A large-current path device for a charging pile

Abstract

The present invention discloses a large-current path device for a charging pile, belonging to the field of charging control of charging piles, and solving the problem that the large-current path of the charging pile is prone to overheating and even burning due to carrying a large current for a long time; it includes: a printed circuit board, on the top layer of the printed circuit board, there are a relay, a first bent thick copper sheet, a second bent thick copper sheet, a first thick copper wire, a second thick copper wire, a first rectangular thick copper sheet, a second rectangular thick copper sheet, a first copper terminal, a second copper terminal, a plurality of screws, a power supply inlet wire and a power supply outlet wire; the first thick copper wire and the second thick copper wire are used to replace the copper foil circuit in the prior art, and a thick copper core is used to carry the large charging current, and the power supply inlet wire and the power supply outlet wire are respectively connected to the first thick copper wire and the second thick copper wire through the first copper terminal and the second copper terminal. The first thick copper wire and the second thick copper wire provide sufficient current-carrying capacity and safety margin, and can realize long-time operation of the large charging current without overheating or burning.

Description

Technical Field

[0001] The present invention belongs to the field of charging control of charging piles, and specifically relates to a large-current path device for charging piles. Background Art

[0002] AC charging piles provide power for electric vehicles. For a conventional 7kw charging pile, the output charging current can reach 32A. Existing AC charging piles use on-board relays 2 to control the on-off of the charging current, and connect the power supply, control components, and output through the copper foil of the original printed circuit board to form a current-carrying path for the charging circuit. This path has risks such as overheating or burning during long-term use.

[0003] Affected by the manufacturing process, cost, etc. of the original printed circuit board, the thickness and width of the copper foil are limited, so its long-term current-carrying capacity is insufficient. A compensation method is to make the copper foil circuit open-window and non-insulated, and add additional solder during the welding stage to increase the circuit thickness. As Figure 1-2 shown, this method has a relatively complex process, and it cannot ensure uniform thickness increase, resulting in uncontrollable current-carrying bottlenecks. When an electric vehicle is charging, the copper foil circuit of the charging pile will carry a large current for several hours, and the copper foil circuit usually overheats. Especially when there are defects in the manufacturing of the copper foil circuit, it may even burn out.

[0004] Therefore, the present invention proposes a large-current path device for charging piles, which can effectively solve the above problems. Summary of the Invention

[0005] The present invention aims to solve at least one of the technical problems existing in the prior art. For this purpose, the present invention proposes a large-current path device for charging piles, which solves the problem that the large-current path of the charging pile is prone to overheating and even burning when carrying a large current for a long time.

[0006] To achieve the above object, according to an embodiment of the present invention, a large-current path device for charging piles is proposed, including: a printed circuit board, on the top layer of the printed circuit board, there are a relay, a first bent thick copper sheet, a second bent thick copper sheet, a first thick copper wire, a second thick copper wire, a first rectangular thick copper sheet, a second rectangular thick copper sheet, a first copper terminal, a second copper terminal, a plurality of screws, a power supply inlet wire, and a power supply outlet wire;

[0007] One end of the first bent thick copper sheet is electrically connected to one end of the relay, and the other end of the first bent thick copper sheet is electrically connected to one end of the first thick copper wire;

[0008] The other end of the first thick copper wire is electrically connected to one end of the first rectangular thick copper sheet. A circular through-hole is provided at the other end edge of the first rectangular thick copper sheet for fastening with one end of the first copper terminal provided with the same circular through-hole by a screw;

[0009] The other end of the first copper terminal is provided with a circular opening, and a cylindrical cavity is arranged inside the first copper terminal. Two identical circular through-holes are arranged in parallel above the first copper terminal; one end of the power supply incoming line is embedded into the cylindrical cavity of the first copper terminal through the circular opening of the first copper terminal, and two screws are respectively used to rotate into the internal cavity of the first copper terminal from above the first copper terminal through the two parallel circular through-holes, so that the first copper terminal is firmly combined with the power supply incoming line;

[0010] Correspondingly, the second bent thick copper sheet, the second thick copper wire, the second rectangular thick copper sheet, the second copper terminal and the power supply outgoing line are connected in the same way as the above connection method.

[0011] Further, the relay is used to control the on-off of the charging current of the charging pile, and the relay is connected to the printed circuit board through surface mount technology.

[0012] Further, the first bent thick copper sheet and the second bent thick copper sheet have the same structure. The first bent thick copper sheet and the first thick copper wire are welded by pressing, and the second bent thick copper sheet and the second thick copper wire are welded by pressing.

[0013] Further, the first thick copper wire and the second thick copper wire use the same copper wire material, and the inner cores of the first thick copper wire and the second thick copper wire are cylinders after multi-core stranding. The cross-sectional area of the inner core is set at 6-10 square millimeters, and insulators are wrapped outside the inner cores of the first thick copper wire and the second thick copper wire.

[0014] Further, the first rectangular thick copper sheet and the second rectangular thick copper sheet have the same structure. The first rectangular thick copper sheet is used to connect the first thick copper wire and the first copper terminal, and the second rectangular thick copper sheet is used to connect the second thick copper wire and the second copper terminal. The first rectangular thick copper sheet and the second rectangular thick copper sheet are respectively connected to the first thick copper wire and the second thick copper wire by pressing welding.

[0015] Further, the first copper terminal and the second copper terminal have the same structure. By rotating the two screws arranged above the first copper terminal and the second copper terminal, the tightness between the power supply incoming line and the first copper terminal and between the power supply outgoing line and the second copper terminal is adjusted.

[0016] Compared with the prior art, the beneficial effects of the present invention are:

[0017] In the present invention, the AC charging pile adopts an on-board relay, that is, the relay is arranged on the printed circuit board. When the internal circuit of the relay is controlled to be connected, the charging current enters from the power supply inlet wire, and successively passes through the first copper connection terminal, the first rectangular thick copper sheet, and the first thick copper wire into the relay. Then, the charging current passes through the other end of the relay and successively passes through the second bent thick copper sheet, the second thick copper wire, the second rectangular thick copper sheet, and the second copper connection terminal into the power supply outlet wire. In the present invention, the first thick copper wire and the second thick copper wire replace the copper foil circuit in the prior art, and the thick copper core is used to carry the large charging current. Moreover, the power supply inlet wire and the power supply outlet wire are respectively connected to the first thick copper wire and the second thick copper wire through the first copper connection terminal and the second copper connection terminal. The first thick copper wire and the second thick copper wire provide sufficient current-carrying capacity and safety margin, and can realize long-term operation of the large charging current without overheating or burning. Description of the Drawings

[0018] Figure 1 It is a schematic top view of the control circuit board for the large current path of the charging pile in the prior art;

[0019] Figure 2 It is a schematic bottom view of the control circuit board for the large current path of the charging pile in the prior art;

[0020] Figure 3 It is a schematic structural view of the control circuit board of a large current path device of a charging pile in the present invention;

[0021] Figure 1-2 In the figure: 101, original printed circuit board; 102, original relay; 103, copper foil at the inlet end; 104, copper foil at the outlet end; 105, connection terminal at the inlet end; 106, connection terminal at the outlet end; 107, original power supply inlet wire; 108, original power supply outlet wire; 201, first welding foot; 202, second welding foot; 203, third welding foot; 204, fourth welding foot; 205, first solder pile; 206, second solder pile;

[0022] Figure 3 In the figure: 1, printed circuit board; 2, relay; 3, first bent thick copper sheet; 4, second bent thick copper sheet; 5, first thick copper wire; 6, first rectangular thick copper sheet; 7, first copper connection terminal; 8, screw; 9, power supply inlet wire; 10, second thick copper wire; 11, second rectangular thick copper sheet; 12, second copper connection terminal; 13, power supply outlet wire. Detailed Embodiment

[0023] Next, the technical solutions of the present invention will be clearly and completely described in conjunction with the embodiments. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments; based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without making creative efforts shall fall within the protection scope of the present invention.

[0024] As Figure 1-2 is the prior art, that is, an original relay 102 is arranged on the top layer of the original printed circuit board 101. The original relay 102 is respectively connected to an incoming line terminal 105 and an outgoing line terminal 106 through an incoming line end copper foil 103 and an outgoing line end copper foil 104. The incoming line terminal 105 is connected to an original power incoming line 107, and the outgoing line terminal 106 is connected to an original power outgoing line 108. A window is arranged on the bottom layer of the original printed circuit board 101. The first solder pad 201 and the second solder pad 202 in the window are respectively the pins of the incoming line terminal 105 and one end of the original relay 102. The first solder pad 201 and the second solder pad 202 are connected through a first solder pile 205. The third solder pad 203 and the fourth solder pad 204 in the window are respectively the pins of the other end of the original relay 102 and the outgoing line terminal 106. The third solder pad 203 and the fourth solder pad 204 are connected through a second solder pile 206. Thus, the insufficient long-term current-carrying capacity of the incoming line end copper foil 103 and the outgoing line end copper foil 104 is compensated;

[0025] However, this method has a relatively complex process, and it cannot ensure uniformity when increasing the thickness, resulting in uncontrollable current-carrying bottlenecks. Therefore, in this embodiment of the present application, a large-current path device for a charging pile is proposed.

[0026] As Figure 3 shown, a large-current path device for a charging pile includes: a printed circuit board 1. A relay 2, a first bent thick copper sheet 3, a second bent thick copper sheet 4, a first thick copper wire 5, a second thick copper wire 10, a first rectangular thick copper sheet 6, a second rectangular thick copper sheet 11, a first copper terminal 7, a second copper terminal 12, a plurality of screws 8, a power incoming line 9, and a power outgoing line 13 are arranged on the top layer of the printed circuit board 1;

[0027] The relay 2 is used to control the on-off of the charging current of the charging pile. The relay 2 is connected to the printed circuit board 1 through surface mount technology. A first bent thick copper sheet 3 and a second bent thick copper sheet 4 are arranged above the relay 2, and the first bent thick copper sheet 3 and the second bent thick copper sheet 4 have the same structure;

[0028] One end of the first bent thick copper sheet 3 is electrically connected to one end of the relay 2, and the other end of the first bent thick copper sheet 3 is pressure-welded to one end of the first thick copper wire 5;

[0029] The other end of the first thick copper wire 5 is pressure-welded to one end of the first rectangular thick copper sheet 6. A circular through hole is arranged at the edge of the other end of the first rectangular thick copper sheet 6 for fastening with one end of the first copper terminal 7 provided with the same circular through hole through a screw 8;

[0030] The other end of the first copper terminal 7 is provided with a circular opening, and a cylindrical cavity is arranged inside the first copper terminal 7. Two identical circular through-holes are arranged in parallel above the first copper terminal 7. One end of the power supply incoming line 9 is embedded into the cylindrical cavity of the first copper terminal 7 through the circular opening of the first copper terminal 7, and two screws 8 are respectively used to rotate into the inner cavity of the first copper terminal 7 from above the first copper terminal 7 through the two parallel circular through-holes, so that the first copper terminal 7 and the power supply incoming line 9 are firmly combined;

[0031] Correspondingly, one end of the second bent thick copper sheet 4 is electrically connected to one end of the relay 2, and the other end of the second bent thick copper sheet 4 is pressure-welded to one end of the second thick copper wire 10;

[0032] The other end of the second thick copper wire 10 is pressure-welded to one end of the second rectangular thick copper sheet 11. A circular through-hole is arranged at the edge of the other end of the second rectangular thick copper sheet 11 for fastening with one end of the second copper terminal 12 provided with the same circular through-hole through a screw 8;

[0033] The other end of the second copper terminal 12 is provided with a circular opening, and a cylindrical cavity is arranged inside the second copper terminal 12. Two identical circular through-holes are arranged in parallel above the second copper terminal 12. One end of the power supply outgoing line 13 is embedded into the cylindrical cavity of the second copper terminal 12 through the circular opening of the second copper terminal 12, and two screws 8 are respectively used to rotate into the inner cavity of the second copper terminal 12 from above the second copper terminal 12 through the two parallel circular through-holes, so that the second copper terminal 12 and the power supply outgoing line 13 are firmly combined;

[0034] It should be noted that the first thick copper wire 5 and the second thick copper wire 10 use the same copper wire material, and the inner cores of the first thick copper wire 5 and the second thick copper wire 10 are cylinders after multi-strand stranding, and the cross-sectional area of the inner core is set to be 6-10 square millimeters. Insulators are wrapped outside the inner cores of the first thick copper wire 5 and the second thick copper wire 10 to prevent electric shock or short circuit; among them, the setting of the cross-sectional area of the inner core is obtained based on specific experimental proofs, and the specific experimental data are as follows:

[0035]

[0036] The current and power that can be borne by the inner cores of the thick copper wires with different cross-sectional areas at different temperatures; among them, the cross-sectional area of the inner core that can bear 32A described in the background technology is at least greater than or equal to 4 square millimeters. It can be seen from the above table that when a copper wire inner core with a cross-sectional area of 4 square millimeters is adopted, only 33A can be borne at 40°C. To ensure sufficient current value margin and save costs at the same time, a thick copper wire through-core with a cross-sectional area of 6-10 square millimeters is adopted; among them, the larger the cross-sectional area of the copper core, the higher the cost;

[0037] The structures of the first rectangular thick copper sheet 6 and the second rectangular thick copper sheet 11 are the same. The first rectangular thick copper sheet 6 is used to connect the first thick copper wire 5 and the first copper terminal 7, and the second rectangular thick copper sheet 11 is used to connect the second thick copper wire 10 and the second copper terminal 12. The first rectangular thick copper sheet 6 and the second rectangular thick copper sheet 11 are respectively connected to the first thick copper wire 5 and the second thick copper wire 10 by pressure welding, so as to avoid directly pressure welding the first rectangular thick copper sheet 6 and the second rectangular thick copper sheet 11 to the first copper terminal 7 and the second copper terminal 12 respectively, reduce the scrap rate of the first copper terminal 7 and the second copper terminal 12, and at the same time, the use of screws 8 for fastening makes the process operation more convenient;

[0038] The structures of the first copper terminal 7 and the second copper terminal 12 are the same. By rotating the two screws 8 arranged above the first copper terminal 7 and the second copper terminal 12, the tightness of the power supply incoming line 9 and the first copper terminal 7 and the power supply outgoing line 13 and the second copper terminal 12 can be adjusted.

[0039] In an embodiment of the present invention, the large-current path device of the charging pile replaces the incoming line copper foil 103 and the outgoing line copper foil 104 in the prior art with the first thick copper wire 5 and the second thick copper wire 10. The first thick copper wire 5 and the second thick copper wire 10 provide sufficient current-carrying capacity and safety margin, and can realize long-time operation of large charging current without overheating or burning; now the copper foil circuit used in the prior art is marked as Scheme 1, and the thick copper wire used in the present invention is marked as Scheme 2;

[0040] When Scheme 1 and Scheme 2 are actually put into use in the charging pile, the temperature monitor monitors the temperature of the charging pile at different time periods. The time periods are mainly divided into 0:00 to 8:00 and 11:00 to 15:00. Connecting the charging pile to charge the electric vehicle from 0:00 to 8:00 is called the midnight order, and connecting the charging pile to charge the electric vehicle from 11:00 to 15:00 is called the noon order. By comparing the temperatures at different charging times during 7kw charging, the advantages and disadvantages of Scheme 1 and Scheme 2 can be compared. The experimental comparison data are as follows:

[0041]

[0042] Based on the comparison data between Solution 1 and Solution 2, the following conclusions can be drawn: In the time period from 0:00 to 8:00, the temperature of the charging pile in Solution 1 rises rapidly, with a temperature extreme value of 75°C and a temperature change value of 27°C. In the time period from 11:00 to 15:00, the temperature of the charging pile in Solution 1 also rises rapidly, with a temperature extreme value of 99°C and a temperature change value of 53°C. While in Solution 2, in the time period from 0:00 to 8:00, the temperature of the charging pile rises slowly, with a temperature extreme value of 42.5°C and a temperature change value of 2.5°C. In the time period from 11:00 to 15:00, the temperature of the charging pile in Solution 2 also rises slowly, with a temperature extreme value of 52.4°C and a temperature change value of 12.9°C. That is, Solution 2 can operate with a large current for a long time on the charging pile without overheating. In this embodiment, a preset temperature threshold is set. If the actual temperature exceeds the temperature threshold, it indicates overheating. For example, when the temperature threshold is 90°C, Solution 1 is clearly overheated during the noon order and is prone to the risk of burning out.

[0043] The working principle of the present invention: In the AC charging pile of the present invention, an on-board relay 2 is adopted, that is, the relay 2 is arranged on the printed circuit board 1. When the internal circuit of the relay 2 is controlled to be connected, the charging current enters from the power supply inlet 9, passes through the first copper terminal 7, the first rectangular thick copper sheet 6, and the first thick copper wire 5 in sequence and then enters the relay 2. The charging current then passes through the second bent thick copper sheet 4, the second thick copper wire 10, the second rectangular thick copper sheet 11, and the second copper terminal 12 at the other end of the relay 2 and enters the power supply outlet 13.

[0044] The above content is only an example and explanation of the structure of the present invention. Those skilled in the art of this technology can make various modifications or supplements to the described specific embodiments or use similar methods for substitution. As long as it does not deviate from the structure of the invention or exceed the scope defined by this claim book, it shall fall within the protection scope of the present invention. In addition, the terms "first" and "second" are only used for descriptive purposes and cannot be understood as indicating or implying relative importance or implicitly indicating the quantity of the indicated technical features. Thus, the features defined with "first" and "second" may explicitly or implicitly include at least one of such features. In the description of the present invention, the meaning of "a plurality" is at least two, such as two, three, etc., unless otherwise specifically defined.

[0045] The above embodiments are only used to illustrate the technical method of the present invention and not to limit it. Although the present invention has been described in detail with reference to the preferred embodiments, those of ordinary skill in the art should understand that the technical method of the present invention can be modified or equivalently substituted without departing from the spirit and scope of the technical method of the present invention.

Claims

1. A large current path device for a charging pile, characterized in that, include: A printed circuit board (1), wherein a top layer of the printed circuit board (1) is provided with a relay (2), a first bent thick copper sheet (3), a second bent thick copper sheet (4), a first thick copper wire (5), a second thick copper wire (10), a first rectangular thick copper sheet (6), a second rectangular thick copper sheet (11), a first copper connection terminal (7), a second copper connection terminal (12), a plurality of screws (8), a power supply input line (9), and a power supply output line (13); One end of the first bent thick copper sheet (3) is electrically connected to one end of the relay (2), and the other end of the first bent thick copper sheet (3) is electrically connected to one end of the first thick copper wire (5); The other end of the first thick copper wire (5) is electrically connected to one end of the first rectangular thick copper sheet (6); a circular through hole is provided at the edge of the other end of the first rectangular thick copper sheet (6) for fastening to one end of a first copper terminal (7) provided with the same circular through hole via a screw (8); The other end of the first copper terminal (7) is provided with a circular opening, and a cylindrical cavity is provided inside the first copper terminal (7), and two identical circular through holes are provided above the first copper terminal (7); one end of the power supply line (9) is embedded in the cylindrical cavity of the first copper terminal (7) through the circular opening of the first copper terminal (7), and two screws (8) are used to rotate from the top of the first copper terminal (7) through the two circular through holes in parallel to enter the internal cavity of the first copper terminal (7), so that the first copper terminal (7) and the power supply line (9) are firmly combined; One end of the second bent thick copper sheet (4) is electrically connected to one end of the relay (2), and the other end of the second bent thick copper sheet (4) is pressure-welded to one end of the second thick copper wire (10); The other end of the second thick copper wire (10) is pressure welded to one end of a second rectangular thick copper sheet (11); a circular through hole is provided at the edge of the other end of the second rectangular thick copper sheet (11) for fastening to one end of a second copper terminal (12) provided with the same circular through hole by means of a screw (8); The other end of the second copper connecting terminal (12) is provided with a circular opening, and a cylindrical cavity is provided inside the second copper connecting terminal 12, and two parallel identical circular through holes are provided above the second copper connecting terminal (12); One end of the power outlet wire (13) is inserted into the cylindrical cavity of the second copper terminal (12) through the circular opening of the second copper terminal (12), and two screws (8) are respectively used to rotate from the top of the second copper terminal (12) through two parallel circular through holes into the internal cavity of the second copper terminal (12), so that the second copper terminal (12) and the power outlet wire (13) are firmly combined; The first thick copper wire (5) and the second thick copper wire (10) are made of the same copper wire material, and the inner cores of the first thick copper wire (5) and the second thick copper wire (10) are cylindrical bodies formed by twisting multiple cores, and the cross-sectional area of the inner cores is set at 6-10 square millimeters. The inner cores of the first thick copper wire (5) and the second thick copper wire (10) are both wrapped with an insulator.

2. The large current path device of a charging pile according to claim 1, characterized in that, The relay (2) is used to control the on / off of the charging current of the charging pile, and the relay (2) is connected to the printed circuit board (1) by surface mount technology.

3. The large current path device of a charging pile according to claim 1, wherein The first bent thick copper sheet (3) and the second bent thick copper sheet (4) have the same structure. The first bent thick copper sheet (3) is pressure-welded to the first thick copper wire (5), and the second bent thick copper sheet (4) is pressure-welded to the second thick copper wire (10).

4. A large current path device for a charging pile according to claim 1, characterized in that, The first rectangular thick copper sheet (6) and the second rectangular thick copper sheet (11) have the same structure. The first rectangular thick copper sheet (6) is used to connect the first thick copper wire (5) to the first copper terminal (7), and the second rectangular thick copper sheet (11) is used to connect the second thick copper wire (10) to the second copper terminal (12). The first rectangular thick copper sheet (6) and the second rectangular thick copper sheet (11) are respectively connected to the first thick copper wire (5) and the second thick copper wire (10) by pressure welding.

5. The large current path device of a charging pile according to claim 1, characterized in that, The first copper terminal (7) and the second copper terminal (12) have the same structure. By rotating the two screws (8) provided above the first copper terminal (7) and the second copper terminal (12), the tightness of the power supply incoming line (9) and the first copper terminal (7) and the power supply outgoing line (13) and the second copper terminal (12) is adjusted.

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