Electric drive integrated Boost circuit, charging method and device and vehicle

Abstract

The invention provides an electric drive integrated Boost circuit, a charging method and device and a vehicle, and relates to the technical field of electric drive and charging of electric vehicles. The circuit comprises a three-phase inductor of the motor, an inverter module, a power switch tube, a control unit and a battery, the inverter module is respectively connected with each phase winding of the three-phase inductor, the power switch tube is respectively connected with a center tap of the three-phase inductor and the control unit, and the battery is connected with the inverter module; wherein the control unit is used for conducting the power switch tube when the charging pile is connected with the circuit so as to charge the battery through the circuit. The power switch tube is adopted to replace a traditional relay, higher anti-vibration capacity and reliability are achieved, stable work under the severe working condition can be achieved, the risk caused by too large acceleration impact can be remarkably reduced, the risk of false pull-in is effectively reduced, vehicle faults caused by false pull-in are reduced, and the service life of the vehicle is prolonged. And the safety and the stability of the vehicle are obviously improved.

Description

Technical Field

[0001] The present application relates to the technical field of electric drive and charging of electric vehicles, and in particular to an electric drive integrated Boost circuit, a charging method, a device and a vehicle. Background Art

[0002] In the electric drive systems of new energy vehicles, integrated boost charging is a key technology for achieving efficient charging. Currently, related products use a motor center-tap or U (V / W) phase tap topology to implement boost charging. These solutions leverage the motor's inductance to boost the charging station's input voltage to the battery pack's required charging voltage, enabling rapid charging. However, while new energy vehicles are in motion, the relays in the electric drive's integrated boost circuits may be subjected to significant acceleration shocks, even exceeding the vibration levels the relays can withstand, causing the relays to falsely engage and subsequently causing vehicle failures.

[0003] In related technologies, an additional relay is typically placed between the capacitor and C+ port of the electric drive's integrated boost circuit, with this relay positioned in a different direction from the original relay to prevent acceleration in the same direction from affecting both relays simultaneously. However, the problem of relay misengagement still exists. Summary of the Invention

[0004] The electric drive integrated Boost circuit, charging method, device and vehicle provided in this application are used to improve the problem of false closure of relays.

[0005] In a first aspect, the present application provides an electric drive integrated Boost circuit, comprising: a three-phase inductor of a motor, an inverter module, a power switch tube, a control unit, and a battery, wherein the inverter module is respectively connected to each phase winding of the three-phase inductor, the power switch tube is respectively connected to the center tap of the three-phase inductor and the control unit, and the battery is connected to the inverter module;

[0006] Among them, the control unit is used to turn on the power switch tube when the charging pile is connected to the electric drive integrated Boost boost circuit, so as to charge the battery through the electric drive integrated Boost boost circuit.

[0007] In a possible implementation, the power switch tube is at least one silicon carbide (SiC) transistor.

[0008] In a possible implementation, the power switch tube includes: at least one insulated gate bipolar transistor (IGBT); or a combination of at least one SiC transistor and at least one IGBT.

[0009] In a possible implementation, the power switch tube is integrated into the inverter module.

[0010] In one possible implementation, the inverter module includes multiple bridge arm switching tubes, and the heat conduction surface of the power switching tube is thermally conductively connected to a heat dissipation substrate of a water cooling system of the bridge arm switching tube, and a connected water channel structure is integrated in the heat dissipation substrate.

[0011] In one possible embodiment, multiple bridge arm switching tubes form a three-phase control bridge, and the control unit is also used to: when the electric drive integrated Boost boost circuit is connected to the charging pile, control the upper bridge switching tube of any phase of the three-phase control bridge to be turned on within a set time, and all the lower bridge switching tubes of the three-phase control bridge are turned off; within the set time, obtain the first-level voltage and the second-level voltage of the power switching tube, and turn off the upper bridge switching tube; if the first-level voltage and the second-level voltage are consistent, it is determined that the power switching tube has a straight-through fault; if the first-level voltage is consistent with the DC bus voltage, and the second-level voltage is 0V, it is determined that the power switching tube has no straight-through fault.

[0012] In a second aspect, the present application provides a charging device comprising the electric drive integrated Boost circuit described in any one of the first aspects.

[0013] In a third aspect, the present application provides a vehicle comprising the charging device as described in the second aspect.

[0014] In a fourth aspect, the present application provides a charging method, which is applied to at least one of the control unit in the electric drive integrated Boost circuit according to any one of the first aspects, the charging device according to the second aspect, and the vehicle according to the third aspect, the charging method comprising:

[0015] In response to the charging pile being connected to the electric drive integrated boost circuit, a self-test diagnosis is performed on the power switch tube in the electric drive integrated boost circuit;

[0016] If the power switch tube has no through-fault, the power switch tube is turned on to charge the battery through the electric drive integrated Boost circuit;

[0017] If the power switch tube has a through fault, charging is prohibited and a fault signal is issued.

[0018] In one possible implementation, a self-test diagnosis is performed on the power switch tube in the electric drive integrated Boost boost circuit, including: controlling the upper bridge switch tube of any phase of the three-phase control bridge in the electric drive integrated Boost boost circuit to be turned on within a set time length, and controlling the lower bridge switch tubes of the three-phase control bridge to be turned off; within the set time length, obtaining the first-level voltage and the second-level voltage of the power switch tube, and turning off the upper bridge switch tube; if the first-level voltage and the second-level voltage are consistent, it is determined that the power switch tube has a straight-through fault; if the first-level voltage is consistent with the DC bus voltage, and the second-level voltage is 0V, it is determined that the power switch tube has no straight-through fault.

[0019] The present application provides an electric drive integrated Boost circuit, charging method, device and vehicle, wherein the electric drive integrated Boost circuit includes: a three-phase inductor of a motor, an inverter module, a power switch tube, a control unit and a battery, the inverter module is respectively connected to each phase winding of the three-phase inductor, the power switch tube is respectively connected to the center tap of the three-phase inductor and the control unit, and the battery is connected to the inverter module; wherein the control unit is used to turn on the power switch tube when the charging pile is connected to the electric drive integrated Boost circuit, so as to charge the battery through the electric drive integrated Boost circuit. This application uses power switching tubes to replace traditional relays. Compared with relays, power switching tubes have higher vibration resistance and reliability, and can work stably under harsh working conditions. Therefore, they can significantly reduce the risks caused by excessive acceleration shock, thereby effectively reducing the risk of false attraction, and then reducing vehicle failures caused by false attraction, significantly improving the safety and stability of the vehicle; in addition, by integrating the Boost charging function into the electric drive system and using power switching tubes to replace relays, the number of relays used is reduced, and the weight of the electric drive system is significantly reduced. This optimization not only helps to reduce the overall weight of new energy vehicles, but also has positive significance for improving vehicle energy efficiency, extending cruising range and optimizing vehicle design. At the same time, it also helps to simplify spatial structure design and production assembly processes, and reduce product costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments consistent with the present application and, together with the description, serve to explain the principles of the present application.

[0021] Figure 1 A schematic diagram of a topology architecture using a motor center tap in the related art;

[0022] Figure 2 A schematic structural diagram of an electric drive integrated Boost circuit provided by an exemplary embodiment of the present application;

[0023] Figure 3Another structural schematic diagram of an electric drive integrated Boost circuit provided by an exemplary embodiment of the present application;

[0024] Figure 4 A schematic flow chart of a charging method provided by an exemplary embodiment of the present application;

[0025] Figure 5 A schematic structural diagram of a charging device provided in an exemplary embodiment of the present application.

[0026] The above drawings illustrate specific embodiments of the present application, which will be described in more detail below. These drawings and the textual description are not intended to limit the scope of the present application in any way, but rather to illustrate the concepts of the present application to those skilled in the art by reference to specific embodiments. DETAILED DESCRIPTION

[0027] Exemplary embodiments will be described in detail herein, with examples illustrated in the accompanying drawings. In the following description, when referring to the drawings, identical numerals in different figures represent identical or similar elements, unless otherwise indicated. The embodiments described in the following exemplary embodiments are not intended to represent all embodiments consistent with the present application. Rather, they are merely examples of apparatus and methods consistent with certain aspects of the present application, as detailed in the appended claims.

[0028] The terms "first", "second" etc. in the specification and claims of the present application are used to distinguish similar objects and are not necessarily used to describe a specific order or sequential order. It should be understood that the data used in this way can be interchangeable in appropriate circumstances, so that the embodiments of the present application described herein can, for example, be implemented in an order other than those illustrated or described herein. In addition, the terms "including" and "having" and any of their variations are intended to cover non-exclusive inclusions, for example, the process, system, product or equipment comprising a series of steps or units is not necessarily limited to those steps or units clearly listed, but may include other steps or units that are not clearly listed or that are inherent to these processes, products or equipment.

[0029] It should be noted that the user information (including but not limited to user device information, user personal information, etc.) and data (including but not limited to data used for analysis, stored data, displayed data, etc.) involved in this application are all information and data authorized by the user or fully authorized by all parties, and the collection, use and processing of relevant data must comply with relevant laws, regulations and standards, and corresponding operation entrances must be provided for users to choose to authorize or refuse.

[0030] Figure 1 FIG. 1 is a schematic diagram of a topology structure using a motor center tap in related art. Figure 1As shown, KL30 is a low-voltage power supply line such as 12V, KL31 is a low-voltage ground line, and K7 is a relay in the electric drive integrated Boost boost circuit. In addition, the electric drive integrated Boost boost circuit also includes filters, capacitors, loads, isolation sampling modules, low-voltage power modules and batteries. In the related art, when an additional relay is arranged at the capacitor and C+ port of the electric drive integrated Boost boost circuit, the relay is arranged in a different direction from the original relay in the XYZ direction of the vehicle to avoid acceleration in the same direction affecting two sets of relays at the same time. However, this arrangement poses huge challenges to spatial structure design, production and assembly process, product cost and weight, and cannot fundamentally solve the problem of relays being mistakenly attracted due to the impact of acceleration due to their own structural characteristics. Therefore, the problem of relay misattraction still exists.

[0031] In response to the problems existing in the relevant technologies, the present application proposes an electric drive integrated Boost circuit. By adopting a power switch tube to replace the traditional relay and integrating the Boost charging function in the electric drive system, it can effectively solve the problem that the relay is easily mis-engaged under acceleration impact due to its mechanical structural characteristics, thereby reducing vehicle failures caused by misengagement and significantly improving the safety and stability of the vehicle; in addition, the number of relays used in the electric drive system is reduced, and the weight of the electric drive system is significantly reduced, which not only helps to reduce the overall weight of new energy vehicles, but also has positive significance for improving vehicle energy efficiency, extending cruising range and optimizing vehicle design. At the same time, it also helps to simplify spatial structure design and production assembly processes and reduce product costs.

[0032] The following specific embodiments describe in detail the technical solution of the present application and how the technical solution of the present application solves the above-mentioned technical problems. The following 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 in conjunction with the accompanying drawings.

[0033] Figure 2 This is a schematic diagram of a structure of an electric drive integrated Boost circuit provided by an exemplary embodiment of the present application. Figure 2 As shown, the electric drive integrated Boost circuit 20 provided in the embodiment of the present application includes a three-phase inductor 21 of the motor, an inverter module 22, a power switch tube 23, a control unit 24 and a battery 25. The inverter module 22 is respectively connected to each phase winding of the three-phase inductor 21, the power switch tube 23 is respectively connected to the center tap of the three-phase inductor 21 and the control unit 24, and the battery 25 is connected to the inverter module 22;

[0034] The control unit 24 is configured to turn on the power switch 23 when the charging pile is connected to the electric drive integrated Boost circuit 20 , so as to charge the battery 25 through the electric drive integrated Boost circuit 20 .

[0035] Correspondingly, the three-phase inductor 21 of the motor refers to the three-phase winding inside the motor, which has inductance characteristics and can store and release energy; the inverter module 22 is a power electronic device used to convert direct current into alternating current, or vice versa. In the electric drive integrated Boost circuit 20, the inverter module 22 is connected to each phase winding of the three-phase inductor 21 to control the operation of the motor and the energy conversion of the Boost circuit; the power switch tube 23 is a semiconductor switching device, connected to the center tap of the three-phase inductor 21, and serves as the core switching element of the electric drive integrated Boost circuit 20; the control unit 24 is an embedded controller or microprocessor, which is used to monitor the system status and control the conduction and shutdown of the power switch tube 23; the battery 24 is an energy storage device for storing electrical energy and is connected to the inverter module 22 as the target device for charging; the charging pile is a device that provides electrical energy for new energy vehicles and is usually connected to the vehicle's charging interface through a cable.

[0036] For example, when the charging pile is connected to the electric drive integrated Boost circuit 20, the control unit 24 starts the charging process, and the specific steps are as follows: the control unit 24 detects the connection signal of the charging pile and confirms entering the charging mode; the control unit 24 sends a control signal to turn on the power switch tube 23, so that the center tap of the three-phase inductor 21 forms a loop with the battery 24; while the power switch tube 23 is on, the three-phase inductor 21 absorbs electrical energy from the charging pile and stores it in the magnetic field; the control unit 24 turns off the power switch tube 23, and the energy stored in the three-phase inductor 24 is released to the battery 25 through the inverter module 22 to achieve boost charging; the control unit 24 dynamically adjusts the on and off time of the power switch tube 23 according to the voltage and current requirements of the battery 25 to ensure an efficient and stable charging process.

[0037] The electric drive integrated Boost circuit provided in the embodiment of the present application adopts a power switch tube to replace the traditional relay. Compared with the relay, the power switch tube has higher vibration resistance and reliability, and can work stably under harsh working conditions. Therefore, it can significantly reduce the risk caused by excessive acceleration impact, thereby effectively reducing the risk of false attraction, and further reducing vehicle failures caused by false attraction, and significantly improving the safety and stability of the vehicle; in addition, by integrating the Boost charging function into the electric drive system and adopting a power switch tube to replace the relay, the number of relays used is reduced, and the weight of the electric drive system is significantly reduced. This optimization not only helps to reduce the overall weight of the new energy vehicle, but also has positive significance for improving vehicle energy efficiency, extending cruising range and optimizing vehicle design. At the same time, it also helps to simplify spatial structure design and production assembly processes, and reduce product costs.

[0038] In some embodiments, the power switch is at least one SiC transistor.

[0039] For example, the power switches are two SiC transistors. Correspondingly, the drains of SiC transistor 1 and SiC transistor 2 are connected to the center tap of the three-phase inductor, forming an energy storage and release loop. The sources of SiC transistor 1 and SiC transistor 2 are connected to the charging pile side of the electric drive integrated boost circuit, used to transfer energy from the charging pile to the battery. The gates of SiC transistor 1 and SiC transistor 2 are connected to a control unit to receive control signals. By adjusting the on and off time of the SiC transistors, precise control of the charging current and voltage is achieved.

[0040] It should be noted that the above-mentioned parallel connection of two SiC transistors is only an example of a power switch tube. In actual applications, the power switch tube can be one silicon carbide transistor, three silicon carbide transistors or four silicon carbide transistors, etc. There is no limitation on the number of silicon carbide transistors contained in the power switch tube.

[0041] In some embodiments, the power switch tube includes: at least one IGBT; or a combination of at least one SiC transistor and at least one IGBT.

[0042] For example, in one implementation, the power switches are two IGBTs. Correspondingly, the collectors of IGBT1 and IGBT2 are connected to the center tap of the three-phase inductor, forming an energy storage and release loop. The emitters of IGBT1 and IGBT2 are connected to the charging pile side of the electric drive integrated boost circuit, used to transfer energy from the charging pile to the battery. The gates of IGBT1 and IGBT2 are connected to a control unit to receive control signals. By adjusting the on and off time of the IGBT, precise control of the charging current and voltage is achieved.

[0043] In another implementation, the power switch is, for example, a combination of two SiC transistors and two IGBTs. Correspondingly, the drains of SiC transistors 1 and 2, and the collectors of IGBTs 1 and 2, are connected to the center tap of the three-phase inductor, forming an energy storage and release loop. The sources of SiC transistors 1 and 2, and the emitters of IGBTs 1 and 2 are connected to the charging pile side of the electric drive integrated boost circuit, for transferring energy from the charging pile to the battery. The gates of SiC transistors 1 and 2, and the gates of IGBTs 1 and 2, are connected to a control unit that receives control signals and controls the on and off times of the switches, thereby regulating the charging current and voltage.

[0044] It should be noted that the above-mentioned connection of two IGBTs in parallel, or connection of two SiC transistors and two IGBTs in parallel is only an example of a power switch tube. In actual applications, the power switch tube can be one IGBT, two carbon IGBTs, or two or more SiC transistors and two or more IGBTs in parallel, etc. There is no limitation on the number of SiC transistors or IGBTs contained in the power switch tube.

[0045] The embodiments of the present application, by adopting at least one SiC transistor, at least one IGBT, or a combination of at least one SiC transistor and at least one IGBT, can carry higher currents, thereby flexibly increasing the upper limit of Boost charging current, and better meeting the needs of fast charging; in addition, both the SiC transistor and the IGBT have no mechanical contacts, have strong vibration resistance, and can operate stably under harsh working conditions, effectively reducing the problem of false attraction caused by vibration of traditional relays.

[0046] Based on the above embodiments, in some embodiments, the power switch tube is integrated into the inverter module.

[0047] For example, the power switch tube uses at least one SiC transistor, at least one IGBT, or a combination of at least one SiC transistor and at least one IGBT as the core switching element of the electric drive integrated Boost circuit and is integrated into the inverter module.

[0048] The embodiment of the present application significantly reduces the use of external components by integrating the power switch tube into the inverter module, which not only simplifies the structural design of the electric drive system, but also greatly reduces the complexity and overall cost of the system.

[0049] In some embodiments, the inverter module includes multiple bridge arm switching tubes, and the heat conduction surface of the power switching tube is thermally conductively connected to the heat dissipation substrate of the water cooling system of the bridge arm switching tube, and a connected water channel structure is integrated in the heat dissipation substrate.

[0050] For example, the inverter module employs an integrated design, including multiple arm switches (e.g., six arm switches). The power switches utilize at least one SiC transistor, at least one IGBT, or a combination of at least one SiC transistor and at least one IGBT. The power switches and arm switches are integrated within the inverter module. A water-cooling heat dissipation system is internally provided within the inverter module. The heat dissipation substrate of the water-cooling heat dissipation system incorporates a water channel structure, through which coolant flows, removing heat generated by the power devices and efficiently dissipating heat from the arm switches. Accordingly, by thermally conductively connecting the heat conduction surface of the power switches to the heat dissipation substrate of the water-cooling heat dissipation system for the arm switches, the power switches and the arm switches share the water-cooling heat dissipation system, thereby simultaneously dissipating heat from both the arm switches and the power switches.

[0051] Optionally, the heat-conductive connection includes but is not limited to any one of direct contact connection, heat radiation connection, heat convection connection or indirect heat conduction.

[0052] In the embodiment of the present application, the water-cooling heat dissipation system of the bridge arm switch tube is used to dissipate heat for the power switch tube, thereby effectively ensuring the performance of the power switch tube in a high temperature environment, reducing performance degradation or damage caused by insufficient heat dissipation, and also reducing the risk of device aging and failure due to overheating, thereby significantly improving the reliability of the electric drive integrated Boost circuit; in addition, by integrating the power switch tube and the bridge arm switch tube in the same module and sharing the water-cooling heat dissipation system, not only the use of external heat dissipation devices is reduced and the system structure is simplified, but also the complexity of the system is reduced through integrated design, the difficulty of assembly is reduced, and the production cost is further reduced.

[0053] In related technologies, electric drive systems with traditional relay solutions perform self-tests when powered on. By detecting the voltage difference between the front and rear ends of the relay, it diagnoses whether the relay contacts are in a sticking state. If a sticking state is detected, the system will identify and prevent risks caused by relay failures in the drive mode in advance. Accordingly, when using power switch tubes (such as SiC or IGBT) to replace relays, it is also necessary to diagnose whether there are short circuit or shoot-through risks (similar to relay sticking) during the power-on self-test process to ensure the safety and reliability of the system. Among them, the shoot-through risk diagnosis is similar to the sticking detection of relays. It aims to determine whether the power switch tube has a mis-conduction state. This can be achieved by checking the consistency between the conduction state of the switch tube and the control signal. If a shoot-through risk is detected, the system needs to take corresponding measures to prevent failures in the drive mode.

[0054] Therefore, in some embodiments, multiple bridge arm switching tubes form a three-phase control bridge, and the control unit is also used to: when the electric drive integrated Boost boost circuit is connected to the charging pile, control the upper bridge switching tube of any phase of the three-phase control bridge to be turned on within a set time, and the lower bridge switching tubes of the three-phase control bridge are all turned off; within the set time, obtain the first-level voltage and the second-level voltage of the power switching tube, and turn off the upper bridge switching tube; if the first-level voltage and the second-level voltage are consistent, it is determined that the power switching tube has a direct-through fault; if the first-level voltage is consistent with the DC bus voltage, and the second-level voltage is 0V, it is determined that the power switching tube has no direct-through fault.

[0055] For example, Figure 3 This is another structural diagram of the electric drive integrated Boost circuit provided by the exemplary embodiment of the present application. Figure 3 As shown, six bridge arm switching tubes form a three-phase control bridge, and the power switching tubes are integrated inside the inverter module.

[0056] Correspondingly, in one implementation, the power switch tube is a SiC transistor. Since the SiC transistor itself has a body diode, the diagnostic logic can only be performed after the high voltage power is completed. Accordingly, when the electric drive integrated Boost boost circuit is connected to the charging pile, the upper bridge switch tube of any phase of the three-phase control bridge U / V / W is controlled for a set time, such as T tbd The power switch is turned on internally while keeping the lower bridge switches of U / V / W closed. During the on-state period, the drain D-side voltage Ua and the source S-side voltage Ub of the SiC transistor are obtained respectively. If the two voltages are basically equal, it indicates that the power switch has a shoot-through fault. If the drain D-side voltage Ua of the SiC transistor and the DC bus voltage are basically equal, and the source S-side voltage Ub is close to 0V, it indicates that the power switch has no shoot-through fault. The upper bridges of U / V / W are controlled to turn off the transistors to complete the self-diagnosis.

[0057] In another implementation, the power switch tube is an IGBT. Since the IGBT does not contain a body diode by default, it can be customized to include an IGBT with a matching body diode, that is, IGBT+DIODE as the entire IGBT chip. Therefore, the diagnostic logic is also performed after the high-voltage power-up is completed. Accordingly, when the electric drive integrated Boost circuit is connected to the charging pile, the upper bridge switch tube of any phase of the three-phase control bridge U / V / W is controlled for a set time, such as T tbd The power supply is turned on internally while keeping the lower bridge switches of U / V / W closed. During the on-time, the IGBT collector side voltage Ua and emitter side voltage Ub are obtained respectively. If the two voltages are basically equal, it indicates that the power switch has a shoot-through fault. If the collector voltage Ua of the IGBT and the DC bus voltage are basically equal, and the emitter side voltage Ub is close to 0V, it indicates that the power switch has no shoot-through fault. The upper bridge of U / V / W is controlled to turn off the tube to complete the self-test diagnosis.

[0058] It should be noted that Figure 3 The medium-power switching tube being a SiC transistor or an IGBT is only an example. In actual applications, the power switching tube can also be two or more SiC transistors, two or more IGBTs, or a combination of at least one SiC transistor and at least one IGBT. There is no limitation on the number of SiC transistors or IGBTs in the power switching tube.

[0059] The embodiments of the present application, by timely detecting and identifying direct-through faults of power switching tubes, help prevent circuit short circuits or other safety hazards caused by the faults, thereby improving the safety and reliability of the entire electric drive system. In addition, the diagnostic logic is applicable to different types of power switching tubes (such as SiC transistors or IGBTs), has wide applicability, and can meet the needs of various electric drive systems.

[0060] The above embodiment introduces the implementation of the electric drive integrated Boost circuit. Next, the application of the electric drive integrated Boost circuit will be introduced.

[0061] Figure 4 A flow chart of a charging method provided by an exemplary embodiment of the present application. The charging method provided by the embodiment of the present application is applied to the control unit in the electric drive integrated Boost boost circuit in the above embodiment. Figure 4 As shown, the charging method includes:

[0062] S401: In response to the charging pile being connected to the electric drive integrated Boost circuit, a self-diagnosis is performed on a power switch tube in the electric drive integrated Boost circuit.

[0063] For example, the control unit detects a connection signal from the charging pile and performs a self-diagnosis on the power switch tube in the electric drive integrated Boost circuit.

[0064] S402. If the power switch tube has no through-fault, turn on the power switch tube to charge the battery through the electric drive integrated Boost circuit; if the power switch tube has a through-fault, prohibit charging and issue a fault signal.

[0065] Correspondingly, if the power switch tube has no through-fault, the power switch tube is turned on, so that the center tap of the three-phase inductor forms a loop with the battery; during the period when the power switch tube is turned on, the three-phase inductor absorbs electrical energy from the charging pile and stores it in the magnetic field; the control unit turns off the power switch tube, and the energy stored in the three-phase inductor is released to the battery through the inverter module to achieve boost charging; the control unit dynamically adjusts the on and off time of the power switch tube according to the voltage and current requirements of the battery to ensure an efficient and stable charging process.

[0066] Correspondingly, once a through fault of the power switch is detected, charging is prohibited and a fault signal is issued at the same time; optionally, the fault signal may be issued in the following manner:

[0067] In the first implementation, a red fault indicator light is turned on to alert the user that a fault exists.

[0068] In the second implementation, a buzzer is triggered to sound an alarm to alert the user.

[0069] In the third implementation, a fault code is sent to a host computer via the Controller Area Network (CAN) bus, Recommended Standard 485 (RS485), or other communication protocols. For example, "0x01" indicates a power switch through fault.

[0070] In the fourth implementation, fault information (such as fault time, fault type, and current value) is stored in a non-volatile memory (such as EEPROM or Flash) to facilitate subsequent analysis and maintenance.

[0071] In the fifth implementation, charging is prohibited until the fault is eliminated to prevent further damage to the device. The user needs to clear the fault state through the reset button or remote command before restarting.

[0072] It should be noted that the above-mentioned implementation methods are only examples of sending fault signals. In actual applications, it can be any one of the above-mentioned implementation methods or any combination of several implementation methods. The implementation method of sending fault signals is not limited here.

[0073] In the embodiment of the present application, by performing self-diagnosis on the power switch tube when the charging pile is connected to the electric drive integrated Boost circuit, the direct fault of the power switch tube can be discovered in advance, and the overcurrent, overheating or equipment damage caused by the power switch tube fault can be reduced, thereby significantly improving the safety and reliability of the charging system; if the power switch tube does not have a direct fault, the system will normally turn on the power switch tube to ensure that the electric drive integrated Boost circuit can work stably, thereby achieving efficient and reliable charging of the battery and reducing charging interruptions or efficiency reduction caused by abnormalities of the power switch tube; if a direct fault of the power switch tube is detected, charging is immediately prohibited and a fault signal is issued to prevent the fault from further expanding. This rapid response mechanism can effectively protect the battery, charging pile and related circuits, and reduce potential economic losses and safety risks.

[0074] In some embodiments, a self-test diagnosis is performed on the power switch tube in the electric drive integrated Boost boost circuit, including: controlling the upper bridge switch tube of any phase of the three-phase control bridge in the electric drive integrated Boost boost circuit to be turned on within a set time length, and the lower bridge switch tubes of the three-phase control bridge are all turned off; within the set time length, obtaining the first-level voltage and the second-level voltage of the power switch tube, and turning off the upper bridge switch tube; if the first-level voltage and the second-level voltage are consistent, it is determined that the power switch tube has a straight-through fault; if the first-level voltage is consistent with the DC bus voltage, and the second-level voltage is 0V, it is determined that the power switch tube has no straight-through fault.

[0075] For example, still refer to Figure 3 In one implementation, the power switch is a SiC transistor. Accordingly, when the electric drive integrated Boost circuit is connected to the charging pile, the upper bridge switch of any phase of the three-phase control bridge U / V / W is controlled for a set time, such as T tbd The power switch is turned on internally while keeping the lower bridge switches of U / V / W closed. During the on-state period, the drain D-side voltage Ua and the source S-side voltage Ub of the SiC transistor are obtained respectively. If the two voltages are basically equal, it indicates that the power switch has a shoot-through fault. If the drain D-side voltage Ua of the SiC transistor and the DC bus voltage are basically equal, and the source S-side voltage Ub is close to 0V, it indicates that the power switch has no shoot-through fault. The upper bridges of U / V / W are controlled to turn off the transistors to complete the self-diagnosis.

[0076] In another implementation, the power switch tube is an IGBT. Accordingly, when the electric drive integrated Boost circuit is connected to the charging pile, the upper bridge switch tube of any phase of the three-phase control bridge U / V / W is controlled for a set time, such as T tbd The power supply is turned on internally while keeping the lower bridge switches of U / V / W closed. During the on-time, the IGBT collector side voltage Ua and emitter side voltage Ub are obtained respectively. If the two voltages are basically equal, it indicates that the power switch has a shoot-through fault. If the collector voltage Ua of the IGBT and the DC bus voltage are basically equal, and the emitter side voltage Ub is close to 0V, it indicates that the power switch has no shoot-through fault. The upper bridge of U / V / W is controlled to turn off the tube to complete the self-test diagnosis.

[0077] In summary, this application has at least the following advantages:

[0078] 1. By replacing traditional relays with power switching tubes, which have higher vibration resistance and reliability than relays and can operate stably under harsh working conditions, the risks caused by excessive acceleration shock can be significantly reduced, thereby effectively reducing the risk of false engagement, and thus reducing vehicle failures caused by false engagement, significantly improving vehicle safety and stability. In addition, by integrating the Boost charging function into the electric drive system and replacing relays with power switching tubes, the number of relays used is reduced, significantly reducing the weight of the electric drive system. This optimization not only helps to reduce the overall weight of new energy vehicles, but also has positive significance for improving vehicle energy efficiency, extending cruising range, and optimizing vehicle design. It also helps to simplify spatial structure design and production assembly processes, and reduce product costs.

[0079] Second, by adopting at least one SiC transistor, at least one IGBT, or a combination of at least one SiC transistor and at least one IGBT, it can carry higher currents, thereby flexibly increasing the upper limit of Boost charging current, which can better meet the needs of fast charging; in addition, both SiC transistors and IGBTs have no mechanical contacts, have strong vibration resistance, and can operate stably under harsh working conditions, effectively reducing the problem of false attraction caused by vibration of traditional relays.

[0080] 3. By integrating the power switch tube into the inverter module and sharing the water cooling system with the bridge arm switch tube in the inverter module, the water cooling system is used to dissipate heat for the power switch tube, which can effectively ensure the performance of the power switch tube in a high temperature environment, reduce the performance degradation or damage caused by insufficient heat dissipation, and also reduce the risk of device aging and failure due to overheating, thereby significantly improving the reliability of the electric drive integrated Boost circuit; in addition, by integrating the power switch tube and the bridge arm switch tube in the same module, not only the use of external heat dissipation devices is reduced and the system structure is simplified, but also the system complexity is reduced through integrated design, the assembly difficulty is reduced, and the production cost is further reduced.

[0081] 4. By performing self-diagnosis on the power switch tube when the charging pile is connected to the electric drive integrated Boost circuit, direct faults of the power switch tube can be discovered in advance, reducing overcurrent, overheating or equipment damage caused by power switch tube faults, and significantly improving the safety and reliability of the charging system; if the power switch tube does not have a direct fault, the system will normally turn on the power switch tube to ensure that the electric drive integrated Boost circuit can operate stably, thereby achieving efficient and reliable charging of the battery and reducing charging interruptions or efficiency reduction caused by abnormalities of the power switch tube; if a direct fault of the power switch tube is detected, charging is immediately prohibited and a fault signal is issued to prevent the fault from further expanding. This rapid response mechanism can effectively protect the battery, charging pile and related circuits, reducing potential economic losses and safety risks.

[0082] Figure 5 A schematic diagram of a charging device provided by an exemplary embodiment of the present application. Figure 5 As shown, the charging device 50 includes the electric drive integrated Boost circuit 51 described in the above embodiment.

[0083] Accordingly, the electric drive integrated boost circuit 51, as the core component of the charging device 50, is responsible for increasing the voltage during the charging process to meet the charging requirements of new energy vehicle batteries. This charging device is suitable for various types of electric vehicles, especially in applications requiring fast charging and efficient energy conversion. By integrating the boost circuit, the charging device 50 can provide stable and reliable charging services under various input voltage conditions.

[0084] The charging device provided in the embodiment of the present application can implement the technical solution shown in the above-mentioned charging method embodiment. Its implementation principle and beneficial effects are similar and will not be repeated here.

[0085] An embodiment of the present application further provides a vehicle, comprising the charging device described in the above embodiment, to implement the charging method in the above embodiment.

[0086] Those skilled in the art will readily appreciate other embodiments of the present application after considering the specification and practicing the invention disclosed herein. This application is intended to cover any variations, uses, or adaptations of the present application that follow the general principles of the present application and include common knowledge or customary techniques in the art not disclosed herein. The description and examples are to be considered as exemplary only, and the true scope and spirit of the present application are indicated by the following claims.

[0087] It should be understood that the present application is not limited to the exact structure described above and shown in the drawings, and that various modifications and changes may be made without departing from the scope thereof. The scope of the present application is limited only by the appended claims.

Claims

1. An electric drive integrated Boost circuit, characterized in that: include: The motor's three-phase inductor, inverter module, power switch tube, control unit, and battery, the inverter module is respectively connected to each phase winding of the three-phase inductor, the power switch tube is respectively connected to the center tap of the three-phase inductor and the control unit, and the battery is connected to the inverter module; The control unit is configured to turn on the power switch tube when the charging pile is connected to the electric drive integrated Boost circuit, so as to charge the battery through the electric drive integrated Boost circuit.

2. The electric drive integrated Boost circuit according to claim 1, characterized in that: The power switch tube is at least one silicon carbide transistor.

3. The electric drive integrated Boost circuit according to claim 1, characterized in that: The power switch tube includes: at least one insulated gate bipolar transistor; Or, a combination of at least one silicon carbide transistor and at least one insulated gate bipolar transistor.

4. The electric drive integrated Boost circuit according to any one of claims 1 to 3, characterized in that: The power switch tube is integrated into the inverter module.

5. The electric drive integrated Boost circuit according to claim 4, characterized in that: The inverter module includes a plurality of bridge arm switching tubes, and the heat conduction surface of the power switching tube is heat-conductively connected to a heat dissipation substrate of a water cooling system of the bridge arm switching tube, wherein a communicating water channel structure is integrated in the heat dissipation substrate.

6. The electric drive integrated Boost circuit according to any one of claim 5, characterized in that: The multiple bridge arm switch tubes form a three-phase control bridge, and the control unit is further used for: When the electric drive integrated Boost circuit is connected to a charging pile, the upper bridge switch tube of any phase of the three-phase control bridge is controlled to be turned on within a set time, and the lower bridge switch tubes of the three-phase control bridge are all turned off; Within the set time period, obtaining the first-level voltage and the second-level voltage of the power switch tube, and turning off the upper bridge switch tube; If the first-level voltage is consistent with the second-level voltage, it is determined that a through fault exists in the power switch tube; If the first-level voltage is consistent with the DC bus voltage and the second-level voltage is 0V, it is determined that the power switch tube has no shoot-through fault.

7. A charging device, characterized in that: The invention comprises the electric drive integrated Boost circuit according to any one of claims 1 to 6.

8. A vehicle, characterized in that: Comprising the charging device as claimed in claim 7.

9. A charging method, characterized in that: The charging method is applied to at least one of a control unit in an electric drive integrated Boost circuit according to any one of claims 1 to 6, a charging device according to claim 7, and a vehicle according to claim 8, wherein the charging method comprises: In response to a charging pile being connected to the electric drive integrated Boost circuit, performing a self-diagnosis on a power switch tube in the electric drive integrated Boost circuit; If the power switch tube has no through-fault, turning on the power switch tube to charge the battery through the electric drive integrated Boost circuit; If the power switch tube has a through fault, charging is prohibited and a fault signal is issued.

10. The charging method according to claim 9, characterized in that: The self-diagnosis of the power switch tube in the electric drive integrated Boost circuit includes: Controlling the upper bridge switch tube of any phase of the three-phase control bridge in the electric drive integrated Boost circuit to be turned on within a set time length, and controlling the lower bridge switch tubes of the three-phase control bridge to be turned off; Within the set time period, obtaining the first-level voltage and the second-level voltage of the power switch tube, and turning off the upper bridge switch tube; If the first-level voltage is consistent with the second-level voltage, it is determined that a through fault exists in the power switch tube; If the first-level voltage is consistent with the DC bus voltage and the second-level voltage is 0V, it is determined that the power switch tube has no shoot-through fault.

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