A DC charger shutdown detection control system

Abstract

The application discloses a kind of DC charger shutdown detection control systems, it is related to DC charger shutdown control technical field, solve the technical problem that existing technology cannot guarantee that output current has been reduced to 0 when disconnecting output relay, and cannot guarantee the timeliness of output disconnection, easy to lead to the damage of output relay;The control module of the application controls the on-off of the power module and the output relay;Power module detects the signal S3 formed by shutdown circuit, and carries out shutdown processing in time;Realize that during the process that control module detects shutdown signal S1, shutdown signal S1 forms signal S3 through shutdown circuit, power module detects signal S3 simultaneously, so as to ensure that when control module carries out filtering processing to shutdown signal S1, and prepares to disconnect output relay, power module also completes filtering detection processing to signal S3 and shutdown, avoid the fault problem caused by the damage of output relay.

Description

TECHNICAL FIELD

[0001] The application belongs to the field of DC charger shutdown control, and particularly relates to a DC charger shutdown detection control system. BACKGROUND

[0002] With the development of new energy vehicles, DC chargers also develop rapidly; the core part of the DC charger mainly comprises a main control board, a power module, output relays, a charging gun and a wire harness; for charging piles and other equipment, in order to protect the safety of users in an emergency, a shutdown button is arranged; when starting the shutdown device or stopping charging due to system failure in the charging service, the DC output should be disconnected within 100 ms; the common DC charging pile system directly disconnects the output relay when an emergency shutdown occurs, and there may be a situation that the output relay is disconnected with current, thereby causing the output relay to be burned and a safety hazard.

[0003] In order to realize the requirement of disconnecting the DC output within 100 ms, the prior art takes the following two measures: 1. the main control board disconnects the output relays K1 and K2 while sending shutdown on CAN, but at this time, the output relays may be disconnected with current; 2. the output relays K1 and K2 are disconnected after a delay, which cannot meet the requirement of being disconnected within 100 ms.

[0004] Therefore, the application provides a DC charger shutdown detection control system. SUMMARY

[0005] The application aims to at least solve one of the technical problems in the prior art; for this purpose, the application provides a DC charger shutdown detection control system, which is used to solve the technical problems that the prior art cannot guarantee that the output current is reduced to 0 when the output relay is disconnected, and cannot guarantee the timeliness of output disconnection, which easily leads to damage of the output relay.

[0006] To achieve the above purpose, a first aspect of the application provides a DC charger shutdown detection control system, comprising a control module, and a power module, a shutdown device, a shutdown circuit, an output relay and a power battery connected to the control module; the output relay is used to connect the power module and the power battery; the shutdown circuit is used to connect the shutdown device and the power module;

[0007] The control module is used to control the voltage, current and power of the output, control the on-off of the power module, acquire power battery information and charging demand information, control the on-off of the output relay, and detect a shutdown signal S1 of the shutdown device; wherein the shutdown device sends the shutdown signal S1 to the control module and the shutdown circuit;

[0008] Power module: used for detecting the validity of the signal S3 formed by the shutdown circuit, and performing shutdown processing in time; wherein, the input signal of the shutdown circuit includes the shutdown signal S1 sent by the shutdown device and the shutdown signal S2 sent by the control module.

[0009] Preferably, the detection of the validity of the signal S3 formed by the shutdown circuit includes:

[0010] When the control module detects system abnormalities, it will send the shutdown signal S2 to the shutdown circuit; the shutdown circuit distinguishes the shutdown signal S1 and the shutdown signal S2, and when one of the two signals is valid, the signal S3 formed by the shutdown circuit is valid.

[0011] Preferably, the power module performs shutdown processing in time based on the signal S3 formed by the shutdown circuit, including:

[0012] Step a1: the power module detects the signal S3 in real time; when the signal S3 is detected, the stop flag Stop_Flag is set to 1, and the counting function is started; wherein, the counting period is set to Q, 0 < Q ≤ 10 ms;

[0013] Step a2: determine whether the signal S3 exists within the counting time T1; if yes, set the real shutdown signal Real_Stop_Flag to 1; if no, set Stop_Flag and Real_Stop_Flag to 0, and clear the count; wherein, T1 is a positive integer greater than 0;

[0014] Step a3: if Real_Stop_Flag = 1, it indicates that there is a real shutdown demand, the charger is quickly turned off, and the shutdown signal is sent to the control module; if Real_Stop_Flag = 0, it indicates that there is no shutdown demand, and the charger operates normally.

[0015] Preferably, when the control module detects a system failure signal during the charging process, the control module controls the shutdown circuit as follows, including:

[0016] Step b1: when the control module detects a system failure signal during the charging process, it will send the shutdown signal S2 to the shutdown circuit and start the counting function;

[0017] Step b2: when the counting time is T2, set the control flag bit Relay_Ctr_Flag of the output relay to 1;

[0018] Step b3: when the control task function of the output relay detects Relay_Ctr_Flag = 1, it is disconnected, and sends a shutdown instruction to the power module.

[0019] Preferably, when the control module detects the stop signal S1, the control module controls the stop circuit as follows, including:

[0020] Step c1: when the control module detects the stop signal S1, the stop flag Stop_Flag is set to 1, and the counting function is started;

[0021] Step c2: when counting for a time length T2, it is judged whether the stop signal S1 exists; if yes, the real stop signal Real_Stop_Flag is set to 1; if no, the Stop_Flag and the Real_Stop_Flag are set to 0, and the counting is cleared; wherein T2 is a positive integer greater than 0;

[0022] Step c3: if Real_Stop_Flag = 1, it indicates that there is a real stop demand, the output relay is disconnected, and a shutdown instruction is sent to the power module; if Real_Stop_Flag = 0, it indicates that there is no stop demand, and the charger is normally operated without disconnecting the output relay.

[0023] Preferably, the output relay is composed of a relay K1 and a relay K2, and is used for connecting the power module and the power battery.

[0024] Preferably, the shutdown time of the power module is less than the relay disconnection time of the control module, and T1 < T2 < 100 ms.

[0025] Compared with the prior art, the present application has the following beneficial effects:

[0026] 1. When the charger system normally charges the power battery, the output relays K1 and K2 are in a closed state; the stop circuit can directly detect the stop signal S1 of the stop device, and transmit the signal S3 to the power module through the isolation optical coupler in the circuit, so that when the control module detects the stop signal S1, the stop signal S1 forms the signal S3 through the stop circuit, and the power module simultaneously detects the signal S3, thereby ensuring that when the control module is ready to disconnect the output relay after filtering and processing the stop signal S1, the power module also completes the filtering and detection processing of the signal S3 and shuts down, that is, the situation of disconnecting the relay with current does not occur;

[0027] 2. The power module of the present application can quickly detect faults and the signal S3, which can not only realize the quick shutdown of the power module, improve the shutdown response time of the system, and effectively prevent the output contactor from being disconnected with current to avoid damage to the contactor, but also can meet the requirement of disconnecting the output within 100 ms in an emergency, ensure the safety of the system, improve the stability and reliability of the system, and reduce the failure rate of the system. BRIEF DESCRIPTION OF DRAWINGS

[0028] In order to make the technical solutions of the embodiments of the present application or the prior art clearer, the accompanying drawings needed in the embodiments or prior art description will be briefly introduced. Obviously, the accompanying drawings in the following description only aim to some embodiments of the present application, and other drawings can be obtained by those skilled in the art without any creative effort.

[0029] Figure 1 The circuit block diagram of the DC charger of the present application;

[0030] Figure 2 The control method flow chart of the control module to the shutdown circuit when the control module detects the system fault signal in the charging process;

[0031] Figure 3 The control method flow chart of the control module to the shutdown circuit when the control module detects the shutdown signal S1;

[0032] Figure 4 The control method flow chart of the power module based on the signal S3 formed by the shutdown circuit. DETAILED DESCRIPTION

[0033] The technical solutions of the present application will be described clearly and completely in combination with the embodiments. Obviously, the described embodiments are only some of the embodiments of the present application, but not all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without any creative effort are within the protection scope of the present application.

[0034] Please refer to Figure 1 The first aspect embodiment of the present application provides a DC charger shutdown detection control system, which comprises a control module, and a power module, a shutdown device, a shutdown circuit, an output relay and a power battery connected with the control module; the output relay is used to connect the power module and the power battery; the shutdown circuit is used to connect the shutdown device and the power module;

[0035] It should be noted that the control module respectively communicates with the power module and the power battery BMS system through CAN.

[0036] The control module is used to control the output voltage, current and power, control the switching on and off of the power module, acquire the power battery information and charging demand information, control the on-off of the output relay, and detect the shutdown signal S1 of the shutdown device; wherein the shutdown device sends the shutdown signal S1 to the control module and the shutdown circuit; the output relay is composed of a relay K1 and a relay K2.

[0037] The control method of the control module to the shutdown circuit is as follows:

[0038] Please refer to Figure 2 When the control module detects the system fault signal during the charging process, the control module controls the shutdown circuit as follows:

[0039] Step b1: When the control module detects the system fault signal during the charging process, a shutdown signal S2 is sent to the shutdown circuit, and a counting function is started; wherein the counting period is set as Q, 0 < Q ≤ 10 ms;

[0040] Step b2: When the counting time is T2, the control flag bit Relay_Ctr_Flag of the output relay is set to 1;

[0041] Step b3: When the control task function of the output relay detects Relay_Ctr_Flag = 1, it is disconnected, and a shutdown instruction is sent to the power module.

[0042] Please refer to Figure 3 When the control module detects the shutdown signal S1, the control module controls the shutdown circuit as follows:

[0043] Step c1: When the control module detects the shutdown signal S1, the shutdown flag Stop_Flag is set to 1, and the counting function is started; wherein the counting period is set as Q, 0 < Q ≤ 10 ms;

[0044] Step c2: Within the counting time T2, it is judged whether the shutdown signal S1 exists; if yes, the real shutdown signal Real_Stop_Flag is set to 1; if no, Stop_Flag and Real_Stop_Flag are set to 0, and the counting is cleared; wherein T2 is a positive integer greater than 0;

[0045] Step c3: If Real_Stop_Flag = 1, it indicates that there is a real shutdown demand, the output relay is disconnected, and a shutdown instruction is sent to the power module; if Real_Stop_Flag = 0, it indicates that there is no shutdown demand, and the charger operates normally without disconnecting the output relay.

[0046] Power module: used for detecting the validity of the signal S3 formed by the shutdown circuit, and timely performing shutdown processing;

[0047] Wherein, the shutdown circuit is composed of diode D1, diode D2 and isolation chip; the shutdown device is connected with the positive electrode of diode D1, the control module is connected with the positive electrode of diode D2, the negative electrodes of diode D1 and diode D2 are connected with the input end of the isolation chip, and the output end of the isolation chip is connected with the power module;

[0048] The input signals of the shutdown circuit include a shutdown signal S1 sent by the shutdown device and a shutdown signal S2 sent by the control module; and the output signal S3 of the shutdown circuit is used to inform the power module to perform shutdown processing.

[0049] When the control module detects a system abnormality, the shutdown signal S2 is sent to the shutdown circuit; wherein the shutdown circuit distinguishes the shutdown signal S1 and the shutdown signal S2, and when one of the two signals is valid, the signal 3 output by the shutdown circuit is valid.

[0050] It should be noted that the shutdown signal S1 and the shutdown signal S2 are distinguished by a diode in the shutdown circuit, and the two signals realize an “or” relationship through hardware, and when one of the signals is valid, the output signal 3 is valid; the input and the output of the shutdown signal can be isolated by light or magnet.

[0051] Please refer to Figure 4 , the power module performs shutdown processing in time based on the signal S3 formed by the shutdown circuit, including:

[0052] Step a1: the power module detects the signal S3 in real time; when the signal S3 is detected, the shutdown flag Stop_Flag is set to 1, and the counting function is started; wherein the counting period is set to Q, 0

[0053] Step a2: it is judged whether the signal S3 exists within the counting time T1; if yes, the real shutdown signal Real_Stop_Flag is set to 1; if no, the Stop_Flag and the Real_Stop_Flag are set to 0, and the counting is cleared; wherein T1 is a positive integer greater than 0.

[0054] Step a3: if Real_Stop_Flag = 1, it indicates that there is a real shutdown demand, the charger is quickly turned off, and a shutdown signal is sent to the control module; if Real_Stop_Flag = 0, it indicates that there is no shutdown demand, and the charger operates normally.

[0055] Wherein, the counting period of the main control module and the counting period of the power module can be different, and each can set its own counting period, but T1 is a multiple of the counting period of the power module, and T2 is a multiple of the counting period of the main control module, in order to ensure that the power module is turned off before the main control module turns off the output contactor, it is required that T1 < T2 < 100 ms, for example, T1 = 60 ms, T2 = 90 ms.

[0056] It should be noted that when the system has an abnormal situation and needs to close the output relay, the control module first sends a shutdown signal S2, the shutdown signal S2 inputs the shutdown circuit to form a signal S3, and the power module detects the signal S3 after filtering and performs shutdown processing; wherein the control module delays a period of time to close the output relay to achieve the current-free disconnection of the relay; and

[0057] The shutdown time of the power module after filtering the signal S3 needs to be less than the time of the control module to disconnect the relay after filtering, and both the shutdown time and the time to disconnect the relay are less than 100 ms, which meets the requirement of disconnecting the output within 100 ms.

[0058] Part of the data in the above formula is calculated by removing the dimension to obtain the numerical value, and the formula is obtained by simulating a large amount of collected data to obtain a formula closest to the real situation; the preset parameters and the preset threshold in the formula are set by the person skilled in the art according to the actual situation or obtained by a large amount of data simulation.

[0059] The above embodiments are only used to illustrate the technical method of the present application and are not limited. Although the present application has been described in detail with reference to the preferred embodiments, it should be understood by those skilled in the art that the technical method of the present application can be modified or replaced equivalently without departing from the spirit and scope of the technical method of the present application.

Claims

1. A DC charger shutdown detection control system, characterized by, The control module, the power module, the shutdown device, the shutdown circuit, the output relay and the power battery are connected; the output relay is used for connecting the power module and the power battery; the shutdown circuit is used for connecting the shutdown device and the power module; The control module is used for controlling the voltage, the current and the power of the output, and controlling the switching of the power module; the control module is used for acquiring the power battery information and the charging demand information; the control module is used for controlling the on-off of the output relay, and detecting the shutdown signal S1 of the shutdown device; the shutdown device sends the shutdown signal S1 to the control module and the shutdown circuit; When the control module detects the shutdown signal S1, the control module controls the shutdown circuit as follows: Step c1: when the control module detects the shutdown signal S1, the shutdown flag Stop_Flag is set to 1, and the counting function is started; Step c2: when the counting time T2, it is judged whether the shutdown signal S1 exists; if yes, the real shutdown signal Real_Stop_Flag is set to 1; if no, the Stop_Flag and the Real_Stop_Flag are set to 0, and the counting is cleared; wherein T2 is a positive integer greater than 0; Step c3: if Real_Stop_Flag = 1, it indicates that there is a real shutdown demand, the output relay is disconnected and the shutdown instruction is sent to the power module; if Real_Stop_Flag = 0, it indicates that there is no shutdown demand, the charger is normally operated, and the output relay is not disconnected; When the control module detects the system fault signal in the charging process, the control module controls the shutdown circuit as follows: Step b1: when the control module detects the system fault signal in the charging process, the shutdown signal S2 is sent to the shutdown circuit, and the counting function is started; Step b2: when the counting time is T2, the control flag bit Relay_Ctr_Flag of the output relay is set to 1; Step b3: when the control task function of the output relay detects Relay_Ctr_Flag = 1, it is disconnected, and the shutdown instruction is sent to the power module; The power module is used for detecting the validity of the signal S3 formed by the shutdown circuit, and performing shutdown processing in time, including: Step a1: the power module detects the signal S3 in real time; when the signal S3 is detected, the stop flag Stop_Flag is set to 1, and the counting function is started; wherein the counting period is set to Q, ; Step a2: it is judged whether the signal S3 exists within the counting time T1; if yes, the real shutdown signal Real_Stop_Flag is set to 1; if no, the Stop_Flag and the Real_Stop_Flag are set to 0, and the counting is cleared; wherein T1 is a positive integer greater than 0; Step a3: if Real_Stop_Flag = 1, it indicates that there is a real shutdown demand, the charger is quickly closed, and the shutdown signal is sent to the control module; if Real_Stop_Flag = 0, it indicates that there is no shutdown demand, the charger is normally operated; The input signal of the shutdown circuit includes the shutdown signal S1 sent by the shutdown device and the shutdown signal S2 sent by the control module.

2. The DC charger shutdown detection control system of claim 1, wherein, The validity of the signal S3 formed by the shutdown circuit is detected, including: When the control module detects system abnormality, a shutdown signal S2 is sent to the shutdown circuit; the shutdown circuit distinguishes the shutdown signal S1 and the shutdown signal S2, and when one of the two signals is valid, a signal S3 formed by the shutdown circuit is valid.

3. The DC charger shutdown detection control system of claim 1, wherein, The output relay is composed of a relay K1 and a relay K2, and is used for connecting the power module and the power battery.

4. The DC charger shutdown detection control system of claim 1, wherein, The power module's shutdown time is less than the control module's relay disconnection time, and .

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