Direct-current output module of battery replacing and charging machine and battery replacing and charging machine

Abstract

The invention discloses a direct-current output module of a battery replacing and charging machine and the battery replacing and charging machine, and belongs to the technical field of electric vehicle charging. According to the scheme, the direct current output modules of the battery replacing and charging machine are integrated in the shells, two sets of direct current output units are symmetrically arranged in each shell, and each set of direct current output unit comprises a controller, a switching power supply, an axial flow fan, a direct current electric energy meter, a copper bar, a direct current contactor, a shunt and a fuse; the outer wall of the housing is provided with a signal terminal and a power terminal. The DC output module of the scheme is compact in structure, high in integration level, convenient to disassemble and assemble and convenient for subsequent maintenance and replacement, simplifies the design complexity of a battery replacement cabinet, greatly improves the space utilization rate, and reduces the maintenance difficulty and cost.

Description

Technical Field

[0001] The present invention relates to the technical field of electric vehicle charging, and in particular to a battery-swap charger DC output module and a battery-swap charger. Background Art

[0002] With the rapid development of China's new energy industry, the market share of electric vehicles has increased rapidly. In order to meet the needs of electric vehicle users for fast and convenient charging, the construction of supporting facilities for electric vehicles has become particularly important. The charging piles on the current market are gradually developing towards high-power charging, but the charging speed is still not as fast as battery swapping. Therefore, the development of battery swapping stations is particularly critical, especially the need for battery swapping chargers that can charge multiple battery packs at the same time.

[0003] The common multi-output battery-swap chargers on the market are usually designed with output power circuits arranged in parallel or in layers. Due to the limited space in the cabinet, power supply, control, and metering components are often stacked on both sides or distributed in other locations. Figure 1 As shown, this is a common layout of existing battery swap chargers, wherein: the charging module is arranged on the top layer, the lower layer of the charging module is the controller of each DC output, the lower layer of the controller is the copper busbar connected to the DC contactor and the shunt, and the bottom layer is the copper busbar connected to the DC contactor and the fuse.

[0004] However, the design of the battery swap station is limited by the size and layout of other equipment such as the battery compartment and robotic arm, and has strict requirements on the size of the equipment. The existing design scheme of DC output circuit arrangement or stacking arrangement will increase the size of the equipment, which is contrary to the compact design requirements of the equipment. In addition, the position arrangement of the power supply, control, and metering components in the cabinet is relatively chaotic, which makes the initial design difficult, the investment cost is high, and the equipment wiring is complicated, which is not conducive to subsequent maintenance and troubleshooting.

[0005] Therefore, it is necessary to propose a new design scheme for a multi-output battery swap charger to solve the problems of increased size, complex design and difficult maintenance in the existing design scheme, and to meet the strict requirements of battery swap stations on equipment size and layout. Summary of the invention

[0006] The technical problem to be solved by the present invention is: in view of the above-mentioned defects of the prior art, a DC output module of a battery swap charger and a battery swap charger are provided.

[0007] To achieve the above-mentioned object, the present invention provides a DC output module for a battery-swap charger, comprising a housing, wherein two groups of DC output units are symmetrically arranged in the depth direction in the housing, wherein the DC output units include a controller, a switching power supply, an axial flow fan, a DC electric energy meter, a copper busbar, a DC contactor, a shunt, and a fuse; and a signal terminal and a power terminal are arranged on the outer wall of the housing;

[0008] The signal terminal includes a power supply and a communication terminal. The signal terminal is connected to a switching power supply, a controller, a battery pack, a charging terminal, and a battery-swap charger control board, and is used to provide input power to the DC output module and provide the controller with a communication interface with the battery pack, the charging terminal, and the battery-swap charger control board;

[0009] The switching power supply is used to supply power to the internal components of the DC output module;

[0010] The axial flow fan is disposed close to a side wall of the housing and is used to dissipate heat from the DC output module;

[0011] The DC energy meter is connected to the shunt and the copper busbar and is used to measure the power consumption of the battery pack power circuit inside the DC output module;

[0012] The charging module in the battery-swapping charger is connected to the power terminal, and the power terminal is connected to the DC contactor, the shunt, and the fuse through the copper busbar, and then connected to the battery pack or the charging terminal;

[0013] The controller is connected to the DC power meter and the DC contactor. The controller is used to feed back battery charging information, metering information of the power circuit, and status information inside the DC output module to the battery swap charger control board, and to adjust the power output inside the DC output module by controlling the on and off of the DC contactor.

[0014] Preferably, the shell includes a first side wall, a second side wall, a third side wall, and a fourth side wall; the first side wall and the second side wall are respectively located at the top and the bottom of the shell, and the copper busbar is arranged along the height direction of the DC output module; through holes for the copper busbar to pass through are arranged at positions opposite to the copper busbar on the first side wall and the second side wall; the third side wall is arranged opposite to the axial flow fan, and heat dissipation holes are arranged at positions opposite to the axial flow fan on the third side wall; the signal terminal and the power terminal are arranged on the fourth side wall.

[0015] Preferably, in the shell, the axial flow fan is arranged at a position close to the lower part of the third side wall, the switching power supply is arranged on the side of the axial flow fan away from the third side wall, the controller is arranged above the axial flow fan and the switching power supply, the DC power meter is arranged below the switching power supply, and the copper busbar is arranged on the side of the controller and the switching power supply away from the third side wall.

[0016] Preferably, two groups of DC output units share the axial flow fan and the DC power meter.

[0017] Preferably, the signal terminal supplies power to the switching power supply and the DC power meter, the switching power supply supplies power to the controller, the axial flow fan, and the DC contactor, and the switching power supply also supplies power to the battery pack through the signal terminal.

[0018] Preferably, the DC contactor includes a first DC contactor, a second DC contactor, a third DC contactor, a fourth DC contactor, a fifth DC contactor, and a sixth DC contactor; the copper bar includes a first copper bar and a second copper bar; the first copper bar is connected with the fifth DC contactor, the third DC contactor, the fuse, and the first DC contactor from top to bottom; the second copper bar is connected with the sixth DC contactor, the fourth DC contactor, the second DC contactor, and the shunt from top to bottom.

[0019] Preferably, the first copper bus is provided with a first power terminal access point, a second power terminal access point, a charging terminal positive electrode, and a battery pack positive electrode; the first power terminal access point is located between the fuse and the third DC contactor; the second power terminal access point is located between the fifth DC contactor and the third DC contactor; the charging terminal positive electrode is located at the upper end of the fifth contactor, and the battery pack positive electrode is located at the lower end of the first contactor;

[0020] The second copper bus is provided with a third power terminal access point, a fourth power terminal access point, a negative pole of a charging terminal, and a negative pole of a battery pack; the third power terminal access point is located between the fourth DC contactor and the second DC contactor; the fourth power terminal access point is located between the sixth DC contactor and the fourth DC contactor; the negative pole of the charging terminal is located at the upper end of the sixth contactor, and the negative pole of the battery pack is located at the lower end of the shunt.

[0021] Preferably, the power terminal includes a first power terminal positive electrode, a first power terminal negative electrode, a second power terminal positive electrode, and a second power terminal negative electrode;

[0022] The charging module includes a first charging module and a second charging module;

[0023] The positive pole of the first charging module output is connected to the positive pole of the first power terminal, and the positive pole of the first power terminal is connected to the first power terminal access point; the negative pole of the first charging module output is connected to the negative pole of the first power terminal, and the negative pole of the first power terminal is connected to the third power terminal access point;

[0024] The positive pole of the second charging module output is connected to the positive pole of the second power terminal, and the positive pole of the second power terminal is connected to the second power terminal access point; the negative pole of the second charging module output is connected to the negative pole of the second power terminal, and the negative pole of the second power terminal is connected to the fourth power terminal access point.

[0025] An embodiment of the present invention also provides a battery-swap charger, comprising a plurality of the battery-swap charger DC output modules as described above.

[0026] The present invention has the following beneficial effects: This solution integrates the DC output module of the battery-swap charger into the housing, and two groups of DC output units are symmetrically arranged in each housing. Each group of DC output units includes a controller, a switching power supply, an axial fan, a DC energy meter, a copper bus, a DC contactor, a shunt, and a fuse; signal terminals and power terminals are arranged on the outer wall of the housing. The DC output module of this solution has a compact structure, high integration, and is easy to disassemble and assemble, which is convenient for subsequent maintenance and replacement. It simplifies the complexity of the battery-swap cabinet design, greatly improves space utilization, and reduces maintenance difficulty and cost. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] The drawings described herein are used to provide a further understanding of the present invention and constitute a part of the present invention. The exemplary embodiments of the present invention and their descriptions are used to explain the present invention and do not constitute an improper limitation of the present invention. In the drawings:

[0028] Figure 1 This is a schematic diagram of the layout of a battery replacement charger in the prior art.

[0029] Figure 2 An exploded diagram of the DC output module of the battery swap charger provided in an embodiment of the present invention.

[0030] Figure 3 A three-dimensional assembly diagram of the DC output module of the battery swap charger provided in an embodiment of the present invention.

[0031] Figure 4 This is a front view of the DC output module of the battery swap charger provided in an embodiment of the present invention.

[0032] Figure 5 This is a rear view of the DC output module of the battery swap charger provided in an embodiment of the present invention.

[0033] Figure 6 This is a left view of the DC output module of the battery swap charger provided in an embodiment of the present invention.

[0034] Figure 7 This is a right view of the DC output module of the battery swap charger provided in an embodiment of the present invention.

[0035] Figure 8 A bottom view of the DC output module of the battery swap charger provided in an embodiment of the present invention.

[0036] Fig. 9 A top view of the DC output module of the battery swap charger provided in an embodiment of the present invention.

[0037] Fig.10 Detailed schematic diagram of the copper busbar and DC contactor of the DC output module of the battery swap charger provided in an embodiment of the present invention.

[0038] Fig.11 A schematic diagram of the details of the power terminals of the DC output module of the battery swap charger provided in an embodiment of the present invention.

[0039] Fig.12 Schematic diagram of the wiring terminals of the DC output module of the battery swap charger provided in an embodiment of the present invention.

[0040] Fig.13 A schematic diagram of assembling multiple DC output modules of a battery swap charger provided in an embodiment of the present invention.

[0041] Fig.14 A schematic assembly diagram of multiple DC output modules of the battery swap charger provided in an embodiment of the present invention from another perspective.

[0042] Fig.15 A schematic diagram of the layout of a battery swap charger provided in an embodiment of the present invention. DETAILED DESCRIPTION

[0043] In order to make the purpose, technical solution and advantages of the embodiments of the present invention clearer, the technical solution in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are 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 creative work are within the scope of protection of the present invention.

[0044] The embodiments of the present invention are further described in detail below in conjunction with the accompanying drawings of the specification. It should be understood that the embodiments described herein are only used to illustrate and explain the present invention, and are not used to limit the present invention.

[0045] The battery swap charger DC output module provided in the embodiment of the present invention serves as a DC output control unit inside the battery swap charger, which is responsible for receiving the charging requirements of the battery BMS, sending the charging requirements and battery BMS information to the battery swap charger control board, controlling the power output of the battery swap charger to the battery pack and electric vehicle, and measuring the charging data.

[0046] like Figure 2-9 As shown, an embodiment of the present invention provides a DC output module for a battery-swap charger, comprising a housing 1, wherein two groups of DC output units are symmetrically arranged in the depth direction of the housing 1, wherein the DC output units include a controller 2, a switching power supply 3, an axial flow fan 4, a DC power meter 5, a copper bus 7, a DC contactor 8, a shunt 10, and a fuse 11; a signal terminal 6 and a power terminal 9 are arranged on the outer wall of the housing;

[0047] The signal terminal 6 includes a power supply and a communication terminal. The signal terminal 6 is connected to the switching power supply 3, the controller 2, the battery pack, the charging terminal, and the battery swap charger control board, and is used to provide input power for the DC output module and provide the controller with a communication interface with the battery pack, the charging terminal, and the battery swap charger control board.

[0048] The signal terminal 6 is the interactive interface between the DC output module of the battery swap charger and the battery swap charger and the battery BMS. The signal terminal 6 has the functions of powering the module, communicating between the module and the battery swap charger, signal feedback, powering the battery BMS, powering the battery auxiliary power supply, and communicating with the battery BMS. The signal terminal 6 has a set of power supply interfaces. The AC220V power supply of the battery swap charger is connected to the signal terminal 6 to provide working power for the DC output module.

[0049] The switching power supply 3 is used to supply power to the internal components of the DC output module.

[0050] In some embodiments of the present invention, the signal terminal 6 supplies power to the switching power supply 3 and the DC power meter 5 , the switching power supply 3 supplies power to the controller 2 , the axial flow fan 4 , and the DC contactor 8 , and the switching power supply 3 also supplies power to the battery pack through the signal terminal 6 .

[0051] The axial flow fan 4 is disposed close to a side wall of the housing 1 and is used to dissipate heat from the DC output module.

[0052] The DC energy meter 5 is connected to the shunt 10 and the copper bus 7, and is used to measure the power consumption of the battery pack power circuit inside the DC output module;

[0053] The charging module in the battery-swapping charger is connected to the power terminal 9, and the power terminal 9 is connected to the DC contactor 8, the shunt 10, and the fuse 11 through the copper bus 7, and then connected to the battery pack or the charging terminal.

[0054] The battery swap charger DC output module provided by the present invention includes two groups of DC output units, each group of DC output units can charge the battery pack in the battery swap station separately, and can also provide output power to the charging pile connected outside the battery swap station, and is also compatible with providing power output to the charging pile outside the battery swap station when replenishing the battery pack. The two groups of DC output units are symmetrically arranged, making the overall structure of the DC output module more compact and smaller in size.

[0055] In the embodiment of the present invention, the housing 1 includes a first side wall 1A, a second side wall 1B, a third side wall 1C, and a fourth side wall 1D; the first side wall 1A and the second side wall 1B are respectively located at the top and bottom of the housing 1, and the copper bar 7 is arranged along the height direction of the DC output module; the first side wall 1A and the second side wall 1B are provided with a through hole 1B1 for the copper bar to pass through at a position opposite to the copper bar 7; the third side wall 1C is arranged opposite to the axial flow fan 4, and an air inlet 1C1 is arranged at a position opposite to the axial flow fan 4 on the third side wall 1C, and an air outlet 1D1 is arranged in the middle of the fourth side wall 1D. During charging, the axial flow fan 4 inhales the cold air at the rear of the DC output module through the air inlet 1C1, and then pushes the internal hot air out through the air outlet 1D1. The signal terminal 6 and the power terminal 9 are arranged on the fourth side wall 1D.

[0056] like Figure 3 , Figure 4 As shown, specifically, in the housing, the axial flow fan 4 is arranged at a position close to the lower part of the third side wall 1C, the switching power supply 3 is arranged on the side of the axial flow fan 4 away from the third side wall 1C, the controller 2 is arranged above the axial flow fan 4 and the switching power supply 3, the DC power meter 5 is arranged below the switching power supply 3, and the copper busbar 7 is arranged on the side of the controller 2 and the switching power supply 3 away from the third side wall 1C. Among the six surfaces of the housing, the two surfaces facing the DC output unit are not sealed, so as to facilitate the rapid disassembly and replacement of internal components.

[0057] In some embodiments of the present invention, two groups of DC output units share the axial flow fan 4 and the DC power meter 5. The DC power meter 5 supports dual-channel measurement.

[0058] like Figure 2 , Figure 3 , Figure 4 , Fig.11 , Fig.14 In the embodiment of the present invention, a handle is provided on the fourth side wall, through which the DC output module can be easily plugged in and out of the plug-in frame in the cabinet. The bottom of the housing 1 is flat, which is convenient for plugging in and out. The housing 1 has screw holes on the left and right sides, and the DC output module can be locked on the plug-in frame in the cabinet through the screw holes.

[0059] The controller 2 is connected to the DC power meter 5 and the DC contactor 8. The controller 2 is used to feed back battery charging information, metering information of the power circuit, and status information inside the DC output module to the battery swap charger control board, and to adjust the power output inside the DC output module by controlling the on and off of the DC contactor 8.

[0060] The controller 2 obtains the battery charging information from the battery pack through the signal terminal 6. The battery charging information includes the battery code, battery power, and charging requirements. The state information inside the DC output module includes the DC contactor state, fuse state, and controller communication state.

[0061] The shunt 10 is always connected in the power circuit, the DC energy meter 5 is connected to the signal interface of the shunt 10 through a cable for current sampling, connected to the copper bus 7 for voltage sampling, and connected to the controller 2 to upload the power data. The controller 2 transmits the power data to the battery swap charger control board through the signal terminal 6, and the battery swap charger control board completes real-time display and billing.

[0062] The copper busbar 7 and the power terminal 9 provide a power interface and power transmission for the entire DC output module, and complete the power control and output by connecting the charging power module, the battery power interface, and the charging terminal. The copper busbar 7 is connected to the DC contactor 8, the power terminal 9, the shunt 10, and the fuse 11 inside the DC output module, and is connected to the external battery pack and the DC charging terminal (pile) through a cable. The charging module is outside the DC output module, and outputs power to the DC output module through the power terminal 9, and then the DC output module controls the output to the battery pack and the charging terminal. The fuse 11 is used for short-circuit and overload protection of the power output circuit.

[0063] The DC contactor 8 is controlled by the control board 2 to complete the power distribution, pre-charging stage, and output control of the charging stage of the battery replacement charger. Fig.10 As shown, in the embodiment of the present invention, in each group of the DC output units, the DC contactor 8 includes a first DC contactor 81, a second DC contactor 82, a third DC contactor 83, a fourth DC contactor 84, a fifth DC contactor 85, and a sixth DC contactor 86; the copper bar 7 includes a first copper bar 71 and a second copper bar 72; the first copper bar 71 is connected with the fifth DC contactor 85, the third DC contactor 83, the fuse 11, and the first DC contactor 81 from top to bottom; the second copper bar 72 is connected with the sixth DC contactor 86, the fourth DC contactor 84, the second DC contactor 82, and the shunt 10 from top to bottom.

[0064] The first copper busbar 71 is provided with a first power terminal access point 711, a second power terminal access point 712, a charging terminal positive pole 713, and a battery pack positive pole 714; the first power terminal access point 711 is located between the fuse 11 and the third DC contactor 83; the second power terminal access point 712 is located between the fifth DC contactor 85 and the third DC contactor 83; the charging terminal positive pole 713 is located at the upper end of the fifth contactor 85, and the battery pack positive pole 714 is located at the lower end of the first contactor 81.

[0065] The second copper busbar 72 is provided with a third power terminal access point 721, a fourth power terminal access point 722, a charging terminal negative pole 723, and a battery pack negative pole 724; the third power terminal access point 723 is located between the fourth DC contactor 84 and the second DC contactor 82; the fourth power terminal access point 84 is located between the sixth DC contactor 83 and the fourth DC contactor 84; the charging terminal negative pole 723 is located at the upper end of the sixth contactor 86, and the battery pack negative pole 724 is located at the lower end of the shunt 10.

[0066] like Fig.11 As shown, corresponding to each group of the DC output units, the power terminal 9 includes a first power terminal positive electrode 91 , a first power terminal negative electrode 92 , a second power terminal positive electrode 93 , and a second power terminal negative electrode 94 .

[0067] The charging module includes a first charging module and a second charging module;

[0068] The positive output electrode of the first charging module is connected to the positive electrode 91 of the first power terminal, and the positive electrode 91 of the first power terminal is connected to the first power terminal access point 711; the negative output electrode of the first charging module is connected to the negative electrode 92 of the first power terminal, and the negative electrode 92 of the first power terminal is connected to the third power terminal access point 721;

[0069] The positive pole of the second charging module output is connected to the positive pole of the second power terminal 93, and the positive pole of the second power terminal 93 is connected to the second power terminal access point 712; the negative pole of the second charging module output is connected to the negative pole of the second power terminal 94, and the negative pole of the second power terminal 94 is connected to the fourth power terminal access point 722.

[0070] In the embodiment of the present invention, the upper end of the copper busbar is the positive and negative electrode interface of the charging terminal, the lower end is the positive and negative electrode interface of the battery pack, and the shunt 10 and the fuse 11 are connected to the power circuit of the battery pack. The lower end of the copper busbar can also be used as the positive and negative electrode interface of the charging terminal, and the upper end as the positive and negative electrode interface of the battery pack. Accordingly, the shunt 10 and the fuse 11 need to be adjusted to the power circuit where the positive and negative electrode interfaces of the battery pack are located.

[0071] In some embodiments of the present invention, the on and off of the DC contactor 8 is all controlled by the controller 2. In other embodiments of the present invention, the controller 2 controls the on and off of the first contactor and the second contactor to realize the control of the charging of the battery pack, and the battery charger control board controls the on and off of the remaining contactors, such as Fig.12The schematic diagram of the corresponding terminal block 6 is shown, including seven areas of the terminal block, namely X1, X2, X3, X4, X5, X6, and X7, and two USB interfaces. The two USB interfaces are USB external interfaces of two groups of DC output units, which are used to upgrade the system and export charging information. The X1 area includes a DC output module power supply interface and an axial fan feedback signal interface. The battery swap charger supplies power to the DC output module through the DC output module power supply interface, and the controller 2 feeds back the axial fan status information to the battery swap charger control board through the axial fan feedback signal interface. The X2 and X3 areas respectively include the control and feedback signal interfaces of the third contactor 83, the fourth contactor 84, the fifth contactor 85, and the sixth contactor 86 of the two groups of DC output units. The X4 area includes the communication interaction interface between the DC output module and the battery pack, the charging terminal, and the battery swap charger control board. Specifically, the X4 area is a CAN bus interface. The X5 and X6 areas include two sets of battery pack control guide ports, which are used for CAN interaction between the DC output module and the battery pack, providing BMS auxiliary source for the battery pack, waking up the power supply, and confirming the connection between the DC output module and the battery pack; the battery pack connector temperature sampling can be customized according to the battery pack and connector with different requirements. The X7 area includes two sets of charging CAN ports for DC output units, which are used for debugging.

[0072] The working principle of each group of DC output units in the DC output module of the battery swap charger in the embodiment of the present invention is as follows:

[0073] After the controller 2 receives the charging demand of the battery and the electric vehicle through the signal terminal 6, the switching power supply 3 provides auxiliary power for the battery BMS; by controlling the DC contactor 8, the self-test of the power supply circuit is completed. The power supply circuit includes a copper bus 7, a DC contactor 8, a shunt 10, and a fuse 11. The specific method of self-test is: an insulation detection circuit is integrated in the controller 2, and the insulation resistance between the high-voltage DC circuit and the ground is measured by controlling the closing of the first DC contactor 81 and the second DC contactor 82.

[0074] After the self-test is completed, the DC contactor 8 is closed to connect the battery side power output circuit and the charging terminal power output circuit. Each group of DC output units includes 6 DC contactors, and the purpose of charging the battery pack and the electric vehicle is achieved by closing different contactors.

[0075] When the battery needs to be charged, the first contactor 81 and the second contactor 82 are closed, the battery pack charging circuit is turned on, and the first charging module is connected. According to the power demand, it is determined whether to close the third contactor and the fourth contactor at the same time to connect to the second charging module to provide more charging power. The charging module output passes through the power terminal 9, the DC contactor 8, the shunt 10, the fuse 11, and the copper bus 7 to complete the charging of the battery. The DC energy meter 5 performs current sampling through the shunt 10 and voltage sampling on the DC output circuit to complete the measurement of the battery side power data.

[0076] When charging the electric vehicle, the fifth contactor 85 and the sixth contactor 86 are closed, the charging terminal circuit is turned on, and the second charging module is connected. It is determined whether to close the third contactor 83 and the fourth contactor 84 at the same time to connect to the first charging module according to the power demand.

[0077] When a group of DC output units has both battery pack charging needs and electric vehicle charging needs, the first contactor 81 and the second contactor 82 are closed, and the battery pack charging circuit is turned on; the fifth contactor 85 and the sixth contactor 86 are closed, and the charging terminal circuit is turned on, and the battery pack and the electric vehicle are charged at the same time.

[0078] During the charging process, the axial flow fan 4 is started to drive the air flow inside the module to cool the power devices.

[0079] The working principle of the other group of DC output units is the same as above. When there are multiple DC output modules in the battery swap charger, after the battery pack is connected to any group of DC output units of a DC output module, the group of DC output units is connected to the battery pack signal terminal through the signal terminal 6. After confirming the signal connection, the internal controller 2 of the module uploads the successful connection confirmation information to the battery swap charger control board, and then the battery swap charger control board controls the DC output module to start the group of DC output units, perform self-test, and start charging after the self-test is completed.

[0080] like Fig.13 , Fig.14 The figure shows the assembly diagram of multiple DC output modules. When multiple DC output modules are connected in parallel, the upper charging terminal copper busbar can be connected to the charging terminal alone, or the charging terminal copper busbars of each module can be connected in parallel to realize multiple DC output modules in parallel, and then connected to the super charging terminal to achieve high power output.

[0081] The embodiment of the present invention also provides a battery swap charger, including a plurality of battery swap charger DC output modules as described above. In addition to the DC output module, the battery swap charger also includes an AC incoming line switch, an AC contactor, a surge protector, a charging module, a battery swap charger control board, an emergency stop button, a status indicator light, and a system fan. The battery swap charger control board can control the start and stop of the DC output module.

[0082] like Fig.15 The following is a schematic diagram of the layout of a battery replacement charger in some embodiments of the present invention. The upper row is the charging module, and the lower row is the DC output module. Fig.15 It includes 6 DC output modules, a total of 12 DC output units, providing 12 DC outputs. Figure 1 It is a battery replacement charger based on the prior art, and also includes 12 DC outputs. Figure 1 In the process, the controller and metering unit (shunt) of the DC output are arranged in layers. Figure 1 The width of the battery swap charger from the main view angle is 1474mm and the height is 2420mm; Fig.15 In the front view of the battery swap charger, the width is 1474mm and the height is 1555mm, and the depth of the two cabinets is the same. It can be seen that through the improvement of the embodiment of the present invention, the height of the cabinet is reduced by 864mm, and the reduction ratio is about 36%. In addition to reducing the space, the improvement of the embodiment of the present invention simplifies the overall design of the battery swap charging cabinet, and integrates each DC module into a shell, making the overall layout of the cabinet more orderly and reducing the difficulty and cost of maintenance.

[0083] The present invention has the following beneficial effects: the present invention integrates the DC output module of the battery-swap charger into the shell, and each shell is symmetrically provided with two groups of DC output units, which has a compact structure, high integration, convenient disassembly and assembly, and is convenient for subsequent maintenance and replacement. A single module supports two-way battery and two-way electric vehicle charging at the same time, improving the utilization rate of the module in different scenarios. The DC output module of the battery-swap charger of the present invention can support upper-end output and lower-end output, and supports the simple parallel connection of multiple modules to achieve high-power output. The corresponding number of modules can be configured according to different application scenarios to meet the needs of the station, simplifying the design complexity of the battery-swap cabinet, greatly improving the space utilization, and reducing the difficulty and cost of maintenance.

[0084] The above are only specific implementations of the present invention, which cannot be used to limit the scope of the present invention. Equivalent changes made by ordinary technicians in this technical field based on this creation, as well as changes known to technicians in this field, should still fall within the scope of the present invention.

Claims

1. A DC output module for a battery replacement charger, characterized in that: The device comprises a shell, wherein two groups of DC output units are symmetrically arranged in the depth direction of the shell, wherein the DC output units include a controller, a switching power supply, an axial flow fan, a DC electric energy meter, a copper bus, a DC contactor, a shunt, and a fuse; and a signal terminal and a power terminal are arranged on the outer wall of the shell; The signal terminal includes a power supply and a communication terminal. The signal terminal is connected to a switching power supply, a controller, a battery pack, a charging terminal, and a battery-swap charger control board, and is used to provide input power to the DC output module and provide the controller with a communication interface with the battery pack, the charging terminal, and the battery-swap charger control board; The switching power supply is used to supply power to the internal components of the DC output module; The axial flow fan is disposed close to a side wall of the housing and is used to dissipate heat from the DC output module; The DC energy meter is connected to the shunt and the copper busbar and is used to measure the power consumption of the battery pack power circuit inside the DC output module; The charging module in the battery-swapping charger is connected to the power terminal, and the power terminal is connected to the DC contactor, the shunt, and the fuse through the copper busbar, and then connected to the battery pack or the charging terminal; The controller is connected to the DC power meter and the DC contactor. The controller is used to feed back battery charging information, metering information of the power circuit, and status information inside the DC output module to the battery swap charger control board, and to adjust the power output inside the DC output module by controlling the on and off of the DC contactor.

2. The DC output module of the battery replacement charger according to claim 1, characterized in that: The shell includes a first side wall, a second side wall, a third side wall, and a fourth side wall; the first side wall and the second side wall are respectively located at the top and the bottom of the shell, and the copper busbar is arranged along the height direction of the DC output module; through holes for the copper busbar to pass through are arranged at positions opposite to the copper busbar on the first side wall and the second side wall; the third side wall is arranged opposite to the axial flow fan, and heat dissipation holes are arranged at positions opposite to the axial flow fan on the third side wall; the signal terminal and the power terminal are arranged on the fourth side wall.

3. The DC output module of the battery replacement charger according to claim 2, characterized in that: In the shell, the axial flow fan is arranged at a position close to the lower part of the third side wall, the switching power supply is arranged on a side of the axial flow fan away from the third side wall, the controller is arranged above the axial flow fan and the switching power supply, the DC power meter is arranged below the switching power supply, and the copper busbar is arranged on a side of the controller and the switching power supply away from the third side wall.

4. The DC output module of the battery replacement charger according to claim 3, characterized in that: The two groups of DC output units share the axial flow fan and the DC electric energy meter.

5. The DC output module of the battery replacement charger according to claim 1, characterized in that: The signal terminal supplies power to the switching power supply and the DC energy meter. The switching power supply supplies power to the controller, the axial flow fan, and the DC contactor. The switching power supply also supplies power to the battery pack through the signal terminal.

6. The DC output module of the battery replacement charger according to claim 3, characterized in that: The DC contactor includes a first DC contactor, a second DC contactor, a third DC contactor, a fourth DC contactor, a fifth DC contactor, and a sixth DC contactor; the copper bar includes a first copper bar and a second copper bar; the first copper bar is connected with the fifth DC contactor, the third DC contactor, the fuse, and the first DC contactor from top to bottom; the second copper bar is connected with the sixth DC contactor, the fourth DC contactor, the second DC contactor, and the shunt from top to bottom.

7. The DC output module of the battery replacement charger according to claim 6, characterized in that: The first copper bus is provided with a first power terminal access point, a second power terminal access point, a positive electrode of a charging terminal, and a positive electrode of a battery pack; the first power terminal access point is located between the fuse and the third DC contactor; the second power terminal access point is located between the fifth DC contactor and the third DC contactor; the positive electrode of the charging terminal is located at the upper end of the fifth contactor, and the positive electrode of the battery pack is located at the lower end of the first contactor; The second copper bus is provided with a third power terminal access point, a fourth power terminal access point, a negative pole of a charging terminal, and a negative pole of a battery pack; the third power terminal access point is located between the fourth DC contactor and the second DC contactor; the fourth power terminal access point is located between the sixth DC contactor and the fourth DC contactor; the negative pole of the charging terminal is located at the upper end of the sixth contactor, and the negative pole of the battery pack is located at the lower end of the shunt.

8. The DC output module of the battery replacement charger according to claim 7, characterized in that: The power terminal comprises a first power terminal positive electrode, a first power terminal negative electrode, a second power terminal positive electrode, and a second power terminal negative electrode; The charging module includes a first charging module and a second charging module; The positive pole of the first charging module output is connected to the positive pole of the first power terminal, and the positive pole of the first power terminal is connected to the first power terminal access point; the negative pole of the first charging module output is connected to the negative pole of the first power terminal, and the negative pole of the first power terminal is connected to the third power terminal access point; The positive pole of the second charging module output is connected to the positive pole of the second power terminal, and the positive pole of the second power terminal is connected to the second power terminal access point; the negative pole of the second charging module output is connected to the negative pole of the second power terminal, and the negative pole of the second power terminal is connected to the fourth power terminal access point.

9. A battery-swap charger, comprising a plurality of battery-swap charger DC output modules as described in any one of claims 1-8.

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