A BOOST system and method for electric vehicles

Abstract

The present invention belongs to the field of electric vehicle charging and discloses a BOOST boost system and method for electric vehicles, including a BOOST boost device, a motor controller, a power battery and a DC charging pile. The BOOST boost device is connected to the motor controller to form a BOOST circuit, and the BOOST boost device is connected to the power battery and the DC charging pile respectively. Through the BOOST boost system and method for electric vehicles of the present invention, the boost charging requirements of electric vehicles with an 800V voltage platform on a maximum 500V charging pile can be met, avoiding the problem that the 500V voltage charging pile cannot be charged. In addition, the BOOST boost device of the present invention is easy to cancel and replace. When the 500V charging piles on the market are continuously upgraded to achieve a 1000V voltage output, and the proportion of 500V charging piles is less than 5%, it is convenient to cancel the BOOST boost device without causing a significant compatibility impact on the entire vehicle.

Description

Technical Field

[0001] The present invention belongs to the field of electric vehicle charging, and in particular relates to a BOOST voltage boosting system and method for an electric vehicle. Background Art

[0002] With the continuous improvement of battery power and range of mainstream electric vehicles, users' range anxiety has been alleviated to a certain extent, but the anxiety about slow and difficult charging still restricts the development of electric vehicles.

[0003] Existing charging technology requires consumers to wait 40 minutes or even longer for a full charge. "Charging for one hour and waiting in line for four hours" during holiday travel has become a deep pain for new energy vehicle owners. Making fast charging as convenient as refueling has become the direction of efforts of electric vehicle industry chain companies.

[0004] Currently, there are several main solutions for fast charging, including high current, high voltage, and quick battery replacement. The high voltage solution is expected to become one of the mainstream directions. Relevant car manufacturers are already actively deploying 800V high-voltage platforms to meet the needs of fast charging of electric vehicles and effectively improve user experience. Since the beginning of this year, many 800V models will be mass-produced in the market.

[0005] However, the current market has DC charging piles with maximum output voltages of 500V, 750V, and 1000V, of which 500V DC charging piles account for approximately 20%-30%. As a result, vehicles equipped with 800V high-voltage platforms are charged at charging piles with a maximum output voltage of 500V, and the charging speed does not meet expectations. In addition, due to voltage matching issues, there are cases where charging cannot be performed, which greatly affects the user experience. In some cases, it even affects customers' charging plans, resulting in vehicles being unable to charge in time and causing vehicle power feeding problems. Currently, 500V charging piles on the market are mainly concentrated in charging piles built by the State Grid in the early days. The present invention aims to solve this problem and enable 800V electric vehicles to be compatible with DC charging piles of different output voltage platforms. Summary of the Invention

[0006] In order to overcome the defects of the above-mentioned prior art, the purpose of the present invention is to provide an electric vehicle BOOST boosting system and method. By setting an electric vehicle BOOST boosting device and cooperating with a motor controller to form a BOOST circuit, it is possible to boost the voltage below 500V to about 800V, thereby meeting the demand for fast charging of electric vehicles with an 800V voltage platform using a 500V charging pile.

[0007] To achieve the above object, the present invention provides the following technical solutions:

[0008] A BOOST voltage boosting system for an electric vehicle comprises a BOOST voltage boosting device, a motor controller, a power battery and a DC charging pile. The BOOST voltage boosting device and the motor controller are connected to form a BOOST circuit. The BOOST voltage boosting device is connected to the power battery and the DC charging pile respectively.

[0009] Furthermore, the BOOST boost device includes a shell, which includes a base and an upper cover. A boost auxiliary circuit and a BOOST control unit are arranged inside the shell. A DC charging interface, a low-voltage port, a motor controller high-voltage input interface, a motor controller high-voltage output interface and a battery high-voltage port are respectively provided on three sides of the shell. The motor controller high-voltage input interface, the motor controller high-voltage output interface and the battery high-voltage port are located on the same side, and the DC charging interface and the low-voltage port are located on the other two sides and are opposite to each other.

[0010] Furthermore, installation panel openings are provided on the three sides of the base, corresponding to the DC charging interface, low-voltage port, motor controller high-voltage input interface, motor controller high-voltage output interface and battery high-voltage port respectively. Four fixed legs are provided at the bottom of the base, and a mounting hole is provided in the center of the fixed legs. The mounting hole is used to fix the BOOST boost device to the vehicle body.

[0011] Furthermore, one end of the low-voltage port is connected to the low-voltage wiring harness of the vehicle, and the other end of the low-voltage port is connected to the BOOST control unit. The low-voltage wiring harness of the vehicle includes the power supply, grounding and network lines of the motor controller.

[0012] Furthermore, the battery high-voltage port is connected to the power battery through a high-voltage wiring harness, the DC charging interface is connected to the DC charging pile through a high-voltage wiring harness, and the motor controller high-voltage input interface and the motor controller high-voltage output interface are connected to the motor controller through a high-voltage wiring harness.

[0013] Furthermore, the boost auxiliary circuit includes a fast charging positive relay, a fast charging negative relay and a voltage switching relay.

[0014] The negative end of the battery high-voltage port, the negative end of the motor controller high-voltage input interface, and the negative end of the motor controller high-voltage output interface are star-connected, and the positive end of the battery high-voltage port is connected to the positive end of the motor controller high-voltage output interface;

[0015] The positive terminal of the DC charging interface is connected to the positive terminal of the battery high-voltage port through the two switch contacts of the fast-charge positive relay; the negative terminal of the DC charging interface is connected to the battery high-voltage port, the negative terminal of the motor controller high-voltage input interface, and the negative terminal of the motor controller high-voltage output interface through the two switch contacts of the voltage switching relay;

[0016] The positive terminal of the high-voltage input interface of the motor controller is connected to the battery plug-in port and the positive terminal of the high-voltage output interface of the motor controller through the two switch contacts of the fast charging negative pole relay 7.

[0017] Furthermore, the boost auxiliary circuit also includes a high-voltage capacitor, one contact of the high-voltage capacitor is located at the center of the positive pole of the DC charging interface, the switch contact of the fast charging positive relay and the voltage cut-off relay, and the other contact of the high-voltage capacitor is located at the center of the switch contact of the fast charging negative relay and the negative pole of the battery high-voltage interface, the negative pole of the motor control output interface, and the negative pole of the motor control input interface.

[0018] Furthermore, the BOOST control unit includes several control signal terminals, which are connected to the low-voltage ports of the fast-charging positive relay, the fast-charging negative relay, and the voltage cut-off relay. The BOOST control unit is used to control the on-off of the contacts of the fast-charging positive relay, the fast-charging negative relay, and the voltage cut-off relay according to the charging strategy.

[0019] The BOOST control unit also includes a CAN signal output terminal, which is connected to the vehicle CAN network and is used to receive network information sent by the vehicle CAN network in real time and / or send internal status information of the BOOST boost device to the vehicle CAN network.

[0020] Furthermore, the shell is made of aluminum alloy material after passivation treatment, and a sealing ring is provided between the base and the upper cover.

[0021] On the other hand, the present invention also discloses a BOOST charging method, which uses the above-mentioned electric vehicle BOOST system to enable a 500V charging pile to charge an 800V voltage platform electric vehicle.

[0022] Technical effects and advantages of the present invention:

[0023] 1. The present invention can realize the boost charging demand of electric vehicles with an 800V voltage platform on a maximum 500V charging pile, avoiding the problem that a 500V voltage charging pile cannot charge electric vehicles with an 800V voltage platform.

[0024] 2. The BOOST auxiliary boost system of the present invention is easy to cancel and replace. When 500V charging piles on the market are continuously upgraded to achieve 1000V voltage output and the proportion of 500V charging piles is less than 5%, it is convenient to cancel the BOOST boost device without causing a major compatibility impact on the entire vehicle.

[0025] 3. The BOOST auxiliary boost system of the present invention shares some high-power components in the motor to form a BOOST boost circuit, which can effectively reduce development costs and circuit weight and volume.

[0026] Other features and advantages of the present invention will be described in the following description, and in part will become apparent from the description, or will be understood by practicing the present invention. The purpose and other advantages of the present invention can be realized and obtained by the structures pointed out in the description, claims and drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 This is a schematic structural diagram of the BOOST boost system for an electric vehicle according to the present invention;

[0028] Figure 2 This is a schematic structural diagram of the BOOST boost device for an electric vehicle according to the present invention;

[0029] Figure 3 This is a circuit diagram of the BOOST boost system for electric vehicles of the present invention;

[0030] Figure 4 This is a schematic diagram of the high-voltage circuit of the motor controller of the present invention.

[0031] Figure markings: 1. Shell; 2. Battery high-voltage port; 3. Motor controller high-voltage input interface; 4. Motor controller high-voltage output interface; 5. DC charging interface; 6. Fast charging positive relay; 7. Fast charging negative relay; 8. Voltage switching relay; 9. High-voltage capacitor; 10. BOOST control unit; 11. Sealing ring; 12. Fixed support foot; 13. Low-voltage port; 14. Power battery; 15. DC charging pile; 16. BOOST boost device; 17. Motor controller. DETAILED DESCRIPTION

[0032] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0033] Figure 1 FIG. 1 is a schematic structural diagram of the BOOST boost system of an electric vehicle according to this exemplary embodiment. Figure 1 As shown, the present invention provides a BOOST boost system for an electric vehicle, comprising: a BOOST boost device 16, a motor controller 17, a power battery 14 and a DC charging pile 15. The BOOST boost device 16 is connected to the motor controller 17 to form a BOOST circuit, and the BOOST boost device 16 is connected to the power battery 14 and the DC charging pile 15 respectively.

[0034] Optionally, Figure 2FIG. 1 is a schematic structural diagram of the BOOST boost device 16 of the electric vehicle according to this exemplary embodiment. Figure 2 As shown, the BOOST device 16 includes a housing 1, which includes a base and a top cover. The housing 1 houses a boost auxiliary circuit and a BOOST control unit 10. Three sides of the housing 1 are provided with a DC charging port 5, a low-voltage port 13, a motor controller high-voltage input port 3, a motor controller high-voltage output port 4, and a battery high-voltage port 2. The motor controller high-voltage input port 3, the motor controller high-voltage output port 4, and the battery high-voltage port 2 are located on the same side, with the DC charging port 5 and the low-voltage port 13 facing each other. Mounting panel openings are provided on three sides of the base, corresponding to the DC charging port 5, the low-voltage port 13, the motor controller high-voltage input port 3, the motor controller high-voltage output port 4, and the battery high-voltage port 2. The bottom of the base is provided with four fixing legs 12, each with a mounting hole in the center. The mounting hole has a diameter of approximately 7 mm and is used to secure the BOOST device 16 to the vehicle body.

[0035] Optionally, the outside of the low-voltage port 13 is connected to the low-voltage wiring harness of the vehicle, and the inside of the low-voltage port 13 is connected to the BOOST control unit, wherein the low-voltage wiring harness of the vehicle includes the power supply, grounding and network lines of the motor controller.

[0036] Optionally, the battery high-voltage port 2 is connected to the power battery 14 through a high-voltage wiring harness. When DC fast charging is performed, the charging current charges the power battery 14 through the battery high-voltage port 2.

[0037] The DC charging interface 5 is connected to the DC charging pile 15 through a high-voltage wiring harness. When DC fast charging is performed, the charging current of the fast charging pile enters the BOOST boost device 16 through the DC charging interface 5;

[0038] The motor controller high-voltage input interface 3 and the motor controller high-voltage output interface 4 are connected to the motor controller 17 through a high-voltage wiring harness. When the BOOST boost device 16 is connected to a 500V low-voltage charging pile, current will enter the motor controller 17 through the motor controller high-voltage input interface 3, and together with the BOOST auxiliary circuit form a boost circuit, boosting 500V to about 800V, and then reaching the BOOST boost device 16 through the output interface, and finally charging the power battery 14.

[0039] Optionally, Figure 3 The circuit schematic diagram of the BOOST boost system of the electric vehicle of the present invention is as follows: Figure 3As shown, the boost auxiliary circuit includes a fast charge positive relay 6, a fast charge negative relay 7 and a voltage switching relay 8. The negative end of the battery high voltage port 2, the negative end of the motor controller high voltage input interface 3 and the negative end of the motor controller high voltage output interface 4 are star-connected, and the positive end of the battery high voltage port 2 and the positive end of the motor controller high voltage output interface 4 are connected;

[0040] The positive terminal of the DC charging interface 5 is connected to the positive terminal of the battery high voltage port 2 through the two switch contacts of the fast charge positive relay 6; the negative terminal of the DC charging interface 5 is connected to the battery high voltage port 2, the negative terminal of the motor controller high voltage input interface 3, and the negative terminal of the motor controller high voltage output interface 4 through the two switch contacts of the voltage switching relay 8; the positive terminal of the motor controller high voltage input interface 3 is connected to the positive terminal of the battery plug-in port 2 and the motor controller high voltage output interface 4 through the two switch contacts of the fast charge negative relay 7. The boost auxiliary circuit also includes a high voltage capacitor 9, one contact of the high voltage capacitor 9 is located at the center of the positive pole of the DC charging interface 5, the switch contact of the fast charge positive relay 7, and the voltage cut-off relay 8, and the other contact of the high voltage capacitor 9 is located at the center of the switch contact of the fast charge negative relay 6 and the negative pole of the battery high voltage interface 2, the negative pole of the motor control output interface 4, and the negative pole of the motor control input interface 3;

[0041] Figure 4 This is a schematic diagram of the high-voltage circuit of the motor controller 17 of the present invention, as shown in FIG. Figure 4 As shown, the BOOST voltage boosting device 16 is connected to the motor controller 17 to form a BOOST circuit.

[0042] Optionally, the BOOST control unit 10 includes several control signal terminals, which are connected to the low-voltage ports 13 of the fast-charging positive relay 6, the fast-charging negative relay 7, and the voltage cut-off relay 8. The BOOST control unit 10 is used to control the on-off of the contacts of the fast-charging positive relay 6, the fast-charging negative relay 7, and the voltage cut-off relay 8 according to the charging strategy.

[0043] The BOOST control unit 10 further includes a CAN signal output terminal connected to the vehicle CAN network for receiving network information sent by the vehicle CAN network in real time and / or sending internal status information of the BOOST boost device to the vehicle CAN network.

[0044] Optionally, the housing 1 is made of passivated aluminum alloy material to ensure equipotential balance between the BOOST boost device 16 and the vehicle body ground platform, and a sealing ring 11 is provided between the base and the upper cover to ensure that the vehicle's waterproof level can reach IP67 or above.

[0045] In addition, the present invention also discloses a BOOST charging method, which uses the above-mentioned electric vehicle BOOST charging system to achieve the demand of fast charging of 800V voltage platform electric vehicles using a 500V charging pile.

[0046] In some embodiments of the present invention, the power battery 14 is directly connected to the high-voltage end of the BOOST boost device 16. In driving mode, the power battery outputs 800V high-voltage current to the BOOST boost device 16 to achieve driving discharge; in charging mode, the BOOST boost device 16 outputs 800V high-voltage current to the power battery 14 to achieve charging of the power battery 14.

[0047] In some embodiments of the present invention, the high-voltage terminals of the motor controller 17 and the BOOST device 16 each have two output paths: an input and an output. In driving mode, the BOOST device 16 outputs an 800V high-voltage current to the motor controller 17 to drive discharge. In external 800V charging mode, no current flows between the BOOST device 16 and the motor controller 17. In external 500V charging mode, the BOOST device 16 and the motor controller 17 together form a BOOST boost circuit. 500V current enters the motor controller 17 through the input terminal, is boosted by the BOOST boost circuit, and then enters the BOOST device 16 through the output terminal.

[0048] In some embodiments of the present invention, including the current and voltage trends under different voltage charging modes, when the DC charging pile 15 outputs a voltage and current below 500V, the current is output through the DC charging pile 15 to the BOOST boost device 16. The BOOST boost device 16 outputs the current to the motor controller 17 through the switching of the relay. The current is boosted to 800V through the BOOST boost device 16 and then returns to the BOOST boost device 16. The 800V voltage and current are then output to the power battery 14. When the DC charging pile 15 outputs a voltage and current of approximately 800V, the current is output through the DC charging pile 15 to the BOOST boost device 16. The BOOST boost device 16 outputs the 800V voltage and current directly to the power battery 14 through the switching of the relay.

[0049] In some embodiments of the present invention, interaction logic under different voltage charging modes is also included. When an external 500V DC charging pile 15 is connected, the power battery 14 management system interacts with the DC charging pile 15 for charging, identifies the DC charging pile 15 as a 500V voltage charging pile, and makes a charging voltage request below 500V to the DC charging pile 15. At the same time, a CAN message is sent to the BOOST boost device 16 and the motor controller 17 to make a boost request and a requested voltage. After receiving the request, the BOOST boost device 17 boosts the voltage according to the requested voltage of the power battery 14.

[0050] When connected to an external 1000V DC charging pile 15, the power battery 14 management system interacts with the DC charging pile 15 for charging, identifies the charging pile as a 1000V voltage charging pile, and makes a charging voltage request of about 800V to the DC charging pile 15. At the same time, it sends a CAN message to the BOOST boost device 16 and the motor controller 17, sending the charging pile request voltage information and the request not to boost. After receiving the request, the BOOST boost device 16 outputs the voltage and current of the DC charging pile 15 directly to the power battery 14 through relay switching according to the battery request information.

[0051] The electric vehicle BOOST boost system and method of the present invention can realize the boost charging demand of electric vehicles with an 800V voltage platform on a maximum 500V charging pile, avoiding the problem of 500V voltage charging piles being unable to charge. In addition, the BOOST boost device of the present invention is easy to cancel and replace. When the 500V charging piles on the market are continuously upgraded to achieve 1000V voltage output, and the proportion of 500V charging piles is less than 5%, it is convenient to cancel the BOOST boost device without causing a large compatibility impact on the entire vehicle. The BOOST auxiliary boost system of the present invention shares some high-power components in the motor to jointly constitute the BOOST boost circuit, which can effectively reduce development costs and the weight and volume of the circuit.

[0052] Finally, it should be noted that the above is only a preferred embodiment of the present invention and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art can still modify the technical solutions described in the aforementioned embodiments or make equivalent substitutions for some of the technical features therein. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the scope of protection of the present invention.

Claims

1. A BOOST boost system for electric vehicles, characterized in that: It comprises a BOOST boost device (16), a motor controller (17), a power battery (14) and a DC charging pile (15), wherein the BOOST boost device (16) is connected to the motor controller (17) to form a BOOST circuit, and the BOOST boost device (16) is connected to the power battery (14) and the DC charging pile (15) respectively; The BOOST boost device (16) comprises a housing (1), the housing (1) comprises a base and an upper cover, a boost auxiliary circuit and a BOOST control unit (10) are arranged inside the housing (1), and a DC charging interface (5), a low-voltage port (13), a motor controller high-voltage input interface (3), a motor controller high-voltage output interface (4) and a battery high-voltage port (2) are respectively arranged on three sides of the housing (1), wherein the motor controller high-voltage input interface (3), the motor controller high-voltage output interface (4) and the battery high-voltage port (2) are located on the same side, and the DC charging interface (5) and the low-voltage port (13) are located on the other two sides and are opposite to each other; The boost auxiliary circuit includes a fast charging positive relay (6), a fast charging negative relay (7) and a voltage switching relay (8). The negative terminal of the battery high-voltage port (2), the negative terminal of the motor controller high-voltage input interface (3) and the negative terminal of the motor controller high-voltage output interface (4) are star-connected, and the positive terminal of the battery high-voltage port (2) and the positive terminal of the motor controller high-voltage output interface (4) are connected; The positive terminal of the DC charging interface (5) is connected to the positive terminal of the battery high-voltage port (2) through the two switch contacts of the fast-charging positive relay (6); the negative terminal of the DC charging interface (5) is connected to the battery high-voltage port (2), the negative terminal of the motor controller high-voltage input interface (3), and the negative terminal of the motor controller high-voltage output interface (4) through the two switch contacts of the voltage switching relay (8); The positive terminal of the motor controller high-voltage input interface (3) is connected to the battery high-voltage port (2) and the positive terminal of the motor controller high-voltage output interface (4) through the two switch contacts of the fast-charge negative relay (7); The boost auxiliary circuit further includes a high-voltage capacitor (9), one contact of the high-voltage capacitor (9) is located at the center of the positive pole of the DC charging interface (5), the switch contact of the fast-charge positive relay (6), and the voltage switching relay (8), and another contact of the high-voltage capacitor (9) is located at the center of the switch contact of the fast-charge negative relay (7), the negative pole of the battery high-voltage port (2), the negative pole of the motor controller high-voltage output interface (4), and the negative pole of the motor controller high-voltage input interface (3); The BOOST control unit (10) includes a plurality of control signal terminals, the control signal terminals being connected to the low-voltage ports (13) of the fast-charging positive relay (6), the fast-charging negative relay (7), and the voltage switching relay (8), and the BOOST control unit (10) is used to control the on-off switching of the contacts of the fast-charging positive relay (6), the fast-charging negative relay (7), and the voltage switching relay (8) according to a charging strategy; The BOOST control unit (10) further comprises a CAN signal output terminal connected to the vehicle CAN network and used for receiving network information sent by the vehicle CAN network in real time and / or sending internal status information of the BOOST boost device to the vehicle CAN network.

2. The electric vehicle BOOST boost system according to claim 1, characterized in that: The three sides of the base are provided with mounting panel openings corresponding to the DC charging interface (5), the low-voltage port (13), the motor controller high-voltage input interface (3), the motor controller high-voltage output interface (4) and the battery high-voltage port (2), respectively. The bottom of the base is provided with four fixing legs (12), and the center of the fixing legs (12) is provided with a mounting hole, and the mounting hole is used to fix the BOOST boost device (16) to the vehicle body.

3. The electric vehicle BOOST boost system according to claim 2, characterized in that: One end of the low-voltage port (13) is connected to a low-voltage wiring harness of the entire vehicle, and the other end of the low-voltage port (13) is connected to a BOOST control unit (10). The low-voltage wiring harness of the entire vehicle includes a power supply, a grounding circuit, and a network circuit of the motor controller (17).

4. The electric vehicle BOOST boost system according to claim 1, characterized in that: The battery high-voltage port (2) is connected to the power battery (14) via a high-voltage wiring harness, the DC charging interface (5) is connected to the DC charging pile (15) via a high-voltage wiring harness, and the motor controller high-voltage input interface (3) and the motor controller high-voltage output interface (4) are connected to the motor controller (17) via a high-voltage wiring harness.

5. The electric vehicle BOOST boost system according to any one of claims 1 to 4, characterized in that: The housing (1) is made of a passivated aluminum alloy material, and a sealing ring (11) is provided between the base and the upper cover.

6. A BOOST charging method, characterized in that: The charging method adopts the electric vehicle BOOST boost system according to any one of claims 1 to 5 to realize charging of an 800V voltage platform electric vehicle by a 500V charging pile.

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