Direct current charging pile

Abstract

This application provides a DC charging pile, which includes an expansion dock, a power conversion module, and a charging gun. The power conversion module is detachably connected to the expansion dock. The expansion dock includes a heat dissipation device. The power conversion module can be installed and operated within the expansion dock. The expansion dock is connected to the AC power grid, and the power conversion module is connected to the expansion dock. The power conversion module converts the AC power output from the AC power grid into the DC power required by the electric vehicle. The heat dissipation device in the expansion dock dissipates the heat generated by the power conversion module. The power conversion module can also be detached from the expansion dock and connected to the AC power grid in the absence of an expansion dock. The power conversion module converts the AC power output from the AC power grid into the DC power required by the electric vehicle, making it suitable for electric vehicle charging scenarios without charging piles or onboard computer (OBC).

Description

Technical Field

[0001] This application relates to the field of charging technology, and in particular to a DC charging pile. Background Technology

[0002] Against the backdrop of dual-carbon goals, the electric vehicle industry has achieved rapid development, and charging equipment is a crucial guarantee for the electric vehicle industry chain. Charging piles can be fixed to the ground or walls and installed in public places (commercial buildings, parking lots, charging stations, etc.), ensuring the widespread adoption of electric vehicles. With the rapid development and widespread application of electric vehicles, the requirements for the usage scenarios and charging power of charging piles have also increased. However, the insufficient construction of charging piles, mainly concentrated in large cities, has become the primary factor restricting the development of the electric vehicle industry. Users face difficulties in charging and low charging power in scenarios without charging piles or on-board computers (OBCs).

[0003] Furthermore, due to the heat dissipation and waterproofing requirements of existing charging piles for outdoor applications, the cabinets must be at least IP54 rated. However, charging piles generate significant heat, and current cooling methods mostly rely on direct ventilation, including dust filters. Direct ventilation allows dust and oil to easily enter the cabinet, leading to high charging pile failure rates and poor reliability. The dust filters also require regular replacement, resulting in high maintenance costs. Summary of the Invention

[0004] This application provides a DC charging pile to meet the charging needs of electric vehicles in various scenarios. The DC charging pile provided by this application can be fixed on a building or on the ground, and the power conversion module can be removed and carried with the vehicle, facilitating electric vehicle charging when charging piles are insufficient.

[0005] In one aspect, this application provides a DC charging pile, which includes: an expansion dock, a power conversion module, and a charging gun.

[0006] The power conversion module and the expansion dock are detachably connected. Detachable means the power conversion module can be installed in the expansion dock and operate after connection. Alternatively, the power conversion module can be removed from the expansion dock. In scenarios without an expansion dock, the input interface of the power conversion module connects to the AC power grid, and the output interface connects to the charging gun. The charging gun then connects to the electric vehicle, transmitting current to the vehicle and meeting the user's needs in out-of-home scenarios.

[0007] This application does not specify the detachable method of the expansion dock and the power conversion module. For example, a latch or mounting slot can be provided inside the expansion dock for installing the power conversion module.

[0008] The expansion dock includes a heat dissipation device, an AC input interface, and an AC output interface. The power conversion module includes at least one input interface, an AC / DC conversion module, and at least one output interface. The expansion dock's AC input interface connects to the AC power grid, and its AC output interface connects to the power conversion module's input interface, transmitting AC power from the power grid to the power conversion module. The AC / DC conversion module converts the AC power received from the input interface into DC power required by the electric vehicle. One end of the charging gun connects to the power conversion module's output interface, and the other end connects to the electric vehicle, transmitting DC power to the electric vehicle. The heat dissipation device is located around the power conversion module. When the power conversion module is operating, the heat dissipation device activates, promptly removing the heat generated during operation and improving heat dissipation efficiency.

[0009] This application does not specify the fixed location of the expansion dock. For example, the expansion dock can be fixed to a building or to the ground.

[0010] After the power conversion module is removed from the expansion dock, its input interface can be connected to the AC power grid. The AC / DC conversion module converts the AC power received by the input interface into the DC power required by the electric vehicle. One end of the charging gun is connected to the output interface of the power conversion module, and the other end is connected to the electric vehicle to transmit DC power to the electric vehicle.

[0011] This application does not specifically limit the type of AC power grid. For example, a docking station can be used to connect to mains power or industrial power.

[0012] In one possible implementation, when the input interface of the power conversion module is connected to the interface of the expansion dock, the expansion dock is connected to the power conversion module, and the rated power of the power conversion module is a first power. When the input interface of the power conversion module is connected to the AC power grid, the rated power of the power conversion module is a second power. When the power conversion module is installed inside the expansion dock, the heat dissipation device located inside the expansion dock carries away the heat generated by the power conversion module, improving the heat dissipation effect. Therefore, the first power can be greater than the second power.

[0013] In one possible implementation, the DC charging pile includes an identification module, which comprises an identification circuit or a capacitive sensor, used to identify whether the power conversion module is connected to the expansion dock, or to identify whether the power conversion module has started operating. When the power conversion module is installed in the corresponding position within the expansion dock, connected to the expansion dock, and outputting power, the heat dissipation device starts working to remove the heat generated by the power conversion module, enhancing heat dissipation and thus increasing the output power of the power conversion module.

[0014] In one possible implementation, the power conversion module includes a first control module. When the identification module detects that the power conversion module is connected to the expansion dock, the first control module controls the rated power of the power conversion module to a first power. When the identification module detects that the power conversion module is connected to the AC power grid, the first control module controls the rated power of the power conversion module to a second power.

[0015] In one possible implementation, the docking station includes a first housing that meets at least an IP55 protection rating, completely preventing the intrusion of foreign objects and water spray into the docking station, achieving good waterproof and dustproof performance. The power conversion module includes a second housing that meets at least an IP67 protection rating, completely preventing foreign objects and dust from entering the power conversion module, and preventing water from entering the power conversion module in the event of immersion. This avoids the bottom surface of the power conversion module being contaminated by rainwater or accumulated water when using the power conversion module in scenarios without a docking station, improving the reliability and safety of charging. Therefore, the charging pile provided in this application can be designed without a dustproof screen, eliminating the need for regular replacement of the dustproof screen, and significantly reducing the failure rate of the power conversion module, thereby greatly reducing the maintenance cost of the charging pile.

[0016] In one possible implementation, the second housing of the power conversion module is made of a thermally conductive material. When the power conversion module is working, the heat generated by the main heat-generating components inside the power conversion module is dissipated through the second housing, achieving natural cooling. This application does not specifically limit the thermally conductive material; for example, the thermally conductive material can be metals such as iron and aluminum, or other thermally conductive materials such as thermally conductive ceramics.

[0017] In one possible implementation, the second housing of the power conversion module is provided with heat dissipation fins. When the power conversion module is working, the heat generated by the main heat-generating components inside the power conversion module is discharged through the second housing, achieving natural cooling. This application does not specifically limit the structure of the heat dissipation fins, such as sheet-like heat dissipation fins, mesh heat dissipation fins, or columnar heat dissipation fins.

[0018] In one possible implementation, the heat dissipation device includes at least one fan. When the power conversion module is operating, the heat generated by the main heat-generating components inside the power conversion module is exhausted through the second housing. The fan carries the heat away, achieving air cooling for the power conversion module. This application does not specifically limit the position of the fan. For example, when the heat dissipation fins are plate-shaped, the fan blades can be perpendicular to the direction of the heat dissipation fins. When the heat dissipation fins are mesh-shaped, the fan blades can be parallel to the heat dissipation fins. When the heat dissipation fins are columnar, the fan blades can be perpendicular or parallel to the heat dissipation fins.

[0019] In one possible implementation, the power conversion module includes at least one temperature sensor for measuring the temperature of the power conversion module. This application does not specifically limit the number or location of the temperature sensors; for example, the temperature sensors can be placed around heat-generating components inside the power conversion module. In this way, the temperature sensors can accurately measure the temperature of the power conversion module, and the DC charging pile can accurately control the operation of the heat dissipation device based on the temperature.

[0020] In one possible implementation, the power conversion module controls the fan's on / off state. The power conversion module includes a first control module. When the identification module detects that the power conversion module is connected to the docking station, or when the identification module detects that the power conversion module has started operating, or when a first preset temperature threshold is less than or equal to the temperature measured by the temperature sensor, the first control module controls the fan to start, carrying away the heat generated by the power conversion module during operation. When the power conversion module is removed from the docking station, the first control module controls the fan to turn off.

[0021] In one possible implementation, the first control module acquires the temperature measured by a temperature sensor and adjusts the fan speed accordingly. When the temperature measured by the temperature sensor is less than or equal to a second preset temperature threshold, the first control module controls the fan to operate at a first speed. When the second preset temperature threshold is less than or equal to a third preset temperature threshold, the first control module controls the fan to operate at a second speed to accelerate heat dissipation and rapidly reduce the temperature of the power conversion module. When the temperature measured by the temperature sensor is greater than the third preset temperature threshold, the first control module controls the fan to operate at a third speed to meet heat dissipation requirements and accelerate charging. By controlling the fan to operate at different speeds at different temperatures, energy is saved, rather than having the fan run at a fixed speed continuously.

[0022] In one possible implementation, a docking station controls the fan's on / off state and / or speed. The docking station includes a second control module. When the identification module detects that the power conversion module is connected to the docking station, or when the identification module detects that the power conversion module has started operating, or when a first preset temperature threshold is less than or equal to the temperature measured by a temperature sensor, the second control module controls the fan to start, carrying away the heat generated by the power conversion module during operation and improving heat dissipation. The second control module can also acquire the temperature measured by the temperature sensor and adjust the fan speed accordingly. When the temperature measured by the temperature sensor is less than or equal to the second preset temperature threshold, the second control module controls the fan at a first speed. When the second preset temperature threshold is less than or equal to a third preset temperature threshold, the second control module controls the fan at a second speed to accelerate heat dissipation and rapidly reduce the temperature of the power conversion module. When the temperature measured by the temperature sensor is greater than the third preset temperature threshold, the second control module controls the fan at a third speed to meet heat dissipation requirements and accelerate charging. By controlling the fan at different speeds at different temperatures, energy is saved, rather than having the fan run at a fixed speed continuously. When the power conversion module is removed from the docking station, the second control module controls the fan to shut down.

[0023] In one possible implementation, the fan's on / off state and / or speed are controlled jointly by the expansion dock and the power conversion module. The power conversion module includes a first control module, and the expansion dock includes a second control module. When the identification module detects that the power conversion module is connected to the expansion dock, or when the identification module detects that the power conversion module has started working, or when a first preset temperature threshold is less than or equal to the temperature measured by a temperature sensor, the first control module sends a control command to the second control module. This control command instructs the second control module to start the fan, which then operates to dissipate the heat generated by the power conversion module. The first control module can also acquire the temperature measured by the temperature sensor and send a control command to the second control module based on the temperature. This control command instructs the second control module to adjust the fan speed. When the temperature measured by the temperature sensor is less than or equal to a second preset temperature threshold, the first control module sends a control command to the second control module, instructing the second control module to control the fan at a first speed. When the second preset temperature threshold is less than or equal to a third preset temperature threshold, the first control module sends a control command to the second control module, instructing the second control module to control the fan at a second speed to accelerate heat dissipation and rapidly reduce the temperature of the power conversion module. When the temperature measured by the temperature sensor exceeds a third preset temperature threshold, the first control module sends a control command to the second control module. This command instructs the second control module to control the fan at a third speed to meet heat dissipation requirements and accelerate charging. By controlling the fan at different speeds at different temperatures, energy is saved, rather than having the fan run at a fixed speed continuously. When the power conversion module is removed from the docking station, the second control module shuts off the fan.

[0024] In one possible implementation, the heat dissipation device further includes at least one cooling channel that contacts the second housing of the power conversion module, and coolant flows through the cooling channel. In this way, the heat generated by the power conversion module can be transferred to the coolant in the cooling channel through the sidewall, and then discharged with the coolant, thereby cooling the power conversion module and ensuring its normal operation.

[0025] In one possible implementation, the output interface of the power conversion module is connected to a charging gun, which in turn is connected to an electric vehicle. The charging gun transmits DC power from the electric vehicle's battery to the power conversion module. The AC / DC conversion module within the power conversion module converts the DC power received at the output interface into AC power. The input interface of the power conversion module is connected to an external load, transmitting the AC power to the external load to supply power. The external load can be, but is not limited to, an induction cooker, rice cooker, mobile phone, refrigerator, etc., thereby meeting the power needs of the user's devices. Attached Figure Description

[0026] Figure 1This is a usage scenario diagram of a DC charging pile provided in an embodiment of this application;

[0027] Figure 2 This is another usage scenario diagram of the DC charging pile provided in the embodiments of this application;

[0028] Figure 3 This is a schematic diagram of a DC charging pile provided in an embodiment of this application;

[0029] Figure 4 This is another structural schematic diagram of the DC charging pile provided in the embodiments of this application;

[0030] Figure 5 This is a schematic diagram of the identification module provided in an embodiment of this application;

[0031] Figure 6 This is another structural schematic diagram of the DC charging pile provided in the embodiments of this application;

[0032] Figure labeling: 100 - Dock; 200 - Power conversion module; 300 - Charging gun; 400 - AC mains; 500 - Electric vehicle;

[0033] 101-First housing; 102-Heat dissipation device; 103-AC output interface; 104-Fan; 106-Second control module; 107-Cooling channel;

[0034] 201-Input interface; 202-Second housing; 203-Output interface; 204-Heat dissipation fins; 205-Identification module; 206-Temperature sensor; 208-AC / DC conversion module; 209-First control module. Detailed Implementation

[0035] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the embodiments of this application will be described in detail below with reference to the accompanying drawings. The terminology used in the implementation section of this application is only used to explain specific embodiments of this application and is not intended to limit this application. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of the embodiments. Based on the embodiments in this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0036] The following explanations of some terms used in the embodiments of this application are provided to facilitate understanding by those skilled in the art.

[0037] (1) In the embodiments of this application, the term "multiple" refers to two or more, and other quantifiers are similar.

[0038] (2) The term "connection" in the embodiments of this application should be interpreted broadly. "Connection" in the embodiments of this application can be understood as an electrical connection, where the connection between two electrical components can be a direct or indirect connection between the two components. For example, the connection between A and B can be a direct connection between A and B, or an indirect connection between A and B through one or more other electrical components, such as A and B being connected. Alternatively, it can be a direct connection between A and C, with C directly connected to B, and A and B connected through C. "Connection" in the embodiments of this application can also be understood as a wireless connection, meaning that the connection between two electrical components can be an electromagnetic connection between the two components. "Connection" in the embodiments of this application can also be understood as a detachable connection. For those skilled in the art, the specific meaning of the above terms in this invention can be understood according to the specific circumstances.

[0039] (3) In the embodiments of this application, terms such as "first" and "second" are used to distinguish similar objects and are for descriptive purposes only. They are not necessarily used to describe a specific order or sequence, nor should they be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. It should be understood that such data can be interchanged where appropriate so that the embodiments of this application described herein can be implemented in orders other than those illustrated or described herein. The implementation methods described in the following exemplary embodiments do not represent all implementation methods consistent with this application. Rather, they are merely examples of apparatuses and methods consistent with some aspects of this application as detailed in the appended claims.

[0040] (4) Direct Current (DC) and Alternating Current (AC). In this embodiment, DC refers to an electrical form in which electrical energy is conducted in a circuit along a constant direction. The direction of energy conduction is also called phase, and the phase of DC can be either positive or negative. The energy intensity of most DC is fixed, but in some special DC types (such as pulsed DC), the energy intensity changes over time. Energy intensity is also called current amplitude. Common DC power sources include dry cell batteries, storage batteries, or DC generators. In this embodiment, AC refers to an electrical form in which electrical energy is conducted in a circuit along a periodically changing direction. The energy intensity of most AC also changes periodically over time. The periodic change in the conduction direction of AC is defined by its frequency. The higher the frequency of AC, the faster the AC can change its conduction direction; the lower the frequency, the slower the AC can change its conduction direction. Common AC power sources include mains power, industrial and agricultural power, and residential power.

[0041] (5) DC charging pile. The DC charging pile in this embodiment is connected to the AC power grid and converts the AC power output from the AC power grid into the DC power required by the electric vehicle, providing a DC charging solution for the electric vehicle.

[0042] See Figure 1 , Figure 1 This is a usage scenario diagram of a DC charging pile provided in an embodiment of this application.

[0043] Specifically, the DC charging station includes a docking station 100, a power conversion module 200, and a charging gun 300. The power conversion module 200 is detachably connected to the docking station 100. Detachable means that the power conversion module 200 can be installed inside the docking station 100 and operate after connection; it can also be removed from the docking station 100. In scenarios without the docking station 100, the power conversion module 200's input interface 201 connects to the AC power grid 400, and its output interface 203 connects to the charging gun 300. The charging gun 300 connects to an electric vehicle 500, transmitting current to the electric vehicle 500 to meet the user's needs when on the go.

[0044] This application embodiment does not specifically limit the detachable connection method of the power conversion module 200 installed inside the expansion dock 100. For example, a latch or mounting slot can be provided inside the expansion dock 100 to fix the power conversion module 200. The expansion dock 100 includes a heat dissipation device 102, an AC input interface (not shown in the figure), and an AC output interface 103. The power conversion module 200 includes at least one input interface 201, an AC / DC conversion module 208, and at least one output interface 203.

[0045] The input interface 201 of the power conversion module 200 is connected to the AC output interface 103 of the docking station 100, and the output interface 203 of the power conversion module 200 is connected to the charging gun 300, which is connected to the electric vehicle 500. The AC / DC conversion module 208 converts the AC power received from the docking station 100 into the DC power required by the electric vehicle 500, and then transmits it to the electric vehicle 500 through the charging gun 300. See also... Figure 2 , Figure 2 This is another usage scenario diagram of the DC charging pile provided in this application embodiment. When the power conversion module 200 is detached from the expansion dock 100, the input interface 201 of the power conversion module 200 can be connected to the AC power grid 400, and the output interface 203 of the power conversion module 200 is connected to the charging gun 300, which is connected to the electric vehicle 500. The AC / DC conversion module 208 converts the AC power received from the expansion dock 100 into the DC power required by the electric vehicle 500, and transmits it to the electric vehicle 500 through the charging gun 300.

[0046] The DC charging pile provided in this application embodiment includes an expansion dock 100 and a power conversion module 200. The power conversion module 200 is detachably connected to the expansion dock 100. The power conversion module 200 can be installed inside the expansion dock 100, which is connected to an AC power grid 400, and the power conversion module 200 receives AC power output from the expansion dock 100. Alternatively, the power conversion module 200 can be removed from the expansion dock 100 and carried with the electric vehicle. In scenarios where there is no expansion dock 100 or charging pile, it can be directly connected to the AC power grid 400 to convert the AC power output from the AC power grid 400 into DC power, providing a DC charging solution for the electric vehicle 500, supporting charging scenarios without a charging pile or onboard OBC.

[0047] This application embodiment does not specifically limit the input interface 201 of the power conversion module 200. For example, the input interface 201 can be a plug that can be directly connected to the expansion dock 100 or the AC power grid 400. The input interface 201 can also be a connector, with one end connected to the expansion dock 100 or the AC power grid 400, and the other end connected to the AC / DC conversion module 208. The AC / DC conversion module 208 converts the AC power input from the AC power grid 400 into DC power required by the electric vehicle 500, and transmits it to the electric vehicle 500 through the charging gun 300.

[0048] The heat dissipation device 102 of the expansion dock 100 is located around the power conversion module 200. When the power conversion module 200 starts working, it promptly dissipates the heat generated by the power conversion module 200, thereby improving the heat dissipation effect.

[0049] The embodiments of this application do not limit the installation location of the docking station 100. For example, the docking station 100 can be fixed to the wall of a building or placed on the ground.

[0050] This application embodiment does not specifically limit the type of AC power grid 400. For example, the expansion dock 100 can be connected to mains power or industrial power, receiving 220V AC mains power or 380V AC industrial power.

[0051] In some examples, when the input interface 201 of the power conversion module 200 is connected to the AC output interface 103 of the docking station 100, the docking station 100 transmits AC power output from the AC power grid 400 to the power conversion module 200, the power conversion module 200 starts working, and the heat dissipation device 102 removes the heat generated by the power conversion module 200, improving the heat dissipation capacity of the power conversion module 200. In this scenario, the rated power of the power conversion module 200 is the first power.

[0052] Since the docking station 100 is not portable, it is generally fixed in commonly used locations, such as underground parking lots and residential areas. In scenarios where the docking station 100 is unavailable, the power conversion module 200 can be used alone to charge the electric vehicle 500. The input interface 201 of the power conversion module 200 connects to the AC power grid 400, receiving AC power output from the AC power grid 400. The AC / DC conversion module 208 converts the AC power input from the AC power grid 400 into DC power required by the electric vehicle 500, which is then transmitted to the electric vehicle 500 through the charging gun 300. In this scenario, the rated power of the power conversion module 200 is the second power. When the power conversion module 200 is connected to the docking station 100, the heat dissipation device 102 removes the heat generated by the power conversion module 200, improving heat dissipation. Therefore, the second power can be less than the first power.

[0053] In some examples, the DC charging station includes an identification module 205, which is used to identify whether the power conversion module 200 is connected to the docking station 100 or to identify whether the power conversion module 200 has started operating. The power conversion module 200 includes a first control module 209. When the identification module 205 identifies that the power conversion module 200 is connected to the docking station 100, the first control module 209 controls the rated power of the power conversion module 200 to a first power. When the identification module 205 identifies that the power conversion module 200 is connected to the AC power grid 400, the first control module 209 controls the rated power of the power conversion module 200 to a second power. The second power is less than the first power.

[0054] For example, the power conversion module 200 can limit the output current of the AC / DC conversion module 208 under different charging voltages. For instance, with a first power of 20kW, when the electric vehicle 500 requires a charging voltage of 400V, the output current of the power conversion module 200 is 50A; when the electric vehicle 500 requires a charging voltage of 800V, the output current of the power conversion module 200 is 25A. With a second power of 5kW, when the electric vehicle 500 requires a charging voltage of 400V, the output current of the power conversion module 200 is 12.5A. The first power of 20kW is greater than the second power of 5kW. This application embodiment does not limit the charging voltage of the electric vehicle 500; for example, the charging voltage of the electric vehicle 500 can be 400V or 300V. This application embodiment does not specifically limit the values ​​of the first and second power values. The rated power can vary under different ambient temperatures. The real factor limiting the rated power of the power conversion module 200 is the degree of heating of the heating element, which is affected by the current.

[0055] In specific implementations, the first control module 209 can be a general-purpose central processing unit (CPU), a general-purpose processor, a digital signal processing unit (DSP), an application-specific integrated circuit (ASIC), a field-programmable gate array (FPGA), or other programmable logic devices, transistor logic devices, hardware components, or any combination thereof. The aforementioned processors can also be combinations that implement computational functions. For example, the first control module 209 may include one or more microprocessor combinations, a combination of a DSP and a microprocessor, etc.

[0056] The location of the identification module 205 is not specifically limited in this embodiment. For example, the identification module 205 may be located only in the power conversion module 200, or the identification module 205 may include two parts, with the first part located in the expansion dock 100 and the second part located in the power conversion module 200.

[0057] This application does not specifically limit the components of the identification module 205. For example, the identification module 205 can be an identification circuit or a capacitive sensor. When the identification module 205 is an identification circuit, the specific form of the identification circuit is also not limited, for example: Figure 5 This is a schematic diagram of the identification module provided in an embodiment of this application. Figure 5 The identification circuit includes resistors R1 and R2, and a voltage source. Resistors R1 and R2 are located within the docking station 100 and the power conversion module 200, respectively. When the docking station 100 is connected to the power conversion module 200, resistors R1 and R2 are connected in series, causing a change in the voltage U across R1, thus identifying the connection between the docking station 100 and the power conversion module 200. The identification module 205 can also be a capacitance sensor. When the docking station 100 is connected to the power conversion module 200, the capacitance sensor can determine the connection based on the voltage value it receives.

[0058] In some examples, the docking station 100 includes a first housing 101, which is designed to meet at least an IP55 protection rating, completely preventing the intrusion of foreign objects and the entry of sprayed water into the docking station 100, achieving good waterproof and dustproof effects. The power conversion module 200 includes a second housing 202, which is designed to meet at least an IP67 protection rating, completely preventing the entry of foreign objects and dust into the power conversion module 200, and preventing water from entering the power conversion module 200 during immersion. This avoids the bottom surface of the power conversion module 200 being contaminated by rainwater or accumulated water when using the power conversion module 200 in scenarios without the docking station 100, thus improving the reliability and safety of charging. Therefore, the charging pile provided in this application can be designed without a dustproof screen, eliminating the need for regular replacement of the dustproof screen, and significantly reducing the failure rate of the power conversion module 200, thereby greatly reducing the maintenance cost of the charging pile.

[0059] The explanations for protection ratings IP55 and IP67 are as follows: IP represents the letter designation, and the numbers 5 and 6 are the first designation digits, indicating the dust resistance rating. 5 indicates "protection against foreign objects and dust," completely preventing the intrusion of foreign objects. While not completely preventing dust intrusion, the amount of dust intrusion will not affect the normal operation of the appliance. 6 also indicates "protection against foreign objects and dust," completely preventing the entry of foreign objects and dust. The numbers 5 and 7 are the second designation digits, indicating the water resistance rating. 5 indicates "protection against water jets," preventing the intrusion of low-pressure water jets for at least 3 minutes. 7 indicates "protection against water ingress during immersion," protecting against immersion in water up to 1 meter deep for 30 minutes. IP55 protection rating protects against foreign objects and dust and also prevents water jets from entering. IP67 completely prevents the intrusion of foreign objects and dust and also prevents water ingress during immersion. In other embodiments, the protection rating of the first housing 101 may be higher than IP55, and the protection rating of the second housing 202 may be higher than IP67.

[0060] In some examples, the second housing 202 of the power conversion module 200 is made of a thermally conductive material. The heat-generating devices inside the power conversion module 200 are in contact with the second housing 202, and the heat generated when the power conversion module 200 outputs power can be dissipated through the thermally conductive material. This application does not specifically limit the thermally conductive material; for example, it can be metals such as iron and aluminum, or other thermally conductive materials such as thermally conductive ceramics. The specific application is not limited here. The heat-generating devices inside the power conversion module 200 mainly include semiconductor switching devices and magnetic devices. Semiconductor switching devices / magnetic devices are numerous, generate a large amount of heat, have concentrated heat, and high heat density. Other heat-generating devices are relatively dispersed and have low heat density. The power devices can be soldered onto an aluminum substrate, and the aluminum substrate can be installed onto the second housing 202 of the power conversion module 200 using screws. Thermally conductive gel or thermally conductive grease can be used to fill the gap between the aluminum substrate and the second housing 202 of the power conversion module 200, ensuring close contact, reducing thermal resistance, and forming a heat transfer channel from the magnetic device to the aluminum substrate, then to the thermally conductive gel or thermally conductive grease, and finally to the second housing 202. It is understood that the above heat transfer method is only one possible implementation method, and no specific limitation is made here. For example, in other implementation methods, PCB through-hole heat dissipation can be used to transfer the heat of the semiconductor switching device to the second housing 202 through the PCB through-hole.

[0061] In some examples, the second housing 202 of the power conversion module 200 has heat dissipation fins 204, through which heat generated by the heat-generating devices inside the power conversion module 200 can be dissipated. The structure of the heat dissipation fins 204 is not limited, and can be a sheet-like heat dissipation fin, a mesh-like heat dissipation fin, or a columnar heat dissipation fin.

[0062] Figure 3 This is a schematic diagram of a DC charging pile provided in an embodiment of this application. In some examples, the heat dissipation device 102 includes at least one fan 104 for air cooling of the power conversion module 200. This application embodiment does not specifically limit the location and number of fans 104; for example, the number of fans 104 can be one, two, or three. When the heat dissipation fins 204 are sheet-shaped, the fan surface of the fan 104 can be perpendicular to the direction of the heat dissipation fins 204. When the heat dissipation fins 204 are mesh-shaped, the fan surface of the fan 104 can be parallel to the heat dissipation fins 204. When the heat dissipation fins 204 are columnar, the fan surface of the fan 104 can be perpendicular or parallel to the heat dissipation fins 204.

[0063] In some examples, the power conversion module 200 includes at least one temperature sensor 206, which measures the temperature of the heat-generating components inside the power conversion module 200. The main heat-generating components inside the power conversion module 200 include semiconductor switching devices, magnetic devices, etc. This application does not specifically limit the location and number of temperature sensors 206. For example, the temperature sensors 206 can be located around the heat-generating components inside the power conversion module 200, and the number of temperature sensors 206 is determined based on the number of heat-generating components inside the power conversion module 200. Those skilled in the art can select the number and placement of temperature sensors 206 based on the internal structure of the power conversion module 200.

[0064] This application does not limit the implementation method of controlling the switching and speed of fan 104. For example, the switching and / or speed of fan 104 can be controlled by power conversion module 200, or by expansion dock 100. Alternatively, the switching and / or speed of fan 104 can be controlled by power conversion module 200 and expansion dock 100 working together.

[0065] For example, in one implementation, the power conversion module 200 controls the fan's on / off state and / or speed. The power conversion module 200 includes a first control module 209. When the identification module 205 detects that the power conversion module 200 is connected to the docking station 100, or when the identification module 205 detects that the power conversion module 200 has started operating, or when a first preset temperature threshold is less than or equal to the temperature measured by the temperature sensor 206, the first control module 209 controls the fan 104 to start, carrying away the heat generated by the power conversion module 200 during operation, thus improving heat dissipation. The first control module 209 can also acquire the temperature measured by the temperature sensor 206 and adjust the fan speed 104 according to the temperature measured by the temperature sensor 206. For example, when the temperature measured by temperature sensor 206 is ≤ a second preset temperature threshold, the first control module 209 controls fan 104 to operate at a first speed. When the second preset temperature threshold < the temperature measured by temperature sensor 206 ≤ a third preset temperature threshold, the first control module 209 controls fan 104 to operate at a second speed to accelerate heat dissipation and rapidly reduce the temperature of power conversion module 200. When the temperature measured by temperature sensor 206 > the third preset temperature threshold, the first control module 209 controls fan 104 to operate at a third speed to meet heat dissipation requirements and accelerate charging. By controlling fan 104 at different speeds at different temperatures, energy is saved, rather than having fan 104 run at a fixed speed continuously. This embodiment does not specifically limit the fan speed levels; in other embodiments, the fan may have one, two, or four speed levels. When power conversion module 200 is removed from docking station 100, the first control module 209 controls fan 104 to turn off.

[0066] For example, in one implementation, the docking station 100 controls the fan's on / off state and / or speed. See also Figure 4 , Figure 4 This is another structural schematic diagram of the DC charging pile provided in this application embodiment. The expansion dock 100 includes a second control module 106. When the identification module 205 identifies that the power conversion module 200 is connected to the expansion dock 100, or when the identification module 205 identifies that the power conversion module 200 has started working, or when the first preset temperature threshold is less than or equal to the temperature measured by the temperature sensor 206, the second control module 106 controls the fan 104 to start, carrying away the heat generated by the power conversion module 200 during operation, thereby improving the heat dissipation effect. The second control module 106 can also obtain the temperature measured by the temperature sensor 206 and adjust the speed of the fan 104 according to the temperature of the temperature sensor 206. For example, when the temperature measured by temperature sensor 206 is ≤ a second preset temperature threshold, the second control module 106 controls fan 104 to operate at a first speed. When the second preset temperature threshold < the temperature measured by temperature sensor 206 ≤ a third preset temperature threshold, the second control module 106 controls fan 104 to operate at a second speed to accelerate heat dissipation and rapidly reduce the temperature of power conversion module 200. When the temperature measured by temperature sensor 206 > the third preset temperature threshold, the second control module 106 controls fan 104 to operate at a third speed to meet heat dissipation requirements and accelerate charging. By controlling fan 104 at different speeds at different temperatures, energy is saved, rather than having fan 104 run at a fixed speed continuously. This embodiment does not specifically limit the speed levels of fan 104; in other embodiments, fan 104 may have one, two, or four speed levels. When power conversion module 200 is removed from docking station 100, the second control module 106 controls fan 104 to turn off.

[0067] For example, in one implementation, the switching and / or speed of the fan is controlled jointly by the docking station 100 and the power conversion module 200. The power conversion module 200 includes a first control module 209, and the docking station 100 includes a second control module 106. When the identification module 205 detects that the power conversion module 200 is connected to the docking station 100, or when the identification module 205 detects that the power conversion module 200 has started working, or when a first preset temperature threshold is less than or equal to the temperature measured by the temperature sensor 206, the first control module 209 sends a control command to the second control module 106. The control command instructs the second control module 106 to start the fan 104, and the fan 104 starts working, carrying away the heat generated by the power conversion module 200 during operation. The first control module 209 can also acquire the temperature measured by the temperature sensor 206 and send a control command to the second control module 106 based on the temperature measured by the temperature sensor 206. The control command instructs the second control module 106 to adjust the speed of the fan 104. When the temperature measured by temperature sensor 206 is ≤ a second preset temperature threshold, the first control module 209 sends a control command to the second control module 106, instructing the second control module 106 to control fan 104 at a first speed. When the second preset temperature threshold < the temperature measured by temperature sensor 206 ≤ a third preset temperature threshold, the first control module 209 sends a control command to the second control module 106, instructing the second control module 106 to control fan 104 at a second speed to accelerate heat dissipation and rapidly reduce the temperature of power conversion module 200. When the temperature measured by temperature sensor 206 > the third preset temperature threshold, the first control module 209 sends a control command to the second control module 106, instructing the second control module 106 to control fan 104 at a third speed to meet heat dissipation requirements and accelerate charging. By controlling fan 104 at different speeds at different temperatures, energy is saved, rather than having fan 104 run at a fixed speed continuously. When power conversion module 200 is removed from docking station 100, second control module 106 controls fan 104 to turn off. This application embodiment does not specifically limit the speed levels of fan 104. In other embodiments, fan 104 may also have one, two, or four speed levels. When the power conversion module 200 is removed from the expansion dock 100, the first control module 209 sends a control command to the second control module 106, which instructs the second control module 106 to control fan 104 to turn off.

[0068] It should be noted that the second control module 106 and the first control module 209 can communicate via wired or wireless means. For example, the second control module 106 and the first control module 209 can communicate based on ModBus (e.g., based on RS-485 bus) or based on the CAN (Controller Area Network) protocol. In other embodiments, other communication methods can also be used, and this application does not limit them.

[0069] Understandably, the speed of fan 104 can be adjusted by regulating the duty cycle of the pulse width modulation (PWM) signal of fan 104. For example, increasing the duty cycle of the PWM signal can increase the speed of fan 104, while decreasing it can decrease it. The speed of fan 104 can also be regulated by adjusting its voltage or current. For example, increasing the voltage or current can increase the speed of fan 104, while decreasing it can decrease it.

[0070] In specific implementations, the second control module 106 can be a general-purpose central processing unit (CPU), a general-purpose processor, a digital signal processing unit (DSP), an application-specific integrated circuit (ASIC), a field-programmable gate array (FPGA), or other programmable logic devices, transistor logic devices, hardware components, or any combination thereof. The aforementioned processors can also be combinations that implement computational functions. For example, the second control module 106 may include one or more microprocessor combinations, a combination of a DSP and a microprocessor, etc.

[0071] See Figure 6 , Figure 6This is another structural schematic diagram of the DC charging pile provided in the embodiments of this application. In some examples, the heat dissipation device 102 includes at least one cooling channel 107. The cooling channel 107 is in contact with the second housing 202 of the power conversion module 200, and coolant flows through the cooling channel 107. In this way, the heat generated by the power conversion module 200 can be transferred to the coolant in the cooling channel 107 through the side wall of the cooling channel 107, and then discharged with the coolant, so that the power conversion module 200 can be cooled down, thereby ensuring the normal operation of the power conversion module 200. The embodiments of this application do not limit the specific type of coolant. For example, the coolant can be water or a water + ethylene glycol mixture. Optionally, the cooling channel 107 is disposed on the side of the second housing 202 of the power conversion module 200. The structure of the cooling channel 107 is not limited. For example, the cooling channel 107 is a liquid cooling water pipe that is arranged in a serpentine manner and wrapped around at least one side of the second housing 202 of the power conversion module 200. Alternatively, the cooling channel 107 is disposed on a liquid cooling heat sink, the liquid cooling heat sink and the second housing 202 of the power conversion module 200 are in contact, and the liquid cooling heat sink has coolant channels inside.

[0072] It should be noted that the above heat dissipation systems can be combined. For example, the DC charging pile can operate in air-cooled mode, liquid-cooled mode, or both air-cooled and liquid-cooled modes at the same time. That is, the heat dissipation device 102 can include both the fan 104 and the cooling channel 107.

[0073] In some examples, the power conversion module 200 can be used to supply power to an external load. The output interface 203 of the power conversion module 200 is connected to a charging gun 300, which is connected to an electric vehicle 500. The charging gun 300 transmits the DC power from the battery of the electric vehicle 500 to an AC / DC conversion module 208. The AC / DC conversion module 208 converts the DC power received by the output interface 203 into AC power. The input interface 201 of the power conversion module 200 is connected to an external load, transmitting the AC power to the external load, thus supplying power to the external load. The external load can be, but is not limited to, an induction cooker, a rice cooker, a mobile phone, a refrigerator, etc.

[0074] Specifically, when a user drives the vehicle out, if there is no AC charging station or power strip in the area where the vehicle is located, the input interface 201 of the power conversion module 200 can be connected to an external AC load. The power conversion module 200 can obtain DC power from the battery of the electric vehicle 500 and convert the obtained DC power into AC power required by the external load to supply power to the external AC load, thereby meeting the power needs of the user's equipment.

[0075] In this document, the term "embodiment" means that a particular feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment of this application. The appearance of this phrase in various places throughout the specification does not necessarily refer to the same embodiment, nor is it a separate or alternative embodiment mutually exclusive with other embodiments. It will be explicitly and implicitly understood by those skilled in the art that the embodiments described herein can be combined with other embodiments.

[0076] The specific embodiments described above further illustrate the purpose, technical solution, and beneficial effects of this application. It should be understood that the above description is only a specific embodiment of this application and is not intended to limit the scope of protection of this application. Any modifications, equivalent substitutions, improvements, etc., made on the basis of the technical solution of this application should be included within the scope of protection of this application.

Claims

1. A direct current charging pile, characterized in that, include: The system includes a docking station, a power conversion module, and a charging gun; wherein the power conversion module is detachably connected to the docking station. The expansion dock includes an AC input interface, a heat dissipation device, and an AC output interface; The power conversion module includes at least one input interface, an AC / DC conversion module, and at least one output interface; The AC input interface of the expansion dock is used to connect to the AC power grid, and the AC output interface of the expansion dock is used to connect to the input interface of the power conversion module to transmit the AC power from the AC power grid to the power conversion module. The heat dissipation device is used to dissipate heat from the power conversion module; The input interface of the power conversion module is used to connect to the AC output interface of the expansion dock, or to connect to the AC power grid; The AC / DC conversion module is used to convert the AC power received by the input interface into DC power. The output interface of the power conversion module is used to connect to the charging gun; The charging gun is used to transmit the DC power to the electric vehicle; The DC charging pile also includes an identification module, which includes an identification circuit or a capacitance sensor. The identification module is used to identify whether the power conversion module is connected to the expansion dock or to identify whether the power conversion module is working. The power conversion module includes a first control module; When the identification module detects that the power conversion module is connected to the expansion dock, the first control module controls the rated power of the power conversion module to the first power. When the identification module detects that the power conversion module is connected to the AC power grid, the first control module controls the rated power of the power conversion module to the second power. The second power is less than the first power.

2. The direct current charging pile according to claim 1, characterized in that, The expansion dock also includes a first housing that meets the IP55 protection rating; the power conversion module also includes a second housing that meets the IP67 protection rating.

3. The direct current charging pile according to claim 2, characterized in that, The material of the second housing includes thermally conductive materials; The thermally conductive material is used to remove the heat generated by the power conversion module.

4. The direct current charging pile according to claim 2, characterized in that, The second housing is provided with heat dissipation fins, which are used to dissipate the heat generated by the power conversion module.

5. The direct current charging pile according to any one of claims 1-4, characterized in that, The heat dissipation device includes at least one fan, which is used to provide air cooling for the power conversion module.

6. The direct current charging pile according to claim 5, characterized in that, The power conversion module includes at least one temperature sensor for measuring the temperature of the power conversion module.

7. The direct current charging pile according to claim 6, characterized in that, When the identification module detects that the power conversion module is connected to the expansion dock, or when the identification module detects that the power conversion module has started working, or when the temperature of the power conversion module is greater than a preset temperature threshold, the first control module is used to control the fan to start.

8. The direct current charging pile according to claim 6, characterized in that, The first control module is also used to adjust the fan speed according to the temperature of the power conversion module measured by the temperature sensor.

9. The direct current charging pile according to claim 6, characterized in that, The expansion dock also includes a second control module; When the identification module detects that the power conversion module is connected to the expansion dock, or when the identification module detects that the power conversion module has started working, or when the temperature of the power conversion module is greater than a preset temperature threshold, the second control module is used to control the start of the fan; The second control module is also used to adjust the fan speed according to the temperature of the power conversion module measured by the temperature sensor.

10. The direct current charging pile according to claim 8, characterized in that, The expansion dock also includes a second control module; The second control module is used to communicate with the first control module and control the start and / or speed of the fan according to the control instructions of the first control module.

11. The direct current charging pile according to any one of claims 1-4, characterized in that, The heat dissipation device includes at least one cooling channel; When the power conversion module is connected to the expansion dock, the cooling channel is located on at least one side of the power conversion module and is in contact with the second housing of the power conversion module; Coolant flows through the cooling channel to provide liquid cooling for the power conversion module.

12. The direct current charging pile according to any one of claims 1-4, characterized in that, The charging gun is also used to transmit DC power from the electric vehicle battery to the power conversion module; The power conversion module is also used to convert the direct current into alternating current; The input interface of the power conversion module is also used to connect to an external load, transmit the AC power to the external load, and supply power to the external load.

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