A power distribution device based on DC contactor

Abstract

A power distribution device based on DC contactors includes a plurality of DC contactors arranged in two rows, each of which is used to connect busbar group 1 and busbar group 2 to the main circuit terminals of the DC contactors. The device is characterized in that busbar group 1 and busbar group 2 form a series ring structure after being connected to the main circuit terminals of the DC contactors, and busbar group 1 and busbar group 2 respectively have input terminals and output terminals extending from either side of a power stack device. The present invention improves the output terminal method of a charging pile power stack, simplifies the output terminal structure of the charging pile power stack, and improves the energy utilization efficiency of the charging pile.

Description

Technical Field

[0001] The present invention belongs to the technical field of electric vehicle charging, and specifically relates to a power distribution device based on a DC contactor, which can connect the output ends of several DC power sources in parallel to achieve collaborative operation of multiple power sources for outputting the required single group power or multiple groups of power, while also isolating the output ends of the power sources from each other. Background Art

[0002] With the rapid development of the new energy vehicle industry, the demand for charging piles is increasing, and the demand for charging speeds is also increasing. Commercially available charging piles all utilize a three-phase AC circuit through a circuit breaker and AC contactor, then converted to DC power (20kW per unit according to State Grid standards) via multiple power modules (rectifiers). This power is then delivered to the vehicle via a control unit, billing unit, human-machine interface unit, and charging interface. Based on the relationship between the charging pile control unit, billing unit, human-machine interface unit, charging interface, and front-end power stack, charging piles can be categorized as either integrated or split-type. Traditionally, integrated charging piles feature dual charging stations, which are further categorized as either wheel charging or balanced charging. When charging only one vehicle and the vehicle's CAN protocol allows, the charging pile consolidates all power onto a single charging station, known as wheel charging. When charging two vehicles simultaneously, each station delivers only half the total charging power of the entire charging station, known as balanced charging. Existing integrated charging piles offer low charging power and slow charging speeds. Traditionally, large-scale split-type charging piles utilize a single large power stack with multiple charging guns, forming multiple charging terminals. These terminals are linearly connected using DC contactors. Dynamic distribution of the power module's output power is achieved by controlling the on and off of the corresponding DC contactors. Split-type charging piles have become a mainstream trend in charging pile development due to their high total power stack output power, fast speed, numerous charging guns, and high efficiency. However, existing split-type charging piles suffer from an overly complex structure due to the linear array structure of their power distribution devices. This leads to excessive copper plate transfer points, chaotic wiring, low space utilization within the total power stack, and an inability to freely integrate power source output. This is particularly true when a non-edge port is occupied, preventing the remaining ports from freely integrating output power. This results in poor overall power distribution flexibility and reduces the energy output efficiency of the charging pile. Summary of the Invention

[0003] The purpose of the present invention is to address the technical defects of the above-mentioned existing split-type charging piles, such as complex structure, low space utilization in the total power stack, and low energy output efficiency, and to provide a power distribution device based on a DC contactor to improve the output end mode of the charging pile power stack, simplify the output end structure of the charging pile power stack, and improve the energy utilization efficiency of the charging pile.

[0004] Technical Solution

[0005] In order to achieve the above technical objectives, the present invention provides a power distribution device based on a DC contactor, including a plurality of DC contactors, wherein the array of the plurality of DC contactors is arranged in two rows, and is used to connect busbar group 1 and busbar group 2 of the main circuit terminals of the plurality of DC contactors. It is characterized in that: the busbar group 1 and busbar group 2 form a series ring structure after being connected to the main circuit terminals of the plurality of DC contactors, and the busbar group 1 and busbar group 2 respectively extend input terminals and output terminals on both sides of the power stack device.

[0006] Furthermore, the busbar group 1 includes two side busbars mirroring the center of the power stack device, and the busbar group 2 includes a number of intermediate busbars corresponding to the number of the DC contactors;

[0007] The connection terminals at the front and rear ends of the DC contactors are connected in series using corresponding side busbars, and the connection terminals at the sides of adjacent DC contactors in the DC contactors are connected in series using two mirror-image middle busbars.

[0008] Furthermore, the side busbar includes a side busbar piece, and side input terminals and side output terminals extend from both side ends of the side busbar piece. Terminal 1 and terminal 2 also extend from the side busbar piece. Terminal 1 and terminal 2 of the two mirrored side busbars are connected to corresponding terminal 1 and terminal 2 on one side of the terminals of the two DC contactors at the front and rear ends of the plurality of DC contactors.

[0009] The intermediate busbar includes an intermediate busbar piece, which is provided with terminal three and terminal four. Terminal three and terminal four on two mirror-image intermediate busbar pieces connect the terminals on the side close to each other of adjacent DC contactors in a plurality of arrays arranged in two columns. The intermediate busbar piece is provided with an intermediate input terminal and an intermediate output terminal at both ends.

[0010] Furthermore, the connection terminals of the plurality of DC contactors are connection posts or connection holes.

[0011] Furthermore, the terminal 1 and the terminal 2 are flange 1 and flange 2 with mounting holes, and the flange 1 and flange 2 are located in the middle part of the side end busbar.

[0012] Furthermore, the intermediate busbar is in the shape of a "J", with a straight section at one end, an intermediate input terminal at the end of the straight section, and a "7" shape between the intermediate raised section and the other end, and the "7"-shaped end is provided with terminal three, terminal four and the intermediate output terminal in sequence.

[0013] Beneficial effects

[0014] The present invention provides a power distribution device based on a DC contactor, which adopts a ring array method to connect the output ends of the power stack in parallel, thereby improving the flexibility of the output end power distribution. When a charging gun is occupied, the required output power can still be integrated through the remaining ring parts. Due to the unique modular design, the shell and the DC contactor module can be expanded along with the power stack, which not only reduces the cost of parts and molds of the charging pile, but also reduces the difficulty of subsequent charging pile upgrades. At the same time, the modular array structure has high integration, short copper plates, and compact layout, which greatly reduces the volume of the charging pile power stack distribution device and improves the economy and practicality of the charging pile. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Attachment Figure 1 It is a product diagram of a power distribution device in an embodiment of the present invention.

[0016] Attachment Figure 2 It is a schematic diagram of the modular assembly of the power distribution device in an embodiment of the present invention.

[0017] Attachment Figure 3 Schematic diagram of the ring structure in an embodiment of the present invention.

[0018] Attachment Figure 4 Schematic diagram of the ring structure connection in an embodiment of the present invention.

[0019] Attachment Figure 5 2 is a product diagram of a DC contactor according to an embodiment of the present invention.

[0020] Attachment Figure 6 This is a product picture of the side busbar in an embodiment of the present invention.

[0021] Attachment Figure 7 This is a product diagram of the intermediate busbar in an embodiment of the present invention.

[0022] Attachment Figure 8 This is a diagram showing the working principles of all charging guns in the embodiments of the present invention.

[0023] Attachment Figure 9a The working principle of the embodiment of the present invention is to integrate the output power of two power sources into one muzzle. Figure 1 .

[0024] Attachment Figure 9b The working principle of the embodiment of the present invention is to integrate the output power of two power sources into one muzzle. Figure 1 .

[0025] Attachment Figure 10a The working principle of the present invention is to integrate the output power of three power sources into one muzzle. Figure 1 .

[0026] Attachment Figure 10bThe working principle of the present invention is to integrate the output power of three power sources into one muzzle. Figure 2 .

[0027] Attachment Figure 10c The working principle of the present invention is to integrate the output power of three power sources into one muzzle. Figure 3 . DETAILED DESCRIPTION

[0028] The technical solution of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the embodiments described are only some embodiments of the present invention, not all embodiments. All other embodiments obtained by ordinary technicians in this field based on the embodiments of the present invention without making any creative efforts shall fall within the scope of protection of the present invention.

[0029] In the description of the present invention, it should be noted that the terms "inner" and "outer," etc., indicating orientations or positional relationships, are based on the orientations or positional relationships shown in the accompanying drawings and are intended solely to facilitate and simplify the description of the present invention. They are not intended to indicate or imply that the devices or components referred to must have, be constructed, or operate in a specific orientation, and therefore should not be construed as limitations on the present invention. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0030] In the description of the present invention, it should be noted that, unless otherwise expressly specified or limited, the terms "mounted" and "connected" should be understood in a broad sense. For example, they can refer to fixed connections, detachable connections, or integral connections; mechanical connections, electrical connections; direct connections, indirect connections through an intermediate medium, and internal connections 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.

[0031] The present invention will be further described in detail below through specific embodiments in conjunction with the accompanying drawings.

[0032] Example

[0033] As attached Figure 1 , 2, 3 and 4, a power distribution device based on DC contactor, which includes a plurality of arrays arranged in two columns as shown in the attached Figure 5The DC contactors K1, K2, K3, K4, K5, K6, K7, K8, K9, and K10 shown are used to connect busbar group A and busbar group B of the main circuit terminals of the DC contactors K1, K2, K3, K4, K5, K6, K7, K8, K9, and K10. The busbar group A and busbar group B are connected to the main circuit terminals of the DC contactors K1, K2, K3, K4, K5, K6, K7, K8, K9, and K10 to form a series ring structure O. The busbar group A and busbar group B respectively extend with input terminals M and output terminals N on both sides of the power stack device. The busbar group A includes two side busbars A1 and A2 that are mirror images of the center of the power stack device, and the busbar group B includes a number of intermediate busbars B1, B2, B3, B4, B5, B6, B7, and B8 corresponding to the number of DC contactors K1, K2, K3, K4, K5, K6, K7, K8, K9, and K10;

[0034] The connection terminals of the front and rear ends of the DC contactors K1, K2, K3, K4, K5, K6, K7, K8, K9, and K10 are connected in series using corresponding side busbars A1 and A2. The connection terminals of adjacent DC contactors in the DC contactors K1, K2, K3, K4, K5, K6, K7, K8, K9, and K10 on the sides close to each other are connected in series using corresponding mirrored intermediate busbars B1, B2, B3, B4, B5, B6, B7, and B8. The relationship between two adjacent intermediate busbars of the intermediate busbars B1, B2, B3, B4, B5, B6, B7, and B8 is that they are mirrored with each other along the horizontal center line of the corresponding two adjacent groups of DC contactors, and then mirrored again along the vertical center line of the ring structure. Specifically, for example, as shown in the attached figure, Figure 3 and 4 As shown, the intermediate busbar B2 is an image of the intermediate busbar B1 mirrored along the center line L between the two adjacent groups of DC contactors K1, K2, K3, and K4, and then mirrored along the center line in the vertical direction of the annular structure.

[0035] The side busbars A1 and A2 include side busbar pieces, as shown in the attached Figure 6As shown, the side end busbar has side end input terminals 201 and side end output terminals 202 extending from both side ends, and the side end busbar also has terminal one 203 and terminal two 204 extending therefrom. In this embodiment, the terminal one 203 and terminal two 204 are flange one and flange two with mounting holes, and the flange one and flange two are located in the middle part of the side end busbar. The flange one and flange two with mounting holes of the two mirrored side end busbars are connected to the corresponding terminal one K1-101 and terminal two K2-102 on one side of the terminal of the two DC contactors K1 and K2 at the front and rear ends of the multiple DC contactors. In this embodiment, the terminal of the multiple DC contactors is a terminal post or a terminal hole.

[0036] The intermediate busbars B1, B2, B3, B4, B5, B6, B7, and B8 include intermediate busbar pieces, as shown in the attached Figure 7 As shown, the intermediate busbar is provided with an intermediate input terminal 301 and an intermediate output terminal 302 at both ends. The intermediate busbar is in the shape of a "F", with a straight section at one end, the end of the straight section being provided with an intermediate input terminal 301, the intermediate raised section and the other end forming a "7" shape, and the "7" shaped end being provided with terminal three 303, terminal four 304 and intermediate output terminal 302 in sequence. Terminal three 303 and terminal four 304 on the two mirror-image intermediate busbars connect the terminals on the side close to each other of the adjacent DC contactors in a plurality of arrays arranged in two columns. Specifically, as shown in the attached figure, Figure 4 As shown, terminal 3 303 and terminal 4 304 on intermediate busbar B1 are connected to corresponding terminal 1 K4-102 and terminal 2 K2-101 on adjacent sides of adjacent DC contactors K4 and K2, respectively. Terminal 3 303 and terminal 4 304 on intermediate busbar B2 are connected to corresponding terminal 1 K1-102 and terminal 2 K3-101 on adjacent sides of adjacent DC contactors K1 and K3, respectively. Multiple arrays are formed sequentially, with one side terminal on the last DC contactor connected to the terminal on the side busbar. The entire mechanism is modular in design. The number of DC contactors and busbars in this embodiment is merely illustrative of the structure of this embodiment and does not limit the number of DC contactors and busbars that can be supported by the power distribution device of this embodiment. If capacity expansion is required, simply add the corresponding modular components (i.e., additional intermediate busbars, corresponding DC contactors, and corresponding bases).

[0037] In this embodiment, the positive and negative input terminals of all charging guns are connected in parallel with the positive and negative terminals of two adjacent charging guns through DC contactors, thus forming a unique ring array structure. By controlling the conduction and disconnection of the corresponding DC contactors, the output power of the power modules can be freely distributed. When all charging guns need to work independently, all DC contactors can be disconnected to make all power sources work independently, as shown in the attached figure. Figure 8 As shown in the figure, when the output power of a gun needs to be doubled, a DC contactor connected to it can be put into the energized state, and the other DC contactor can be put into the disconnected state, and the output end of the corresponding charging gun can be cut off at the same time; as shown in the figure Figure 9a and 9b As shown in the figure, when charging gun 1 needs to output twice the power, a DC contactor k1 on the connection row of charging gun 1 can be closed and the output end of charging gun 2 can be cut off, or DC contactor k2 can be closed and the output end of charging gun 3 can be disconnected. All other gun ports can still freely distribute power by closing the corresponding DC contactors when needed, without being restricted by charging gun 1. When a gun port needs to output three times the power, it is only necessary to pull in the two DC contactors connected to the gun port, or pull in the two DC contactors on the gun head connected on one side, and keep the DC contactors of the other gun heads connected to the corresponding gun head in the disconnected state, and disconnect the output end of the corresponding gun head. Specifically, as shown in the figure, Figure 10a As shown in Figures 10b and 10c, when charging gun 1 needs to output triple the power, the two DC contactors k1 and k2 on the connection row of charging gun 1 can be closed to disconnect the output terminals of charging guns 2 and 3, or the DC contactors k1 and k3 can be closed to disconnect the output terminals of charging guns 3 and 5, or the DC contactors k2 and k4 can be closed to disconnect the output terminals of charging guns 2 and 4. All other gun ports can still freely distribute power when needed by closing the corresponding DC contactors, without being restricted by charging gun 1. By analogy, this solution allows each charging gun head to output any power below the total power, and can also freely distribute the power of the total power stack to allow multiple gun heads to output simultaneously. Compared to charging guns that need to output double the power, this solution connects the positive and negative poles of the power module output terminals of adjacent charging guns in series by closing the DC contactors connected to them, and finally integrates them into the required gun head, thereby achieving parallel integration of the power stack.

[0038] The present invention provides a power distribution device based on a DC contactor, which adopts a ring array method to connect the output ends of the power stack in parallel, thereby improving the flexibility of the output end power distribution. When a charging gun is occupied, the required output power can still be integrated through the remaining ring parts. Due to the unique modular design, the shell and the DC contactor module can be expanded along with the power stack, which not only reduces the cost of parts and molds of the charging pile, but also reduces the difficulty of subsequent charging pile upgrades. At the same time, the modular array structure has high integration, short copper plates, and compact layout, which greatly reduces the volume of the charging pile power stack distribution device and improves the economy and practicality of the charging pile.

[0039] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the above embodiments, those skilled in the art should understand that the technical solutions described in the above embodiments can still be modified, or some or all of the technical features therein can be replaced by equivalents. However, these modifications or replacements do not deviate the essence of the corresponding technical solutions from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A power distribution device based on a DC contactor, comprising a plurality of DC contactors, wherein the plurality of DC contactors are arranged in an array of two columns, and are used to connect a busbar group 1 and a busbar group 2 of main circuit terminals of the plurality of DC contactors, characterized in that: The busbar group one and the busbar group two are connected to the main circuit terminals of the several DC contactors to form a series ring structure. The busbar group one and the busbar group two respectively extend input terminals and output terminals on both sides of the power stack device; wherein, the busbar group two includes a number of intermediate busbars corresponding to the number of the several DC contactors, and the intermediate busbar includes an intermediate busbar piece, and the intermediate busbar piece is in the shape of a "J", with a straight section at one end, and an intermediate input terminal at the end of the straight section, and the intermediate raised section and the other side end are in the shape of a "7", and the "7"-shaped end is sequentially provided with terminal three, terminal four and intermediate output terminal.

2. A power distribution device based on a DC contactor according to claim 1, characterized in that: The busbar group 1 includes two side busbars that are mirror images of the center of the power stack device, and the busbar group 2 includes a number of intermediate busbars corresponding to the number of the DC contactors; The connection terminals at the front and rear ends of the DC contactors are connected in series using corresponding side busbars, and the connection terminals at the sides of adjacent DC contactors in the DC contactors are connected in series using two mirror-image middle busbars.

3. A power distribution device based on a DC contactor according to claim 2, characterized in that: The side busbar includes a side busbar piece, and the side input terminal and the side output terminal extend from both side ends of the side busbar piece. The side busbar piece also extends a terminal 1 and a terminal 2. The terminal 1 and the terminal 2 of the two mirrored side busbars are connected to the corresponding terminal 1 and terminal 2 on one side of the terminal of the two DC contactors at the front and rear ends of the plurality of DC contactors; The intermediate busbar includes an intermediate busbar piece, which is provided with terminal three and terminal four. Terminal three and terminal four on two mirror-image intermediate busbar pieces connect the terminals on the side close to each other of adjacent DC contactors in a plurality of arrays arranged in two columns. The intermediate busbar piece is provided with an intermediate input terminal and an intermediate output terminal at both ends.

4. A power distribution device based on a DC contactor according to claim 1, characterized in that: The connection terminals of the plurality of DC contactors are connection posts or connection holes.

5. A power distribution device based on a DC contactor according to claim 3, characterized in that: The first terminal and the second terminal are flanges 1 and 2 with mounting holes, and the first flange and the second flange are located in the middle of the side end busbar.

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