Charging module capable of switching heat dissipation modes

Abstract

The invention relates to the technical field of a charging module capable of switching heat dissipation modes, and the charging module comprises an air-cooled charging module assembly and a liquid-cooled charging module assembly which can be mutually replaced, the air-cooled charging module assembly comprises a first heat dissipation system composed of a heat dissipation end plate, an air-cooled heat dissipation module, a fan and an internal unit gap, the liquid cooling charging module assembly comprises a second heat dissipation system composed of a liquid cooling plate and a liquid cooling connecting plate. Wherein the heat dissipation end plate and the sealing end plate, the air cooling heat dissipation module and the liquid cooling connecting plate, and the internal unit fixing plate and the liquid cooling plate are respectively provided with an interchangeable assembly structure, and the air cooling charging module assembly comprises a module upper cover plate, an AC-DC unit, a DC-DC unit, a module shell, an acquisition and detection unit and a control unit. The AC-DC unit, the DC-DC unit, the acquisition and detection unit and the control unit are integrally mounted in the module shell through an internal unit fixing plate; the charging module capable of switching the heat dissipation modes is good in heat dissipation effect.

Description

Technical Field

[0001] The present application relates to the technical field of charging modules with switchable heat dissipation methods, and in particular, to a charging module with a switchable heat dissipation method. Background Art

[0002] The present invention belongs to a charging device for new energy vehicles, specifically a charging module for DC charging. It specifically relates to new energy vehicle charging, charging pile modules, and module heat dissipation systems; this solution is also applicable to other fields.

[0003] Currently, charging in the new energy vehicle industry is divided into AC charging and DC charging. When normal-speed charging is required, such as charging in 8 hours, AC charging can be selected and achieved through power supply from an AC charging pile; when fast charging is required, such as charging in 1 hour, only DC fast charging can meet the need and is achieved through power supply from a DC charging pile. The core component of a DC charging pile is the charging module, which accounts for nearly 50% of the cost of the DC charging pile. Its function is to convert the 380V high-voltage power provided by the power grid into the DC high-voltage power required by new energy vehicles. The charging power of the charging pile is designed by stacking the power of the charging modules. For example, a 120kw DC charging pile can be composed of 6 20kw charging modules to form an output power of 120kw.

[0004] When a new energy vehicle undergoes DC fast charging, the charging module itself will generate energy loss during the power conversion process during operation, which is manifested in the form of heat, resulting in the heating of the charging module, reducing the power conversion efficiency of the power supply, affecting the normal operation of the charging module, and shortening the lifespan of components. When the charging module fails, it will directly lead to the failure of DC fast charging of new energy vehicles. At the same time, during the gradual aging process of the charging module, the heat generation will further increase, which will increase the failure rate, shorten the service life, reduce the operation efficiency of the charging pile, and reduce the operation revenue of the charging pile. Moreover, in recent years, the global temperature has risen, and the summer temperature has repeatedly reached record highs with a long duration of high temperature. The outer shell of the charging pile is mostly made of sheet metal, which has the characteristics of fast heat transfer and poor heat dissipation. The internal components also generate heat loss during operation. The charging pile continuously outputs high power in hot summer weather, exacerbating the problem of overheating of the module, resulting in an increase in the failure rate of the charging pile, thus affecting the normal operation of the station. Currently, most charging station operators are not professionals in the charging industry, lacking professional knowledge and weak in maintenance awareness. To save costs, they do not hire professional maintenance personnel and cannot clean the air duct in time to assist in heat dissipation, resulting in overheating of the module in summer and an increase in the failure rate of the charging pile, etc. According to industry statistics, 70% of the charging pile failures come from the module, and 90% of them come from the overheating failure of the module. Technical personnel in this field have provided a charging module with a switchable heat dissipation method to solve the problems raised in the above background art. Summary of the Invention

[0005] To solve the problems raised in the above background art, the present application provides a charging module with a switchable heat dissipation method.

[0006] The charging module with a switchable heat dissipation method provided by the present application adopts the following technical solutions:

[0007] A charging module with a switchable heat dissipation method includes an air-cooled charging module assembly and a liquid-cooled charging module assembly that can be mutually replaced. The air-cooled charging module assembly includes a first heat dissipation system composed of a heat dissipation end plate, an air-cooled heat dissipation module, a fan, and an internal unit gap. The liquid-cooled charging module assembly includes a second heat dissipation system composed of a liquid-cooled plate and a liquid-cooled connection plate.

[0008] Among them, the heat dissipation end plate and the sealing end plate, the air-cooled heat dissipation module and the liquid-cooled connection plate, and the internal unit fixing plate and the liquid-cooled plate respectively have interchangeable assembly structures.

[0009] Preferably, the air-cooled charging module assembly includes a module upper cover plate, an AC-DC unit, a DC-DC unit, a module housing, a collection and detection unit, and a control unit. The AC-DC unit, the DC-DC unit, the collection and detection unit, and the control unit are integrally installed in the module housing through an internal unit fixing plate. The fan and the air-cooled heat dissipation module form a forced convection channel.

[0010] Preferably, the liquid-cooled plate includes a liquid inlet, a liquid outlet, a serpentine liquid flow channel, and a heat conduction support plate. The liquid flow channel extends along the surface of the support plate to form a contact heat exchange surface. The liquid-cooled connection plate is provided with a quick interface matching the liquid-cooled plate.

[0011] Preferably, the support plate is in direct contact with the heat-generating components of the AC-DC unit, the DC-DC unit, the collection and detection unit, and the control unit, and a thermal grease layer is provided on the contact surface.

[0012] Preferably, the interchangeable assembly structure specifically includes a bolt hole position matching structure between the heat dissipation end plate and the sealing end plate, a snap-on slide rail structure between the air-cooled heat dissipation module and the liquid-cooled connection plate, and a positioning pin assembly structure between the internal unit fixing plate and the liquid-cooled plate.

[0013] Preferably, the control unit includes a heat dissipation mode switching control module, which automatically selects to start the air-cooled heat dissipation system or the liquid-cooled heat dissipation system through the temperature sensor signal.

[0014] Preferably, a standardized heat dissipation interface installation surface is provided at the bottom of the module housing, and this installation surface includes a common positioning reference compatible with the air-cooled heat dissipation module and the liquid-cooled connection plate.

[0015] In summary, the present application includes the following beneficial technical effects:

[0016] Improved Adaptability to Multiple Environments

[0017] Through the modular design of the heat dissipation end plate, sealing end plate, and rapid replacement structure of the air-cooled heat dissipation module and liquid-cooled connection plate, the same charging module can flexibly switch between air-cooled and liquid-cooled modes according to conditions such as ambient temperature and working load, effectively solving the compatibility problems of condensation in winter in high-latitude regions and high-temperature heat dissipation in tropical regions.

[0018] Doubled Thermal Management Efficiency

[0019] Adopting the contact heat conduction design of the liquid flow channel of the liquid-cooled plate and the support plate, compared with the traditional air-cooled system, the heat dissipation efficiency is increased by 2.8 - 3.5 times (the measured thermal resistance ≤ 0.15 °C / W). When the charging module operates at full load, the temperature of core components such as IGBT can be stably controlled within the 85 °C safety threshold, thereby increasing the power density to more than 18 kW / L.

[0020] Enhanced Safety Redundancy

[0021] The combination of the three-level protection mechanism and the real-time monitoring of the acquisition and detection unit can switch to the standby air-cooled heat dissipation within 0.5 seconds when the liquid-cooled system leaks, and automatically trigger the power cut-off and BMS linkage protection, reducing the risk incidence of thermal runaway.

[0022] Optimized Total Life Cycle Cost

[0023] The modular interchange design enables the upgrade of the heat dissipation system without replacing the entire machine. Only by replacing core components such as the heat dissipation end plate and liquid-cooled plate can the heat dissipation capacity be iterated, reducing the equipment transformation cost. At the same time, the liquid-cooled mode can reduce the average annual failure rate of mechanical components such as fans from 12.3% to 2.1%, significantly extending the service life of the equipment. Description of the Drawings

[0024] Figure 1 It is the overall assembly drawing of the air-cooled charging module of a charging module with a switchable heat dissipation method in an embodiment of the present application;

[0025] Figure 2 It is the exploded view of the air-cooled charging module of a charging module with a switchable heat dissipation method in an embodiment of the present application;

[0026] Figure 3 It is the overall assembly drawing of the liquid-cooled charging module of a charging module with a switchable heat dissipation method in an embodiment of the present application;

[0027] Figure 4 It is the exploded view of the liquid-cooled charging module of a charging module with a switchable heat dissipation method in an embodiment of the present application;

[0028] Figure 5 It is the schematic diagram of the liquid-cooled plate structure of a charging module with a switchable heat dissipation method in an embodiment of the present application.

[0029] Description of the reference numerals: 1, air-cooled charging module assembly; 11, upper cover plate of the module; 12, AC-DC unit; 13, heat dissipation end plate; 14, DC-DC unit; 15, internal unit fixing plate; 16, module housing; 17, acquisition and detection unit; 3, air-cooled heat dissipation module; 31, fan; 19, control unit; 2, liquid-cooled charging module assembly; 23, sealing end plate; 28, liquid-cooled connecting plate; 4, liquid-cooled plate; 41, liquid inlet; 42, liquid outlet; 43, liquid flow channel; 44, support plate. Specific embodiments

[0030] In order to make the technical means, creative features, achieved purposes and effects of the present invention easy to understand, the present invention will be further described below in conjunction with specific embodiments.

[0031] As Figure 1 - Figure 2 shown, an air-cooled charging module with a switchable heat dissipation method, the air-cooled charging module assembly 1 is composed of an upper cover plate 11 of the module, an AC-DC unit 12, a heat dissipation end plate 13, a DC-DC unit 14, an internal unit fixing plate 15, a module housing 16, an acquisition and detection unit 17, an air-cooled heat dissipation module 3, a fan 31 and a control unit 19; wherein the AC-DC unit 12, the DC-DC unit 14, the acquisition and detection unit 17 and the control unit 19 form the internal unit of the charging module; the heat dissipation end plate 13, the air-cooled heat dissipation module 3, the fan 31 and the internal unit gap form an air-cooled heat dissipation system.

[0032] As Figure 2 shown, when the air-cooled charging module needs to dissipate heat, the fan 31 starts to work, and air heat exchange is carried out on the AC-DC unit 12, the DC-DC unit 14, the acquisition and detection unit 17, and the control unit 19 to reduce their temperatures;

[0033] As Figure 3 、 4 shown, the liquid-cooled charging module assembly 2 is composed of an upper cover plate 11 of the module, an AC-DC unit 12, a sealing end plate 23, a DC-DC unit 14, a liquid-cooled plate 4, a module housing 16, an acquisition and detection unit 17, a liquid-cooled connecting plate 28 and a control unit 19; wherein the AC-DC unit 12, the DC-DC unit 14, the acquisition and detection unit 17 and the control unit 19 form the internal unit of the charging module; the liquid-cooled plate 4 and the liquid-cooled connecting plate 28 form a liquid-cooled heat dissipation system.

[0034] As Figure 5As shown, the liquid cooling plate 4 is composed of a liquid inlet 41, a liquid outlet 42, a liquid flow channel 43, and a support plate 44. When the liquid cooling system needs to work, the cooling liquid enters the liquid cooling plate 4 from the liquid inlet 41, flows through the liquid flow channel 43, and exchanges heat with the AC-DC unit 12, DC-DC unit 14, acquisition and detection unit 17, and control unit 19 through the support plate 44, and finally flows out from the liquid outlet 42, thus achieving temperature reduction.

[0035] As Figure 2 , 4 shown, when it is necessary to improve the heat dissipation performance, the air cooling system can be switched to the liquid cooling system. Specifically: the heat dissipation end plate 13 is switched to the sealed end plate 23, the internal unit fixing plate 15 is switched to the liquid cooling plate 4, and the air cooling module 3 is switched to the liquid cooling connection plate 28. Thus, the problems that the air cooling charging module cannot meet, such as aging, different regions, different seasons, and the change of heat dissipation capacity requirements due to the increase of output power, are solved, and the safety performance of new energy charging is further improved, and major safety risks are avoided; the reliability, warranty life, power conversion performance of the charging module are further improved, and the economic benefits of the overall operation are maximized.

[0036] The implementation principle of a charging module with a switchable heat dissipation method in this application embodiment is: a dual-mode heat dissipation mechanism. In the air cooling mode, when the ambient temperature is lower than the preset threshold or the heat dissipation requirement is low, the system defaults to start the air cooling mode. The control unit 19 monitors the real-time temperature of the heat-generating components such as the AC-DC unit 12 and DC-DC unit 14 through the acquisition and detection unit 17, and drives the fan 31 to generate a forced convection air flow. The air flow sequentially passes through the fin structure of the air cooling module 3, the diversion channel of the heat dissipation end plate 13, and the internal unit gap, and takes away the heat from the surface of the heat-generating components, realizing air-solid contact heat transfer. In the liquid cooling mode: when any of the following conditions is detected, the system switches to the liquid cooling mode. The component temperature exceeds the air cooling heat dissipation limit threshold. The external ambient temperature is higher than the set value, such as in a high-temperature environment in summer. The increase in charging power leads to a sudden increase in the heat load. At this time, the coolant is injected into the liquid inlet 41 of the liquid cooling plate 4 through the quick interface of the liquid cooling connection plate 28 and flows along the serpentine liquid flow channel 43. The support plate 44 is in direct contact with the heat-generating components, conducts the heat to the coolant in the flow channel, and transports the heat to the external radiator (not shown) through the liquid circulation. The coolant finally discharges from the liquid outlet 42, forming a closed liquid cooling circulation system.

[0037] The following points should be noted: First, in the description of this application, it should be noted that unless otherwise specified and limited, the terms "installed", "connected", and "coupled" should be understood in a broad sense, which can be a mechanical connection or an electrical connection, or can be the internal communication of two components, and can be directly connected. The terms "upper", "lower", "left", "right", etc. are only used to represent the relative positional relationship. When the absolute position of the object being described changes, the relative positional relationship may change;

[0038] Second: In the drawings of the disclosed embodiments of the present invention, only the structures related to the disclosed embodiments are involved. Other structures can refer to the general design. Without conflict, the same embodiment and different embodiments of the present invention can be combined with each other;

[0039] Finally: The above are only the preferred embodiments of the present invention and are not used to limit the present invention. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

Claims

1. A charging module with a switchable heat dissipation method, characterized in that: It includes an interchangeable air-cooled charging module assembly (1) and a liquid-cooled charging module assembly (2). The air-cooled charging module assembly (1) includes a first heat dissipation system composed of a heat dissipation end plate (13), an air-cooled heat dissipation module (3), a fan (31) and an internal unit gap. The liquid-cooled charging module assembly (2) includes a second heat dissipation system composed of a liquid-cooled plate (4) and a liquid-cooled connection plate (28). Among them, the heat dissipation end plate (13) and the sealing end plate (23), the air-cooled heat dissipation module (3) and the liquid-cooled connection plate (28), and the internal unit fixing plate (15) and the liquid-cooled plate (4) respectively have interchangeable assembly structures.

2. The charging module with a switchable heat dissipation method according to claim 1, wherein: The air-cooled charging module assembly (1) includes a module upper cover plate (11), an AC-DC unit (12), a DC-DC unit (14), a module housing (16), a collection and detection unit (17) and a control unit (19). The AC-DC unit (12), the DC-DC unit (14), the collection and detection unit (17) and the control unit (19) are integrally installed in the module housing (16) through an internal unit fixing plate (15). The fan (31) and the air-cooled heat dissipation module (3) form a forced convection channel.

3. The charging module with a switchable heat dissipation method according to claim 1, characterized in that: The liquid-cooled plate (4) includes a liquid inlet (41), a liquid outlet (42), a serpentine liquid flow channel (43) and a heat conduction support plate (44). The liquid flow channel (43) extends along the surface of the support plate (44) to form a contact heat exchange surface. The liquid-cooled connection plate (28) is provided with a quick interface matching the liquid-cooled plate (4).

4. The charging module with a switchable heat dissipation method according to claim 3, characterized in that: The support plate (44) is in direct contact with the heat-generating components of the AC-DC unit (12), the DC-DC unit (14), the collection and detection unit (17) and the control unit (19), and a thermal grease layer is provided on the contact surface.

5. The charging module with a switchable heat dissipation method according to claim 1, wherein: The interchangeable assembly structure specifically includes a bolt hole position matching structure between the heat dissipation end plate (13) and the sealing end plate (23), a snap-on slide rail structure between the air-cooled heat dissipation module (3) and the liquid-cooled connection plate (28), and a positioning pin assembly structure between the internal unit fixing plate (15) and the liquid-cooled plate (4).

6. The rechargeable module with a switchable heat dissipation method according to claim 1, wherein: The control unit (19) includes a heat dissipation mode switching control module, which automatically selects to start the air-cooled heat dissipation system or the liquid-cooled heat dissipation system through the temperature sensor signal.

7. A charging module with a switchable heat dissipation method according to any one of claims 1-6, characterized in that: The bottom of the module housing (16) is provided with a standardized heat dissipation interface installation surface, which includes a common positioning reference compatible with the air-cooled heat dissipation module (3) and the liquid-cooled connection plate (28).

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