A charge module with switchable heat dissipation mode

Abstract

The application relates to a charging module with switchable heat dissipation modes, which comprises a replaceable air-cooled charging module assembly and a liquid-cooled charging module assembly. 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-cooled charging module assembly comprises a second heat dissipation system composed of a liquid-cooled plate and a liquid-cooled connecting plate. The heat dissipation end plate, the air-cooled heat dissipation module, the liquid-cooled connecting plate, the internal unit fixing plate and the liquid-cooled plate have interchangeable assembly structures. The air-cooled charging module assembly comprises a module upper cover plate, an AC-DC unit, a DC-DC unit, a module shell, 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 integrated and installed in the module shell through the internal unit fixing plate. The charging module with switchable heat dissipation modes has good heat dissipation effect.

Description

TECHNICAL FIELD

[0001] The application relates to the technical field of a charging module with switchable heat dissipation modes. BACKGROUND

[0002] The application belongs to a charging device for new energy vehicles, in particular to a charging module for direct current charging. It specifically relates to new energy vehicle charging, charging pile modules and module heat dissipation systems. The scheme is also applicable to other fields.

[0003] At present, the charging of the new energy vehicle industry is divided into alternating current charging and direct current charging. When ordinary speed charging is required, such as 8 hours of full charging, alternating current charging can be selected to achieve power supply through an alternating current charging pile. When fast charging is required, such as 1 hour of full charging, direct current fast charging can be selected to meet the requirement, and power supply is achieved through a direct current charging pile. The core component of the direct current charging pile is the charging module, which accounts for nearly 50% of the cost of the direct current charging pile. Its function is to convert 380V high-voltage power provided by the power grid into direct current high-voltage power required by new energy vehicles. The charging power of the charging pile is designed by stacking the power of the charging module. For example, a 120kw direct current charging pile can be composed of 6 20kw charging modules, thereby forming an output power of 120kw.

[0004] When the new energy vehicle is subjected to direct current fast charging, the charging module itself will generate heat due to energy loss in the process of power conversion, which is manifested in the form of heat energy, thereby causing the heating of the charging module, reducing the conversion efficiency of the power supply, affecting the normal operation of the charging module and shortening the service life of the components. When the charging module fails, it will further directly cause the failure of the direct current fast charging of the new energy vehicle. Meanwhile, 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 income of the charging pile. In addition, in recent years, the global temperature has been rising, and the temperature in summer has repeatedly broken historical records. The duration of high temperature is long. The charging pile shell 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 the scorching summer, which aggravates the problem of module overheating, thereby increasing the failure rate of the charging pile and affecting the normal operation of the station. At present, most charging pile operators are not employees in the charging industry, and they lack professional knowledge and maintenance awareness. In order to save costs, they have not hired professional maintenance personnel, and they cannot clean the air duct for auxiliary heat dissipation in time, which leads to module overheating in summer, charging pile failure and the like. According to industry statistics, 70% of charging pile failures come from modules, and 90% of them come from module overheating failures. The technical personnel in the field provide a charging module with switchable heat dissipation modes to solve the problems raised in the background technology. SUMMARY

[0005] In order to solve the problems in the background art, the application provides a charging module with switchable heat dissipation modes.

[0006] The application provides a charging module with switchable heat dissipation modes, which adopts the following technical scheme:

[0007] The application provides a charging module with switchable heat dissipation modes, which adopts the following technical scheme:

[0008] The application provides a charging module with switchable heat dissipation modes, which adopts the following technical scheme:

[0009] Preferably, the air-cooled charging module assembly comprises a module upper cover plate, an AC-DC unit, a DC-DC unit, a module shell, 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 integrated and installed in the module shell through the internal unit fixing plate, and the fan and the air-cooled heat dissipation module form a forced convection channel.

[0010] Preferably, the liquid cooling plate comprises a liquid inlet, a liquid outlet, a serpentine liquid flow channel, and a heat-conducting support plate, the liquid flow channel extends along the surface of the support plate to form a contact heat exchange surface, and the liquid cooling connecting plate is provided with a quick connector matched with the liquid cooling 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 the contact surface is provided with a heat-conducting silicone grease layer.

[0012] Preferably, the interchangeable assembly structure specifically comprises a bolt hole matching structure of the heat dissipation end plate and the sealing end plate, a buckle type sliding rail structure of the air-cooled heat dissipation module and the liquid cooling connecting plate, and a positioning pin assembly structure of the internal unit fixing plate and the liquid cooling plate.

[0013] Preferably, the control unit comprises 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 a temperature sensor signal.

[0014] Preferably, the bottom of the module shell is provided with a standardized heat dissipation interface mounting surface, and the mounting surface comprises a universal positioning reference compatible with the air-cooled heat dissipation module and the liquid cooling connecting plate.

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

[0016] Multi-environment adaptability improvement

[0017] The sealing end plate of the heat dissipation end plate, the air-cooled heat dissipation module and the liquid-cooled connecting plate are quickly replaced through the modular design, so that the same charging module can flexibly switch between air cooling and liquid cooling modes according to environmental temperature, working load and other conditions, effectively solving the compatibility problem of condensation in winter in high-latitude areas and high-temperature heat dissipation in tropical areas.

[0018] ‌Heat management efficiency multiplication‌

[0019] The liquid flow channel of the liquid cooling plate is in contact with the support plate for heat conduction design. Compared with the traditional air cooling system, the heat dissipation efficiency is increased by 2.8-3.5 times (measured thermal resistance ≤0.15℃ / W), so that the charging module can stably control the temperature of the core device such as IGBT within the safety threshold of 85℃ when operating at full load, thereby increasing the power density to more than 18kW / L.

[0020] ‌Safety redundancy enhancement‌

[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 cooling system leaks, and automatically trigger the power cut-off and BMS linkage protection, so as to reduce the risk of thermal runaway.

[0022] ‌Full life cycle cost optimization‌

[0023] The modular interchange design makes it unnecessary to replace the whole machine for upgrading the heat dissipation system, and only the core components such as the heat dissipation end plate and the liquid cooling plate need to be replaced to realize the iteration of heat dissipation capacity, thereby reducing the equipment modification cost. At the same time, the liquid cooling mode can reduce the annual average failure rate of mechanical components such as fans from 12.3% to 2.1%, thereby significantly prolonging the service life of the equipment. BRIEF DESCRIPTION OF DRAWINGS

[0024] Figure 1 is an air-cooled charging module assembly diagram of a charging module with switchable heat dissipation mode in the embodiments of the present application;

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

[0026] Figure 3 is a liquid-cooled charging module assembly diagram of a charging module with switchable heat dissipation mode in the embodiments of the present application;

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

[0028] Figure 5 is a liquid cooling plate structure schematic diagram of a charging module with switchable heat dissipation mode in the embodiments of the present application.

[0029] Explanation of reference signs: 1, air-cooled charging module assembly; 11, module upper cover plate; 12, AC-DC unit; 13, heat dissipation end plate; 14, DC-DC unit; 15, internal unit fixing plate; 16, module shell; 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. DETAILED DESCRIPTION

[0030] In order to make the technical means, creative features, purposes and effects of the present application easy to understand, the present application is further described below in combination with specific embodiments.

[0031] As shown in Figures 1-2 , an air-cooled charging module assembly 1 is composed of a module upper cover plate 11, an AC-DC unit 12, a heat dissipation end plate 13, a DC-DC unit 14, an internal unit fixing plate 15, a module shell 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 constitute 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 constitute the air-cooled heat dissipation system.

[0032] As shown in Figure 2 , when the air-cooled charging module needs to be cooled, the fan 31 starts to work to perform air heat exchange on the AC-DC unit 12, the DC-DC unit 14, the acquisition and detection unit 17 and the control unit 19 to reduce the temperature thereof.

[0033] As shown in Figure 3 , 4 , a liquid-cooled charging module assembly 2 is composed of a module upper cover plate 11, an AC-DC unit 12, a sealing end plate 23, a DC-DC unit 14, a liquid-cooled plate 4, a module shell 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 constitute the internal unit of the charging module; the liquid-cooled plate 4 and the liquid-cooled connecting plate 28 constitute the liquid-cooled heat dissipation system.

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

[0035] As shown in Figure 2 , 4 When it is necessary to improve the heat dissipation performance, the air cooling heat dissipation system can be switched to the liquid cooling heat dissipation 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 heat dissipation module 3 is switched to the liquid cooling connection plate 28. Thus, the problem that the air cooling charging module cannot meet the requirements of aging, different regions, different seasons, output power improvement and changes in heat dissipation capacity is solved, further improving the safety performance of new energy charging, avoiding major safety risks, further improving the reliability of the charging module, the warranty life, the electric energy conversion performance and realizing the maximization of economic benefits of overall operation.

[0036] The implementation principle of the charging module with switchable heat dissipation mode in the embodiment of the application is: a dual-mode heat dissipation mechanism, an air cooling mode, when the ambient temperature is lower than a preset threshold or the heat dissipation demand 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 the DC-DC unit 14 through the acquisition and detection unit 17, and drives the fan 31 to generate forced convection airflow. The airflow flows through the fin structure of the air cooling heat dissipation module 3, the flow guide channel of the heat dissipation end plate 13 and the internal unit gap in turn, carries away the heat from the surface of the heat generating components, and realizes air-solid contact heat exchange. 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 environment temperature is higher than the set value such as summer high temperature environment, the charging power is increased, which causes the heat load to increase sharply, at this time, the cooling liquid is injected into the inlet 41 of the liquid cooling plate 4 through the quick connector 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 heat to the cooling liquid in the flow channel, and transports heat to the external heat sink (not shown) through liquid circulation. The cooling liquid is finally discharged from the outlet 42, forming a closed liquid cooling circulation system.

[0037] Finally should be explained a few points are: first, in the description of the present application, it should be pointed out that, unless otherwise specified and limited, the term "installation", "connected", "connection" should be broad, can be mechanical or electrical connection, but also can be two elements inside the communication, can be directly connected, "up", "down", "left", "right" and so on, only for indicating the relative position relationship, when the absolute position of the described object changes, the relative position relationship may change;

[0038] Second: the present application discloses the embodiment in the drawing, only relates to the structure involved in the present application, other structures can refer to the usual design, in the case of no conflict, the same embodiment and different embodiments of the present application can be combined with each other;

[0039] Finally: the above only for the preferred embodiment of the present application, and not for limiting the present application, any modification, equivalent replacement, improvement, etc. within the spirit and principles of the present application, should be included in the protection scope of the present application.

Claims

1. A charging module with switchable heat dissipation methods, 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 consisting of a heat dissipation end plate (13), an air-cooled heat dissipation module (3), a fan (31) and internal unit gaps. The liquid-cooled charging module assembly (2) includes a second heat dissipation system consisting of a liquid-cooled plate (4) and a liquid-cooled connecting plate (28). The heat dissipation end plate (13) and the sealing end plate (23), the air-cooled heat dissipation module (3) and the liquid-cooled connecting plate (28), the internal unit fixing plate (15) and the liquid-cooled plate (4) have interchangeable assembly structures. The air-cooled charging module assembly (1) includes a module cover plate (11), an AC-DC unit (12), a DC-DC unit (14), a module housing (16), a data acquisition and detection unit (17), and a control unit (19). The AC-DC unit (12), the DC-DC unit (14), the data acquisition and detection unit (17) and the control unit (19) are integrated and installed in the module housing (16) through the internal unit fixing plate (15). The fan (31) and the air-cooled heat dissipation module (3) form a forced convection channel. The liquid-cooled plate (4) includes a liquid inlet. (41), liquid outlet (42), serpentine liquid flow channel (43) and heat-conducting 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 cooling connection plate (28) is provided with a quick interface that matches the liquid cooling plate (4), the support plate (44) is in direct contact with the heating components of the AC-DC unit (12), DC-DC unit (14), acquisition and detection unit (17) and control unit (19), and the contact surface is provided with a thermally conductive silicone grease layer, the interchangeable assembly structure specifically includes the bolt hole matching structure of the heat dissipation end plate (13) and the sealing end plate (23), the snap-on slide rail structure of the air-cooled heat dissipation module (3) and the liquid cooling connection plate (28), and the positioning pin assembly structure of the internal unit fixing plate (15) and the liquid cooling plate (4).

2. The charging module with switchable heat dissipation mode according to claim 1, characterized in that: The control unit (19) includes a heat dissipation mode switching control module, which automatically selects to start the air cooling system or the liquid cooling system through temperature sensor signals.

3. A charging module with switchable heat dissipation mode according to any one of claims 1-2, characterized in that: The bottom of the module housing (16) is provided with a standardized heat dissipation interface mounting surface, which includes a universal positioning reference compatible with air-cooled heat dissipation modules (3) and liquid-cooled connecting plates (28).

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