A DC output module for a battery-swapping charger and a battery-swapping charger

Abstract

The present invention discloses a DC output module of a battery-swapping charger and a battery-swapping charger, belonging to the technical field of electric vehicle charging. This solution integrates the DC output module of the battery-swapping charger into a shell, and two groups of DC output units are symmetrically arranged in each shell. Each group of DC output units includes a controller, a switching power supply, an axial fan, a DC power 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 shell. 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 design complexity of the battery-swapping cabinet, greatly improves space utilization, and reduces 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, electric vehicles are rapidly increasing their market share. To meet the needs of electric vehicle users for quick and convenient recharging, the development of supporting infrastructure for electric vehicles has become increasingly important. While charging stations are currently moving towards higher-power charging, charging speeds are still slower than battery swapping. Therefore, the development of battery swapping stations is crucial, particularly those with chargers capable of simultaneously charging multiple battery packs.

[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 The figure shows a common layout of existing battery swap chargers, in which: the charging module is set 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 shunt, and the bottom layer is the copper busbar connected to the DC contactor and fuse.

[0004] However, the design of battery swap stations is constrained by the size and layout of other equipment, such as battery compartments and robotic arms, placing strict requirements on equipment size. Existing designs that arrange or stack DC output circuits increase equipment size, contradicting the requirement for a compact design. Furthermore, the layout of power supply, control, and metering components within the cabinet is chaotic, making initial design difficult and costly. The complex wiring of the equipment hinders 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 objectives, 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 of the housing, and the DC output units include a controller, a switching power supply, an axial flow fan, a DC energy meter, a copper busbar, a DC contactor, a shunt, and a fuse; and signal terminals and power terminals are provided 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 the switching power supply, the controller, the battery pack, the charging terminal, and the battery swap charger control board 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;

[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 arranged near a side wall of the housing 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 feedback battery charging information, power circuit metering information, 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 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 provided on the first side wall and the second side wall at positions opposite to the copper busbar; the third side wall is arranged opposite to the axial flow fan, and a heat dissipation hole is provided on the third side wall at a position opposite to the axial flow fan; 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 energy 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 to 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 to 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 the charging terminal, and a negative pole of the 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 output electrode of the first charging module is connected to the positive electrode of the first power terminal, and the positive electrode of the first power terminal is connected to the first power terminal access point; the negative output electrode of the first charging module is connected to the negative electrode of the first power terminal, and the negative electrode 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 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. Each housing has two symmetrically arranged groups of DC output units. Each group of DC output units includes a controller, a switching power supply, an axial-flow fan, a DC energy meter, a copper busbar, a DC contactor, a shunt, and a fuse. Signal terminals and power terminals are provided 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, facilitating subsequent maintenance and replacement. This simplifies the design complexity of the battery-swap cabinet, 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 the battery swap charger in the existing technology.

[0029] Figure 2 This is an exploded view 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] Figure 9 A top view of the DC output module of the battery swap charger provided in an embodiment of the present invention.

[0037] Figure 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] Figure 11 Detailed schematic diagram of the power terminals of the DC output module of the battery swap charger provided in an embodiment of the present invention.

[0039] Figure 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] Figure 13 Schematic diagram of the assembly of multiple DC output modules of the battery swap charger provided in an embodiment of the present invention.

[0041] Figure 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] Figure 15 A schematic diagram of the battery swap charger layout provided in an embodiment of the present invention. DETAILED DESCRIPTION

[0043] To make the objectives, technical solutions, and advantages of the embodiments of the present invention more clear, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. All other embodiments obtained by ordinary technicians in this field based on the embodiments of the present invention without making any creative efforts shall fall within the scope of protection of the present invention.

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

[0045] The battery swap charger DC output module provided in the embodiment of the present invention serves as the 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, and the DC output units include a controller 2, a switching power supply 3, an axial flow fan 4, a DC energy 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 provided 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 battery BMS. Signal terminal 6 has functions such as 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. Signal terminal 6 has a set of power supply interfaces. The AC220V power supply of the battery swap charger is connected to 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 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 near 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 this invention includes two sets of DC output units. Each set of DC output units can independently charge the battery packs within the battery swap station, provide output power to charging piles connected to the station, and simultaneously provide power output to charging piles outside the station while recharging the battery packs. The symmetrical arrangement of the two sets of DC output units makes the DC output module more compact and smaller in size.

[0055] In this 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 located at the top and bottom of the housing 1, respectively. The copper busbar 7 is arranged along the height direction of the DC output module. A through hole 1B1 for the copper busbar to pass through is provided on the first side wall 1A and the second side wall 1B at a position opposite the copper busbar 7. The third side wall 1C is arranged opposite the axial flow fan 4. An air inlet 1C1 is provided on the third side wall 1C at a position opposite the axial flow fan 4. An air outlet 1D1 is provided in the middle of the fourth side wall 1D. During charging, the axial flow fan 4 draws cool air from 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 provided on the fourth side wall 1D.

[0056] like Figure 3 、 Figure 4 Specifically, within the housing, the axial fan 4 is positioned near the lower portion of the third side wall 1C, the switching power supply 3 is positioned on the side of the axial fan 4 away from the third side wall 1C, the controller 2 is positioned above the axial fan 4 and the switching power supply 3, the DC power meter 5 is positioned below the switching power supply 3, and the copper busbar 7 is positioned on the side of the controller 2 and the switching power supply 3 away from the third side wall 1C. Of the six sides of the housing, the two sides directly facing the DC output unit are unsealed, facilitating quick 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 metering.

[0058] like Figure 2 、 Figure 3 、 Figure 4 、 Figure 11 、 Figure 14 In this embodiment of the present invention, a handle is provided on the fourth side wall, which facilitates the insertion and removal of the DC output module from the enclosure within the cabinet. The housing 1 has a flat bottom for easy insertion and removal, and has screw holes on both sides of the housing 1, which allow the DC output module to be locked to the enclosure within the cabinet.

[0059] The controller 2 is connected to the DC power meter 5 and the DC contactor 8. The controller 2 is used to feedback battery charging information, power circuit metering information, 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 status information inside the DC output module includes the DC contactor status, fuse status, and controller communication status.

[0061] The shunt 10 is always connected to the power circuit. The DC energy meter 5 is connected to the signal interface of the shunt 10 via 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 performs real-time display and billing.

[0062] The copper bus 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 bus 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, which is then controlled by the DC output module to 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 charging stage output control of the battery charger. Figure 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 to 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 to 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 Figure 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 of the first power terminal 91, which 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 of the first power terminal 92, which is connected to the third power terminal access point 721;

[0069] The positive output pole of the second charging module 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 output pole of the second charging module 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 this embodiment of the present invention, the upper end of the copper busbar serves as the positive and negative terminals for the charging terminal, while the lower end serves as the positive and negative terminals for the battery pack. The shunt 10 and fuse 11 are connected to the power circuit of the battery pack. Alternatively, the lower end of the copper busbar can serve as the positive and negative terminals for the charging terminal, while the upper end serves as the positive and negative terminals for the battery pack. Accordingly, the shunt 10 and fuse 11 need to be adjusted to the power circuit where the positive and negative terminals of the battery pack are located.

[0071] In some embodiments of the present invention, the on and off of the DC contactor 8 are 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 battery pack charging, and the battery charger control board controls the on and off of the remaining contactors, such as Figure 12The diagram shows the corresponding terminal block 6, which includes seven areas, namely X1, X2, X3, X4, X5, X6 and X7, and two USB interfaces. The two USB interfaces are respectively the USB external interfaces of the 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 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 each include two battery pack control pilot ports, used for CAN communication between the DC output module and the battery pack, providing the battery pack with a BMS auxiliary power source, waking up the power supply, and confirming the connection between the DC output module and the battery pack. They also enable temperature sampling of the battery pack connector and can be customized to meet different battery pack and connector requirements. The X7 area includes two DC output unit charging CAN ports 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 controller 2 receives charging requests from the battery and electric vehicle via signal terminal 6, switching power supply 3 provides auxiliary power to the battery management system (BMS). It then controls DC contactor 8 to perform a self-test of the power supply circuit. This circuit includes a copper busbar 7, DC contactor 8, shunt 10, and fuse 11. The self-test is performed as follows: Controller 2 integrates an insulation detection circuit that controls the closing of first and second DC contactors 81, 82 to measure the insulation resistance between the high-voltage DC circuit and ground.

[0074] After the self-test is complete, the DC contactor 8 is closed to connect the battery side power output circuit and the charging terminal power output circuit. Each DC output unit group includes 6 DC contactors. By closing different contactors, the battery pack and electric vehicle can be charged separately.

[0075] When the battery needs to be charged, the first and second contactors 81 and 82 close, opening the battery pack's charging circuit and connecting to the first charging module. Based on power demand, the third and fourth contactors are closed simultaneously to connect to the second charging module to provide more charging power. The charging module output is then passed through power terminal 9, DC contactor 8, shunt 10, fuse 11, and copper busbar 7 to complete battery charging. The DC energy meter 5 measures battery power by sampling current through shunt 10 and voltage on the DC output circuit.

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

[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 connected; the fifth contactor 85 and the sixth contactor 86 are closed, and the charging terminal circuit is connected, and the battery pack and the electric vehicle are charged at the same time.

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

[0079] The working principle of the other set 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 set of DC output units of a certain DC output module, the set of DC output units is connected to the battery pack signal terminal through signal terminal 6. After confirming the signal connection, the internal controller 2 of the module uploads the connection confirmation success information to the battery swap charger control board, and then the battery swap charger control board controls the DC output module to start the set of DC output units, perform self-test, and start charging after the self-test is completed.

[0080] like Figure 13 、 Figure 14 The figure shows the assembly of multiple DC output modules. When connecting multiple DC output modules in parallel, the upper charging terminal copper busbar can be connected to the charging terminal individually. Alternatively, the charging terminal copper busbars of each module can be connected in parallel to connect multiple DC output modules in parallel, and then connected to the supercharging terminal to achieve high power output.

[0081] An embodiment of the present invention further provides a battery swap charger, comprising multiple battery swap charger DC output modules as described above. In addition to the DC output modules, the battery swap charger also includes an AC 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 modules.

[0082] like Figure 15 The following is a schematic diagram of the layout of the battery replacement charger of some embodiments of the present invention. The upper row is the charging module, and the lower row is the DC output module. Figure 15 It includes 6 DC output modules, a total of 12 DC output units, providing 12 DC outputs. Figure 1 It is a battery-swap charger based on existing technology, and also includes 12 DC outputs. Figure 1 In the system, the controller and metering unit (shunt) of 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; Figure 15 In the main 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 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 in 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 the simultaneous energy replenishment of two batteries and two electric vehicles, thereby 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 space utilization, and reducing maintenance difficulty and cost.

[0084] The above is only a specific embodiment of the present invention and cannot be used to limit the scope of the present invention. Equal changes made by ordinary technicians in this technical field based on this creation, as well as changes well 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 swap charger, characterized in that: The device comprises a housing, wherein two groups of DC output units are symmetrically arranged in the depth direction of the housing, and the DC output units include a controller, a switching power supply, an axial flow fan, a DC 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; The signal terminal includes a power supply and a communication terminal. The signal terminal is connected to the switching power supply, the controller, the battery pack, the charging terminal, and the battery swap charger control board 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; The switching power supply is used to supply power to the internal components of the DC output module; The axial flow fan is arranged near a side wall of the housing 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 energy meter and the DC contactor. The controller is used to feed back battery charging information, power circuit metering information, and internal status information of 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; The housing 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 bottom of the housing, 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 on the first side wall and the second side wall at positions opposite to the copper busbar; the third side wall is arranged opposite to the axial flow fan, and a heat dissipation hole is arranged on the third side wall at a position opposite to the axial flow fan; the signal terminal and the power terminal are arranged on the fourth side wall; In the housing, the axial flow fan is arranged at a position close to the lower portion 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; 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 to 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 to the sixth DC contactor, the fourth DC contactor, the second DC contactor, and the shunt from top to bottom.

2. The DC output module of the battery-swap charger according to claim 1, characterized in that: The two groups of DC output units share the axial flow fan and the DC electric energy meter.

3. The DC output module of the battery-swap 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.

4. The DC output module of the battery-swap charger according to claim 1, characterized in that: The first copper busbar 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 DC contactor, and the battery pack positive electrode is located at the lower end of the first DC contactor; The second copper bus is provided with a third power terminal access point, a fourth power terminal access point, a negative pole of the charging terminal, and a negative pole of the 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 DC contactor, and the negative pole of the battery pack is located at the lower end of the shunt.

5. The DC output module of the battery-swap charger according to claim 4, characterized in that: 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; The charging module includes a first charging module and a second charging module; The positive output electrode of the first charging module is connected to the positive electrode of the first power terminal, and the positive electrode of the first power terminal is connected to the first power terminal access point; the negative output electrode of the first charging module is connected to the negative electrode of the first power terminal, and the negative electrode 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.

6. A battery-swapping charger, comprising a plurality of battery-swapping charger DC output modules as described in any one of claims 1-5.

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