Electric automobile charger and manufacturing method thereof

Abstract

The invention provides an electric vehicle charger and a manufacturing method thereof, and relates to the technical field of electric vehicle charging. The electric automobile charger comprises a base, the top end of the base is fixedly connected with a machine shell, an electric energy conversion module is fixedly installed on the inner wall of the machine shell, the output end of the electric energy conversion module is fixedly connected with a power transmission cable, the other end of the power transmission cable is fixedly connected with a charging gun, and the inner wall of the machine shell is fixedly connected with two sets of charging sockets. The front end of the charging socket penetrates through the outer wall of the machine shell, a connector of the charging gun is rigidly connected to the inner wall of the charging socket in an inserted mode, a control module is arranged on the upper side of the charging socket, the outer wall of the control module is fixedly connected to the inner wall of the machine shell, and the electric energy conversion module is electrically connected with the control module and the charging socket. An EMC filter is integrated through the electric energy conversion module, electromagnetic interference can be suppressed, stable operation of equipment is ensured, electrical fault risks are reduced, and charging safety is guaranteed in an all-around mode.

Description

Technical Field

[0001] The present invention relates to the technical field of electric vehicle charging, and in particular to an electric vehicle charger and a manufacturing method thereof. Background Art

[0002] With the advantages of zero emissions and low energy consumption, electric vehicles have become the core development direction of energy conservation and emission reduction in the transportation sector. As the key hub connecting electric vehicles and the power grid, the performance and reliability of chargers directly affect users' charging experience and industrial development.

[0003] At present, existing electric vehicle chargers still face many technical bottlenecks in practical applications. Traditional chargers are prone to generate electromagnetic interference (EMI) during the power conversion process, which not only affects the normal operation of surrounding electronic equipment, but may also interfere with the stability of the power grid and cause power supply failures. Summary of the Invention

[0004] In view of the shortcomings of the existing technology, the present invention provides an electric vehicle charger and a manufacturing method thereof, which solves the problem of high risk rate of electrical failure.

[0005] To achieve the above objectives, the present invention is implemented through the following technical solutions: A charger for electric vehicles, comprising a base, the top of the base is fixedly connected to a casing, an electric energy conversion module is fixedly installed on the inner wall of the casing, the output end of the electric energy conversion module is fixedly connected to a transmission cable, the other end of the transmission cable is fixedly connected to a charging gun, two groups of charging sockets are fixedly connected to the inner wall of the casing, the front end of the charging socket passes through the outer wall of the casing, the connector of the charging gun is rigidly plugged into the inner wall of the charging socket, a control module is provided on the upper side of the charging socket, the outer wall of the control module is fixedly connected to the inner wall of the casing, and the electric energy conversion module is electrically connected to the control module and the charging socket.

[0006] Preferably, the power conversion module includes multiple groups of AC / DC charging modules, a heat dissipation substrate, an EMC filter and a current sharing controller, and the output ends of the AC / DC charging modules are electrically connected to the input ends of the transmission cables.

[0007] Preferably, the AC / DC charging module is welded to the outer wall of the heat dissipation substrate, and the AC / DC charging module is electrically connected to the EMC filter and the current sharing controller.

[0008] Preferably, a leakage protector is fixedly connected to the outer wall of the input end of the power transmission cable, and the outer wall of the leakage protector is fixedly connected to the inner wall of the casing.

[0009] Preferably, a rain shield is provided on the upper side of the charging gun, and the outer wall of the rain shield is fixedly connected to the front end of the housing.

[0010] Preferably, the left end of the casing is rotatably connected to a side sliding door, and the inner wall of the side sliding door and the top of the casing are both fixedly connected to a heat dissipation net.

[0011] Preferably, the control module includes a control panel, a metal base plate, a human-computer interaction touch screen, a communication module, and a metering module, and the human-computer interaction touch screen, the communication module, and the metering module are connected to the circuit on the metal base plate through lines.

[0012] A method for manufacturing an electric vehicle charger comprises the following steps:

[0013] Step 1: Fix the housing to the top of the base by welding or bolting, ensuring that the connection surface is flat and sealed. Use a spirit level to calibrate the verticality of the housing to within 0.5.

[0014] Step 2: Solder multiple AC / DC charging modules onto the heat sink substrate, install the EMC filter and current sharing controller in sequence, complete the electric fusion connection between the three, and then fix the whole to the inner wall of the casing. Apply thermal grease to the surface where the heat sink substrate and the casing meet.

[0015] Step 3: Connect the output end of the power conversion module to the input end of the transmission cable with high voltage insulation, install a leakage protector on the outer wall of the transmission cable input end, and fix it to the designated position on the inner wall of the casing;

[0016] Step 4: Assemble the control panel's metal base, touch screen, communication module, and metering module into a control module, secure it to the inner wall of the housing above the charging socket, and complete the circuit connection with the power conversion module and the charging socket;

[0017] Step 5. Open a through hole in the front of the case to install two sets of charging sockets. After connecting the other end of the transmission cable to the charging gun, rigidly insert the charging gun connector into the inner wall of the charging socket to ensure good electrical contact;

[0018] Step 6. Weld and fix the rain shield on the front end of the casing to cover the upper side of the charging gun, install the side sliding door on the left end of the casing through the hinge, and install the heat dissipation net on the inner wall of the side sliding door and the top of the casing to complete the installation of the electric vehicle charger.

[0019] The present invention provides an electric vehicle charger and a manufacturing method thereof. It has the following beneficial effects:

[0020] 1. The present invention integrates an EMC filter into the power conversion module to suppress electromagnetic interference, ensure stable operation of the equipment, reduce the risk of electrical failure, and comprehensively guarantee charging safety.

[0021] 2. The present invention equips the power conversion module with a current sharing controller, which enables multiple groups of AC / DC charging modules to work together, ensuring output stability, improving charging efficiency and equipment compatibility. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 It is a three-dimensional schematic diagram of the present invention;

[0023] Figure 2 This is a schematic diagram of the interior of the casing of the present invention;

[0024] Figure 3 Schematic diagram of the charging control process of the present invention.

[0025] Among them, 1. Casing; 2. Control module; 3. Rain shield; 4. Base; 5. Transmission cable; 6. Side sliding door; 7. Charging gun; 8. Leakage protector; 9. Power conversion module; 10. Charging socket; 11. Heat dissipation net. DETAILED DESCRIPTION

[0026] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0027] Example:

[0028] like Figure 1-3As shown, an embodiment of the present invention provides an electric vehicle charger, including a base 4, the top of the base 4 is fixedly connected to the casing 1, and an electric energy conversion module 9 is fixedly installed on the inner wall of the casing 1. The electric energy conversion module 9 includes multiple groups of AC / DC charging modules, a heat dissipation substrate, an EMC filter and a current sharing controller. The output ends of the AC / DC charging modules are electrically connected to the input ends of the transmission cables 5. The AC / DC charging modules are welded to the outer wall of the heat dissipation substrate. The AC / DC charging modules are electrically connected to the EMC filter and the current sharing controller. The output end of the electric energy conversion module 9 is fixedly connected to the transmission cable 5, and the other end of the transmission cable 5 is fixedly connected to the charging gun 7. Two groups of charging sockets 10 are fixedly connected to the inner wall of the casing 1. The front end of the charging socket 10 passes through the outer wall of the casing 1, and the connector of the charging gun 7 is rigidly plugged into the charging socket 10. The control module 2 is arranged on the upper side of the charging socket 10. The outer wall of the control module 2 is fixedly connected to the inner wall of the casing 1. The power conversion module 9 is electrically connected to the control module 2 and the charging socket 10. The AC / DC charging module uses the Infineon FF300R12ME4 IGBT module. The rated power of a single module is 30kW, the conversion efficiency is ≥96%, and the output voltage range is 200-750VDC. The heat dissipation substrate uses 6063 aluminum alloy profile with a thickness of 8mm and an anodized surface. The heat dissipation fin height is 25mm and the spacing is 5mm. The EMC filter uses TDKSCE0325A with a rated current of 50A and an attenuation frequency range of 10kHz-30MHz. The current sharing controller uses the TIUC3907 chip with a current sharing error of ≤±3%, supporting 4-8 modules in parallel.

[0029] The outer wall of the input end of the transmission cable 5 is fixedly connected to a leakage protector 8, and the outer wall of the leakage protector 8 is fixedly connected to the inner wall of the casing 1. A rain shield 3 is provided on the upper side of the charging gun 7, and the outer wall of the rain shield 3 is fixedly connected to the front end of the casing 1. The left end of the casing 1 is rotatably connected to a side sliding door 6, and the inner wall of the side sliding door 6 and the top of the casing 1 are fixedly connected to a heat dissipation net 11.

[0030] Control module 2 includes a control panel, a metal base plate, a human-computer interaction touch screen, a communication module, and a metering module. The human-computer interaction touch screen, the communication module, and the metering module are connected to the circuit on the metal base plate through lines. The human-computer interaction touch screen is used for user operation and information display. The communication module realizes data interaction between the device and the outside world. The metering module is responsible for electricity metering.

[0031] A method for manufacturing an electric vehicle charger comprises the following steps:

[0032] Step 1: Fix the housing 1 to the top of the base 4 by welding or bolting, ensuring that the connection surface is flat and sealed. Use a spirit level to calibrate the verticality of the housing to a deviation of no more than 0.5.

[0033] Step 2: Solder multiple AC / DC charging modules on the heat dissipation substrate, install EMC filters and current sharing controllers in sequence, and complete the electric fusion connection between the three to fix the whole to the inner wall of the case 1. Apply thermal grease to the surface of the heat dissipation substrate and the case. The AC / DC charging module is fixed to the heat dissipation substrate using the reflow soldering process. The thermal grease is Shin-Etsu G-746 silicone grease. 8mm between the modules. 2 Copper busbar connection, bolt torque 8N·m, contact surface silver-plated, reducing contact resistance to ≤50μΩ;

[0034] Step 3: Connect the output end of the power conversion module 9 to the input end of the transmission cable 5 with high voltage insulation. Install the leakage protector 8 on the outer wall of the input end of the transmission cable 5 and fix it to the specified position on the inner wall of the casing 1. The transmission cable 5 adopts YJV-10kV type cable with a rated voltage of 10kV and an insulation layer thickness of ≥4.5mm. DT-120 type copper terminal blocks are crimped at both ends and cold shrink cable terminal heads are used for insulation and sealing.

[0035] Step 4: Assemble the metal base plate, touch screen, communication module and metering module of the control panel into the control module 2, fix it to the inner wall of the housing 1 above the charging socket 10, complete the circuit connection with the power conversion module 9 and the charging socket 10, and connect the communication module and the metering module with 0.75mm 2 The shielded twisted pair is connected to the PCB board on the metal base plate, and the PCB is made of FR-4 material;

[0036] Step 5: Open a through hole at the front end of the housing 1 to install two sets of charging sockets 10. After connecting the other end of the transmission cable 5 to the charging gun 7, rigidly insert the connector of the charging gun 7 into the inner wall of the charging socket 10 to ensure good electrical contact;

[0037] Step 6. Weld and fix the rain shield 3 at the front end of the casing 1 to cover the upper side of the charging gun 7, install the side sliding door 6 at the left end of the casing 1 through the hinge, and install the heat dissipation net 11 on the inner wall of the side sliding door 6 and the top of the casing 1 to complete the installation of the electric vehicle charger.

[0038] After the installation is completed, the power will be turned on to test the output parameters and current sharing effect of the power conversion module, the human-computer interaction function will be tested through the touch screen of the control module 2, the communication handshake function between the charging socket 10 and the vehicle will be verified, the action sensitivity of the leakage protector 8 will be tested, and a full-load aging test will be carried out for 48 hours to monitor the temperature changes of each module; a waterproof tester will be used to spray the sealing part of the casing to ensure that the protection level meets the IP54 standard; and a network analyzer will be used to test the data transmission stability of the communication module.

[0039] While embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions, and variations may be made to these embodiments without departing from the principles and spirit of the invention, and that the scope of the invention is defined by the appended claims and their equivalents.

Claims

1. An electric vehicle charger, characterized in that: The invention comprises a base (4), the top of the base (4) is fixedly connected to the housing (1), an electric energy conversion module (9) is fixedly installed on the inner wall of the housing (1), the output end of the electric energy conversion module (9) is fixedly connected to the transmission cable (5), the other end of the transmission cable (5) is fixedly connected to the charging gun (7), the inner wall of the housing (1) is fixedly connected to two groups of charging sockets (10), the front end of the charging socket (10) passes through the outer wall of the housing (1), the connector of the charging gun (7) is rigidly plugged into the inner wall of the charging socket (10), a control module (2) is provided on the upper side of the charging socket (10), the outer wall of the control module (2) is fixedly connected to the inner wall of the housing (1), and the electric energy conversion module (9) is electrically connected to the control module (2) and the charging socket (10).

2. The electric vehicle charger according to claim 1, characterized in that: The electric energy conversion module (9) comprises a plurality of groups of AC / DC charging modules, a heat dissipation substrate, an EMC filter and a current sharing controller, and the output ends of the AC / DC charging modules are electrically connected to the input ends of the power transmission cables (5).

3. The electric vehicle charger according to claim 2, characterized in that: The AC / DC charging module is welded on the outer wall of the heat dissipation substrate, and the AC / DC charging module is electrically connected to the EMC filter and the current sharing controller.

4. The electric vehicle charger according to claim 1, characterized in that: The outer wall of the input end of the power transmission cable (5) is fixedly connected to a leakage protector (8), and the outer wall of the leakage protector (8) is fixedly connected to the inner wall of the casing (1).

5. The electric vehicle charger according to claim 1, characterized in that: A rain shield (3) is provided on the upper side of the charging gun (7), and the outer wall of the rain shield (3) is fixedly connected to the front end of the housing (1).

6. The electric vehicle charger according to claim 1, characterized in that: The left end of the casing (1) is rotatably connected to a side sliding door (6), and the inner wall of the side sliding door (6) and the top of the casing (1) are both fixedly connected to a heat dissipation net (11).

7. The electric vehicle charger according to claim 1, characterized in that: The control module (2) comprises a control panel, a metal base plate, a human-machine interactive touch screen, a communication module, and a metering module, wherein the human-machine interactive touch screen, the communication module, and the metering module are connected to the circuit on the metal base plate via lines.

8. A method for manufacturing an electric vehicle charger, using the electric vehicle charger according to claims 1-7, characterized in that: The following steps are involved: Step 1: Fix the housing (1) to the top of the base (4) by welding or bolting, ensuring that the connection surface is flat and sealed, and use a spirit level to calibrate the verticality of the housing to a deviation of no more than 0.5; Step 2: Weld multiple sets of AC / DC charging modules onto the heat dissipation substrate, install the EMC filter and the current sharing controller in sequence, complete the electric fusion connection between the three, and fix the whole to the inner wall of the casing (1). The heat dissipation substrate and the casing must be coated with thermal grease; Step 3: Connect the output end of the power conversion module (9) to the input end of the power transmission cable (5) with high voltage insulation, install a leakage protector (8) on the outer wall of the input end of the power transmission cable (5), and fix it to a designated position on the inner wall of the casing (1); Step 4: Assemble the metal base plate, touch screen, communication module, and metering module of the control panel into a control module (2), fix it to the inner wall of the housing (1) above the charging socket (10), and complete the circuit connection with the power conversion module (9) and the charging socket (10); Step 5: Open a through hole at the front end of the housing (1) and install two sets of charging sockets (10). After connecting the other end of the power transmission cable (5) to the charging gun (7), rigidly insert the connector of the charging gun (7) into the inner wall of the charging socket (10) to ensure good electrical contact; Step 6: Weld and fix the rain shield (3) at the front end of the housing (1) to cover the upper side of the charging gun (7), install the side sliding door (6) at the left end of the housing (1) through the hinge, and install the heat dissipation net (11) on the inner wall of the side sliding door (6) and the top of the housing (1), thereby completing the installation of the electric vehicle charger.

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