Busbar Contactor Matrix Module

Abstract

This invention is entitled "Bus Contactor Matrix Module". Various disclosed embodiments include a switching module for a charger, the switching module comprising: a support member; a first bus connected to the support member, the first bus being configured to conduct current; and a second bus connected to the support member, the second bus being configured to conduct current. The switching module further includes a first switch connected to the first bus and configured to move a first contactor. The switching module further includes a second switch connected to the second bus and configured to move a second contactor. The switching module further includes a third switch connected to the first bus and configured to move a third contactor. Furthermore, the switching module includes a fourth switch connected to the second bus and configured to move a fourth contactor, the third switch and the fourth switch being configured to electrically connect and disconnect the first bus and the second bus with at least a second power divider.

Description

[0001] introduction

[0002] This disclosure relates to charging equipment for electric vehicles. The statements in this section are provided only as background information in connection with this disclosure and do not constitute prior art.

[0003] Electric vehicle charging cabinets include high-voltage conductors, insulators, and switching units. These switching units can be segmented together as individual electrical components fixed to the charging cabinet housing. Because the components of the charging cabinet are arranged somewhat independently and connected together with the conductor segments, they can be difficult to repair and diagnose. Summary of the Invention

[0004] Various publicly available implementations include power electronic modules and exemplary switching modules for battery chargers.

[0005] In an exemplary embodiment, the switching module for the charger includes: a support member; a first bus connected to the support member, the first bus being configured to conduct current; and a second bus connected to the support member, the second bus being configured to conduct current. The switching module also includes a first switch connected to the first bus and configured to move a first contactor. The switching module also includes a second switch connected to the second bus and configured to move a second contactor. The switching module also includes a third switch connected to the first bus and configured to move a third contactor. Furthermore, the switching module includes a fourth switch connected to the second bus and configured to move a fourth contactor, the third switch and the fourth switch being configured to electrically connect and disconnect the first and second buses from at least a second power divider.

[0006] In another exemplary embodiment, the battery charger includes a housing and an electrical power input terminal from a power source, which is supported by the housing. The battery charger also includes a power electronic module (PEM) supported within the housing. Further, the battery charger includes a switching module comprising: a support member; at least two buses coupled to the support member; and at least four switches electrically coupled to the buses. The two buses can be configured to carry current, and the switches can be configured to electrically connect and disconnect from at least one power divider.

[0007] In another exemplary embodiment, the power electronic module includes an AC power input terminal and a rectifier circuit electrically connected to both the AC power input terminal and a DC power output terminal. A switching module may be coupled to the power electronic module, the switching module having a support member, at least two buses connected to the support member, and at least four switches electrically connected to the buses. The two buses are configured to conduct current from the DC power output terminal through the switches, which are configured to connect and disconnect with at least one power divider.

[0008] The above description of the invention is merely illustrative and is not intended to be limiting in any way. In addition to the illustrative aspects, embodiments, and features described above, other aspects, embodiments, and features will become apparent from the accompanying drawings and the following detailed description. Attached Figure Description

[0009] Exemplary embodiments are shown in the accompanying drawings. The embodiments and drawings disclosed herein are intended to be illustrative and not restrictive.

[0010] Figure 1 It is a block diagram in the form of a partial schematic of an illustrative vehicle, including various onboard systems and charging stations.

[0011] Figure 2 This is a block diagram of an exemplary power cabinet.

[0012] Figure 3 This is a side plan view of a partial sectional view of an exemplary bus contactor matrix module.

[0013] Figure 4 This is a side plan view of a partial cross-sectional view of another exemplary bus contactor matrix module.

[0014] The same reference symbols in various diagrams generally indicate the same elements. Detailed Implementation

[0015] In the following detailed description, reference is made to the accompanying drawings, which form part of the detailed description. In the drawings, like reference numerals generally identify like parts unless the context otherwise indicates. The exemplary embodiments described in the detailed description, drawings, and claims are not intended to be limiting. Other embodiments may be utilized and other changes may be made without departing from the spirit or scope of the subject matter presented herein.

[0016] By way of overview, various disclosed embodiments include power electronic modules and exemplary switching modules for battery chargers. As will be described below, in various embodiments, the bus contactor matrix module described herein enables the power cabinet to supply power to any combination of distributors, also known as power sharing.

[0017] While contactors (also known as relays) can be connected by wires or busbars to form a matrix, such relays are typically mounted to a wall or panel, and other components may have to be removed to obtain the contactors. However, in various implementations, the contactors are mounted to a board, and a busbar connects the positive and negative contactors. Isolators can be aligned with the busbars and alignment pins to form a module. The module is then mounted to the back of a power electronic module (PEM). In the following text, the busbar contactor matrix module may generally be referred to as a "switching module".

[0018] Now refer to Figure 1 In various embodiments, system 100 includes an electric vehicle 110 and a charging station 115, the electric vehicle being such as, but not limited to, a truck, SUV, minivan, sedan, or any other electrified vehicle. Electric vehicle 110 may include a vehicle chassis 120 and an electric motor drive system 140. Electric vehicle 110 is not limited to one or more drive systems including electric drive motors, but may use any number and arrangement of electric vehicle motors on electric vehicle 110 without departing from the scope of this disclosure. Wheels 150 and 155 support the vehicle chassis 120, which carries a battery pack 160. In various embodiments, electric vehicle 110 also includes a charging port 170 that accepts at least one of a variety of charging connectors, such as, but not limited to, a J1172 Type 1 connector, a J1772 Type 2 connector, a Tesla connector, a United Charging System (CCS) connector, and a CHAdeMo connector.

[0019] In various embodiments, charging station 115 includes charging cabinet 180 having three distributors 182, 184, and 186 coupled to and configured to receive charging power from it. Although three distributors are shown connected to charging cabinet 180, it should be understood that in various embodiments, any number of distributors can be connected to charging cabinet 180. It should be understood that in various embodiments, the use of bus contactor matrix modules allows switching between various distributors or providing service to any combination of distributors.

[0020] Now refer to Figure 2In various embodiments, a power cabinet 200 is depicted. The power cabinet 200 includes a housing 210 and an electrical power input 220 from a power source such as an AC power supply 225. The electrical power input 220 extends into and is thus supported by the housing 210. In various embodiments, a power electronic module (PEM) 230 is supported within the housing 210. In various embodiments, the power cabinet, such as power cabinet 210, may accommodate more than one PEM. In the example shown, a second PEM 232 is depicted within the housing 210. Each of PEM 230 and PEM 232 has a power inversion function, converting the input AC power into DC power. In various embodiments, a switching module 240 is coupled to PEM 230. Similarly, PEM 232 is coupled to switching module 242. In various embodiments, as shown, each of switching modules 240 and 242 includes three power outputs coupled to a distributor connection in the power cabinet 200. For example, switching module 240 is depicted having power output terminals 243, 244, and 245, and PEM 242 is similarly depicted having power output terminals 246, 247, and 248. In various embodiments, any number of output terminals may be used without departing from the scope of this disclosure.

[0021] In operation, in various implementations, PEM 240 converts AC power input from AC power source 225 into DC power. For example, when a vehicle is connected to a distributor coupled to power output 243 for charging, power output 243 can be activated (i.e., the power output of 243 receives DC power from the PEM via switching module 240) and vehicle charging occurs. For example, if a vehicle is connected to a distributor coupled to power output 243 and another vehicle is connected to a vehicle coupled to power output 245, switching module 240 can activate power outputs 243 and 245 simultaneously or one after another.

[0022] For further reference Figure 3In various embodiments, the exemplary switching module 300 includes a support member 310, which may be formed of an electrically insulating material, such as any one or more of many well-known plastics. A first bus 320 is coupled to the support member 310 via a plate 321. A second bus 330 is also coupled to the support member 310 via the plate 321. The first bus 320 may be electrically connected to a PEM output terminal via a first electrical connection 322. The electrical connection 322 may be a positive (+) input terminal or a negative (-) input terminal. The second bus 330 may be electrically connected to a PEM output terminal via a second electrical connection 332. The electrical connection 332 may be a negative (-) input terminal or a positive (+) input terminal, either of which is of opposite polarity to the electrical connection 322. In some embodiments, the electrical connection from the electrical connection 322 to the bus 330 may be made of a fuse or fused wire.

[0023] In various implementations, three pairs of switches, 324 / 334, 326 / 336, and 328 / 338, can exist. During operation, if one pair of switches is activated, the output (e.g., 243, 244, or 245) is activated. Figure 2 One of the options is sent to the distributor (e.g., 182, 184, or 186 (see also...)). Figure 1 One of the switches is activated. For example, when switch 324 is activated (i.e., in response to a control signal switching to open), contactor 325 extends (as shown in the direction from the paper towards the reader via an electromechanical actuator, etc.). Similarly, when switch 334, which is paired with switch 324, is activated, contactor 335 extends in the same direction as contactor 325. It should be understood that contactors 325 / 335, when extended, can form a shape similar to, for example, Figure 1 and Figure 2 The electrical connection of the distributor output terminals (e.g., one of distributor output terminals 243-248) of the power cabinet 200 shown. For example, contactor 325 can be a positive (+) contactor, and contactor 335 can be a negative (-) contactor. Similarly, switch pairs 326 / 336 extend contactors 327 (+) / 337 (-) and switch pairs 328 / 338 when activated, and extend contactors 329 (+) / 339 (-) when activated. Each contactor pair 325 / 335, 327 / 337, and 329 / 339 is electrically connected to a different distributor in the power cabinet 200 via a corresponding connector. It should be noted that although contactors 325, 327 and 339 have been designated as positive (+) contactors and 335, 337 and 339 have been designated as negative (-) contactors, the arrangement of the (+) and (-) contactors may be reversed without departing from the scope of this disclosure, provided that each pair of contactors is a (+) and (-) pair.

[0024] In various embodiments, wiring harnesses 340 and 342 include control lines coupled to switches 324 / 334, 326 / 336, and 328 / 338. Signals provided through the wires of wiring harnesses 340 and 342 control the activation of switches 324 / 334, 326 / 336, and 328 / 338, and consequently control the selective output of distributors such as 182, 184, or 186. Wiring harnesses 340 and 342 are shown with a specific type of connector; however, it should be understood that any connector from a variety of connectors can be used.

[0025] It should be understood that in various embodiments, the switching module 300 is suitably modular, meaning that the switching units are all packaged as a single module, thus requiring less wiring within the power cabinet. It should also be understood that in various embodiments, the use of a modular bus structure can help reduce wiring because the conductive paths to various distributors use shared buses, wherein the switching unit includes positive (+) and negative (-) buses connected to more than one contactor pair and multiple switches used for switching between contactor pairs are assembled into a replaceable module similar to module 300. The modular nature also allows for easier assembly, maintenance, and repair than non-modular implementations. For example, in repair cases, switches may fail, which can be difficult to diagnose. In various embodiments, instead of a lengthy troubleshooting process, the switching module 300 can be replaced in the field. In such cases, older modules can be diagnosed at a later time and may be refurbished. Module 300 also includes a first positioner feature 360 ​​and a second positioner feature 365. The positioner feature may be, but is not limited to, a protruding tapered post, configured to engage with a female receiver on the power cabinet 200. This allows the contactor to be properly aligned with the contactors on the power cabinet 200.

[0026] For further reference Figure 4In various embodiments, the exemplary switching module 400 is functionally equivalent to the switching module 300 with a slightly different structure. In such embodiments, the switching module 400 includes an electrically insulated support member 410 connected via a backplate 421 to two buses 420 and 430. Input 422 is electrically connected to bus 420 via a fuse 423. Input 432 is electrically connected to bus 430. Pairs of switches 424 / 434, 426 / 436, and 428 / 438 correspond to the activation of contactors 425 / 435, 427 / 437, and 429 / 439. Module 440 includes a female pin connector for receiving harness pin connectors from PEM 230 for carrying switching signals. To facilitate assembly of module 400 onto power cabinet 200, male locator features 460 and 465 engage with female locators in power cabinet 200. This engagement of the positioner features helps to align contactors 425 / 435, 427 / 437 and 429 / 439 with their corresponding contactors in the power cabinet, each contactor corresponding to a corresponding distributor.

[0027] While exemplary switching modules 300 and 400 have been shown and described, it should be understood that other configurations utilizing some of these design features and functions are within the scope of this disclosure. Therefore, it should be understood that exemplary switching modules 300 and 400 are provided as non-limiting examples, given by way of illustration only, and should not be considered restrictive.

[0028] In some cases, one or more components may be referred to herein as “configured to,” “configured by,” “configurable to,” “operable / operating as,” “suitable / adaptable to,” “capable of,” “adaptable to,” etc. Those skilled in the art will recognize that, unless the context otherwise requires, such terms (e.g., “configured to”) generally cover active state components and / or passive state components and / or standby state components.

[0029] While specific aspects of the subject matter described herein have been shown and described, it will be apparent to those skilled in the art that changes and modifications may be made based on the teachings herein without departing from the subject matter and its broader aspects, and therefore the appended claims cover all such changes and modifications within their scope, as is the true spirit and scope of the subject matter described herein. Those skilled in the art will understand that, in general, the terminology used herein, particularly in the appended claims (e.g., the body of the appended claims), is intended to denote “open-ended” terms (e.g., the term “comprising” should be interpreted as “including but not limited to,” the term “having” should be interpreted as “at least having,” the term “including” should be interpreted as “comprising but not limited to,” etc.). Those skilled in the art will further understand that if a class intent is a specific number of introduced claim statements, such intent will be explicitly stated in the claims, and if no such statement is present, such intent does not exist. For example, to aid understanding, the following appended claims may contain the use of the introductory phrases “at least one” and “one or more” to introduce claim statements. However, the use of such phrases should not be construed as implying that introducing a claim statement with the indefinite article "a" or "an" limits any particular claim containing such an introduced claim statement to a claim containing only one such statement, even when the same claim includes the introductory phrase "one or more" or "at least one" and indefinite articles such as "a" or "an" (e.g., "a" and / or "an" should generally be interpreted as meaning "at least one" or "one or more"); the same applies to the use of definite articles used to introduce a claim statement. Furthermore, even when a specific number of introduced claim statements are explicitly stated, those skilled in the art will recognize that such a statement should generally be interpreted as meaning at least the number stated (e.g., simply stating "two statements" without further modification generally means at least two statements, or two or more statements). Furthermore, in cases where a convention similar to "at least one of A, B, and C" is used, such a construction is generally intended to mean that a person skilled in the art will understand the convention (e.g., "a system having at least one of A, B, and C" will include, but is not limited to, systems having A alone, having B alone, having C alone, having A and B together, having A and C together, having B and C together, and / or having A, B, and C together, etc.).

[0030] Those skilled in the art will further understand that, unless the context otherwise requires, extractive terms and / or phrases that typically present two or more alternative terms (whether in the specification, claims, or drawings) should be understood to contemplate the possibility of including one, any, or both of the terms. For example, the phrase “A or B” will generally be understood to include the possibility of including “A” or “B” or “A and B”.

[0031] The above-described specific embodiments have illustrated various implementations of the device and / or process using block diagrams, flowcharts, and / or examples. Where such block diagrams, flowcharts, and / or examples contain one or more functions and / or operations, those skilled in the art will understand that each function and / or operation within such block diagrams, flowcharts, or examples can be implemented individually and / or collectively by a wide range of hardware.

[0032] With respect to the appended claims, those skilled in the art will understand that the operations enumerated herein can generally be performed in any order. Furthermore, although the various operational flows are presented sequentially, it should be understood that the various operations can be performed in any order other than that shown, or can be performed simultaneously. Unless the context otherwise requires, examples of such alternative orderings may include overlapping, interleaving, interruption, reordering, ascending, preparatory, supplementary, simultaneous, reverse, or other variations of ordering. Moreover, unless the context otherwise requires, terms such as “in response to,” “related to,” or other past tense adjectives are generally not intended to exclude such variations.

[0033] Although the subject matter disclosed herein has been described with reference to exemplary embodiments, those skilled in the art will understand that various modifications may be made to the subject matter without departing from the scope of the claimed subject matter set forth in the claims.

Claims

1. A switching module for a charger, the switching module comprising: Supporting components; A first bus, connected to the support member, is configured to conduct current; A second bus, connected to the support member, is configured to conduct current; A first switch, the first switch being connected to the first busbar and configured to move the first contactor; A second switch is coupled to the second busbar and configured to move a second contactor. The first switch and the second switch are configured to electrically connect and disconnect the first busbar and the second busbar from at least a first power divider by moving the first contactor and the second contactor. A third switch, which is connected to the first busbar and configured to move a third contactor; A fourth switch, connected to the second bus and configured to move a fourth contactor, wherein the third and fourth switches are configured to electrically connect and disconnect the first and second bus to at least a second power divider by moving the third and fourth contactors.

2. The switching module according to claim 1 further includes: The first power input terminal is electrically connected to the first busbar; and The second power input terminal is electrically connected to the second busbar.

3. The switching module according to claim 2 further includes: A fuse located between the second power input terminal and the second busbar.

4. The switching module according to claim 2, wherein the first power input terminal is a positive power input terminal and the second power input terminal is a negative power input terminal.

5. The switching module according to claim 1, further comprising: A wiring harness electrically connected at a first end to a connector and at a second end to a first switch, a second switch, a third switch, and a fourth switch, the wiring harness being configured to deliver control signals to the switches.

6. The switching module according to claim 1 further includes at least one locator feature connected to the support member.

7. The switching module according to claim 1, wherein the contactor includes a blade contactor.

8. The switching module according to claim 1, wherein the first bus and the second bus are made of copper.

9. The switching module according to claim 1, wherein the support member is made of an electrically insulating material.

10. A battery charger, comprising: case; An electrical power input terminal from a power source, the electrical power input terminal being supported by the housing; A power electronic module, which is supported within the housing; and a switching module, the switching module comprising: Supporting components; Multiple busbars, the multiple busbars being connected to the support member; and A plurality of switches electrically connected to a plurality of busbars configured to carry current, and the plurality of switches configured to be electrically connected and disconnected from a plurality of power dividers via a plurality of contactors, the plurality of switches comprising: A first switch is connected to a first busbar among the plurality of buses and is configured to move a first contactor among the plurality of contactors; A second switch is connected to a second busbar among the plurality of busbars and is configured to move a second contactor among the plurality of contactors; A third switch, connected to a first busbar among the plurality of buses and configured to move a third contactor among the plurality of contactors; and A fourth switch is connected to a second busbar among the plurality of buses and is configured to move a fourth contactor among the plurality of contactors.

11. The battery charger according to claim 10, further comprising: The first power input terminal is electrically connected to the first busbar; and The second power input terminal is electrically connected to the second busbar, and the first power input terminal and the second power input terminal are from the power electronic module.

12. The battery charger according to claim 11, further comprising: A fuse located between the second power input terminal and the second busbar.

13. The battery charger according to claim 11, wherein: The first power input terminal is a positive power input terminal, and the second power input terminal is a negative power input terminal.

14. The battery charger according to claim 10, further comprising: A wiring harness electrically connected at a first end to a connector and at a second end to the plurality of switches, the wiring harness being configured to deliver control signals from the power electronics module to the plurality of switches.

15. The battery charger according to claim 10, further comprising: At least one locator feature is attached to the support member to facilitate positioning of the switching module relative to the housing in terms of position and orientation.

16. The battery charger of claim 10, wherein the contactor comprises a blade contactor.

17. The battery charger of claim 10, wherein the busbar is made of copper.

18. The battery charger of claim 10, wherein the support member is made of an electrically insulating material.

19. The battery charger of claim 10, wherein the housing supports at least three power dividers.

20. A power electronic module, comprising: AC power input terminal; A rectifier circuit, which is electrically connected to the AC power input terminal and electrically connected to the DC power output terminal; and A switching module, connected to the power electronic module, the switching module having a support member, a first bus and a second bus connected to the support member, and four switches electrically connected to the first bus and the second bus. The first bus and the second bus are configured to conduct current from the DC power output terminal through the four switches, the four switches including: A first switch, the first switch being connected to the first busbar and configured to move the first contactor; A second switch is connected to the second busbar and configured to move a second contactor. The first and second contactors are configured to electrically connect and disconnect the first and second busbars from the first power divider. A third switch, the third switch being connected to the first busbar and configured to move a third contactor; and A fourth switch, connected to the second bus and configured to move a fourth contactor, wherein the third and fourth contactors are configured to electrically connect and disconnect the first and second buses from the second power divider.

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