A system and method for allocating power levels of ultra-high power DC charging stacks

Abstract

The present invention discloses a system and method for power level distribution of an ultra-high power DC charging stack. In this system, the charging stack is configured with 4N power modules, wherein the first-level distribution system includes a unit control core board, an A contactor group consisting of 4N A contactors, and a unit busbar group consisting of 2N unit busbars; the second-level distribution system includes a busbar control core board, a B contactor group consisting of 2N B contactors, and an output busbar group consisting of N output busbars; the third-level distribution system includes an output control core board, an output contactor group consisting of N output contactors, and N gun line outlets; the charging stack main control core board is electrically connected to the 4N power modules, the unit control core board, the busbar control core board, and the output control core board via the CAN bus. The present invention can maximize the use of the system's power and facilitate capacity expansion when multiple guns are outputting simultaneously.

Description

Technical Field

[0001] The present invention relates to the technical field of direct current (DC) charging piles, and in particular to a system and method for power level distribution of an ultra-high power DC charging pile. Background Art

[0002] An electric vehicle DC charging stack is a centralized rectifier and converter facility with an output of 240kW or more. As the battery capacity of electric vehicles increases, the demand for high-power DC charging is becoming increasingly important. Traditional charging stacks rely on fixed power allocation, which limits the maximum power output of multiple chargers simultaneously. When a vehicle's charging power drops, excess power modules in the fixed allocation are wasted. Summary of the Invention

[0003] To address the aforementioned technical issues, the present invention proposes a system and method for distributing power levels in ultra-high-power DC charging stacks. This system and method utilizes a hierarchical connection method with a fixed hierarchical distribution scheme, with clear division of labor between each layer. When a single power module fails, the rectifier outputs of other power modules remain unaffected. The layered connection method facilitates capacity expansion, requiring only the addition of units at a fixed level.

[0004] In order to achieve the above object, the technical solution of the present invention is as follows:

[0005] A system for distributing power levels of an ultra-high-power DC charging stack, wherein the charging stack is configured with 4N power modules, including a primary distribution system, a secondary distribution system, a tertiary distribution system, and a charging stack main control core board, wherein:

[0006] The primary distribution system includes a unit control core board, an A contactor group consisting of 4N A contactors, and a unit busbar group consisting of 2N unit busbars. The unit control core board is electrically connected to the A contactor group and the unit busbar group, respectively. The A contactor group is used to electrically connect the corresponding power module to the unit busbar according to the control instruction of the unit control core board;

[0007] The secondary distribution system includes a busbar control core board, a B contactor group consisting of 2N B contactors, and an output busbar group consisting of N output busbars. The busbar control core board is connected to the unit control core board via a CAN bus. The busbar control core board is electrically connected to the B contactor group and the output busbar group, respectively. The B contactor group is used to electrically connect the corresponding unit busbar to the output busbar according to the control instruction of the busbar control core board;

[0008] The three-level distribution system includes an output control core board, an output contactor group consisting of N output contactors, and N gun line outlets. The output control core board is electrically connected to the busbar control core board through a CAN bus. The output control core board is electrically connected to the output contactor group and the gun line outlet respectively. The output contactor group is used to electrically connect the corresponding output busbar to the gun line outlet according to the control instruction of the output control core board;

[0009] The charging stack main control core board is electrically connected to 4N power modules, the unit control core board, the busbar control core board and the output control core board through the CAN bus.

[0010] Preferably, the power of the power module is 20KW to 25KW.

[0011] Preferably, the contact capacity of the A contactor is 85A to 125A.

[0012] Preferably, the contact capacity of the B contactor is 200A to 250A.

[0013] Preferably, the contact capacity of the output contactor is 250A to 300A.

[0014] Preferably, the unit control core board, busbar control core board and output control core board all use microprocessors.

[0015] Preferably, the processing capacity of the charging stack main control core board is higher than the processing capacity of the unit control core board, the busbar control core board and the output control core board.

[0016] Preferably, each of the unit busbars is electrically connected to 1 to 3 power modules.

[0017] Preferably, N is an integer not less than 3.

[0018] A method for allocating power levels of an ultra-high power DC charging stack comprises the following steps:

[0019] Obtain the output power requirement of the gun line outlet, the output control core board determines the three-level allocation plan and generates a two-level allocation plan and sends it to the busbar control core board; the busbar control core board generates a first-level allocation plan based on the second-level allocation plan and sends it to the unit control core board;

[0020] The unit control core board controls the A contactor group based on the first-level distribution scheme to electrically connect the corresponding power module to the unit busbar; the busbar control core board controls the B contactor group based on the second-level distribution scheme to electrically connect the corresponding unit busbar to the output busbar; the output control core board controls the output contactor group based on the third-level distribution scheme to electrically connect the corresponding output busbar to the gun line outlet, completing the construction of the entire power distribution system and sending a power distribution construction completion notification to the charging stack main control core board;

[0021] After the charging stack main control core board detects the correctness of the entire power distribution system, it notifies the start of power output;

[0022] After receiving the charging stop or termination instruction, the charging stack main control core board sends a shutdown instruction to the output level control core board; the output level control core board sends a shutdown instruction to the bus level distribution control core board; the bus level control core sends a shutdown instruction to the unit level distribution control core board;

[0023] The unit control core controls all registered power modules to stop output, disconnects contactor A after stopping output and notifies the busbar control core board; the busbar control core board disconnects contactor B and notifies the output control core board; the output control core board disconnects the output contactor, completes the discharge operation and notifies the human-machine interface processing core;

[0024] The charging stack main control core board issues a shutdown success notification, and charging is completed.

[0025] Based on the above technical solution, the beneficial effects of the present invention are:

[0026] 1) The present invention adopts a hierarchical connection mode and a fixed hierarchical distribution mode, with clear division of labor in each layer. When a single power module fails, the rectifier output of other power modules is not affected;

[0027] 2) The present invention adopts a hierarchical connection method, which can realize hierarchical control and inspection, avoid busbar short circuit caused by misoperation, and prevent busbar output errors;

[0028] 3) The present invention adopts a hierarchical connection method, which is convenient for expansion. It only requires adding units at a fixed level. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] The specific embodiments of the present invention will be further described in detail below with reference to the accompanying drawings.

[0030] Figure 1 This is a structural block diagram of a system for allocating power levels of an ultra-high power DC charging stack in one embodiment;

[0031] Figure 2This is a structural block diagram of a system using a 400kW one-to-five unit model as an example.

[0032] In the attached figure:

[0033] 1. Charging stack; 11. Power module; 2. Charging stack main control core board; 3. Primary distribution system; 31. Unit control core board; 32. Contactor group A; 321. Contactor A; 33. Unit busbar group; 331. Unit busbar; 4. Secondary distribution system; 41. Busbar control core board; 42. Contactor group B; 421. Contactor B; 43. Output busbar group; 431. Output busbar; 5. Tertiary distribution system; 51. Output control core board; 52. Output contactor group; 521. Output contactor; 53. Gun line outlet. DETAILED DESCRIPTION

[0034] In order to explain the present invention more clearly, the present invention is further described below in conjunction with preferred embodiments. Those skilled in the art should understand that the following specific description is illustrative rather than restrictive and should not be used to limit the scope of protection of the present invention.

[0035] In the description of the present invention, it should be understood that the terms "center", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", etc., indicating the orientation or position relationship, are based on the orientation or position relationship shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as limiting the present invention.

[0036] In the description of the present invention, it should be noted that, unless otherwise expressly specified or limited, the terms "mounted," "connected," and "connected" should be understood broadly. For example, they may refer to fixed connections, detachable connections, or integral connections; they may refer to direct connections, indirect connections through an intermediary, or internal communication between two components. Those skilled in the art will understand the specific meanings of the above terms in the present invention based on the specific circumstances.

[0037] like Figure 1 As shown, this embodiment provides a system for power level distribution of ultra-high power DC charging piles, which includes a primary distribution system 3, a secondary distribution system 4, a tertiary distribution system 5 and a charging pile main control core board 2. The three-level distribution structure is suitable for the hierarchical distribution scheme of ultra-high power charging piles, which is specifically described as follows:

[0038] The 400kW charging stack 1 is equipped with 20 20kW power modules 11. The power modules 11 communicate with the charging stack main control core board 2 via the CAN bus. The output DC voltage and current can be adjusted by the power modules 11.

[0039] The primary distribution system 3 includes a unit control core board 31, an A contactor group 32 consisting of 20 A contactors 321, and a unit busbar group 33 consisting of 10 unit busbars 331. The unit control core board 31 is electrically connected to the A contactor group 32 and the unit busbar group 33, respectively. The A contactor group 32 is used to electrically connect the corresponding power module 11 to the unit busbar 331 according to the control instruction of the unit control core board 31, so as to realize parallel output of multiple power modules 11;

[0040] The secondary distribution system 4 includes a busbar control core board 41, a B contactor group 42 consisting of 10 B contactors 421, and an output busbar group 43 consisting of 5 output busbars 431. The busbar control core board 41 is connected to the unit control core board 31 via a CAN bus. The busbar control core board 41 is electrically connected to the B contactor group 42 and the output busbar group 43 respectively. The B contactor group 42 is used to electrically connect the corresponding unit busbar 331 to the output busbar 431 according to the control instruction of the busbar control core board 41, so as to realize parallel output of multiple output busbars 431 to stack power;

[0041] The three-level distribution system 5 includes an output control core board 51, an output contactor group 52 consisting of 5 output contactors 521, and 5 gun line outlets 53. The output control core board 51 is electrically connected to the busbar control core board 41 through a CAN bus. The output control core board 51 is electrically connected to the output contactor group 52 and the gun line outlet 53 respectively. The output contactor group 52 is used to electrically connect the corresponding output busbar 431 to the gun line outlet 53 according to the control instruction of the output control core board 51;

[0042] The charging stack main control core board 2 is electrically connected to 4N power modules 11, the unit control core board 31, the busbar control core board 41 and the output control core board 51 through the CAN bus; it is used for input control and output scheduling execution module inside the charging stack, contains a high-computing power processor, controls the input of the charging stack through opening and output, and schedules the three-layer core control board through the CAN bus.

[0043] In this embodiment, according to the current value and specific conditions of the circuits at different levels, the contact capacity of the A contactor 321 is determined to be 85A; the contact capacity of the B contactor 421 is determined to be 200A; and the contact capacity of the output contactor 521 is determined to be 250A to achieve safety control.

[0044] Due to the hierarchical connection method, the unit busbar group 33 and the output busbar group 43 are only responsible for the upper-level commands. The upper-level control core board reverses the hierarchical power construction results, and the output is started only after the entire system is built correctly. The unit-level allocation adopts two power particle solutions, which are convenient for parallel combination to provide a high-power output solution. The maximum power of each level is fixed, which is convenient for electrical and structural design and does not require redundant redundant design. When a single power module 11 fails and shuts down, it does not affect the output of other modules, and only the corresponding unit busbar needs to downgrade the output. Dynamic allocation and automatic switching are achieved during the charging process, supporting all power modules in the system to be used by any charging gun in the system.

[0045] Among them, the unit control core board 31, the busbar control core board 41 and the output control core board 51 all use microprocessors. The unit control core board 31 can also determine whether the allocation result of the unit busbar 331 complies with the system settings by collecting the status of the unit busbar 331; the busbar control core board 41 can also detect the current and voltage of the output busbar 431 through the output busbar 431 detection circuit to verify whether the second-level allocation is correctly executed; the output control core board 51 receives the charging demand from the car and reports the demand to the main control core board and the busbar control core board 41 at the same time. By verifying the position of the output contactor 521 and the voltage of the front section of the charging gun, it verifies whether the third-level allocation is correctly executed. During the charging process, the real-time current of the gun line is detected to determine whether there is a circuit overload. Due to the use of a layered connection method, layered control and inspection can be achieved, avoiding busbar short circuits caused by misoperation and preventing busbar output errors.

[0046] Take the 400kW one-to-five model as an example. Figure 2As shown, there are five gun line outlets 53 corresponding to five charging guns (charging gun A, charging gun B, charging gun C, charging gun D, charging gun E), and each charging gun has the same capacity. There is an output busbar group 43 consisting of output busbar groups 43 from 1# to 5#, and the total busbar capacity of each output busbar 431 is the same. There are 10 unit busbar groups 33 from 1# to 10#, which together form a unit busbar group 33. Among them, the 1#, 2#, 3#, and 4# unit busbars 331 can be connected to two power modules 11 (40kW), the 5#, 6#, and 7# unit busbars 331 can be connected to three power modules 11 (60kW), and the 8#, 9#, and 10# unit busbars 331 can be connected to one power module 11 (20kW). Each charging gun can independently output 160kW; when two guns are outputting simultaneously, each charging gun can output 160kW; when three charging guns are outputting simultaneously, each charging gun can output 120kW; when four charging guns are outputting simultaneously, each charging gun can output 100kW; when five charging guns are outputting simultaneously, each charging gun can output 80kW. Dynamic allocation and automatic switching are achieved during the charging process, allowing all power modules 11 in the system to be used by any charging gun in the system.

[0047] Taking the scenario where three charging guns (A, B, and C) simultaneously output 120kW as an example, the charging process is explained as follows:

[0048] Phase 1: The user parks the car and plugs in the charging guns. The system recognizes the user's intention and sends a command to charging guns A, B, and C to output 120kW to the output control core board 51. The output control core board 51 confirms the command, calculates the three-level allocation plan, and distributes the second-level allocation plan to the busbar control core board 41. The busbar control core board 41 confirms the command and distributes the first-level allocation plan to the unit control core board 31.

[0049] The second stage: the unit control core board 31 starts to register the power module 11 based on the first-level allocation plan and operates the A contactor group 32, connects the 1#, 2#, and 3# unit busbars 331 to two power modules 11, the 5#, 6#, and 7# unit busbars 331 to three power modules 11, and the 8#, 9#, and 10# unit busbars 331 to one power module 11, completes the construction of the unit busbar 331, and notifies the busbar-level control core board; the busbar control core board 41 starts to register the unit busbar 331 based on the second-level allocation plan, operates the B contactor group 42, connects the 1#, 5#, and 8# unit busbars 331 to three power modules 11, and connects ... 31 is connected to the 1# output busbar 431; the 2#, 6# and 9# unit busbars 331 are connected to the 2# output busbar 431; the 3#, 7# and 10# unit busbars 331 are connected to the 3# output busbar 431, completing the construction of the output busbar 431 and notifying the output level control core board; the output control core board 51 operates the output contactor group 52 based on the three-level distribution scheme, connects the 1# output busbar 431, the 2# output busbar 431, and the 3# output busbar 431 to the A gun, the B gun and the C gun respectively, completing the construction of the entire power distribution system and sending a power distribution construction completion notification to the charging stack main control core board 2;

[0050] Phase 3: The charging stack main control core board 2 detects the correctness of the entire power distribution system, notifies the start of power output, and begins the normal charging process;

[0051] Phase 4: After receiving the user's stop charging instruction, the charging stack main control core board 2 sends a shutdown command and a power distribution system release command to the output level control core board; the output level control core board sends a command to the busbar level distribution control core board; the busbar level control core sends a command to the unit level distribution control core board;

[0052] Phase 5: The unit control core controls all registered power modules 11 to stop output, disconnects contactor A 321 after stopping output, and notifies the busbar control core board 41; the busbar control core board 41 disconnects contactor B 421 and notifies the output control core board 51; the output control core board 51 disconnects the output contactor 521, completing the discharge operation, and notifies the charging stack main control core board 2;

[0053] Stage 6: The charging stack main control core board 2 notifies the customer that the shutdown is successful and charging is completed.

[0054] The above description is merely a preferred embodiment of the system and method for power level allocation of an ultra-high-power DC charging stack disclosed in the present invention and is not intended to limit the scope of protection of the embodiments of this specification. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the embodiments of this specification shall be included in the scope of protection of the embodiments of this specification.

Claims

1. A system for distributing power levels of an ultra-high power DC charging stack, wherein the charging stack is configured with 4N power modules, characterized in that: It includes the first-level distribution system, the second-level distribution system, the third-level distribution system and the charging pile main control core board, among which, The primary distribution system includes a unit control core board, an A contactor group consisting of 4N A contactors, and a unit busbar group consisting of 2N unit busbars. The unit control core board is electrically connected to the A contactor group and the unit busbar group, respectively. The A contactor group is used to electrically connect the corresponding power module to the unit busbar according to the control instruction of the unit control core board; The secondary distribution system includes a busbar control core board, a B contactor group consisting of 2N B contactors, and an output busbar group consisting of N output busbars. The busbar control core board is connected to the unit control core board via a CAN bus. The busbar control core board is electrically connected to the B contactor group and the output busbar group, respectively. The B contactor group is used to electrically connect the corresponding unit busbar to the output busbar according to the control instruction of the busbar control core board; The three-level distribution system includes an output control core board, an output contactor group consisting of N output contactors, and N gun line outlets. The output control core board is electrically connected to the busbar control core board through a CAN bus. The output control core board is electrically connected to the output contactor group and the gun line outlet respectively. The output contactor group is used to electrically connect the corresponding output busbar to the gun line outlet according to the control instruction of the output control core board; The charging stack main control core board is electrically connected to 4N power modules, the unit control core board, the busbar control core board and the output control core board through the CAN bus; Specifically, the power of the power module is 20KW to 25KW, the contact capacity of the A contactor is 85A to 125A, the contact capacity of the B contactor is 200A to 250A, and the contact capacity of the output contactor is 250A to 300A.

2. The system for distributing power levels of ultra-high power DC charging piles according to claim 1, characterized in that: The unit control core board, busbar control core board and output control core board all use microprocessors.

3. The system for distributing power levels of ultra-high power DC charging piles according to claim 2, characterized in that: The processing capability of the charging stack main control core board is higher than that of the unit control core board, the busbar control core board and the output control core board.

4. The system for distributing power levels of ultra-high power DC charging piles according to claim 1, characterized in that: Each of the unit busbars is electrically connected to 1 to 3 power modules.

5. A system for distributing power levels of ultra-high power DC charging stacks according to any one of claims 1 to 4, characterized in that: The N is an integer not less than 3.

6. A method for distributing power levels of a super-high power DC charging stack according to any one of claims 1 to 5, characterized in that: The steps include: Obtain the output power requirement of the gun line outlet, the output control core board determines the three-level allocation plan and generates a two-level allocation plan and sends it to the busbar control core board; the busbar control core board generates a first-level allocation plan based on the second-level allocation plan and sends it to the unit control core board; The unit control core board controls the A contactor group based on the first-level distribution scheme to electrically connect the corresponding power module to the unit busbar; the busbar control core board controls the B contactor group based on the second-level distribution scheme to electrically connect the corresponding unit busbar to the output busbar; the output control core board controls the output contactor group based on the third-level distribution scheme to electrically connect the corresponding output busbar to the gun line outlet, completing the construction of the entire power distribution system and sending a power distribution construction completion notification to the charging stack main control core board; After the charging stack main control core board detects the correctness of the entire power distribution system, it notifies the start of power output; After receiving the charging stop or termination instruction, the charging stack main control core board sends a shutdown instruction to the output level control core board; the output level control core board sends a shutdown instruction to the busbar level distribution control core board; The busbar-level control core issues a shutdown command to the unit-level distribution control core board; The unit control core controls all registered power modules to stop output, disconnects contactor A after output stops, and notifies the busbar control core board; the busbar control core board disconnects contactor B and notifies the output control core board; The output control core board disconnects the output contactor, completes the discharge operation and notifies the human-machine interface processing core; The charging stack main control core board issues a shutdown success notification, and charging is completed.

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