A charging cable system and its charging control method

Abstract

The present application provides a charging cable system and a charging control method thereof, including: at least one cable assembly, a first controller, a cooling system and at least one second controller; one end of the cable assembly is connected to an energy storage device, and the other end of the cable assembly is connected to a charging pile; the first controller is fixed in the energy storage device, the first controller is connected to at least one cable assembly, and the first controller is also connected to an energy storage controller; the cooling system is fixed in the energy storage device, the cooling system is connected to at least one cable assembly, and the first controller is also connected to the cooling system; a second controller is fixed in a charging pile, a second controller is connected to a cable assembly, and a second controller is also connected to a charging controller in a charging pile. The present application improves the service life and use safety of the cable assembly, avoids the expansion of damage to the cable assembly, and improves the service life of the cable assembly.

Description

Technical Field

[0001] The present application relates to the technical field of cables, particularly to the field of the installation of cables or wires, and more particularly to a charging cable system and its charging control method. Background Art

[0002] An energy storage device refers to a device or system involved in the process of storing energy through a medium or device and releasing it when needed. A charging pile refers to a charging device that provides energy replenishment for new energy vehicles. Currently, a high-power cable is usually used to connect an energy storage device and a charging pile, enabling the energy storage device to supply power to multiple charging piles.

[0003] However, the inventor has found that current cables are prone to generating a large amount of heat during long-term high-power operation, causing the cables to be burned out due to excessive temperature, resulting in a relatively low service life and poor safety in use of the cables. Summary of the Invention

[0004] The present application provides a charging cable system and its charging control method to solve the problem that current cables are burned out due to excessive temperature generated during long-term high-power operation, resulting in a relatively low service life and poor safety in use of the cables.

[0005] In a first aspect, the present application provides a charging cable system for connecting an energy storage device and at least one charging pile. The energy storage device is used for storing electric energy, and the charging pile is used for charging new energy vehicles.

[0006] The charging cable system includes: at least one cable assembly, a first controller, a cooling system, and at least one second controller.

[0007] One end of the cable assembly is connected to the energy storage device, and the other end of the cable assembly is connected to one of the charging piles.

[0008] The first controller is fixed in the energy storage device. The first controller is connected to at least one of the cable assemblies and is also connected to the energy storage controller. Wherein, the first controller is used to control the on and off of each cable assembly through the energy storage controller according to the temperature information of each cable assembly. The temperature information is used to characterize the temperature of the power line in the cable assembly.

[0009] The cooling system is fixed in the energy storage device. The cooling system is connected to at least one of the cable assemblies, and the first controller is also connected to the cooling system. Wherein, the cooling system is used to output coolant to each cable assembly. The coolant is used to cool down the cable assembly.

[0010] One of the second controllers is fixed in one of the charging piles. One of the second controllers is connected to one of the cable assemblies, and one of the second controllers is also connected to the charging controller in one of the charging piles. Wherein, the second controller is configured to control the connection and disconnection between the charging pile and the new energy vehicle through the charging controller according to the leakage information of the charging pile; the leakage information reflects the degree of leakage of the charging pile.

[0011] In the above solution, the cable assembly includes: a composite cable, a first connector, and a second connector.

[0012] The composite cable is configured to transmit charging current, transmit communication signals, feedback the temperature information of the cable assembly, receive the coolant output by the cooling system, and output the coolant to the cooling system.

[0013] One end of the composite cable is connected to the first connector, and the first connector is connected to the output end of the energy storage device, the first controller, and the cooling system.

[0014] The other end of the composite cable is connected to the second connector, and the second connector is connected to the input end of the charging pile and the second controller.

[0015] In the above solution, the composite cable includes: a plurality of power lines, at least one temperature line, at least one communication line, a cooling input line, a cooling output line, a cable protective layer, and an overall protective layer.

[0016] The power lines are configured to output energy storage current, and a plurality of the power lines surround to form an annular structure.

[0017] The temperature lines are configured to detect the temperature of the power lines, and at least one of the temperature lines is located inside the annular structure.

[0018] The communication lines are configured to transmit communication signals, and at least one of the communication lines is located outside the annular structure.

[0019] The cooling input line is wound outside the annular structure.

[0020] The cable protective layer is sleeved outside the annular structure and the cooling input line.

[0021] The cooling output line is located outside the cable protective layer.

[0022] The overall protective layer is sleeved outside the cable protective layer, the cooling output line, and at least one of the communication lines.

[0023] In the above solution, the first connector includes: a plurality of first power terminals, at least one first temperature terminal, at least one first communication terminal, a coolant inlet and a coolant outlet;

[0024] One of the first power terminals is connected to one end of the power line; the first power terminal is used to connect to the output end of the energy storage device;

[0025] One of the first temperature terminals is connected to one end of the temperature line; the first temperature terminal is used to connect to the first controller;

[0026] One of the first communication terminals is connected to one end of the communication line; the first communication terminal is used to connect to the first controller; the first communication terminal is also used to connect to the energy storage controller of the energy storage device;

[0027] The coolant inlet is connected to the cooling input line, and the coolant inlet is used to receive the coolant output by the cooling system;

[0028] The coolant outlet is connected to the cooling output line, and the coolant outlet is used to output coolant to the cooling system.

[0029] In the above solution, the second connector includes: a plurality of second power terminals, at least one second temperature terminal, at least one second communication terminal, and two coolant adapters;

[0030] One of the second power terminals is connected to one end of the power line; the second power terminal is used to connect to the input end of the charging pile;

[0031] One of the second temperature terminals is connected to one end of the temperature line; the second temperature terminal is used to output an initial voltage to the temperature line; the temperature line outputs a temperature voltage to the first temperature terminal of the first connector according to the initial voltage; the temperature voltage is temperature information used to characterize the temperature conditions of multiple power lines in the composite cable;

[0032] One of the second communication terminals is connected to one end of the communication line; the second communication terminal is used to connect to the second controller and the charging controller of the charging pile;

[0033] One of the coolant adapters is connected to the cooling input line, and the other coolant adapter is connected to the cooling output line, and the two coolant adapters are connected to each other.

[0034] In the above solution, the first controller includes: at least one temperature sensor and a first processor;

[0035] One of the temperature sensors is connected to the first connector of the cable assembly;

[0036] The temperature sensor is also connected to the first processor, and the temperature sensor is used to send the temperature information of each cable assembly to the first processor;

[0037] The first processor is connected to the energy storage controller. The first processor is used to generate an energy storage path signal or an energy storage break signal for each cable assembly according to the temperature information of each cable assembly; the first processor is also used to send the energy storage path signal and the energy storage break signal to the energy storage controller; the energy storage path signal is used to instruct the energy storage controller to set the connection between the energy storage device and the cable assembly as a path; the energy storage break signal is used to instruct the energy storage controller to set the connection between the energy storage device and the cable assembly as a break;

[0038] The first processor is also connected to the cooling system;

[0039] The first processor is used to generate a cooling level signal for each cable assembly according to the temperature information of each cable assembly; the cooling system adjusts the flow rate of the coolant in each cable assembly according to the cooling level signal.

[0040] In the above solution, the cooling system includes: an input multi-tube joint, a compressor, a condenser, an output multi-tube joint, and at least one flow rate controller;

[0041] The input multi-tube joint has at least one input port and one output port. One input port of the input multi-tube joint is connected to the coolant output port of the first connector of a cable assembly through a pipeline, and the output port of the input multi-tube joint is connected to the input port of the compressor;

[0042] The output port of the compressor is connected to the input port of the condenser;

[0043] The output multi-tube joint has at least one output port and one input port;

[0044] The input port of the output multi-tube joint is connected to the output port of the condenser; one output port of the output multi-tube joint is connected to the coolant input port of the first connector of a cable assembly through a pipeline;

[0045] One of the flow rate controllers is connected to the pipeline between the output multi-tube joint and the coolant input port, and at least one of the flow rate controllers is respectively connected to the first controller; the flow rate controller is used to control the flow rate of the coolant in the pipeline between the output multi-tube joint and the coolant input port.

[0046] In the above solution, the second controller includes: at least one leakage current sensor and a second processor;

[0047] A power transmission loop of one of the cable assemblies passes through one of the leakage current sensors and is connected to the charging pile; wherein, the power transmission loop is used to output a charging current to the charging pile; the power transmission loop includes a power supply branch line and a return branch line, the power supply branch line is connected to the first power line in the cable assembly, and the return branch line is connected to the second power line in the cable assembly; the first power line is one of at least one power line in the cable assembly; the second power line is one of at least one power line in the cable assembly; the first power line and the second power line are different power lines;

[0048] At least one of the leakage sensors is respectively connected to the second processor; the leakage sensor is used to detect the leakage current in the power transmission loop;

[0049] The second processor is used to generate a charging path signal or a charging open circuit signal for each power transmission loop according to the leakage current of each power transmission loop; the second processor is further used to send the charging path signal and the charging open circuit signal to the charging controller; wherein, the charging path signal is used to instruct the charging controller to set the connection between the charging pile and the new energy vehicle as a path; the charging open circuit signal is used to instruct the charging controller to set the connection between the charging pile and the new energy vehicle as an open circuit.

[0050] In a second aspect, the present application provides a charging control method for a charging cable system, including:

[0051] The target first controller and the cooling system respectively respond to the monitoring of the start of the energy storage device, and the target second controller responds to the start of the first charging pile; wherein, the start of the energy storage device indicates that the energy storage device outputs a charging current to at least one charging pile; the first charging pile is one of at least one charging pile that receives the charging current; the target first controller is the first controller connected to the first charging pile; the target second controller is the second controller fixed on the first charging pile; the start of the first charging pile indicates that the first charging pile is connected to the new energy vehicle and outputs a charging current to the new energy vehicle;

[0052] The target first controller receives the first temperature information of the first cable assembly; wherein, the first cable assembly is the cable assembly connecting the energy storage device and the first charging pile; the first temperature information is used to characterize the temperature of the power line in the first cable assembly;

[0053] The target first controller generates a energy storage connection signal or an energy storage disconnection signal according to the first temperature information, and sends the energy storage connection signal or the energy storage disconnection signal to the energy storage controller of the energy storage device; wherein, the energy storage connection signal is used to instruct the energy storage controller to maintain the connection between the energy storage device and the first charging pile; the energy storage disconnection signal is used to instruct the energy storage controller to disconnect the connection between the energy storage device and the first charging pile.

[0054] In response to the target first controller generating the energy storage connection signal, the cooling system outputs coolant to the first cable assembly.

[0055] In response to the target first controller generating the energy storage connection signal, the target second controller detects the leakage degree of the first charging pile to obtain first leakage information.

[0056] The target second controller generates a charging connection signal or a charging disconnection signal according to the first leakage information, and sends the charging connection signal or the charging disconnection signal to the first charging controller of the first charging pile; wherein, the first charging controller is used to control the connection and disconnection between the first charging pile and the new energy vehicle; the charging connection signal is used to instruct the first charging controller to maintain the connection between the first charging pile and the new energy vehicle; the charging disconnection signal is used to instruct the first charging controller to disconnect the connection between the first charging pile and the new energy vehicle.

[0057] In the above solution, after the target first controller generates a energy storage connection signal or an energy storage disconnection signal according to the first temperature information and sends the energy storage connection signal or the energy storage disconnection signal to the energy storage controller of the energy storage device, the method further includes:

[0058] If the target first controller determines that the number of cable assemblies for which the energy storage disconnection signal is generated exceeds a preset energy storage disconnection threshold, the target first controller generates an energy storage stop signal and sends the energy storage stop signal to the energy storage controller; wherein, the energy storage stop signal is used to instruct the energy storage controller to stop the operation of the energy storage device.

[0059] A charging cable system and its charging control method provided by the present application control the connection and disconnection of the cable assembly according to the temperature information of the cable assembly by setting a first controller, so as to prevent the cable assembly from being burned out due to excessive temperature, and improve the service life and use safety of the cable assembly.

[0060] By connecting the first controller to the energy storage controller, when the number of cable assemblies whose temperature exceeds the preset open-circuit temperature due to the temperature exceeding the preset value exceeds the energy storage open-circuit number, it indicates that there is likely an abnormality in the energy storage device. Therefore, the first controller controls the energy storage device to stop through the energy storage controller, and then stops supplying power to all cable assemblies, avoiding the expansion of the damage to the cable assemblies.

[0061] By setting up a cooling system to output coolant to each cable assembly to cool down the cable assembly, avoiding damage to the cable assembly due to overheating, ensuring the safe use of the cable assembly, and extending the service life of the cable assembly.

[0062] By setting up a second controller to control the charging controller to stop working and / or control the open circuit of the cable assembly according to the degree of leakage of the charging pile, so as to ensure that the charging pile will not harm the staff due to leakage or damage the new energy vehicle. Brief Description of the Drawings

[0063] The drawings here are incorporated into the specification and form a part of this specification, showing embodiments consistent with the present application, and are used together with the specification to explain the principles of the present application.

[0064] Figure 1 It is a schematic block diagram of the structure of a charging cable system provided by the present application;

[0065] Figure 2 It is a schematic block diagram of the structure of the cooling system in a charging cable system provided by the present application;

[0066] Figure 3 It is a schematic diagram of the structure of a composite cable in a charging cable system provided by the present application;

[0067] Figure 4 It is a schematic diagram of the structure of the first connector in a charging cable system provided by the present application;

[0068] Figure 5 It is a schematic diagram of the structure of the second connector in a charging cable system provided by the present application;

[0069] Figure 6 It is a flowchart of Embodiment 2 of a charging cable system and its charging control method provided by the present application;

[0070] Figure 7 It is a flowchart of Embodiment 3 of a charging cable system and its charging control method provided by the present application.

[0071] Reference Signs:

[0072] 1: Cable assembly;

[0073] 2: First controller;

[0074] 3: Cooling system;

[0075] 4: Second controller;

[0076] 5: Energy storage device;

[0077] 6: Charging pile;

[0078] 11: Composite cable;

[0079] 12: First connector;

[0080] 13: Second connector;

[0081] 111: Power line;

[0082] 112: Temperature line;

[0083] 113: Communication line;

[0084] 114: Cooling input line;

[0085] 115: Cooling output line;

[0086] 116: Cable protective layer;

[0087] 117: Overall protective layer;

[0088] 1111: Power transmission line;

[0089] 1112: First insulating layer;

[0090] 1121: Temperature sensing wire;

[0091] 1122: Second insulating layer;

[0092] 1131: Communication wire;

[0093] 1132: Third insulating layer;

[0094] 1133: Anti-interference layer;

[0095] 1161: Cable inner protective layer;

[0096] 1162: Cable shielding layer;

[0097] 1163: Cable outer protective layer;

[0098] 1171: Overall inner protective layer;

[0099] 1172: Overall shielding layer;

[0100] 1173: Overall outer protective layer;

[0101] 121: First power terminal;

[0102] 122: First temperature terminal;

[0103] 123: First communication terminal;

[0104] 124: Coolant inlet;

[0105] 125: Coolant outlet;

[0106] 126: First connection housing;

[0107] 127: First locking device;

[0108] 1261: First plug;

[0109] 1262: First annular baffle;

[0110] 1263: First signal protection joint;

[0111] 1264: First sealing joint;

[0112] 1271: First chuck;

[0113] 1272: First bayonet;

[0114] 131: Second power terminal;

[0115] 132: Second temperature terminal;

[0116] 133: Second communication terminal;

[0117] 134: Coolant adapter;

[0118] 135: Second connection housing;

[0119] 136: Second locking device;

[0120] 1351: Second plug;

[0121] 1352: Second annular baffle;

[0122] 1353: Second signal protection joint;

[0123] 1361: Second chuck;

[0124] 1362: Second bayonet;

[0125] 21: Temperature sensor;

[0126] 22: First processor;

[0127] 31: Input multi-coupling;

[0128] 32: Compressor;

[0129] 33: Condenser;

[0130] 34: Output multi-tube joint;

[0131] 35: Flow rate controller;

[0132] 41: Leakage current sensor;

[0133] 42: Second processor;

[0134] 51: Energy storage controller;

[0135] 61: Charging controller.

[0136] Through the above-mentioned drawings, specific embodiments of the present application have been shown, and there will be a more detailed description hereinafter. These drawings and textual descriptions are not intended to limit the scope of the concept of the present application in any way, but to illustrate the concept of the present application to those skilled in the art by referring to specific embodiments. Detailed Description of Specific Embodiments

[0137] Here, the exemplary embodiments will be described in detail, and the examples are shown in the drawings. When the following description refers to the drawings, unless otherwise indicated, the same numbers in different drawings represent the same or similar elements. The embodiments described in the following exemplary embodiments do not represent all embodiments consistent with the embodiments of the present application. On the contrary, they are merely examples of devices and methods consistent with some aspects of the embodiments of the present application as detailed in the appended claims.

[0138] The technical solutions of the embodiments of the present application and how the technical solutions of the embodiments of the present application solve the current problems will be described in detail below with specific embodiments. The following several specific embodiments can be combined with each other, and the same or similar concepts or processes may not be repeated in some embodiments. The embodiments of the present application will be described below with reference to the drawings.

[0139] Embodiment 1: Please refer to Figures 1 - 5 , the present application provides a charging cable system for connecting an energy storage device 5 and at least one charging pile 6. The energy storage device 5 is used for storing electric energy, and the charging pile 6 is used for charging new energy vehicles;

[0140] The charging cable system includes: at least one cable assembly 1, a first controller 2, a cooling system 3 and at least one second controller 4;

[0141] One end of the cable assembly 1 is connected to the energy storage device 5, and the other end of the cable assembly 1 is connected to a charging pile 6;

[0142] The first controller 2 is fixed in the energy storage device 5. The first controller 2 is connected to at least one cable assembly 1, and the first controller 2 is also connected to the energy storage controller 51. Among them, the first controller 2 is used to control the on and off of each cable assembly 1 through the energy storage controller 51 according to the temperature information of each cable assembly 1. The temperature information is used to characterize the temperature of the power line 111 in the cable assembly 1.

[0143] The cooling system 3 is fixed in the energy storage device 5. The cooling system 3 is connected to at least one cable assembly 1, and the first controller 2 is also connected to the cooling system 3. Among them, the cooling system 3 is used to output coolant to each cable assembly 1. The coolant is used to cool down the cable assembly 1.

[0144] A second controller 4 is fixed in a charging pile 6. The second controller 4 is connected to a cable assembly 1, and the second controller 4 is also connected to the charging controller 61 in the charging pile 6. Among them, the second controller 4 is used to control the on and off between the charging pile 6 and the new energy vehicle through the charging controller 61 according to the leakage information of the charging pile 6. The leakage information reflects the degree of leakage of the charging pile 6.

[0145] In this embodiment, by setting the first controller 2 to control the on and off of the cable assembly 1 according to the temperature information of the cable assembly 1, it is possible to avoid the cable assembly 1 from being burned out due to excessive temperature, and improve the service life and use safety of the cable assembly 1.

[0146] By connecting the first controller 2 to the energy storage controller 51, when the number of cable assemblies 1 whose temperature exceeds the preset open-circuit temperature exceeds the energy storage open-circuit number, it indicates that there is likely an abnormality in the energy storage device. Therefore, the first controller 2 controls the energy storage device 5 to stop through the energy storage controller 51, and then stops power supply to all cable assemblies 1, avoiding the expansion of damage to the cable assemblies 1.

[0147] By setting the cooling system 3 to output coolant to each cable assembly 1 to cool down the cable assembly 1, it is possible to avoid the cable assembly 1 from being damaged due to overheating, ensure the use safety of the cable assembly 1, and improve the service life of the cable assembly 1.

[0148] By setting the second controller 4 to control the charging controller 61 to stop working and / or control the open circuit of the cable assembly 1 according to the leakage degree of the charging pile 6, it is possible to ensure that the charging pile 6 will not harm the staff due to leakage or injure the new energy vehicle.

[0149] In a preferred embodiment, the cable assembly 1 includes: a composite cable 11, a first connector 12, and a second connector 13.

[0150] The composite cable 11 is used to transmit charging current, transfer communication signals, feedback the temperature information of the cable assembly 1, receive the coolant output by the cooling system 3, and output the coolant to the cooling system 3;

[0151] One end of the composite cable 11 is connected to the first connector 12, and the first connector 12 is connected to the output end of the energy storage device 5, the first controller 2, and the cooling system 3;

[0152] The other end of the composite cable 11 is connected to the second connector 13, and the second connector 13 is connected to the input end of the charging pile 6 and the second controller 4.

[0153] In this embodiment, by setting the composite cable 11, it is possible to transmit communication signals while transmitting the circuit, and detect the temperature of the power line 111 therein, avoiding the problem that the composite cable 11 is damaged due to overheating.

[0154] By setting the first connector 12, it is ensured that the composite cable 11 can be firmly connected to the output end of the energy storage device 5, the first controller 2, and the cooling system 3. By setting the second connector 13, it is ensured that the composite cable can be firmly connected between the input end of the charging pile 6 and the second controller 4.

[0155] In a preferred embodiment, the composite cable 11 includes: a plurality of power lines 111, at least one temperature line 112, at least one communication line 113, a cooling input line 114, a cooling output line 115, a cable protective layer 116, and an overall protective layer 117;

[0156] The power line 111 is used to output the energy storage current, and a plurality of power lines 111 surround to form an annular structure;

[0157] The temperature line 112 is used to detect the temperature of the power line 111, and at least one temperature line 112 is located inside the annular structure;

[0158] The communication line 113 is used to transfer communication signals, and at least one communication line 113 is located outside the annular structure;

[0159] The cooling input line 114 is wound outside the annular structure;

[0160] The cable protective layer 116 is sleeved outside the annular structure and the cooling input line 114;

[0161] The cooling output line 115 is located outside the cable protective layer 116;

[0162] The overall protective layer 117 is sleeved outside the cable protective layer 116, the cooling output line 115, and at least one communication line 113.

[0163] In this embodiment, since the power line 111 outputs a storage current, its current value is relatively large, so it is easy to cause the power line 111 to generate high temperature and malfunction. To address this, a temperature line 112 is set to monitor the temperature generated by the power line 111 and generate a resistance value or electromotive force representing the temperature of the power line 111. If it is determined according to the resistance value or electromotive force that the temperature generated by the power line 111 exceeds the temperature threshold, the storage current in the power line 111 is cut off to ensure the safety of the power line 111 and the energy storage device, thereby ensuring the reliability of the energy storage battery pack in transmitting the storage current.

[0164] At the same time, since the electromagnetic intensity of the power line 111 is relatively large, it is easy to affect the signals in the communication line 113. Therefore, a cable protective layer 116 is set to reduce the influence of the power line 111 on the communication signals in the communication line 113, ensuring that the controller can effectively control the device through the communication line 113.

[0165] Optionally, one or several of fiber fillers, filling adhesives, and glass fibers are filled between the overall protective layer 117 and the cable protective layer 116.

[0166] Optionally, the power line 111 includes: a power transmission line 1111 and a first insulating layer 1112;

[0167] The first insulating layer 1112 is sleeved outside the power transmission line 1111;

[0168] The first insulating layer 1112 is made of an insulating and heat-conducting material; among them, the insulating and heat-conducting material of the first insulating layer 1112 is one of silicone rubber, glass fiber-reinforced resin, and silicon nitride.

[0169] In this embodiment, silicone rubber has excellent anti-aging properties and can resist the influence of factors such as high temperature, ultraviolet rays, ozone, and oxidation. It is commonly used for cable insulation in high-temperature environments. Its high-temperature resistance is very good, and it can work in a high-temperature environment above 150 °C for a long time. The thermal conductivity of silicone rubber is better than that of ordinary polymers, and some types of silicone rubber cables have good thermal conductivity, which helps to improve the heat dissipation effect of the cable.

[0170] Glass fiber-reinforced resin has good anti-aging properties, especially in terms of temperature resistance, moisture resistance, and oxidation resistance. It can withstand the environmental pressure of long-term use. Glass fiber-reinforced resin has good thermal conductivity, especially in the case of reinforced resin, which can improve the heat dissipation ability of the cable.

[0171] Silicon nitride is a ceramic material with extremely high high-temperature resistance, chemical corrosion resistance, and anti-aging properties. Silicon nitride has very good thermal conductivity, much higher than that of common polymer materials, and can significantly improve the heat dissipation effect of the cable.

[0172] Therefore, by using the insulating and heat-conducting material as the first insulating layer 1112, it is beneficial to the heat dissipation of the power line 111, and further reduces the problem that the power line 111 is short-circuited due to the deformation or melting caused by the high temperature generated by the transmission line 1111.

[0173] Optionally, the temperature line 112 includes: a temperature-sensing wire 1121 and a second insulating layer 1122;

[0174] The temperature wire is one of a thermocouple wire, a thermistor wire, an optical fiber temperature sensing wire, a platinum resistance temperature wire, and a nickel-chromium - nickel-silicon thermocouple wire;

[0175] The second insulating layer 1122 is sleeved outside the temperature-sensing wire 1121;

[0176] The second insulating layer 1122 is made of an insulating and heat-conducting material.

[0177] In this example, the thermocouple wire is mainly used to connect the thermocouple electrodes, move the cold end (free end) of the thermocouple from a high-temperature or unstable environment to a place with a relatively stable temperature and convenient for measurement, usually the instrument terminal in the control room. This can protect the cold end of the thermocouple from the influence of high temperature or unstable temperature, and improve the accuracy and stability of temperature measurement. Transmit the thermoelectric potential signal generated by the thermocouple to the measuring instrument to ensure the integrity and accuracy of the signal. Since the thermocouple material is generally relatively expensive and the distance from the temperature measurement point to the instrument is relatively long, using the thermocouple wire can save the thermocouple material and reduce the cost.

[0178] The thermistor wire is mainly used to connect the thermistor electrodes. The resistance value of the thermistor sensor is relatively large, so the resistance and contact resistance of its connecting wire can be ignored. Therefore, the thermistor sensor can be applied to temperature measurement over a long distance of up to several kilometers. The thermistor sensor can compensate for the humidity of some components within a certain temperature range. For example, the moving coil in the moving coil type instrument meter head is wound with copper wire, and the resistance increases when the temperature rises, causing a temperature error. At this time, compensation can be carried out through the thermistor. For small current occasions, the thermistor sensor can be directly connected in series with the load to prevent overheating damage to protect the device; for large current occasions, it can be used for the protection of relays, transistor circuits, etc.

[0179] The optical fiber temperature sensing wire is a new type of temperature sensor 21 based on the optical principle. Using the optical fiber temperature sensing wire can realize real-time monitoring of temperature, timely detect abnormal temperature conditions, and improve production safety.

[0180] Platinum resistance temperature wires (usually referring to the connecting wires of platinum resistance thermometers) are commonly used to connect platinum resistance thermometers. The resistance value of a platinum resistance thermometer changes with temperature. By measuring the voltage or current value on the platinum resistance temperature wire, the current temperature value can be deduced to achieve accurate temperature measurement. Platinum resistance temperature wires are characterized by high precision and good stability and are widely used in fields such as instrument measurement and environmental detection.

[0181] Nickel-chromium - nickel-silicon thermocouple wires (Type K thermocouple wires) are a commonly used type of thermocouple wire. Type K thermocouples can measure high temperatures of 1000 degrees Celsius for a long time and up to 1200 degrees Celsius in the short term, and are suitable for occasions where relatively high temperatures need to be measured. The positive electrode of a Type K thermocouple is a nickel-chromium alloy containing 10% chromium, and the negative electrode is a nickel-silicon alloy containing 3% silicon, with good high-temperature oxidation resistance and can be applied to oxidizing or neutral media.

[0182] The insulating and heat-conducting material of the second insulating layer 1122 is one of silicone rubber, glass fiber-reinforced resin, and silicon nitride.

[0183] Therefore, by using the insulating and heat-conducting material as the second insulating layer 1122, it is beneficial for the temperature-sensitive wire 1121 to collect the heat dissipated by the power line 111. Therefore, the temperature acquisition accuracy of the temperature line 112 for the power line 111 is ensured.

[0184] In a preferred embodiment, the communication line 113 includes: a communication wire 1131, a third insulating layer 1132, and an anti-interference layer 1133;

[0185] The third insulating layer 1132 is sleeved outside the communication wire 1131; among them, the third insulating layer 1132 is made of polytetrafluoroethylene or fluoroplastics;

[0186] The anti-interference layer 1133 is sleeved outside the third insulating layer 1132; among them, the anti-interference layer 1133 is made of one or several of copper wires, tinned copper wires, and aluminum alloy wires; or the anti-interference layer 1133 is wrapped by a polyester sheath.

[0187] In this example, fluoroplastics (such as FEP, PFA, etc.) have extremely high temperature resistance, chemical resistance, and anti-aging properties, can be used for a long time in harsh environments, and are especially suitable for extreme temperatures, radiation, and chemical media. Fluoroplastics have very excellent electrical insulation properties and are commonly used in high-frequency, high-voltage, or high-temperature cables. The heat insulation performance of fluoroplastics is also good, and can maintain the thermal stability of the cable in a high-temperature environment and reduce heat transfer.

[0188] Polytetrafluoroethylene has excellent anti-aging properties and can be used for a long time in extreme environments such as high temperatures, strong acids, strong alkalis, and ultraviolet rays. The high-temperature resistance of PTFE can reach 250 °C and it is not easy to age. Polytetrafluoroethylene has excellent electrical insulation properties and is especially suitable for applications with high voltages, high frequencies, or special electrical requirements. Polytetrafluoroethylene has very good thermal insulation properties and can effectively prevent heat transfer. Especially in high-temperature environments, PTFE can maintain the thermal stability of the cable.

[0189] Therefore, by setting the third insulating layer 1132 sleeve, it is possible to prevent the temperature of the power line 111 from being transmitted to the communication line 1131, resulting in damage to the communication line 1131.

[0190] By setting the anti-interference layer 1133, it is possible to avoid the electromagnetic interference of the stored energy current of the power line 111 on the communication signal in the communication line 1131, ensuring the reliability of the communication signal.

[0191] Optionally, the cable protective layer 116 includes: a cable inner protective layer 1161, a cable shielding layer 1162, and a cable outer protective layer 1163;

[0192] The cable inner protective layer 1161 is made of epoxy resin;

[0193] The cable shielding layer 1162 is made of a tinned copper wire braided mesh;

[0194] The cable outer protective layer 1163 is made of a polyurethane mixture.

[0195] Optionally, the overall protective layer 117 includes: an overall inner protective layer 1171, an overall shielding layer 1172, and an overall outer protective layer 1173;

[0196] The overall inner protective layer 1171 is made of epoxy resin;

[0197] The overall shielding layer 1172 is made of a tinned copper wire braided mesh;

[0198] The overall outer protective layer 1173 is made of a polyurethane mixture.

[0199] In this example, the cable inner sheath 1161 made of epoxy resin is a high-strength material that can provide reliable mechanical protection for the conductors, insulation layers, and shielding layers inside the cable, preventing cable damage caused by external mechanical stresses (such as bending, extrusion, or stretching). Epoxy resin has good insulation properties, can provide additional electrical isolation for the inner layer of the cable, reduce the risk of leakage current, and improve the overall insulation strength of the cable. Epoxy resin has excellent moisture-proof properties, can effectively prevent moisture or humidity from penetrating into the cable, thus avoiding the performance degradation of the insulation material due to moisture absorption. Epoxy resin has good tolerance to a variety of chemical substances (such as acids, alkalis, oils), can protect the cable to operate stably for a long time in a harsh chemical environment, especially in industrial sites or marine environments. Epoxy resin can maintain stable physical and electrical properties within a wide temperature range, suitable for high-temperature or large temperature difference environments. By providing multi-faceted protection, the epoxy resin inner sheath can delay the aging speed of the internal structure of the cable, improve the reliability and service life of the cable.

[0200] The cable shielding layer 1162 made of tinned copper wire braided mesh can block external electromagnetic interference (EMI) from entering the cable, protecting the integrity of the signals transmitted by the cable, which is particularly important for weak communication signals and high-frequency signals. At the same time, it can also suppress the leakage of internal signals in the cable, avoiding interference with external devices or systems. The copper wire braided mesh can guide the interference current through grounding, discharging the interference signal safely to the ground to ensure stable signal transmission. This is of great significance in industrial environments. The copper wire braided mesh also plays a certain mechanical protection role for the cable, can enhance the strength and tensile properties of the cable, and avoid damage caused by external forces. The tin plating treatment can improve the antioxidant and corrosion resistance of the copper wire, extending the service life of the shielding layer and the cable. In some specific scenarios (such as flammable and explosive environments), the shielding layer can also effectively prevent the accumulation of static electricity, thus reducing the risk of safety accidents caused by electrostatic discharge.

[0201] The cable outer sheath 1163 made of a polyurethane (PUR) mixture has excellent abrasion resistance and tear resistance, and can effectively resist external mechanical damages (such as stretching, extrusion, abrasion, etc.), especially suitable for dynamic application environments (such as mobile cables or drag chain cables). The polyurethane outer sheath can resist the effects of ultraviolet (UV) rays, ozone and harsh climate conditions, and will not easily age or degrade in performance when used outdoors. The PUR mixture has strong tolerance to a variety of chemical substances (such as oils, solvents, fuels, acids and alkalis), and is suitable for use in chemical plants or industrial environments. The polyurethane material can maintain good flexibility and physical properties within a wide temperature range, and is applicable to high-temperature and low-temperature environments. PUR has good flexibility and resilience, and can maintain its structural integrity and is not easily broken even under long-term bending or movement, which is very suitable for drag chain cables or cable systems that need to move frequently. The PUR outer sheath has excellent waterproof performance, can effectively prevent moisture from entering the cable interior, and is especially suitable for humid environments or underwater use. Some PUR mixtures can achieve flame retardant performance through special formulations, meeting application scenarios with higher safety requirements. According to the formulation adjustment, PUR can achieve environmental protection and low toxicity, and is more in line with environmental protection and health and safety requirements in specific occasions.

[0202] In a preferred embodiment, the first connector 12 includes: a plurality of first power terminals 121, at least one first temperature terminal 122, at least one first communication terminal 123, a coolant inlet 124 and a coolant outlet 125;

[0203] A first power terminal 121 is connected to one end of a power line 111; the first power terminal 121 is used to connect to the output end of the energy storage device 5;

[0204] A first temperature terminal 122 is connected to one end of a temperature line 112; the first temperature terminal 122 is used to connect to the first controller 2;

[0205] A first communication terminal 123 is connected to one end of a communication line 113; the first communication terminal 123 is used to connect to the first controller 2; the first communication terminal 123 is also used to connect to the energy storage controller 51 of the energy storage device 5;

[0206] The coolant inlet 124 is connected to the cooling input line 114, and the coolant inlet 124 is used to receive the coolant output by the cooling system 3;

[0207] The coolant outlet 125 is connected to the cooling output line 115, and the coolant outlet 125 is used to output the coolant to the cooling system 3.

[0208] Furthermore, the first connector 12 further includes: a first connection housing 126 and a first locking device 127;

[0209] A plurality of first power terminals 121, at least one first temperature terminal 122, at least one first communication terminal 123, a coolant inlet 124, and a coolant outlet 125 are respectively fixed on a first connection housing 126;

[0210] A first locking device 127 is fixed on the first connection housing 126 and the energy storage device 5. The first locking device 127 is used to detachably connect the first connection housing 126 and the energy storage device 5.

[0211] In this embodiment, by providing the first power terminal 121 and connecting it to the output terminal of the energy storage device 5, the energy storage device 5 outputs a charging current to the power line 111 through the first power terminal 121;

[0212] By providing the first temperature terminal 122 and connecting it to the first controller 2, the temperature information of the composite cable 11 is sent to the first controller 2;

[0213] By providing the first communication terminal 123, the first controller 2 and the energy storage controller 51 can receive the communication signal sent by the charging pile 6, meeting the communication requirements between the energy storage device 5 and the charging pile 6.

[0214] By providing the coolant inlet 124 and the coolant outlet 125, the cooling system 3 outputs coolant to the composite cable 11 and recovers the heated coolant to circulate and cool the composite cable 11.

[0215] Optionally, the first connection housing 126 includes: a first plug 1261, a first annular baffle 1262, two first signal protection joints 1263, and two first sealing joints 1264;

[0216] One end of the first plug 1261 has a first power area, and a plurality of first power terminals 121 are fixed on the first power area. The first annular baffle 1262 is fixed around the first power area on the first plug 1261;

[0217] Two first signal protection joints 1263 are fixed on the area of the first plug 1261 outside the first power area. The first temperature terminal 122 is fixed in one first signal protection joint 1263, and the first communication terminal 123 is fixed in the other first signal protection joint 1263;

[0218] Two first sealing joints 1264 are fixed on the side of the first plug 1261 with the first annular baffle 1262. The coolant inlet 124 is arranged in one first sealing joint 1264, and the coolant outlet 125 is arranged in the other first sealing joint 1264.

[0219] The first locking device 127 includes: a first chuck 1271 and a plurality of first locking corners (not shown in the figure); the first chuck 1271 has a plurality of first bayonets 1272, and one first locking corner corresponds to one first bayonet 1272;

[0220] The first locking corners are fixed on the energy storage device 5, the first chuck 1271 is fixed on the first plug 1261, the first locking corners pass through the first bayonets 1272, so that the chamfers of the first locking corners contact the surface of the first chuck 1271 away from the energy storage device 5, making the first connection housing 126 and the energy storage device 5 detachably connected.

[0221] In a preferred embodiment, the second connector 13 includes: a plurality of second power terminals 131, at least one second temperature terminal 132, at least one second communication terminal 133, and two coolant adapters 134;

[0222] One second power terminal 131 is connected to one end of a power line 111; the second power terminal 131 is used to connect to the input end of the charging pile 6;

[0223] One second temperature terminal 132 is connected to one end of a temperature line 112; the second temperature terminal 132 is used to output an initial voltage to the temperature line 112; the temperature line 112 outputs a temperature voltage to the first temperature terminal 122 of the first connector 12 according to the initial voltage; the temperature voltage is temperature information used to characterize the temperature conditions of the plurality of power lines 111 in the composite cable 11;

[0224] One second communication terminal 133 is connected to one end of a communication line 113; the second communication terminal 133 is used to connect to the second controller 4 and the charging controller 61 of the charging pile 6;

[0225] One coolant adapter 134 is connected to the cooling input line 114, and the other coolant adapter 134 is connected to the cooling output line 115, and the two coolant adapters 134 are connected to each other.

[0226] Furthermore, the second connector 13 further includes: a second connection housing 135 and a second locking device 136;

[0227] At least one second power terminal 131, at least one second temperature terminal 132, at least one communication terminal, and two coolant adapters 134 are respectively fixed on the second connection housing 135;

[0228] The second locking device 136 is fixed on the second connection housing 135 and the charging pile 6, and the second locking device 136 is used to detachably connect the second connection housing 135 and the charging pile 6.

[0229] In this embodiment, the second power terminal 131 is used to output a charging current to the charging pile 6; the temperature line 112 has a resistance, and the second temperature terminal 132 is used to send a temperature voltage to the first temperature terminal 122 according to the initial voltage, and the voltage value of the temperature voltage characterizes the temperature of the power line 111 in the composite cable 11. The temperature change of the power line 111 will cause the temperature change of the temperature line 112. The temperature line 112 will cause its resistance to change with the temperature change. Furthermore, the voltage value of the temperature voltage sent to the first controller 2 will change due to the resistance change of the temperature line 112, achieving the technical effect of real-time detection of the temperature of the power line 111.

[0230] By setting the second communication terminal 133 to be connected to the second controller 4, the second controller 4 can output a communication signal to the first controller 2 through the communication line 113, so that the first controller 2 can control the on / off of the charging controller 61 through the second controller 4; and the charging controller 61 can send a communication signal to the energy storage controller 51 through the communication line 113, so that the energy storage controller 51 can control the stop and operation of the charging pile 6 through the charging controller 61.

[0231] The coolant input line and the coolant output line are connected through the coolant adapter 134, so that the coolant input line and the coolant output line can form a loop on the coolant adapter 134. Therefore, workers can cut the composite cable 11 to the required length as needed, and connect the coolant input line and the coolant output line in the composite cable 11 into a loop at the second connector 13, ensuring the convenience of using the composite cable 11.

[0232] Optionally, the second connection housing 135 includes: a second plug 1351, a second annular baffle 1352, two second signal protection connectors 1353, and a second sealed adapter tube (not shown in the figure);

[0233] One end of the second plug 1351 has a second power area, and a plurality of second power terminals 131 are fixed on the second power area. The second annular baffle 1352 is fixed around the second power area on the second plug 1351;

[0234] Two second signal protection connectors 1353 are fixed on the area of the second plug 1351 outside the second power area. The second temperature terminal 132 is fixed in one second signal protection connector 1353, and the second communication terminal 133 is fixed in the other second signal protection connector 1353;

[0235] Both ends of the two second sealed adapter tubes are respectively connected to the two coolant adapters 134.

[0236] The second locking device 136 includes: a second chuck 1361 and a plurality of second clamping corners (not shown in the figure); the second chuck 1361 has a plurality of second bayonets 1362, and one second clamping corner corresponds to one second bayonet 1362;

[0237] The second clamping corners are fixed on the charging pile 6, the second chuck 1361 is fixed on the second plug 1351, the second clamping corners pass through the second bayonets 1362, so that the chamfers of the second clamping corners are in contact with the surface of the second chuck 1361 away from the charging pile 6, and the second connection housing 135 is detachably connected to the charging pile 6.

[0238] In a preferred embodiment, the first controller 2 includes: at least one temperature sensor 21 and a first processor 22;

[0239] One temperature sensor 21 is connected to the first connector of a cable assembly 1;

[0240] The temperature sensor 21 is also connected to the first processor 22, and the temperature sensor 21 is used to send the temperature information of each cable assembly 1 to the first processor 22;

[0241] The first processor 22 is connected to the energy storage controller 51. The first processor 22 is used to generate an energy storage path signal or an energy storage open circuit signal for each cable assembly 1 according to the temperature information of each cable assembly 1; the first processor 22 is also used to send the energy storage path signal and the energy storage open circuit signal to the energy storage controller 51; the energy storage path signal is used to instruct the energy storage controller 51 to set the connection between the energy storage device 5 and the cable assembly 1 as a path; the energy storage open circuit signal is used to instruct the energy storage controller 51 to set the connection between the energy storage device 5 and the cable assembly 1 as an open circuit;

[0242] The first processor 22 is also connected to the cooling system 3;

[0243] The first processor 22 is used to generate a cooling level signal for each cable assembly 1 according to the temperature information of each cable assembly 1; the cooling system 3 adjusts the flow rate of the coolant in each cable assembly 1 according to the cooling level signal.

[0244] In this example, by setting the temperature sensor 21, the temperature information (temperature voltage) sent by the temperature line 112 is forwarded to the first processor 22, and the first processor 22 judges whether the temperature of the power line 111 of the composite cable 11 exceeds the preset temperature open circuit threshold according to the temperature information; if it exceeds the temperature threshold, it means that the temperature of the composite cable 11 is too high and needs to be opened in time to ensure the safety of the composite cable.

[0245] If the temperature threshold is not exceeded, it indicates that the temperature of the composite cable 11 does not require it to be opened; the first processor 22 determines the cooling level signal of the composite cable 11 according to the temperature information, and this cooling level signal reflects the flow rate of the coolant in the composite cable 11, so as to ensure that the flow rate of the coolant in each composite cable 11 can stably cool the power line 111 therein, ensure that the power of the cooling system 3 can be reasonably distributed according to the actual usage of each composite cable 11, ensure the reasonable configuration of the flow rate of the coolant in all composite cables 11, while reducing the operating power of the cooling system 3, and ensure the cooling efficiency of the cable assembly 1.

[0246] In a preferred embodiment, the cooling system 3 includes: an input multi-tube joint 31, a compressor 32, a condenser 33, an output multi-tube joint 34, and at least one flow rate controller 35;

[0247] The input multi-tube joint 31 has at least one input port and an output port. An input port of the input multi-tube joint 31 is connected to the coolant output port 125 of the first connector 12 of a cable assembly 1 through a pipeline, and the output port of the input multi-tube joint 31 is connected to the input port of the compressor 32;

[0248] The output port of the compressor 32 is connected to the input port of the condenser 33;

[0249] The output multi-tube joint 34 has at least one output port and an input port;

[0250] The input port of the output multi-tube joint 34 is connected to the output port of the condenser 33; an output port of the output multi-tube joint 34 is connected to the coolant input port 124 of the first connector 12 of a cable assembly 1 through a pipeline;

[0251] A flow rate controller 35 is connected to the pipeline between the output multi-tube joint 34 and the coolant input port 124, and at least one flow rate controller 35 is respectively connected to the first controller 2; the flow rate controller 35 is used to control the flow rate of the coolant in the pipeline between the output multi-tube joint 34 and the coolant input port 124.

[0252] In this embodiment, an input multi-tube joint 31 and an output multi-tube joint 34 are provided. By setting the compressor 32, power is provided for the flow of the coolant. By setting the condenser 33, heat dissipation is performed on the coolant recovered from the composite cable 11 to reduce the temperature of the coolant. By setting the input multi-tube joint 31 and the output multi-tube joint 34, the cooling input lines 114 and the cooling output lines 115 of multiple composite cables 11 are integrated, so as to minimize the complexity of the connection between the composite cable 11 and the cooling system 3. By setting the flow rate controller 35, the flow rate of the coolant in the composite cable 11 is adjusted, thereby achieving the technical effect of targeted adjustment of the cooling rate of the composite cable 11.

[0253] In a preferred embodiment, the second controller 4 includes: at least one leakage current sensor 41 and a second processor 42;

[0254] A power transmission loop of a cable assembly 1 passes through a leakage current sensor 41 and is connected to the charging pile 6; wherein, the power transmission loop is used to output a charging current to the charging pile 6; the power transmission loop includes a power supply branch line and a return branch line, the power supply branch line is connected to the first power line 111 in the cable assembly 1, and the return branch line is connected to the second power line 111 in the cable assembly 1; the first power line 111 is one of at least one power line 111 in the cable assembly 1; the second power line 111 is one of at least one power line 111 in the cable assembly 1; the first power line 111 and the second power line 111 are different power lines 111;

[0255] At least one leakage sensor is respectively connected to the second processor 42; the leakage sensor is used to detect the leakage current in the power transmission loop;

[0256] The second processor 42 is used to generate a charging path signal or a charging break signal according to the leakage current value of the leakage current of each power transmission loop; the second processor 42 is further used to send the charging path signal and the charging break signal to the charging controller 61; wherein, the charging path signal is used to instruct the charging controller 61 to set the connection between the charging pile 6 and the new energy vehicle as a path; the charging break signal is used to instruct the charging controller 61 to set the connection between the charging pile 6 and the new energy vehicle as an open circuit.

[0257] The second processor 42 is connected to the first processor 22 of the first controller 2 through the communication line 113 of the cable assembly 1. The second processor 42 sends a charging break signal to the first processor 22, and the first processor 22 sends a charging break signal to the energy storage controller 51 of the energy storage device 5;

[0258] In this embodiment, by setting the leakage current sensor 41, it is detected whether there is a leakage phenomenon in the power transmission loop, and whether the occurring leakage phenomenon is within an acceptable range, thereby ensuring the equipment safety of the charging pile 6, the vehicle safety of the new energy vehicle being charged, and the personal safety of the user.

[0259] By setting the second processor 42, if it is determined that the leakage current exceeds the charging leakage threshold but does not exceed the charging power-off threshold, a leakage message is generated, which indicates that there may be a small leakage point in the charging pile 6 and it should temporarily stop working. Therefore, the second processor 42 sends the leakage message to the charging controller 61 to control the charging controller 61 to stop the charging operation of the new energy vehicle.

[0260] If the second processor 42 determines that the leakage current exceeds the charging power-off threshold, a power-off signal is generated, which indicates that the leakage condition of the charging pile 6 is very serious, and the energy storage device 5 should suspend outputting the charging current to the charging pile 6; therefore, the second processor 42 sends the power-off signal to the first processor 22 of the first controller 2 through the communication line 113 of the cable assembly 1, and the first processor 22 sends the power-off signal to the energy storage controller 51 of the energy storage device 5, so that the power-off signal stops outputting the charging current to the charging pile 6 that sends the power-off signal, fundamentally ensuring the safety of the charging pile 6, as well as the new energy vehicles and personnel around the charging pile 6.

[0261] In this embodiment, the power supply branch line and the return branch line of the power transmission loop will generate magnetic fields with opposite directions on the leakage current sensor 41, and the change of the magnetic field is used to detect the magnitude of the current.

[0262] When the insulation of the power supply branch and the return branch is normal, the magnitudes of the currents flowing through the sensor are equal and the directions are opposite. Therefore, the output signal of the leakage current sensor 41 is zero.

[0263] When the insulation of the power supply branch and the return branch is abnormal, the magnetic fields of the power supply branch and the return branch will be different. Therefore, a differential current will flow through the leakage current sensor 41 and the output signal is not zero; according to the preset output leakage current mapping table, the leakage current value corresponding to the output signal is obtained, and the leakage current value is used to characterize the leakage degree of the charging pile 6.

[0264] Embodiment 2: Please refer to Figures 1 - 6 , this application provides a charging control method for a charging cable system, including:

[0265] S101: The target first controller 2 and the cooling system 3 respectively respond to the monitoring of the startup of the energy storage device 5, and the target second controller 4 responds to the startup of the first charging pile 6; wherein, the startup of the energy storage device 5 indicates that the energy storage device 5 outputs a charging current to at least one charging pile 6; the first charging pile 6 is one of the at least one charging pile 6 that receives the charging current; the target first controller 2 is the first controller 2 connected to the first charging pile 6; the target second controller 4 is the second controller 4 fixed on the first charging pile 6; the startup of the first charging pile 6 indicates that the first charging pile 6 is connected to the new energy vehicle and outputs a charging current to the new energy vehicle.

[0266] S102: The target first controller 2 receives the first temperature information of the first cable assembly 1; wherein, the first cable assembly 1 is the cable assembly 1 connecting the energy storage device 5 and the first charging pile 6; the first temperature information is used to characterize the temperature of the power line 111 in the first cable assembly 1.

[0267] S103: The target first controller 2 generates an energy storage path signal or an energy storage break signal according to the first temperature information, and sends the energy storage path signal or the energy storage break signal to the energy storage controller 51 of the energy storage device 5; wherein, the energy storage path signal is used to instruct the energy storage controller 51 to maintain the connection between the energy storage device 5 and the first charging pile 6; the energy storage break signal is used to instruct the energy storage controller 51 to disconnect the connection between the energy storage device 5 and the first charging pile 6.

[0268] S106: The cooling system 3 responds to the target first controller 2 generating an energy storage path signal, and the cooling system 3 outputs a coolant into the first cable assembly 1.

[0269] S107: The target second controller 4 responds to the target first controller 2 generating an energy storage path signal, and the target second controller 4 detects the leakage degree of the first charging pile 6 to obtain the first leakage information.

[0270] S108: The target second controller 4 generates a charging path signal or a charging break signal according to the first leakage information, and sends the charging path signal or the charging break signal to the first charging controller 61 of the first charging pile 6; wherein, the first charging controller 61 is used to control the connection and disconnection between the first charging pile 6 and the new energy vehicle; the charging path signal is used to instruct the first charging controller 61 to maintain the connection between the first charging pile 6 and the new energy vehicle; the charging break signal is used to instruct the first charging controller 61 to disconnect the connection between the first charging pile 6 and the new energy vehicle.

[0271] Embodiment 3: Please refer to Figures 1 - 5 , and Figure 7 , this application provides a charging control method for a charging cable system, including:

[0272] S201: The target first controller 2 and the cooling system 3 respectively respond to the monitoring of the startup of the energy storage device 5, and the target second controller 4 responds to the startup of the first charging pile 6; wherein, the startup of the energy storage device 5 indicates that the energy storage device 5 outputs a charging current to at least one charging pile 6; the first charging pile 6 is one of the at least one charging pile 6 that receives the charging current; the target first controller 2 is the first controller 2 connected to the first charging pile 6; the target second controller 4 is the second controller 4 fixed on the first charging pile 6; the startup of the first charging pile 6 indicates that the first charging pile 6 is connected to the new energy vehicle and outputs a charging current to the new energy vehicle.

[0273] In this step, by setting the response time points of the target first controller 2 and the cooling system 3 to the time when the energy storage device 5 starts up, the target first controller 2 and the cooling system 3 start to work only when the energy storage device 5 charges the new energy vehicle through the charging pile 6, greatly reducing the working energy consumption of the charging cable system.

[0274] By setting the response time point of the target second controller 4 to the startup of the first charging pile 6, it is avoided that the unstarted charging pile 6 sends signals, resulting in an excessive computing burden on the energy storage controller 51 of the energy storage device 5.

[0275] S202: The target first controller 2 receives the first temperature information of the first cable assembly 1; wherein, the first cable assembly 1 is the cable assembly 1 connected between the energy storage device 5 and the first charging pile 6; the first temperature information is used to characterize the temperature of the power line 111 in the first cable assembly 1.

[0276] In this step, the target first controller 2 receives the first temperature information of the first cable assembly 1 to achieve the technical effect of real-time monitoring of the temperature of the cable assembly 1.

[0277] S203: The target first controller 2 generates an energy storage path signal or an energy storage break signal according to the first temperature information, and sends the energy storage path signal or the energy storage break signal to the energy storage controller 51 of the energy storage device 5; wherein, the energy storage path signal is used to instruct the energy storage controller 51 to maintain the connection between the energy storage device 5 and the first charging pile 6; the energy storage break signal is used to instruct the energy storage controller 51 to disconnect the connection between the energy storage device 5 and the first charging pile 6.

[0278] In this step, if the first cable assembly 1 does not have a risk of high-temperature damage, an energy storage path signal is generated and sent to the energy storage controller 51, so that the energy storage device 5 can continuously output a charging current to the first charging pile 6.

[0279] If the first cable assembly 1 has a risk of high-temperature damage, an energy storage break signal is generated and sent to the energy storage controller 51, so that the energy storage device 5 disconnects the connection with the first charging pile 6.

[0280] Avoid re-outputting the charging current to the cable assembly 1 at risk of high-temperature damage, which may cause damage to the cable assembly 1.

[0281] Specifically, the target first controller 2 generates a power storage path signal or a power storage break signal according to the first temperature information, including:

[0282] If the target first controller 2 determines that the first temperature information does not exceed the preset temperature break threshold, it generates a power storage path signal; the target first controller 2 obtains the first cooling level corresponding to the first temperature information from the preset temperature level mapping table, and generates a first cooling level signal according to the first cooling level;

[0283] If the target first controller 2 determines that the first temperature information exceeds the preset temperature break threshold, it generates a power storage break signal.

[0284] S204: If the target first controller 2 determines that the number of cable assemblies 1 for which a power storage break signal is generated exceeds the preset power storage break threshold, the target first controller 2 generates a power storage stop signal and sends the power storage stop signal to the power storage controller 51; wherein, the power storage stop signal is used to instruct the power storage controller 51 to stop the operation of the energy storage device 5.

[0285] In this step, if the number of power storage break signals is too large, it indicates that there are too many cable assemblies 1 with too high a temperature. Furthermore, it means that the current cable assemblies 1 need to be replaced collectively, or defects such as too large a charging current output by the energy storage device 5 need to be repaired to ensure the safety of the charging system composed of the energy storage device 5 and the charging pile 6. Therefore, in this step, by determining that the number of cable assemblies 1 for which a power storage path signal is generated exceeds the preset power storage break threshold, the target first controller 2 generates a power storage stop signal and sends the power storage stop signal to the power storage controller 51, the problem of large-scale cable collapse caused by a large number of unqualified power lines 111 of the cable assembly 1 and / or too large a charging current output by the energy storage device 5 is restricted from further growing, ensuring the safety of the energy storage device 5, the charging cable system, and the charging pile 6.

[0286] S205: The target first controller 2 generates a first cooling level signal according to the first temperature information and sends the first cooling level signal to the cooling system 3; wherein, the first cooling level signal defines the flow rate of the coolant output by the cooling system 3 to the first cable assembly 1.

[0287] In this step, by generating a first cooling level signal according to the first temperature information to define the flow rate of the coolant in the first cable assembly 1, coolants with different flow rates are input to the cable assemblies 1 at different temperatures to ensure that the temperatures of the cable assemblies 1 can be effectively controlled.

[0288] S206: The cooling system 3 generates an energy storage path signal in response to the target first controller 2, and the cooling system 3 outputs coolant into the first cable assembly 1.

[0289] In this step, by making the cooling system 3 generate an energy storage path signal in response to the target first controller 2, so that the cooling system 3 starts to output coolant into the first cable assembly 1 only when the first cable assembly 1 begins to deliver charging current to the charging pile 6, it is avoided that the cooling system 3 outputs coolant to the inoperative cable assembly 1, resulting in high energy consumption of the cooling system 3.

[0290] Specifically, the cooling system 3 outputs coolant into the first cable assembly 1, including:

[0291] The cooling system 3 determines the gear level of the flow rate controller 35 of the cooling system 3 according to the first cooling level signal; wherein, the gear level defines the flow rate of the coolant at the output end of the flow rate controller 35.

[0292] The compressor 32 of the cooling system 3 starts, and the coolant is output to the first cable assembly 1 through the flow rate controller 35 that determines the gear level.

[0293] S207: The target second controller 4 generates an energy storage path signal in response to the target first controller 2, and the target second controller 4 detects the leakage degree of the first charging pile 6 to obtain the first leakage information.

[0294] In this step, by detecting the leakage condition of the first charging pile 6, the safety of the first charging pile 6 is identified.

[0295] Specifically, the target second controller 4 detects the leakage degree of the first charging pile 6 to obtain the first leakage information, including:

[0296] The target second controller 4 detects the difference between the electromagnetic intensity of the power supply branch line and the electromagnetic intensity of the return branch line to obtain an electromagnetic difference; the electromagnetic difference characterizes the leakage degree of the first charging pile 6.

[0297] The target second controller 4 determines the leakage current value corresponding to the electromagnetic difference according to the preset electromagnetic leakage mapping table, and takes the obtained leakage current value as the first leakage information.

[0298] S208: The target second controller 4 generates a charging path signal or a charging break signal according to the first leakage information, and sends the charging path signal or the charging break signal to the first charging controller 61 of the first charging pile 6; wherein, the first charging controller 61 is used to control the connection and disconnection between the first charging pile 6 and the new energy vehicle; the charging path signal is used to instruct the first charging controller 61 to maintain the connection between the first charging pile 6 and the new energy vehicle; the charging break signal is used to instruct the first charging controller 61 to disconnect the connection between the first charging pile 6 and the new energy vehicle.

[0299] In this step, the target second controller 4 determines the leakage degree of the first charging pile 6 according to the first leakage information, and judges whether the first charging pile 6 can continue to work based on this leakage degree; if it can continue to work, a charging path signal is generated to make the best use of the current charging pile 6 and improve the charging efficiency of a large number of new energy vehicles; if it cannot continue to work, a charging open circuit signal is generated to avoid damage to the new energy vehicle and the user during the use of the charging pile 6.

[0300] Specifically, the target second controller 4 generates a charging path signal or a charging open circuit signal according to the first leakage information, including:

[0301] If the target second controller 4 determines that the first leakage information does not exceed the preset charging leakage threshold, a charging path signal is generated;

[0302] If the target second controller 4 determines that the first leakage information exceeds the charging leakage threshold, a charging open circuit signal is generated; the target second controller 4 also sends the charging open circuit signal to the target first controller 2 through the first cable assembly 1, and the target first controller 2 generates a major repair alarm message according to the charging open circuit signal; the major repair alarm message records the location information and device information of the charging pile 6 where the target second controller 4 that generates the restricted charging indication signal is located.

[0303] Furthermore, after the target second controller 4 generates a charging path signal if it determines that the first leakage information does not exceed the preset charging leakage threshold, the method further includes:

[0304] If the target second controller 4 determines that the first leakage information does not exceed the preset defective leakage threshold, a full-function charging indication signal is generated and sent to the charging controller 61 and the target first controller 2; wherein, the full-function charging indication signal is used to indicate that the charging controller 61 can implement all charging functions for the new energy vehicle;

[0305] If the target second controller 4 determines that the first leakage information exceeds the defective leakage threshold, a restricted charging indication signal is generated and sent to the charging controller 61 and the target first controller 2; wherein, the restricted charging indication signal is used to indicate that the charging controller 61 implements partial charging functions for the new energy vehicle;

[0306] The target first controller 2 generates a maintenance alarm message according to the restricted charging indication signal; wherein, the maintenance alarm message records the location information and device information of the charging pile 6 where the target second controller 4 that generates the restricted charging indication signal is located.

[0307] In this example, the charging controller 61 sets multiple charging functions for the connection between the charging pile 6 and the new energy vehicle, such as: supercharging function, fast charging function, and slow charging function; the supercharging function, fast charging function, and slow charging function are divided according to the charging speed and power. The power of supercharging is above 240kW, and the power battery can be charged to 80% within 40 minutes and fully charged within 80 minutes. The power of fast charging is between 60 and 129kW, and the power battery can be charged to about 80% within 30 to 60 minutes; the power of slow charging is between 3 and 7kW, and it takes 8 to 10 hours to fully charge the power battery.

[0308] When the target second controller 4 generates a full-function indication charging signal, the charging controller 61 will allow the charging pile 6 to implement the supercharging function, fast charging function, and slow charging function for the new energy vehicle.

[0309] When the target second controller 4 generates a restricted indication charging signal, the charging controller 61 will only allow the charging pile 6 to implement the slow charging function for the new energy vehicle, and does not allow the implementation of the supercharging function and fast charging function, so as to reduce the leakage current of the charging pile 6 and avoid further damage to the insulation of the charging pile 6.

[0310] It should be noted that in this article, the terms "include", "comprise" or any other variant thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements not only includes those elements, but also includes other elements not expressly listed, or further includes elements inherent to such process, method, article or device. Without further limitation, an element defined by the statement "including a..." does not exclude the existence of additional identical elements in the process, method, article or device including that element.

[0311] Those skilled in the art will readily think of other implementation schemes of the embodiments of the present application after considering the specification and practicing the invention disclosed herein. The embodiments of the present application are intended to cover any variations, uses or adaptations of the embodiments of the present application, which follow the general principles of the embodiments of the present application and include common general knowledge or conventional technical means in the technical field not disclosed in the embodiments of the present application. The specification and embodiments are only regarded as exemplary, and the true scope and spirit of the embodiments of the present application are pointed out by the following claims.

[0312] It should be understood that the embodiments of the present application are not limited to the exact structures already described and shown in the drawings, and various modifications and changes can be made without departing from its scope. The scope of the embodiments of the present application is only limited by the appended claims.

Claims

1. A charging cable system, characterized in that, For connecting an energy storage device and at least one charging pile, the energy storage device is used for storing electric energy, and the charging pile is used for charging new energy vehicles; The charging cable system includes: at least one cable assembly, a first controller, a cooling system and at least one second controller; One end of the cable assembly is connected to the energy storage device, and the other end of the cable assembly is connected to one of the charging piles; The first controller is fixed in the energy storage device, the first controller is connected to at least one of the cable assemblies, and the first controller is also connected to the energy storage controller; wherein, the first controller is used for controlling the on and off of each cable assembly through the energy storage controller according to the temperature information of each cable assembly; the temperature information is used to characterize the temperature of the power line in the cable assembly; The cooling system is fixed in the energy storage device, the cooling system is connected to at least one of the cable assemblies, and the first controller is also connected to the cooling system; wherein, the cooling system is used to output coolant to each cable assembly; the coolant is used to cool down the cable assembly; One of the second controllers is fixed in one of the charging piles, one of the second controllers is connected to one of the cable assemblies, and one of the second controllers is also connected to the charging controller in one of the charging piles; wherein, the second controller is used for controlling the on and off between the charging pile and the new energy vehicle through the charging controller according to the leakage information of the charging pile; the leakage information reflects the degree of leakage of the charging pile; The cable assembly includes: a composite cable, a first connector, and a second connector; The composite cable is used for transmitting charging current, transmitting communication signals, feedbacking the temperature information of the cable assembly, receiving the coolant output by the cooling system, and outputting coolant to the cooling system; One end of the composite cable is connected to the first connector, and the first connector is connected to the output end of the energy storage device, the first controller and the cooling system; The other end of the composite cable is connected to the second connector, and the second connector is connected to the input end of the charging pile and the second controller; The composite cable includes: a plurality of power lines, at least one temperature line, at least one communication line, a cooling input line, a cooling output line, a cable protective layer and an overall protective layer; The power lines are used for outputting energy storage current, and a plurality of the power lines form a ring structure around; The temperature line is used for detecting the temperature of the power line, and at least one of the temperature lines is located inside the ring structure; The communication line is used for transmitting communication signals, and at least one of the communication lines is located outside the ring structure; The cooling input line is wound outside the ring structure; The cable protective layer is sleeved outside the ring structure and the cooling input line; The cooling output line is located outside the cable protective layer; The overall protective layer is sleeved outside the cable protective layer, the cooling output line and at least one of the communication lines; A fiber filler and / or a filling rubber is filled between the overall protective layer and the cable protective layer; The power line includes: a power transmission line and a first insulating layer; The first insulating layer is sleeved outside the power transmission line; The first insulating layer is made of an insulating and heat-conducting material; wherein, the insulating and heat-conducting material of the first insulating layer is one of silicone rubber, glass fiber reinforced resin and silicon nitride.

2. The charging cable system according to claim 1, wherein The first connector includes: a plurality of first power terminals, at least one first temperature terminal, at least one first communication terminal, a coolant input port and a coolant output port; One of the first power terminals is connected to one end of the power line; the first power terminal is used for connecting to the output end of the energy storage device; One of the first temperature terminals is connected to one end of the temperature line; the first temperature terminal is used for connecting to the first controller; One of the first communication terminals is connected to one end of the communication line; the first communication terminal is used for connecting to the first controller; the first communication terminal is also used for connecting to the energy storage controller of the energy storage device; The coolant input port is connected to the cooling input line, and the coolant input port is used for receiving the coolant output by the cooling system; The coolant output port is connected to the cooling output line, and the coolant output port is used for outputting the coolant to the cooling system.

3. The charging cable system according to claim 1, wherein The second connector includes: a plurality of second power terminals, at least one second temperature terminal, at least one second communication terminal, and two coolant adapters; One of the second power terminals is connected to one end of the power line; the second power terminal is used for connecting to the input end of the charging pile; One of the second temperature terminals is connected to one end of the temperature line; the second temperature terminal is used for outputting an initial voltage to the temperature line; the temperature line outputs a temperature voltage to the first temperature terminal of the first connector according to the initial voltage; the temperature voltage is temperature information used to characterize the temperature conditions of multiple power lines in the composite cable; One of the second communication terminals is connected to one end of the communication line; the second communication terminal is used for connecting to the second controller and the charging controller of the charging pile; One of the coolant adapters is connected to the cooling input line, and the other coolant adapter is connected to the cooling output line, and the two coolant adapters are connected to each other.

4. The charging cable system according to claim 1, wherein, The first controller includes: at least one temperature sensor and a first processor; One of the temperature sensors is connected to the first connector of the cable assembly; The temperature sensor is also connected to the first processor, and the temperature sensor is used for sending the temperature information of each cable assembly to the first processor; The first processor is connected to the energy storage controller. The first processor is configured to generate an energy storage path signal or an energy storage open circuit signal for each cable assembly according to the temperature information of each cable assembly. The first processor is further configured to send the energy storage path signal and the energy storage open circuit signal to the energy storage controller. The energy storage path signal is used to instruct the energy storage controller to set the connection between the energy storage device and the cable assembly as a path. The energy storage open circuit signal is used to instruct the energy storage controller to set the connection between the energy storage device and the cable assembly as an open circuit. The first processor is also connected to the cooling system; The first processor is configured to generate a cooling level signal for each cable assembly according to the temperature information of each cable assembly. The cooling system adjusts the flow rate of the coolant in each cable assembly according to the cooling level signal.

5. The charging cable system according to claim 1, wherein, The cooling system includes: an input multi-tube joint, a compressor, a condenser, an output multi-tube joint, and at least one flow rate controller; The input multi-tube joint has at least one input port and one output port. One input port of the input multi-tube joint is connected to the coolant output port of the first connector of a cable assembly through a pipeline, and the output port of the input multi-tube joint is connected to the input port of the compressor; The output port of the compressor is connected to the input port of the condenser; The output multi-tube joint has at least one output port and one input port; The input port of the output multi-tube joint is connected to the output port of the condenser; one output port of the output multi-tube joint is connected to the coolant input port of the first connector of a cable assembly through a pipeline; One flow rate controller is connected to the pipeline between the output multi-tube joint and the coolant input port, and at least one flow rate controller is respectively connected to the first controller; the flow rate controller is used to control the flow rate of the coolant in the pipeline between the output multi-tube joint and the coolant input port.

6. The charging cable system according to claim 1, characterized in that, The second controller includes: at least one leakage current sensor and a second processor; A power transmission loop of a cable assembly passes through a leakage current sensor and is connected to the charging pile; wherein, the power transmission loop is used to output a charging current to the charging pile. The power transmission loop includes a power supply branch line and a return branch line. The power supply branch line is connected to the first power line in the cable assembly, and the return branch line is connected to the second power line in the cable assembly. The first power line is one of at least one power line in the cable assembly. The second power line is one of at least one power line in the cable assembly. The first power line and the second power line are different power lines; At least one leakage current sensor is respectively connected to the second processor; the leakage current sensor is used to detect the leakage current in the power transmission loop. The second processor is configured to generate a charging path signal or a charging open signal for each of the power transmission circuits according to the leakage current of each of the power transmission circuits; the second processor is further configured to send the charging path signal and the charging open signal to the charging controller; wherein, the charging path signal is used to instruct the charging controller to set the connection between the charging pile and the new energy vehicle as a path; the charging open signal is used to instruct the charging controller to set the connection between the charging pile and the new energy vehicle as an open circuit.

7. A charging control method for a charging cable system, characterized in that, When operating in the charging cable system according to any one of claims 1-6, the charging control method includes: The target first controller and the cooling system respectively respond to the monitoring of the start of the energy storage device, and the target second controller responds to the start of the first charging pile; wherein, the start of the energy storage device indicates that the energy storage device outputs a charging current to at least one charging pile; the first charging pile is one of the at least one charging piles receiving the charging current; the target first controller is the first controller connected to the first charging pile; the target second controller is the second controller fixed to the first charging pile; the start of the first charging pile indicates that the first charging pile is connected to the new energy vehicle and outputs a charging current to the new energy vehicle; The target first controller receives the first temperature information of the first cable assembly; wherein, the first cable assembly is the cable assembly connecting the energy storage device and the first charging pile; the first temperature information is used to characterize the temperature of the power line in the first cable assembly. The target first controller generates a storage path signal or a storage open signal according to the first temperature information, and sends the storage path signal or the storage open signal to the energy storage controller of the energy storage device; wherein, the storage path signal is used to instruct the energy storage controller to maintain the connection between the energy storage device and the first charging pile; the storage open signal is used to instruct the energy storage controller to disconnect the connection between the energy storage device and the first charging pile. The cooling system outputs a coolant to the first cable assembly in response to the target first controller generating the storage path signal. The target second controller detects the leakage degree of the first charging pile in response to the target first controller generating the storage path signal, and obtains the first leakage information. The target second controller generates a charging path signal or a charging open signal according to the first leakage information, and sends the charging path signal or the charging open signal to the first charging controller of the first charging pile; wherein, the first charging controller is used to control the connection and disconnection between the first charging pile and the new energy vehicle; the charging path signal is used to instruct the first charging controller to maintain the connection between the first charging pile and the new energy vehicle; the charging open signal is used to instruct the first charging controller to disconnect the connection between the first charging pile and the new energy vehicle.

8. The charging control method according to claim 7, wherein After the target first controller generates an energy storage path signal or an energy storage open circuit signal according to the first temperature information and sends the energy storage path signal or the energy storage open circuit signal to the energy storage controller of the energy storage device, the method further includes: If the target first controller determines that the number of cable assemblies generating the energy storage open circuit signal exceeds a preset energy storage open circuit threshold, the target first controller generates an energy storage stop signal and sends the energy storage stop signal to the energy storage controller; wherein, the energy storage stop signal is used to instruct the energy storage controller to stop the operation of the energy storage device.

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