC circuit. When a fault occurs, the second control chip acquires the frequency information of the PWM and determines the fault type based on the frequency information of the PWM, and then controls the DC-DC circuit.

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