DCDC-based liquid cooling charging gun and control method thereof

Abstract

The invention relates to the technical field of new energy, and discloses a DCDC-based liquid cooling charging gun and a control method thereof, and the method comprises the steps: obtaining the data of each temperature sensor in the charging gun, calculating a temperature change rate and a multi-dimensional thermal gradient, and judging whether the charging gun is overheated or not; and if the temperature is over-high, analyzing the micro-bubble concentration of the cooling liquid through hydraulic and sound wave data, and if the bubble concentration is over-limit, executing high-frequency flow velocity back-flushing excitation operation to remove bubbles. The back-flushing flow rate is dynamically adjusted according to the microbubble concentration, the fluctuation frequency is calculated based on the bubble concentration and a set threshold value, and efficient bubble removal is ensured. And meanwhile, the system generates a temperature target track according to the charging power and the environment temperature, the flow speed of cooling liquid is adjusted in a closed loop mode based on the actually measured temperature error, precise temperature control is achieved, and the safety and cooling efficiency of the charging gun are improved. The whole method has the capabilities of adaptive adjustment, anomaly detection and intelligent response.

Description

Technical Field

[0001] The present invention relates to the technical field of new energy, and particularly to a liquid-cooled charging gun based on DCDC and its control method. Background Art

[0002] With the rapid popularization of electric vehicles, high-power charging technology has become the core requirement for improving user experience and shortening the energy replenishment time. However, during high-power charging, the Joule heat generated inside the charging gun due to current transmission will increase sharply. If the heat dissipation efficiency is insufficient, it may lead to overheating of the equipment, material aging, and even potential safety hazards. The traditional air-cooled heat dissipation scheme is limited by the low specific heat capacity of air and space structure constraints, and it is difficult to meet the heat dissipation requirements in large-current scenarios. Therefore, liquid-cooling technology has gradually become the mainstream scheme for charging gun heat dissipation, which efficiently conducts heat through the circulation of coolant and significantly improves the heat dissipation efficiency. Nevertheless, there are still many technical bottlenecks in the existing liquid-cooled charging guns in practical applications and further optimization is urgently needed.

[0003] Firstly, the ability to dynamically monitor the internal temperature distribution of the charging gun is insufficient. Existing solutions mostly rely on single or a small number of temperature sensors, which cannot comprehensively reflect the thermal field gradient changes inside the charging gun. Local temperature anomalies (such as overheating at the contact point) may be ignored due to monitoring blind spots, resulting in a lag in heat dissipation response. In addition, traditional methods usually trigger cooling only based on absolute temperature thresholds, lacking predictive control of temperature change trends and being difficult to cope with transient thermal shocks. Secondly, the problem of microbubble accumulation inside the coolant has not been effectively solved. Under high-flow-rate or high-temperature working conditions, the coolant is prone to generate microbubbles. These bubbles not only reduce the effective thermal conductivity of the liquid but also cause cavitation effects in the pump-valve system, exacerbating equipment losses. Existing technologies mostly deal with bubbles through passive precipitation or simple filtration, but they cannot real-time monitor the bubble concentration and are difficult to efficiently remove them during dynamic operation.

[0004] On the other hand, the flow rate control strategy of the liquid-cooling system urgently needs to be upgraded intelligently. Currently, most solutions adopt fixed flow rates or segmented regulation based on temperature thresholds, lacking dynamic matching with real-time heat loads. For example, when the charging power fluctuates or the ambient temperature changes, a fixed flow rate may lead to insufficient cooling or energy waste. In addition, sudden changes in the coolant flow rate may cause pressure fluctuations, further exacerbating the problem of bubble generation. How to achieve closed-loop optimization control of the flow rate while taking into account heat dissipation efficiency and system stability has become a key challenge in the design of liquid-cooled charging guns.

[0005] In summary, developing a liquid-cooled charging gun and its control method that can real-time sense the thermal field gradient, accurately identify the bubble concentration, and dynamically adjust cooling parameters is of great significance for improving the safety, efficiency, and equipment life of high-power charging. Summary of the Invention

[0006] The present invention provides a liquid-cooled charging gun based on DCDC and its control method, which is used to help solve the problems mentioned in the above background technology.

[0007] The present invention provides the following technical solutions: A liquid-cooled charging gun based on DCDC and its control method, including:

[0008] Obtain all the temperature sensors inside the charging gun;

[0009] Each temperature sensor corresponds to an internal position of the charging gun;

[0010] For each internal position, calculate the rate of change of its temperature over time, denoted as

[0011] where, T i (T) represents the temperature of the i-th temperature sensor at time t;

[0012] Design a multi-dimensional thermal gradient algorithm to calculate the thermal gradient of the charging gun, specifically:

[0013]

[0014] where, N is the total number of temperature sensors inside the charging gun, T i+1 (t) represents the temperature sensor closest to the i-th temperature sensor inside the charging gun;

[0015] Set the normal temperature threshold

[0016] If is less than the normal temperature threshold then no operation is performed;

[0017] Otherwise, by analyzing the pressure fluctuation and acoustic disturbance of the coolant, calculate the determination value of the microbubble concentration of the current coolant.

[0018] Optionally, the calculating the determination value of the microbubble concentration of the current coolant by analyzing the pressure fluctuation and acoustic disturbance of the coolant specifically includes:

[0019] Mark n time points before time t, and the time intervals between adjacent time points are the same;

[0020] Collect the hydraulic and acoustic fluctuation data at each time point through a hydraulic sensor and an acoustic sensor;

[0021] According to the collected hydraulic data at each time point, calculate the pressure fluctuation σ P (t) of the coolant at time t, specifically:

[0022]

[0023] Among them, P j represents the instantaneous coolant pressure value at the j-th time point, which is expressed as the average pressure of n time points, specifically:

[0024] According to the acoustic fluctuation data collected at each time point, calculate the acoustic wave perturbation intensity σ of the coolant at time t A (t), specifically:

[0025]

[0026] Among them, A j represents the acoustic wave signal amplitude at the j-th time point, which is expressed as the average value of the acoustic wave signal amplitudes of n time points, specifically:

[0027] Design a hybrid microbubble judgment function, specifically:

[0028]

[0029] Among them, B bubble (t) represents the microbubble concentration determination value;

[0030] Set the bubble threshold B thresh ;

[0031] If the microbubble concentration determination value B bubble (t) is less than the bubble threshold B thresh , no operation is performed;

[0032] Otherwise, perform a high-frequency flow rate recoil excitation operation to remove the bubbles in the coolant.

[0033] Optionally, the operation of performing a high-frequency flow rate recoil excitation operation to remove the bubbles in the coolant specifically includes:

[0034] Calculate the instantaneous velocity of the coolant when performing the high-frequency flow rate recoil excitation operation, specifically as follows:

[0035] Obtain the initial flow rate of the coolant in the charging gun, denoted as Q init ;

[0036] Design a high-frequency flow rate recoil algorithm to calculate the instantaneous flow rate of the coolant when performing the high-frequency flow rate recoil excitation operation, specifically:

[0037] Q pulse (t) = Q init + ΔQ(t)·sin(2πf pulse t);

[0038] Among them, Qpulse (t) represents the instantaneous flow rate of the coolant at time t, and ΔQ(t) represents the amplitude of the flow rate fluctuation, f pulse represents the frequency of the coolant's backflush excitation;

[0039] Design a flow rate fluctuation algorithm to calculate the amplitude of the flow rate fluctuation, specifically:

[0040] ΔQ(t) = α · (B bubble (T) - B thresh );

[0041] Among them, α represents the adjustment factor of the flow rate fluctuation amplitude, specifically:

[0042]

[0043] Among them, max(B bubble (t)) represents the maximum value of the bubble concentration determination values corresponding to all time points before time t, and min(B bubble (t)) represents the minimum value of the bubble concentration determination values corresponding to all time points before time t;

[0044] Calculate the flow rate fluctuation frequency of the coolant during the high-frequency flow rate backflush excitation operation according to the microbubble concentration determination value and the bubble threshold.

[0045] Optionally, the calculating the flow rate fluctuation frequency of the coolant during the high-frequency flow rate backflush excitation operation according to the microbubble concentration determination value and the bubble threshold specifically includes:

[0046] Set the minimum value f min and the maximum value f max ;

[0047] The flow rate fluctuation frequency f pulse satisfies f min < f pulse < f max ;

[0048] Design a fluctuation frequency algorithm to calculate the execution frequency of the high-frequency flow rate backflush excitation operation, specifically:

[0049]

[0050] Among them, f pulse represents the execution frequency of the high-frequency flow rate backflush excitation operation.

[0051] Optionally, the high-frequency flow rate backflush excitation operation specifically is:

[0052] Set the backflush excitation duration f time ;

[0053] Use an electronic pump to accelerate the coolant so that the instantaneous speed of the coolant is equal to Q pulse (t);

[0054] When the instantaneous speed of the coolant is equal to Q pulse (t), stop accelerating the coolant;

[0055] If the instantaneous speed of the coolant is equal to Q pulse (t) and the duration of the recoil excitation is equal to f time , perform a periodic high-frequency flow velocity recoil excitation operation with a frequency of f pulse ;

[0056] After each execution of the high-frequency flow velocity recoil excitation operation, calculate the current microbubble concentration determination value B bubble (t);

[0057] If the current microbubble concentration determination value B bubble (t) is greater than or equal to the bubble threshold B thresh , perform a high-frequency flow velocity recoil excitation operation on the coolant;

[0058] Otherwise, end the high-frequency flow velocity recoil excitation operation.

[0059] Optionally, it also includes generating a temperature target trajectory, specifically:

[0060] Obtain the current charging power P charge (t);

[0061] Obtain the current ambient temperature T env ;

[0062] Design a temperature target trajectory algorithm to calculate the temperature target trajectory T target (t) of the charging gun, specifically:

[0063]

[0064] Among them, T max represents the maximum safe temperature of the charging gun, and P rated represents the rated power of the charging gun.

[0065] Optionally, it also includes a closed-loop regulation of the cooling flow rate based on the temperature target trajectory, specifically:

[0066] Calculate the difference between the temperature target trajectory T target (t) of the charging gun at time t and the measured temperature of the charging gun:

[0067] ε T (t) = T gun (t) - T target (t);

[0068] Among them, T gun (t) represents the currently measured temperature of the charging gun, and ε T (t) represents the actual temperature error;

[0069] Design a cooling flow rate algorithm to calculate the flow rate of the coolant, specifically:

[0070]

[0071] Among them, Q cool (t) represents the flow rate of the coolant.

[0072] The present invention has the following beneficial effects:

[0073] 1. For the liquid-cooled charging gun based on DCDC and its control method, the present invention obtains the data of all temperature sensors inside the charging gun, combines the calculation of the temperature change rate at each position over time, and designs a multi-dimensional thermal gradient algorithm to monitor the internal thermal state of the charging gun in real time. When it is detected that the thermal gradient of a local area is abnormally exceeded the set threshold, further combined with the analysis of the cooling hydraulic pressure fluctuation and acoustic disturbance, the determination value of the microbubble concentration of the current coolant is deduced, so as to realize the early identification of the potential overheating and cooling failure risks of the system. Based on this solution, the safety and stability of the liquid-cooled charging gun system during operation can be significantly improved. Traditional methods mostly rely on single-point temperature detection, which has hysteresis and cannot timely reflect local hot spots or coolant bubble problems. However, the present invention can accurately identify local temperature rise anomalies through multi-source data fusion and dynamic thermal gradient analysis, and combine with microbubble concentration monitoring to trigger subsequent cleaning actions in a timely manner when the bubble concentration is too high. This can not only effectively prevent the decrease in cooling efficiency and local overheating caused by the accumulation of microbubbles, but also extend the service life of the charging gun and internal components, and greatly reduce the failure rate. The overall system realizes the intelligent transformation from "post-treatment" to "active early warning", significantly improving the operation reliability and technical advancement of the liquid-cooled charging gun.

[0074] 2. For the liquid-cooled charging gun based on DCDC and its control method, the present invention proposes to collect the hydraulic data and acoustic fluctuation data of the coolant at consecutive time points, calculate the pressure fluctuation amplitude and the acoustic wave perturbation intensity respectively, and design a hybrid microbubble judgment function to estimate the microbubble concentration determination value in real time. Compared with the method that solely relies on hydraulic changes or acoustic signals, the present invention adopts a fusion analysis method, which can effectively avoid misjudgment caused by single signal distortion or noise interference. The most beneficial effect brought by this innovative method is the significant improvement in the accuracy and stability of microbubble detection. Since the generation and dissipation of microbubbles in the coolant have obvious dynamic change characteristics, simply relying on pressure or acoustic signals is extremely vulnerable to external factors such as environmental temperature changes and pump working state fluctuations, resulting in detection errors. However, the present invention couples and analyzes the hydraulic and acoustic double signals, which can not only verify each other and reduce errors, but also more sensitively capture the early generation trend of microbubbles inside the coolant, thereby realizing more accurate dynamic monitoring of bubble concentration, providing solid data support for the subsequent efficient maintenance and safety guarantee of the cooling system.

[0075] 3. For the liquid-cooled charging gun based on DCDC and its control method, the present invention designs a high-frequency flow rate reverse impact excitation operation based on the dynamic change of microbubble concentration, including refined algorithms such as flow rate fluctuation amplitude calculation and flow rate fluctuation frequency adjustment. Specifically, the flow rate fluctuation amplitude is automatically adjusted according to the historical maximum and minimum values of microbubble concentration, and the flow rate reverse impact frequency is dynamically calculated according to the relationship between the current microbubble concentration and the threshold, so that each reverse impact excitation action is targeted and self-adaptive. The direct beneficial effect brought by this mechanism is the significant improvement in the microbubble removal efficiency in the coolant. When dealing with the bubble problem in the traditional cooling system, fixed frequency or fixed flow rate perturbation is mostly adopted, resulting in deficiencies in dealing with different degrees of bubble accumulation. Either the excitation intensity is insufficient, resulting in incomplete removal, or the excitation is excessive, increasing energy consumption. However, the present invention flexibly adjusts the reverse impact parameters according to the real-time bubble concentration, enabling the reverse impact operation to enhance the perturbation force when the bubble concentration is high for rapid removal, and to reduce the frequency and amplitude when the bubble concentration is low, saving energy and prolonging the system life, thereby achieving the optimal balance between the operation efficiency and economy of the cooling system.

[0076] 4. For the liquid-cooled charging gun based on DCDC and its control method, the present invention further proposes a backflush vibration closed-loop control strategy, that is, by setting the backflush vibration duration and real-time monitoring the instantaneous velocity of the coolant and the determination value of the microbubble concentration, it is decided whether to continue the vibration operation according to the detection results after each backflush. If the bubble concentration does not meet the standard, continue to execute; otherwise, terminate to avoid ineffective vibration. This design effectively brings double optimization of the dynamic defoaming ability of the cooling system and energy consumption management. Traditional methods often use fixed-period vibration, and continue to vibrate even if the bubbles have been cleared, resulting in energy waste and excessive wear of the equipment. The present invention can accurately control the opening and closing of the vibration action by real-time detecting the microbubble concentration and adjusting the vibration period based on the concentration feedback, enabling the cooling system to significantly reduce unnecessary energy consumption and mechanical load while ensuring the purity of the coolant. This not only improves the cooling reliability of the charging gun under high-intensity charging conditions, but also contributes to the long-term stable operation of the overall system and the reduction of maintenance costs, reflecting high intelligence and energy-saving characteristics.

[0077] 5. For the liquid-cooled charging gun based on DCDC and its control method, the present invention innovatively introduces a temperature target trajectory generation and a closed-loop regulation mechanism of cooling flow rate based on the trajectory. Specifically, according to the current charging power and ambient temperature of the charging gun, a safe and reasonable temperature target trajectory is dynamically generated, and the error between the measured temperature and the target trajectory is real-time monitored, and accordingly the flow rate of the coolant is adjusted to achieve closed-loop optimization of temperature control. The beneficial effect brought by this design is that it greatly improves the temperature control accuracy of the liquid-cooled charging gun under different working loads and environmental conditions. Traditional liquid-cooled systems mostly use a fixed flow rate or simply adjust the flow rate according to the current temperature, with a lag in response and a rough adjustment range, which is likely to cause insufficient or excessive cooling. The present invention dynamically plans a reasonable temperature rise trajectory according to the power and ambient temperature, and precisely regulates the cooling flow rate based on the error, so that the temperature of the charging gun is always stable in the optimal range, avoiding both the risk of overheating and the energy consumption waste caused by excessive cooling. This adaptive and closed-loop optimized temperature control strategy significantly improves the reliability, energy efficiency level and user charging experience of the charging system, reflecting high intelligent perception and self-regulation ability. Brief Description of the Drawings

[0078] Figure 1 It is a schematic flow chart of the present invention. Detailed Embodiments

[0079] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present invention.

[0080] Example 1, refer to Figure 1 , a liquid-cooled charging gun based on DCDC and its control method, including:

[0081] Obtain all temperature sensors inside the charging gun;

[0082] Each temperature sensor corresponds to an internal position of the charging gun;

[0083] For each internal position, calculate the rate of change of its temperature over time, denoted as

[0084] where, T i (t) represents the temperature of the i-th temperature sensor at time t;

[0085] Design a multi-dimensional thermal gradient algorithm to calculate the thermal gradient of the charging gun, specifically:

[0086]

[0087] where, N is the total number of temperature sensors inside the charging gun, T i+1 (t) represents the temperature sensor closest to the i-th temperature sensor inside the charging gun;

[0088] Set the normal temperature threshold This threshold is set according to the actual usage of the liquid-cooled charging gun. If the set normal temperature threshold is too large, it will increase the warning standard of the liquid-cooled charging gun and greatly increase the usage risk of the liquid-cooled charging gun. If the set normal temperature threshold is too small, it will waste the resources used for cooling and cause unnecessary cooling operations to be performed;

[0089] If is less than the normal temperature threshold then no operation is performed;

[0090] Otherwise, by analyzing the pressure fluctuation and acoustic disturbance of the coolant, calculate the determination value of the microbubble concentration of the current coolant.

[0091] The present invention designs a high-frequency flow velocity reverse shock excitation operation based on the dynamic change of microbubble concentration, including refined algorithms such as flow velocity fluctuation amplitude calculation and flow velocity fluctuation frequency adjustment. Specifically, the flow velocity fluctuation amplitude is automatically adjusted according to the maximum and minimum values of historical microbubble concentration, and the flow velocity reverse shock frequency is dynamically calculated according to the relationship between the current microbubble concentration and the threshold value, so that each reverse shock excitation action has pertinence and self-adaptability. The direct beneficial effect brought by this mechanism is the significant improvement of the microbubble removal efficiency in the coolant. When dealing with the bubble problem, traditional cooling systems mostly adopt fixed frequency or fixed flow velocity disturbance, resulting in deficiencies in dealing with different degrees of bubble accumulation. Either the excitation intensity is insufficient, resulting in incomplete removal, or the excitation is excessive, increasing energy consumption. However, the present invention flexibly adjusts the reverse shock parameters according to the real-time bubble concentration, enabling the reverse shock operation to not only enhance the disturbance force when the bubble concentration is high to achieve rapid removal, but also reduce the frequency and amplitude when the bubble concentration is low, saving energy and extending the system life, thus achieving the optimal balance between the operating efficiency and economy of the cooling system.

[0092] By analyzing the pressure fluctuation and acoustic wave disturbance of the coolant, the determination value of the microbubble concentration of the current coolant is calculated, specifically including:

[0093] Mark n time points before the moment t, and the time interval between adjacent time points is the same;

[0094] Through a hydraulic sensor and an acoustic wave sensor, the hydraulic and acoustic wave fluctuation data at each time point are collected;

[0095] According to the hydraulic data collected at each time point, the pressure fluctuation σ P (t) of the coolant at the moment t is calculated, specifically as:

[0096]

[0097] where P j represents the instantaneous pressure value of the coolant at the j-th time point, represents the average pressure of n time points, specifically expressed as:

[0098] According to the acoustic wave fluctuation data collected at each time point, the acoustic wave disturbance intensity σ A (t) of the coolant at the moment t is calculated, specifically as:

[0099]

[0100] where A j represents the amplitude of the acoustic wave signal at the j-th time point, represents the average value of the acoustic wave signal amplitudes of n time points, specifically expressed as:

[0101] Design a hybrid microbubble judgment function, specifically as follows:

[0102]

[0103] Among them, B bubble (t) represents the microbubble concentration determination value;

[0104] Set the bubble threshold B thresh , and this threshold is set according to the self - properties of the liquid - cooled charging gun. If the threshold is set too large, microbubbles in the coolant cannot be effectively detected, resulting in an excessive microbubble concentration, and then reducing the refrigeration effect of the coolant. If the threshold is set too small, the microbubble removal operation will be frequently executed, wasting resources;

[0105] If the microbubble concentration determination value B bubble (t) is less than the bubble threshold B thresh , no operation is performed;

[0106] Otherwise, perform a high - frequency flow - rate reverse impact excitation operation to remove bubbles in the coolant.

[0107] The present invention proposes to collect the hydraulic data and acoustic fluctuation data of the coolant at continuous time points, calculate the pressure fluctuation amplitude and acoustic wave disturbance intensity respectively, and design a hybrid microbubble judgment function to estimate the microbubble concentration determination value in real - time. Compared with the method that solely relies on hydraulic changes or acoustic signals, the present invention adopts a fusion analysis method, which can effectively avoid misjudgment caused by single - signal distortion or noise interference. The greatest beneficial effect brought by this innovative method is that the accuracy and stability of microbubble detection are greatly improved. Since the generation and dissipation of microbubbles in the coolant have obvious dynamic change characteristics, simply relying on pressure or acoustic signals is extremely vulnerable to external factors such as environmental temperature changes and pump working - state fluctuations, resulting in detection errors. The present invention couples and analyzes the dual signals of hydraulic pressure and acoustic waves, which can not only verify each other and reduce errors, but also more sensitively capture the early generation trend of microbubbles inside the coolant, thereby realizing more accurate dynamic monitoring of bubble concentration, providing solid data support for the subsequent efficient maintenance and safety guarantee of the cooling system.

[0108] The execution of the high - frequency flow - rate reverse impact excitation operation to remove bubbles in the coolant specifically includes:

[0109] Calculate the instantaneous velocity when the coolant performs the high - frequency flow - rate reverse impact excitation operation, specifically as follows:

[0110] Obtain the initial flow rate of the coolant in the charging gun, denoted as Q init ;

[0111] Design a high - frequency flow - rate reverse algorithm to calculate the instantaneous flow rate of the coolant when performing the high - frequency flow - rate reverse impact excitation operation, specifically as:

[0112] Q pulse Q(t) = init + ΔQ(t)·sin(2πf pulse t);

[0113] Wherein, Q pulse (t) represents the instantaneous flow rate of the coolant at time t, ΔQ(t) represents the amplitude of the flow rate fluctuation, and f pulse represents the frequency of the coolant's reverse impulse vibration;

[0114] Design a flow rate fluctuation algorithm to calculate the amplitude of the flow rate fluctuation, specifically:

[0115] ΔQ(t) = α·(B bubble (t) - B thresh );

[0116] Wherein, α represents the adjustment factor of the flow rate fluctuation amplitude, specifically:

[0117]

[0118] Wherein, max(B bubble (t)) represents the maximum value of the bubble concentration determination values corresponding to all time points before time t, and min(B bubble (t)) represents the minimum value of the bubble concentration determination values corresponding to all time points before time t;

[0119] Calculate the flow rate fluctuation frequency of the coolant during the high-frequency flow rate reverse impulse vibration operation according to the micro-bubble concentration determination value and the bubble threshold.

[0120] The calculation of the flow rate fluctuation frequency of the coolant during the high-frequency flow rate reverse impulse vibration operation according to the micro-bubble concentration determination value and the bubble threshold specifically includes:

[0121] Set the minimum value f min and the maximum value f max ;

[0122] The flow rate fluctuation frequency f pulse satisfies f min < f pulse < f max ;

[0123] Design a fluctuation frequency algorithm to calculate the execution frequency of the high-frequency flow rate reverse impulse vibration operation, specifically:

[0124]

[0125] Wherein, f pulse represents the execution frequency of the high-frequency flow rate reverse impulse vibration operation.

[0126] The present invention designs a high-frequency flow velocity backflush excitation operation based on the dynamic change of microbubble concentration, including refined algorithms such as flow velocity fluctuation amplitude calculation and flow velocity fluctuation frequency adjustment. Specifically, the flow velocity fluctuation amplitude is automatically adjusted according to the maximum and minimum values of the historical microbubble concentration, and the flow velocity backflush frequency is dynamically calculated according to the relationship between the current microbubble concentration and the threshold value, so that each backflush excitation action has pertinence and self-adaptability. The direct beneficial effect brought by this mechanism is the significant improvement of the microbubble removal efficiency in the coolant. When dealing with the bubble problem, traditional cooling systems mostly adopt fixed frequency or fixed flow velocity perturbation, resulting in deficiencies in dealing with different degrees of bubble accumulation. Either the excitation intensity is insufficient, resulting in incomplete removal, or the excitation is excessive, increasing energy consumption. However, the present invention flexibly adjusts the backflush parameters according to the real-time bubble concentration, enabling the backflush operation to enhance the perturbation force when the bubble concentration is high to achieve rapid removal, and to reduce the frequency and amplitude when the bubble concentration is low, saving energy and extending the system life, thus achieving the optimal balance between the operating efficiency and economy of the cooling system.

[0127] The high-frequency flow velocity backflush excitation operation is specifically as follows:

[0128] Set the backflush excitation duration f time ;

[0129] Use an electronic pump to accelerate the coolant so that the instantaneous velocity of the coolant is equal to Q pulse (t);

[0130] When the instantaneous velocity of the coolant is equal to Q pulse (t), stop the acceleration operation of the coolant;

[0131] If the instantaneous velocity of the coolant is equal to Q pulse (t) and the duration of the continuous time is equal to the backflush excitation duration f time , perform a periodic high-frequency flow velocity backflush excitation operation, and the execution frequency is f pulse ;

[0132] After each execution of the high-frequency flow velocity backflush excitation operation, calculate the current microbubble concentration determination value B bubble (t);

[0133] If the current microbubble concentration determination value B bubble (t) is greater than or equal to the bubble threshold B thresh , then perform a high-frequency flow velocity backflush excitation operation on the coolant;

[0134] Otherwise, end the high-frequency flow velocity backflush excitation operation.

[0135] The present invention further proposes a recoil vibration excitation closed-loop control strategy, that is, by setting the recoil vibration excitation duration and real-time monitoring of the instantaneous velocity of the coolant and the determination value of the microbubble concentration, it is decided whether to continue the vibration excitation operation according to the detection results after each recoil. If the bubble concentration does not meet the standard, the operation continues; otherwise, it terminates to avoid ineffective vibration excitation. This design effectively brings about a dual optimization of the dynamic defoaming ability of the cooling system and energy consumption management. Traditional methods often use fixed-cycle vibration excitation, and continue to vibrate even if the bubbles have been cleared, resulting in energy waste and excessive wear of the equipment. By real-time detecting the microbubble concentration and adjusting the vibration excitation cycle based on the concentration feedback, the present invention can accurately control the opening and closing of the vibration excitation action, enabling the cooling system to significantly reduce unnecessary energy consumption and mechanical load while ensuring the purity of the coolant. This not only improves the cooling reliability of the charging gun under high-intensity charging conditions, but also contributes to the long-term stable operation of the overall system and the reduction of maintenance costs, demonstrating high intelligence and energy-saving characteristics.

[0136] It also includes the generation of the temperature target trajectory, specifically:

[0137] Obtain the current charging power P charge (t);

[0138] Obtain the current ambient temperature T env ;

[0139] Design a temperature target trajectory algorithm to calculate the temperature target trajectory T target (t), specifically:

[0140]

[0141] Among them, T max represents the maximum safe temperature of the charging gun, and P rated represents the rated power of the charging gun.

[0142] It also includes the closed-loop regulation of the cooling flow rate based on the temperature target trajectory, specifically:

[0143] Calculate the difference between the temperature target trajectory T target (t) of the charging gun at time t and the measured temperature of the charging gun:

[0144] ε T (t) = T gun (t) - T target (t);

[0145] Among them, T gun (t) represents the current measured temperature of the charging gun, and ε T (t) represents the actual temperature error;

[0146] Design a cooling flow rate algorithm to calculate the flow rate of the coolant, specifically:

[0147]

[0148] Among them, Q cool (t) represents the flow rate of the coolant.

[0149] The present invention innovatively introduces a temperature target trajectory generation and a closed-loop regulation mechanism for cooling flow rate based on the trajectory. Specifically, according to the current charging power of the charging gun and the ambient temperature, a safe and reasonable temperature target trajectory is dynamically generated, and the error between the measured temperature and the target trajectory is monitored in real time. Based on this, the flow rate of the coolant is adjusted to achieve closed-loop optimization of temperature control. The beneficial effect brought by this design is that it greatly improves the temperature control accuracy of the liquid-cooled charging gun under different working loads and environmental conditions. Most traditional liquid-cooling systems adopt a fixed flow rate or simply adjust the flow rate according to the current temperature, resulting in a lag in response and a rough adjustment range, which is likely to cause insufficient or excessive cooling. However, the present invention dynamically plans a reasonable temperature rise trajectory according to the power and ambient temperature, and precisely regulates the cooling flow rate based on the error, so that the temperature of the charging gun is always stable in the optimal range, avoiding both the risk of overheating and the energy consumption waste caused by excessive cooling. This adaptive and closed-loop optimized temperature control strategy significantly improves the reliability, energy efficiency level and user charging experience of the charging system, demonstrating a high level of intelligent perception and self-regulation ability.

[0150] It should be noted that in this article, relational terms such as first and second are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any actual relationship or order between these entities or operations. Moreover, 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 also includes elements inherent to such process, method, article or device.

[0151] The above are only the preferred embodiments of the present invention. It should be pointed out that for those of ordinary skill in the art, without departing from the technical principle of the present invention, several improvements and refinements can be made, and these improvements and refinements should also be regarded as the protection scope of the present invention.

Claims

1. A liquid-cooled charging gun based on DCDC and its control method, characterized in that, Including: Obtain all the temperature sensors inside the charging gun; Each temperature sensor corresponds to an internal position of the charging gun; For each internal location, calculate the rate of change of its temperature over time, denoted as where, T i (t) represents the temperature of the i-th temperature sensor at time t; Design a multi-dimensional thermal gradient algorithm to calculate the thermal gradient of the charging gun, specifically: where N is the total number of internal temperature sensors of the charging gun, and T i+1 (t) represents the temperature sensor closest to the i-th temperature sensor inside the charging gun; Set the normal temperature threshold If less than the normal temperature threshold then no operation is performed; Otherwise, analyze the pressure fluctuation and acoustic disturbance of the coolant to calculate the determination value of the microbubble concentration of the current coolant.

2. The liquid-cooled charging gun based on DCDC and its control method according to claim 1, characterized in that: The step of analyzing the pressure fluctuation and acoustic disturbance of the coolant to calculate the determination value of the microbubble concentration of the current coolant specifically includes: Mark n time points before time t, and the time interval between adjacent time points is the same; Collect the hydraulic and acoustic fluctuation data at each time point through a hydraulic sensor and an acoustic sensor; According to the hydraulic data collected at each time point, calculate the pressure fluctuation σ P (t) of the coolant at time t, specifically as follows: Among them, P j represents the instantaneous coolant pressure value at the j-th time point, and is expressed as the average pressure of n time points, specifically expressed as: According to the acoustic fluctuation data collected at each time point, calculate the acoustic wave disturbance intensity σ A (t) of the coolant at time t, specifically as follows: Among them, A j represents the amplitude of the acoustic wave signal at the j-th time point, which is expressed as the average value of the amplitudes of the acoustic wave signals at n time points, specifically expressed as: Design a hybrid microbubble judgment function, specifically: Among them, B bubble (t) represents the determination value of microbubble concentration; Set the bubble threshold B thresh ; If the microbubble concentration determination value B bubble (t) is less than the bubble threshold B thresh , the operation is not performed; Otherwise, perform a high-frequency flow rate reverse impact vibration operation to remove the bubbles in the coolant.

3. A liquid-cooled charging gun based on DCDC and its control method according to claim 2, characterized in that: The step of performing a high-frequency flow rate reverse impact vibration operation to remove the bubbles in the coolant specifically includes: Calculate the instantaneous velocity of the coolant when performing the high-frequency flow rate reverse impact vibration operation, specifically as follows: Obtain the initial flow rate of the coolant in the charging gun, denoted as Q init ; Design a high-frequency flow rate reverse algorithm to calculate the instantaneous flow rate of the coolant when performing the high-frequency flow rate reverse impact vibration operation, specifically: Q pulse Q(t) = Q init + ΔQ(t)·sin(2πft pulse t); Among them, Q pulse (t) represents the instantaneous flow rate of the coolant at time t, ΔQ(t) represents the flow rate fluctuation amplitude, and f pulse represents the frequency of the coolant's reverse impulse excitation; Design a flow rate fluctuation algorithm to calculate the flow rate fluctuation amplitude, specifically: ΔQ(t) = α·(B bubble (t) - B thresh ); Where α represents the adjustment factor of the flow rate fluctuation amplitude, specifically: where, max(B bubble (t)) represents the maximum value of the bubble concentration determination values corresponding to all time points before time t, and min(B bubble (t)) represents the minimum value of the bubble concentration determination values corresponding to all time points before time t; Calculate the flow rate fluctuation frequency of the coolant during the high-frequency flow rate reverse impact vibration operation according to the microbubble concentration determination value and the bubble threshold.

4. The liquid-cooled charging gun based on DCDC and its control method according to claim 3, wherein: The step of calculating the flow rate fluctuation frequency of the coolant during the high-frequency flow rate reverse impact vibration operation according to the microbubble concentration determination value and the bubble threshold specifically includes: Set the minimum value \(f\) of the flow rate fluctuation frequency threshold min and the maximum value \(f\) max ; Flow velocity fluctuation frequency f pulse Satisfy f min <f pulse <f max ; Design a fluctuation frequency algorithm to calculate the execution frequency of the high-frequency flow rate reverse impact vibration operation, specifically: Among them, f pulse represents the execution frequency of the high-frequency flow velocity backwashing and exciting operation.

5. The liquid-cooled charging gun based on DCDC and its control method according to claim 2, characterized in that, The high-frequency flow rate reverse impact vibration operation specifically is: Set the anti-surge excitation duration f time ; Use an electronic pump to accelerate the coolant so that the instantaneous speed of the coolant is equal to Q pulse (t); When the instantaneous speed of the coolant is equal to Q pulse (t), stop accelerating the coolant; If the instantaneous speed of the coolant is equal to Q pulse (t)'s duration is the same as the duration of the recoil excitation f time is equal, then perform a periodic high-frequency flow velocity recoil excitation operation, with an execution frequency of f pulse ; After each high-frequency flow velocity backwashing and exciting operation, calculate the current determination value B of the microbubble concentration bubble (t); If the current microbubble concentration determination value B bubble (t) is greater than or equal to the bubble threshold f thresh , then perform a high-frequency flow rate reverse shock excitation operation on the coolant; Otherwise, end the high-frequency flow rate reverse impact vibration operation.

6. The liquid-cooled charging gun based on DCDC and its control method according to claim 1, characterized in that, It also includes the generation of a temperature target trajectory, specifically: Obtain the current charging power P of the charging gun charge (t); Obtain the current ambient temperature T env ; Design a temperature target trajectory algorithm to calculate the temperature target trajectory T target (t) of the charging gun, specifically as follows: Among them, T max represents the maximum safe temperature of the charging gun, and P rated represents the rated power of the charging gun.

7. The liquid-cooled charging gun based on DCDC and its control method according to claim 1, characterized in that, It also includes a closed-loop regulation of the cooling flow rate based on the temperature target trajectory, specifically: Calculate the temperature target trajectory T of the charging gun at time t target (t) and the difference between the measured temperature of the charging gun: ε T (t) = T gun (t) - T target (t); Among them, T gun (t) represents the currently measured temperature of the charging gun, and ε T (t) represents the actual temperature error; Design a cooling flow rate algorithm to calculate the flow rate of the coolant, specifically: Among them, Q cool (t) represents the flow rate of the coolant.

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