New energy power box charging device for rail car

Abstract

The invention provides a new energy power box charging device for a rail car. A red copper brush block and a copper carbon electrode carbon brush are installed through a flat-plate-shaped vehicle-mounted connector and a flat-plate-shaped ground connector correspondingly. The ground connector is installed beside a rail in the direction facing the rail, and the vehicle-mounted connector is installed on the side wall of a rail car in the direction facing the ground connector. When the rail car runs beside the ground device along the rail, the rail car stops, based on the vehicle-mounted connector and the ground connector, the red copper brush block and the copper carbon electrode carbon brush can be in direct butt joint, a butt joint for charging does not need to be dragged manually, the steps of manual operation are reduced, and the charging efficiency of the rail car is improved.

Description

Technical Field

[0001] The present invention relates to the technical field of charging devices, and in particular to a charging device for a new energy power supply box for a rail vehicle. Background Art

[0002] Railcars in the metallurgical industry are mainly used to provide transportation services for the smelting process of steel mills. Ladles of molten iron, ladles of molten steel, slag pots, slabs, etc. are placed on railcars and transported to corresponding locations for production via fixed rail lines. With the advancement of new energy technologies, many railcars are powered by new energy sources. During operation, they need to be charged by chargers installed on the ground. Figure 1 This is a schematic diagram of the vehicle plug connection interface and contact layout in the DC charging interface defined in the national charging standard. Based on the national standard DC charging interface, the charging sequence is: a1: Complete the physical connection; After the charging gun is inserted, the physical connection between the charging gun and the on-board charging head is realized. This process is realized based on the charging connection signals CC1 and CC2; a2: Low-voltage auxiliary power-on: The ground charger wakes up the BMS (BATTERY MANAGEMENT SYSTEM) through the low-voltage auxiliary power signals (A+ and A-); a3: Realize communication connection based on CAN bus and complete charging handshake; this step is completed based on charging communication signals CAN_H(S+) and CAN_H(S-); a4: Configure charging parameters; The BMS sends a charging request to the ground charger, which determines whether charging can begin. a5: Charging process; The BMS sends a charging request to the ground charger to complete the charging process; a6: Charging ends; When charging is completed, the BMS sends a charging end instruction message to the charger to complete charging; based on Figure 1 The charging principle diagram of the interface is as follows Figure 2 As shown in the figure, resistors R2, R3, and R4 are all 1kΩ resistors. The specific implementation process of step a1 is as follows: the on-site operator manually inserts the charging plug into the vehicle. After the plug is inserted, the resistance on CC1 of the ground charger changes from resistor R2 to resistor R2 and resistor R4 in parallel. Then, the resistance changes from 1kΩ to 500Ω. Simultaneously, resistor R3 (1kΩ) is also connected to CC2 of the BMS. The ground charger and BMS detect the resistance changes on CC2 and CC1, respectively, to determine the completion of the plug insertion action, and then start the subsequent charging process steps a2 to a6.

[0003] In existing technology, when a railcar needs to be charged, it runs along the track to a ground charging area. The on-site operator manually inserts the charging gun into the vehicle's onboard plug, completing step a1. After step a6, the charging gun needs to be manually unplugged. However, this requires a dedicated staff member to be stationed in the charging area to assist the railcar in completing the charging process. However, in actual operations, this position is not fully utilized, and the overall efficiency of manual operation is low. Summary of the Invention

[0004] In order to solve the problem of low efficiency in the rail vehicle charging process in the prior art, the present invention provides a new energy power box charging device for a rail vehicle, which can effectively reduce the degree of manual participation in the docking process between the rail vehicle and the ground charging equipment, and improve the charging efficiency of the rail vehicle.

[0005] The structure of the present invention is as follows: a new energy power supply box charging device for rail vehicles, characterized in that it includes: a charging power supply, a vehicle-mounted connection device and a ground connection device; The charging power supply is arranged in a charging area beside the track; the on-board connection device is arranged on the rail vehicle, and the ground connection device is installed in the charging area beside the track; The ground connection device includes: a ground support frame, a ground connection head, and copper-carbon electrode carbon brushes. The ground connection head is flat, and the copper-carbon electrode carbon brushes are arranged on one surface of the ground connection head. Each copper-carbon electrode carbon brush is respectively connected to the charging circuit of the charging power supply. The ground connection head is installed next to the track through the ground support frame in a direction facing the track. The on-board connection device includes: an on-board support frame, an on-board connector, and a copper brush block. The on-board connector is flat, and the copper-carbon electrode carbon brush is arranged on the plate surface of the on-board connector. Each copper brush block is electrically connected to the charging line of the new energy power box of the rail car. The on-board connector is mounted on the side wall of the rail car through the on-board support frame in a direction facing the ground connector. The installation heights of the ground connector and the vehicle connector are adapted to each other; the number and type of the copper-carbon electrode carbon brushes are set correspondingly to the copper-carbon electrode carbon brushes, and the copper-carbon electrode carbon brushes and the copper brush blocks are installed in a corresponding manner.

[0006] It is further characterized by: It also includes: a connection confirmation module, a vehicle connection signal generation module and a ground connection signal generation module; The connection confirmation module includes: a ground sensor module, a vehicle-mounted sensor module, a first reflector and a second reflector; The vehicle-mounted sensor module and the first reflector are arranged on the vehicle-mounted connecting device, and the ground sensor module and the second reflector are arranged on the ground connecting device; When the railcar reaches the charging position and the copper-carbon electrode carbon brush is successfully docked with the copper brush block, the ground sensor module and the first reflector are used in combination to send a ground feedback position signal; the vehicle-mounted sensor module and the second reflector are used in combination to send a vehicle-mounted feedback position signal; The ground connection signal generating module generates a CC1 gun plug signal analog signal based on the ground feedback position signal; The vehicle connection signal generation module generates a CC2 charging gun insertion analog signal and a low-voltage auxiliary power supply analog signal based on the vehicle feedback position signal; The ground sensor module and the vehicle-mounted sensor module are both implemented based on photoelectric sensors, namely photoelectric sensor SE1 and photoelectric sensor SE2; The second reflector is arranged on the plate surface where the copper-carbon electrode carbon brushes are located on the ground connection head; the second reflector is arranged parallel to the copper-carbon electrode carbon brushes; the second reflector is arranged symmetrically in the horizontal direction with the center line connecting all the copper-carbon electrode carbon brushes as the center line; The vehicle-mounted sensor module is arranged on the vehicle-mounted connector, and is located on the extension line of the line connecting the center points of all the copper brush blocks; the light signal emission direction of the vehicle-mounted sensor module is toward the second reflector; In the direction of travel of the railcar, the length of the second reflector is less than the length of the copper carbon electrode carbon brush; the lengths of the first reflector and the second reflector are the same; The ground sensor module is arranged on the ground connector, and the optical signal emission direction of the ground sensor module is parallel to the center point connection line of all the copper-carbon electrode carbon brushes and is located in the vertical direction of the center point connection line of the copper-carbon electrode carbon brushes; the signal emission direction of the ground sensor module is toward the first reflector; The first reflector is parallel to the plug-in direction of the copper brush block and is arranged on the vehicle-mounted support frame; the first reflector is symmetrically arranged in the horizontal direction on both sides of the line connecting the center points of all copper brush blocks; The ground connection signal generating module includes: a relay K1, a resistor R2 and a resistor R4; One end of the resistor R2 is connected to the negative electrode of the DC power supply, and the other end of the resistor R2 is connected to pin 30 of the relay K2 and serves as the CC1 signal output pin. One end of the resistor R4 is connected to the negative electrode of the DC power supply, and the other end of the resistor R4 is connected to pin 87 of the relay K1. Pin 86 of the relay K1 is connected to the signal output pin of the photoelectric sensor SE1. Pin 85 of the relay K1 is connected to the positive electrode of the power supply. The positive power pin of the photoelectric sensor SE1 is connected to the positive electrode of the DC power supply, and the negative power pin of the photoelectric sensor SE1 is connected to the negative electrode of the DC power supply. The vehicle connection signal generating module includes: a resistor R3, a relay K2 and a relay K3; One end of the resistor R3 is connected to the negative electrode of the DC power supply, and the other end of the resistor R3 is connected to pin 87 of the relay K3. Pin 30 of the relay K3 is the CC2 signal output pin. Pin 85 of the relay K3 is connected to pin 30 of the relay K2 and pin 85 of the relay K2, and then connected to the positive electrode of the DC power supply. Pin 86 of the relay K3 is connected to pin 86 of the relay K2 and the signal output pin of the photoelectric sensor SE2. Pin 87 of the relay K2 serves as the output pin of the signal A+. The positive power pin of the photoelectric sensor SE2 is connected to the positive electrode of the DC power supply, and the negative power pin of the photoelectric sensor SE2 is connected to the negative electrode of the DC power supply. The docking modes of the copper-carbon electrode carbon brush and the copper brush block include: vertical docking and left-right docking; The copper brush blocks are set to 4 pieces, which are respectively connected to the DC+, DC-, S+, and S- of the new energy power supply box; the copper carbon electrode carbon brushes are set to 4 pieces, which are respectively connected to the DC+, DC-, S+, and S- of the charging power supply; The width of the copper-carbon electrode carbon brush is greater than the width of the elastic block, and the length of the copper-carbon electrode carbon brush is greater than the length of the elastic block; The copper brush block includes: a shell, a spring block, a wire, a spring, a wire connector and a base plate; the base plate is mounted on the mounting surface of the vehicle-mounted connector; the shell is a cavity structure with openings at both ends, the spring block is inserted into the inner cavity of the shell from one end opening, and the other end opening of the shell is mounted on the base plate; the spring is mounted in the inner cavity of the spring block, and the two ends of the spring respectively press against the spring block and the base plate; the wire connector is fixedly connected to the spring block, and the two ends of the wire are respectively connected to the wire connector and the charging circuit of the new energy battery box of the rail car; The housing comprises: a basic housing, a trapezoidal guide plate and a limiting slider. The inner cavity of the basic housing is adapted to the length and width of the bullet block, and the height is lower than the height of the bullet block. Two trapezoidal guide plates are arranged on the basic housing along the running direction of the bullet block railcar. The limiting slider is arranged on the inner wall of the guide plate on the side adjacent to the bullet block. The spring block includes: a block body, a spring guide cavity, a limiting slide groove and an insertion guide surface. After one end of the block body is inserted into the inner cavity of the shell, the insertion guide surface is set at the other end; the spring guide cavity is opened at one end of the block body located in the inner cavity of the shell, one end of the spring is inserted into the spring guide cavity, and the other end is pressed against the bottom plate; the limiting slide groove is opened on the two side walls adjacent to the block body and the guide plate, and the position and groove width of the limiting slide groove are adapted to the position and size of the limiting slider.

[0007] The present application provides a new energy power box charging device for a rail vehicle, which is respectively installed with a copper brush block and a copper-carbon electrode carbon brush through a flat-plate on-board connector and a ground connector; the ground connector is installed next to the track facing the track, and the on-board connector is installed on the side wall of the rail vehicle facing the ground connector; when the rail vehicle travels along the track and stops next to the ground device, the copper brush block and the copper-carbon electrode carbon brush can be directly docked based on the on-board connector and the ground connector, without the need for manual dragging of the charging docking connector, thereby reducing the steps of manual operation and improving the charging efficiency of the rail vehicle. This application uses a ground sensor module and an on-board sensor module to simultaneously detect the docking position of the on-board connection device and the ground connection device, and uses two sensors to detect whether the docking of the copper-carbon electrode carbon brush and the copper brush block is successful to ensure the accuracy of the detection result; the ground connection signal generation module generates a CC1 gun plug signal simulation signal based on the ground feedback position signal; the on-board connection signal generation module generates a CC2 charging gun insertion simulation signal and a low-voltage auxiliary power supply based on the on-board feedback position signal to wake up the BMS for subsequent charging process; based on this solution, the docking process between the rail vehicle and the ground charging equipment can be completed without human intervention. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Figure 1 This is the DC charging vehicle plug layout diagram defined in the national charging standard; Figure 2 This is a schematic diagram of the charging connection interface defined in the national standard; Figure 3 This is a schematic diagram of the overall structure of the new energy power box charging device for rail vehicles; Figure 4 This is a schematic diagram of the electrical connection relationship between the components in the new energy power box charging device for rail vehicles; Figure 5This is a structural diagram of the ground connection device and the vehicle connection device in the docking state; Figure 6 It is a structural diagram of the ground connection device; Figure 7 It is a structural schematic diagram of the vehicle-mounted connection device; Figure 8 It is a schematic diagram of the overall structure of the copper brush block; Figure 9 is a structural schematic diagram of the shell; Figure 10 Schematic diagram of the structure of the bullet block; Figure 11 This is a schematic diagram of the circuit structure of the ground connection signal generation module; Figure 12 This is a schematic diagram of the circuit structure of the vehicle connection signal generation module. DETAILED DESCRIPTION

[0009] like Figure 3 and Figure 4 As shown, the present application includes a new energy power box charging device for a rail vehicle, which includes: a charging power supply (not labeled in the figure), a controller (not labeled in the figure), a ground connection device 3, and an onboard connection device 4. The charging power supply is arranged in a charging area next to the track 2; the rail vehicle 1 runs on the track 2, the onboard connection device 4 is arranged on the rail vehicle 1, and the ground connection device 3 is installed in the charging area next to the track 2.

[0010] like Figure 5 and Figure 6 As shown, the ground connection device 3 includes a ground support frame 31, a ground connection head 32, and copper-carbon electrode brushes 33. The ground connection head 32 is flat, with copper-carbon electrode brushes 33 mounted on one surface of the ground connection head 32. Each copper-carbon electrode brush 33 is connected to a charging circuit of a charging power supply. A brush plate PE substrate and other related structural components are located between the copper-carbon electrode brushes 33. The specific connection method can be implemented based on existing technology. The ground connection head 32 is installed next to the track 2 via the ground support frame 31, facing the track 2.

[0011] like Figure 5 and Figure 7 As shown, the onboard connection device 4 comprises an onboard connector 41, copper brush blocks 42, and an onboard support frame 44. The onboard connector 41 is flat, with copper-carbon electrode brushes 33 mounted on its surface. A PE substrate and related structural components are located between the copper brush blocks 42. The specific connection method is based on the technology of a national standard charging station. Each copper brush block 42 is electrically connected to the charging circuit of the new energy power supply box (not labeled in the figure) of the railcar 1. The onboard connector 41 is mounted on the side wall of the railcar 1 via the onboard support frame 44, facing the ground connector 32.

[0012] According to the setting connection mode of the vehicle connector 41 and the ground connector 32, the docking mode of the copper-carbon electrode carbon brush 33 and the copper brush block 42 includes: vertical docking and left-right docking; when the ground connector 32 and the vehicle connector 41 are both set to the vertical direction, the docking mode of the copper-carbon electrode carbon brush 33 and the copper brush block 42 is left-right docking; when the ground connector 32 and the vehicle connector 41 are both set to the horizontal direction, the docking mode of the copper-carbon electrode carbon brush 33 and the copper brush block 42 is vertical docking. In this embodiment, the docking mode of the copper-carbon electrode carbon brush 33 and the copper brush block 42 is set to vertical docking. The copper brush block 42 can be on top, or the copper-carbon electrode carbon brush 33 can be on top. In this embodiment, the copper-carbon electrode carbon brush 33 is set on top.

[0013] During specific installation, the installation heights of the ground connector 32 and the vehicle connector 41 are adapted to each other; the number and type of copper-carbon electrode carbon brushes 33 are set corresponding to the copper-carbon electrode carbon brushes 33, the copper-carbon electrode carbon brushes 33 are set on the lower end face of the ground connector 32, and the copper brush block 42 is set on the upper end face of the vehicle connector 41. When the rail vehicle 1 travels along the track 2 to the preset position next to the ground device 3 and stops, the copper-carbon electrode carbon brushes 33 installed on the vehicle connector 32 and the ground connector 41 and the copper brush block 42 can be directly docked without manual position correction.

[0014] When the vehicle needs to be charged, the remote control platform automatically directs the railcar to the charging area, connects the onboard connection device 4 to the ground connection device 3, and completes the connection between the DC+, DC-, S+, and S- of the power box and the DC+, DC-, S+, and S- of the charging station, thereby enabling charging. The onboard PLC can disable the railcar during charging. After charging is complete, the railcar's existing electronic control system can feedback a charging completion instruction to the remote control platform, simultaneously releasing the onboard PLC's control prohibiting the railcar from operating.

[0015] The specific preset parking position can be determined manually, or the current vehicle position can be determined based on the position sensor 5. In this application, a position sensor 5 is provided, and the position sensor 5 is provided on the body of the rail vehicle 1. The position sensor 5 is implemented by a sensor module that can determine the position in the prior art, such as a laser sensor or a radar positioning module. Assuming that it is implemented based on a laser sensor, the laser sensor is provided at Figure 3As shown in the figure, a laser reflector (not marked in the figure) is installed outside the track at the preset parking position. When the railcar reaches the preset position, the laser light generated by the laser sensor is reflected at close range, and the position sensor module issues a stop signal. The stop signal is sent to the controller, which can stop the railcar 1 manually or automatically. The system uses position sensor 5 to collect the real-time position of railcar 1.

[0016] To ensure more accurate control of the railcar's position, a ground position sensor (not shown) can be installed near the ground connection device 3 in the charging area. When the ground position sensor and the onboard position sensor 5 simultaneously transmit position signals, the accuracy of the railcar's parking position can be determined. This prevents problems caused by signal mistransmission from the onboard position sensor 5 during operation.

[0017] At the same time, to ensure compatibility with structural errors between different railcars 1 and rails 2, the width of the copper-carbon electrode brush 33 is greater than the width of the spring 422, and the length of the copper-carbon electrode brush 33 is greater than the length of the spring 422. Even if the parking position of the railcar 1 is slightly incorrect, the spring 422 can still connect with the copper-carbon electrode brush 33. The specific length and width of the copper-carbon electrode brush 33 are set based on historical data on the parking position errors of the railcar 1.

[0018] In order to ensure that the installation height error between the ground connector 32 and the vehicle connector 41 can be compatible when the ground connector 32 and the vehicle connector 41 are connected in the vertical direction or when the left and right distance error is caused when the left and right connectors are connected, the copper brush block 42 is designed to have an elastic structure. The structure of the copper brush block 42 can be implemented based on any structure in the prior art that can achieve the same function. Figures 8 to 10 The structure shown is implemented.

[0019] like Figure 8As shown, the copper brush block 42 includes: a shell 421, a spring block 422, a wire 423, a spring 424, a wire connector 425 and a base plate 426; the base plate 426 is installed on the mounting surface of the vehicle-mounted connector 41; the shell 421 is a cavity structure with openings at both ends, the spring block 422 is inserted into the inner cavity of the shell 421 from one end opening of the shell 421, and the other end opening of the shell 421 is installed on the base plate 426, and the shell 421 is provided with a bolt hole 4214, which is fixed to the base plate 426 based on bolts; the spring 424 is installed in the inner cavity of the spring block 422, and the two ends of the spring respectively press the spring block 422 and the base plate 426; the wire connector 425 is fixedly connected to the spring block 422 to prevent the wire from falling off during the operation of the vehicle, and the two ends of the wire 423 are respectively connected to the wire connector 425 and the charging circuit of the new energy power box of the rail vehicle 1. When there is an error in the distance between the ground connector 32 and the vehicle connector 41 being too large or too small, during the process of inserting the spring block 422 between the ground connector 32 and the vehicle connector 41, the position of the spring block 422 can be flexibly adjusted by the spring 424 installed between the spring block 422 and the base plate 426 to adapt to various errors.

[0020] like Figure 9 As shown, the shell 421 includes a rectangular base shell 4211, a trapezoidal guide plate 4212 and a limit slider 4213. The inner cavity size of the base shell 4211 is adapted to the length and width of the bullet 422, and the height is lower than the height of the bullet 422. Two trapezoidal guide plates 4212 are arranged on the base shell 4211 along the running direction of the bullet rail car, and the limit slider 4213 is arranged on the inner wall of the guide plate 4212 on the side adjacent to the bullet 422. The guide plate 4212 with low ends and high middle can ensure that the bullet 422 can smoothly enter a narrow space. The two trapezoidal guide plates 4212 are arranged on both sides of the bullet 422 along the running direction of the bullet rail car to ensure that the bullet 422 will not swing greatly during the docking process with the copper carbon electrode carbon brush 33, thereby ensuring successful charging.

[0021] like Figure 10 As shown, the spring block 422 includes: a block body 4222, a spring guide cavity 424, a limiting slide groove 4224 and an insertion guide surface 4221. After one end of the block body 4222 is inserted into the inner cavity of the shell 421, the other end is provided with an insertion guide surface 4221; the insertion guide surface 4221 can be an arc shape or an inclined surface, and is set as an inclined surface in this embodiment; when the distance between the ground connector 32 and the vehicle connector 41 is small, the spring block 422 can be inserted between the ground connector 32 and the vehicle connector 41 based on the insertion guide surface 4221. As the spring block 422 is inserted, the spring 424 is gradually compressed into the spring guide cavity 424. The force of the spring 424 makes the spring block 422 and the copper carbon electrode carbon brush 33 tightly connected during the charging process.

[0022] The limiting groove 4224 is opened on the two side walls adjacent to the block 4222 and the guide plate 4212. The position and groove width of the limiting groove 4224 are adapted to the position and size of the limiting slider 4213. During assembly, the bottom end of the block 4222 is arranged in the inner cavity of the basic shell 4211, between the two guide plates 4212, and the limiting slider 4213 is inserted into the limiting groove 4224. The limiting groove 4224 is closed at one end adjacent to the bottom plate 426. Through the cooperation of the limiting groove 4224 and the limiting slider 4213, the bullet block 422 can slide smoothly in the inner cavity of the shell 421, while ensuring that the bullet block 422 will not fall off from the inner cavity of the shell 421.

[0023] The spring guide cavity 424 is opened at one end of the block 4222 located in the inner cavity of the shell 421. The size of the spring guide cavity 424 is adapted to the spring 424. When the shell 421 is fixedly mounted on the base plate 426, one end of the spring 424 is inserted into the spring guide cavity 424, and the other end is pressed against the base plate 426. The setting of the spring guide cavity 424 ensures that the spring 424 will not deviate during the compression process.

[0024] Because the rail car 1 is running in a processing workshop, in order to protect the on-board connector 41, an on-board protection device is also provided in the present application. The on-board protection device includes a protective cover and a heat insulation layer (not marked in the figure). The heat insulation layer is provided on the protective cover, and the protective cover is provided on the on-board support frame 44 on the side of the on-board connector 41 away from the body of the rail car 1; the probability of the on-board connector 41 being damaged by objects other than splashing during the operation of the rail car is reduced.

[0025] The controller, based on PLC technology, is electrically connected to the railcar 1, the charging power source, and the position sensor 5. In practical applications, the hardware architecture described in this application, combined with existing PLC technology, enables remote control of the charger via a local area network, enabling unmanned operation at the production site. When the vehicle reaches the charging station, it automatically connects to the charger, and on-site charging is then performed remotely. The specific control method can be implemented based on existing technology.

[0026] The specific electrical connection relationship between the structures of the vehicle-mounted connection device 4 and the ground connection device 3 is as follows: Figure 4As shown. The connection pins between the charging power supply and the ground charging device include: T1+\T1-, DC+, S+, S-, DC-, T2+\T2-, PE. The connection pins between the on-board charging device and the new energy power supply box on the rail car 1 are DC+, S+, S-, DC-, and . The copper brush block 42 in the on-board connector 41 is set to 4 pieces, which are respectively connected to the DC+, DC-, S+, and S- pins of the new energy power supply box; the copper carbon electrode carbon brush 33 on the ground connector 32 is set to 4 pieces, which are respectively connected to the DC+, DC-, S+, and S- pins of the charging power supply. The specific connection method is based on the existing technology to ensure that the copper brush block and the copper carbon electrode carbon brush are effectively connected after docking. Among them, the S+ and S- pins realize communication data transmission, and the DC+ and DC- pins are positive and negative power pins to provide charging power. When charging in this application, the docking of these four pins is guaranteed to be at least guaranteed. The remaining pins in the national standard, such as A+, A- (BMS charging wake-up), CC1-2 (charging gun inserted into the charging base signal), and CC1-1 (charging gun inserted into the charging base signal), are implemented in the form of analog signals based on the cooperation of the connection confirmation module, the vehicle connection signal generation module, and the ground connection signal generation module.

[0027] The connection confirmation module includes: a ground sensor module 35, a vehicle-mounted sensor module 45, a first reflector 46 and a second reflector 34; the vehicle-mounted sensor module 45 and the first reflector 46 are arranged on the vehicle-mounted connecting device 4, and the ground sensor module 35 and the second reflector 34 are arranged on the ground connecting device 3.

[0028] When the rail car reaches the charging position and the copper-carbon electrode carbon brush 33 and the copper brush block 42 are successfully docked, the ground sensor module 35 and the first reflector 46 are used in combination to send a ground feedback position signal; the on-board sensor module 45 and the second reflector 34 are used in combination to send a on-board feedback position signal.

[0029] The ground connection signal generation module is provided in the ground connection device 3 and generates a CC1 gun insertion signal simulation signal based on the ground feedback position signal.

[0030] The vehicle connection signal generation module is set in the vehicle connection device 4, and generates a CC2 charging gun insertion analog signal and an A+ low-voltage auxiliary power analog signal based on the vehicle feedback position signal.

[0031] like Figure 6 As shown, the second reflector 34 is arranged on the board surface where the copper carbon electrode brushes 33 are located on the ground connector 32; the second reflector 34 is arranged parallel to the copper carbon electrode brushes 33, and the second reflector 34 is arranged horizontally symmetrically with the center line L2 of all the copper carbon electrode brushes 33 as the center line.

[0032] like Figure 7As shown, the vehicle-mounted sensor module 45 is set on the vehicle-mounted connector 41 and is located on the extension line L1 of the center point connection line of all the copper brush blocks 42 ; the light signal emission direction of the vehicle-mounted sensor module 45 is toward the second reflector 34 .

[0033] The floor sensor module 35 is mounted on the floor connector 32. The optical signal emission direction of the floor sensor module 35 is parallel to the line L2 connecting the centers of all the copper-carbon electrode brushes 33 and is located perpendicular to the line L2 connecting the centers of the copper-carbon electrode brushes 33. The floor sensor module 35 can be positioned above or below the line L2 connecting the centers. In this embodiment, the floor sensor module 35 is positioned above the line L1 connecting the centers, and the first reflector 46 is correspondingly positioned above the copper-carbon electrode brushes 33. The floor sensor module 35 emits signals toward the first reflector 46.

[0034] The first reflector 46 is parallel to the insertion direction of the copper brush block 42 and is arranged on the vehicle support frame; the first reflector 46 is symmetrically arranged in the horizontal direction on both sides of the line L1 connecting the center points of all the copper brush blocks 42.

[0035] Figure 7 The state shown in the figure is after the copper-carbon electrode brush 33 and the copper brush block 42 are aligned, and the center point connection lines L2 and L3 coincide. In order to clearly see the structure after docking, Figure 7 The ground connector 32 and the copper-carbon electrode carbon brush 33 are cut in half with the center line L2 of the copper-carbon electrode carbon brush 33 as the boundary, so you can see the cross-section of the ground connector 32 and the copper-carbon electrode carbon brush 33, and the ground sensor module 35 installed above the cross-section.

[0036] In the present application, the first reflector 46 and the second reflector 34 have the same length and are both arranged along the direction of travel of the rail vehicle; in the direction of travel of the rail vehicle, the length of the second reflector 34 is less than the length of the copper carbon electrode carbon brush 33; specifically, in this embodiment, the length of the copper carbon electrode carbon brush 33 is 700 mm, while the length of the first reflector 46 and the second reflector 34 is set at 300 mm~600 mm.

[0037] The first reflector 46 is set to be horizontally symmetrical with the center point line L1 of the copper brush block 42 as the axis, and the second reflector 34 is set to be horizontally symmetrical with the center point line L2 of the copper carbon electrode carbon brush 33 as the axis. At the same time, the ground sensor module 35 is set above the center point line L1 of the copper carbon electrode carbon brush 33, and the vehicle-mounted sensor module 45 is set on the extension line L1 of the center point line of the copper brush block 42. In conjunction with the length setting of the first reflector 46 and the second reflector 34, it is ensured that when the copper carbon electrode carbon brush 33 and the copper brush block 42 have a certain docking contact surface, the vehicle-mounted sensor module 45 and the ground sensor module 35 can detect the corresponding reflector and send a signal of successful physical docking.

[0038] The specific lengths of the first reflector 46 and the second reflector 34 are determined based on the docking area between the copper-carbon electrode brush 33 and the copper brush block 42 for successful charging. Assuming that successful charging is achieved when the copper-carbon electrode brush 33 and the copper brush block 42 dock for 50 mm, the lengths of the first reflector 46 and the second reflector 34 can be set to 600 mm. Because the two reflectors are symmetrically arranged about the horizontal points of the center lines L1 and L2, when the copper-carbon electrode brush 33 and the copper brush block 42 dock for 50 mm, the on-board sensor module 45 and the ground sensor module 35 can receive the infrared signal reflected by the corresponding reflector and simultaneously send a docking signal.

[0039] The ground sensor module 35 and the vehicle-mounted sensor module 45 can be implemented based on any sensor capable of position detection in the prior art. In this embodiment, both the ground sensor module 35 and the vehicle-mounted sensor module 45 are implemented based on an NPN normally-open photoelectric sensor switch. Specifically, they are implemented based on an infrared diffuse reflection proximity photoelectric sensor switch model E3F-DS30C, which supports transparent or opaque objects such as metal, plastic, peeled wood, paper, or magnets, and supports automatic signal input after connection with a PLC, servo controller, controller, etc. The photoelectric sensor switch in this embodiment is a three-wire sensor, one for the positive power line (24V), one for the negative power line (0V), and the other for the signal output line. When the NPN normally-open photoelectric sensor switch does not detect the light signal reflected by the reflector, there is no output. When the light signal reflected by the reflector is detected, the output becomes a low level, i.e., a signal indicating that the docking is in place is sent.

[0040] Figure 11 and Figure 12 In the embodiment, the ground sensor module is marked as photoelectric sensor SE1, and the vehicle sensor module is marked as photoelectric sensor SE2. The relays K1, K2 and K3 in this embodiment are implemented based on a DC24 / 20A five-pin automotive relay, specifically the Chint ZTV4 / 024-1Z.

[0041] like Figure 11As shown, the ground connection signal generating module includes: relay K1, resistor R2 and resistor R4; One end of resistor R2 is connected to the negative pole of the DC power supply, and the other end of resistor R2 is connected to pin 30 of relay K2 and serves as the CC1 signal output pin. One end of resistor R4 is connected to the negative pole of the DC power supply, and the other end of resistor R4 is connected to pin 87 of relay K1. Pin 86 of relay K1 is connected to the signal output pin of photoelectric sensor SE1. Pin 85 of relay K1 is connected to the positive pole of the power supply, the positive power pin of photoelectric sensor SE1 is connected to the positive pole of the DC power supply, and the negative power pin of photoelectric sensor SE1 is connected to the negative pole of the DC power supply.

[0042] In this embodiment, the operating power supply is 24V. Pin 1 of switch S1 inside relay K1 is connected to pin 30 of relay, pin 2 of switch S1 is connected to pin 87a of relay, and pin 3 of switch S1 is connected to pin 87 of relay. In the default state, pins 1 and 2 of switches S1 are connected, and pin 3 of switch S1 is disconnected. Pin CC1-2, which transmits the CC1 signal, is also disconnected and has no resistor.

[0043] After the working power is turned on, photoelectric sensor SE1 begins to operate. Photoelectric sensor SE1 emits light waves. When the copper-carbon electrode brush 33 and the copper brush block 42 are properly connected, photoelectric sensor SE1 receives feedback light waves. The signal output pin of photoelectric sensor SE1 sends a low level, then pin 86 of relay K1 is connected to the charging instruction 24V- power supply. The 24V+ power supply flows from pin 85 of relay K1 through the block (coil) and then through pin 86 to the power supply V-, forming a loop. The coil generates magnetic force, attracting switch S1 from 87a to pin 87, then connecting pins 1 and 3 of switch S1, connecting pin 30 of relay K1 to pin 87 of relay K1, and connecting R4 and R2 in parallel. R2 and R4 are both 1kΩ, which becomes 500Ω in parallel. The ground charging device detects that the CC1-2 resistance value has changed from 1kΩ to 500Ω, determines that the charging gun has been inserted into the charging base, and sends a handshake message CRM (charger identification message) to wait for the BMS response.

[0044] like Figure 12 As shown, the vehicle connection signal generating module includes: resistor R3, relay K2 and relay K3; One end of resistor R3 is connected to the negative electrode of the DC power supply, and the other end of resistor R3 is connected to pin 87 of relay K3. Pin 30 of relay K3 is the CC2 signal output pin. Pin 85 of relay K3 is connected to pin 30 of relay K2 and pin 85 of relay K2, and then to the positive electrode of the DC power supply. Pin 86 of relay K3 is connected to pin 86 of relay K2 and the signal output pin of photoelectric sensor SE2. Pin 87 of relay K2 serves as the output pin of signal A+. The positive power pin of photoelectric sensor SE2 is connected to the positive electrode of the DC power supply, and the negative power pin of photoelectric sensor SE2 is connected to the negative electrode of the DC power supply.

[0045] Similar to relay K1, pin 1 of switches s2 and s3 inside relays K2 and K3 is connected to pin 30 of relay, pin 2 of switch s1 is connected to pin 87a of relay, and pin 3 of switch s1 is connected to pin 87 of relay. By default, pins 1 and 2 of switch s1 are connected, and pin 3 is disconnected. Pin 30 of relay K3 is the CC2 signal output pin, and pin 87 of relay K2 is the A+ signal output pin. Both pins are disconnected.

[0046] When the copper-carbon electrode brush 33 and the copper brush block 42 are docked, the photoelectric sensor SE2 receives the feedback light wave, and the signal output pin of the photoelectric sensor SE2 sends a low level. The switches inside the relays K2 and K3 are also attracted by the magnetic force of the coil, and the 30th and 87th pins of the two relays are turned on at the same time. The signal A- uses the working power supply 24V- as the signal source. Figure 4 As shown, when the new energy battery box detects CC2-2, it indicates that it has received a successful CC2 charging cable insertion analog signal from the vehicle-mounted device. The new energy battery box determines that a charging cable has been inserted into the charging base and wakes up the BMS through low-voltage auxiliary power signals (A+ and A-). The BMS then sends a BHM (BMS vehicle identification message) and waits for the charger's response to proceed with the subsequent charging process. At this point, the BMS is in a charging ready state and proceeds with the subsequent charging process. The specific subsequent charging process is implemented based on existing technologies.

[0047] In the present application, by respectively setting a ground sensor module 35 and a vehicle-mounted sensor module 45 on the ground connection device 3 and the vehicle-mounted connection device 4, the docking position of the copper-carbon electrode carbon brush 33 and the copper brush block 42 is confirmed from both the ground connection device 3 and the vehicle-mounted connection device 4, thereby effectively preventing the occurrence of misjudgment. Moreover, the ground sensor module 35 and the vehicle-mounted sensor module 45 are implemented based on photoelectric sensors, and based on the circuit structure in the vehicle-mounted connection signal generation module and the ground connection signal generation module, it is ensured that once the ground sensor module 35 and the vehicle-mounted sensor module 45 detect that the docking is successful, the docking signals CC1 and CC2 can be directly sent to the ground charging device and the new energy battery box through the signals emitted by the two sensors. The whole process can be automatically implemented with high implementation efficiency. The controller will only issue a charging instruction to ensure successful charging if it receives the positioning signals of the ground charging device and the new energy battery box at the same time.

[0048] The technical solution of the present application realizes the hardware docking process through the copper brush block 42 in the vehicle-mounted connector 41 and the copper-carbon electrode brush 33 on the ground connector 32. Based on the ground sensor module 35 and the vehicle-mounted sensor module 45, the resistance changes on CC2 and CC1 are simulated through the vehicle-mounted connection signal generation module and the ground connection signal generation module, thereby realizing the generation process of the analog signal of the physical connection of the charging gun to the vehicle-mounted charging head. The entire process is based on the national standard charging workflow, avoiding changes to the charger and battery management system, and replacing the gun insertion action with the docking action, effectively realizing the unmanned operation of the docking process in the rail vehicle charging process, which can improve the charging efficiency of the rail vehicle.

Claims

1. A new energy power supply box charging device for rail vehicles, characterized in that: It includes: Charging power source, onboard connection device and ground connection device; The charging power supply is arranged in a charging area beside the track; The on-board connection device is provided on the rail vehicle, and the ground connection device is installed in the charging area beside the track; The ground connection device includes: a ground support frame, a ground connection head, and copper-carbon electrode carbon brushes. The ground connection head is flat, and the copper-carbon electrode carbon brushes are arranged on one surface of the ground connection head. Each copper-carbon electrode carbon brush is respectively connected to the charging circuit of the charging power supply. The ground connection head is installed next to the track through the ground support frame in a direction facing the track. The on-board connection device includes: an on-board support frame, an on-board connector, and a copper brush block. The on-board connector is flat, and the copper-carbon electrode carbon brush is arranged on the plate surface of the on-board connector. Each copper brush block is electrically connected to the charging line of the new energy power box of the rail car. The on-board connector is mounted on the side wall of the rail car through the on-board support frame in a direction facing the ground connector. The installation heights of the ground connector and the vehicle connector are adapted to each other; the number and type of the copper-carbon electrode carbon brushes are set correspondingly to the copper-carbon electrode carbon brushes, and the copper-carbon electrode carbon brushes and the copper brush blocks are installed in a corresponding manner.

2. The new energy power supply box charging device for a rail vehicle according to claim 1, characterized in that: It also includes: a connection confirmation module, a vehicle connection signal generation module and a ground connection signal generation module; The connection confirmation module includes: a ground sensor module, a vehicle-mounted sensor module, a first reflector and a second reflector; The vehicle-mounted sensor module and the first reflector are arranged on the vehicle-mounted connecting device, and the ground sensor module and the second reflector are arranged on the ground connecting device; When the railcar reaches the charging position and the copper-carbon electrode carbon brush is successfully docked with the copper brush block, the ground sensor module and the first reflector are used in combination to send a ground feedback position signal; the vehicle-mounted sensor module and the second reflector are used in combination to send a vehicle-mounted feedback position signal; The ground connection signal generating module generates a CC1 gun plug signal analog signal based on the ground feedback position signal; The vehicle connection signal generation module generates a CC2 charging gun insertion analog signal and a low-voltage auxiliary power supply analog signal based on the vehicle feedback position signal.

3. The new energy power supply box charging device for a rail vehicle according to claim 2, characterized in that: The ground sensor module and the vehicle-mounted sensor module are both implemented based on photoelectric sensors, namely photoelectric sensor SE1 and photoelectric sensor SE2.

4. The new energy power supply box charging device for a rail vehicle according to claim 2, characterized in that: The second reflector is arranged on the plate surface where the copper-carbon electrode carbon brushes are located on the ground connection head; the second reflector is arranged parallel to the copper-carbon electrode carbon brushes; the second reflector is arranged symmetrically in the horizontal direction with the center line connecting all the copper-carbon electrode carbon brushes as the center line; The vehicle-mounted sensor module is arranged on the vehicle-mounted connector, and is located on the extension line of the line connecting the center points of all the copper brush blocks; the light signal emission direction of the vehicle-mounted sensor module is toward the second reflector; In the direction of travel of the railcar, the length of the second reflector is less than the length of the copper carbon electrode carbon brush; the lengths of the first reflector and the second reflector are the same; The ground sensor module is arranged on the ground connector, and the optical signal emission direction of the ground sensor module is parallel to the center point connection line of all the copper-carbon electrode carbon brushes and is located in the vertical direction of the center point connection line of the copper-carbon electrode carbon brushes; the signal emission direction of the ground sensor module is toward the first reflector; The first reflector is parallel to the plug-in direction of the copper brush block and is arranged on the vehicle-mounted support frame; the first reflector is symmetrically arranged in the horizontal direction on both sides of the line connecting the center points of all copper brush blocks.

5. The new energy power supply box charging device for rail vehicles according to claim 3, characterized in that: The ground connection signal generating module includes: a relay K1, a resistor R2 and a resistor R4; One end of the resistor R2 is connected to the negative electrode of the DC power supply, and the other end of the resistor R2 is connected to pin 30 of the relay K2 and serves as the CC1 signal output pin. One end of the resistor R4 is connected to the negative electrode of the DC power supply, and the other end of the resistor R4 is connected to pin 87 of the relay K1. Pin 86 of the relay K1 is connected to the signal output pin of the photoelectric sensor SE1. Pin 85 of the relay K1 is connected to the positive electrode of the power supply. The positive power supply pin of the photoelectric sensor SE1 is connected to the positive electrode of the DC power supply, and the negative power supply pin of the photoelectric sensor SE1 is connected to the negative electrode of the DC power supply.

6. The new energy power supply box charging device for a rail vehicle according to claim 3, characterized in that: The vehicle connection signal generating module includes: a resistor R3, a relay K2 and a relay K3; One end of the resistor R3 is connected to the negative electrode of the DC power supply, and the other end of the resistor R3 is connected to pin 87 of the relay K3. Pin 30 of the relay K3 is the CC2 signal output pin. Pin 85 of the relay K3 is connected to pin 30 of the relay K2 and pin 85 of the relay K2, and then to the positive electrode of the DC power supply. Pin 86 of the relay K3 is connected to pin 86 of the relay K2 and the signal output pin of the photoelectric sensor SE2. Pin 87 of the relay K2 serves as the output pin of the signal A+. The positive power pin of the photoelectric sensor SE2 is connected to the positive electrode of the DC power supply, and the negative power pin of the photoelectric sensor SE2 is connected to the negative electrode of the DC power supply.

7. The rail vehicle new energy power supply box charging device according to claim 1, characterized in that: The docking modes of the copper-carbon electrode carbon brush and the copper brush block include: vertical docking and horizontal docking.

8. The new energy power supply box charging device for a rail vehicle according to claim 1, characterized in that: The copper brush blocks are set to 4 pieces, which are respectively connected to the DC+, DC-, S+, and S- of the new energy power supply box; the copper carbon electrode carbon brushes are set to 4 pieces, which are respectively connected to the DC+, DC-, S+, and S- of the charging power supply.

9. The new energy power supply box charging device for a rail vehicle according to claim 1, characterized in that: The width of the copper-carbon electrode carbon brush is greater than the width of the elastic block, and the length of the copper-carbon electrode carbon brush is greater than the length of the elastic block.

10. The new energy power supply box charging device for a rail vehicle according to claim 1, characterized in that: The copper brush block includes: a shell, a spring block, a wire, a spring, a wire connector and a base plate; the base plate is mounted on the mounting surface of the vehicle-mounted connector; the shell is a cavity structure with openings at both ends, the spring block is inserted into the inner cavity of the shell from one end opening, and the other end opening of the shell is mounted on the base plate; the spring is mounted in the inner cavity of the spring block, and the two ends of the spring respectively press against the spring block and the base plate; the wire connector is fixedly connected to the spring block, and the two ends of the wire are respectively connected to the wire connector and the charging circuit of the new energy battery box of the rail car; The housing comprises: a basic housing, a trapezoidal guide plate and a limiting slider. The inner cavity of the basic housing is adapted to the length and width of the bullet block, and the height is lower than the height of the bullet block. Two trapezoidal guide plates are arranged on the basic housing along the running direction of the bullet block railcar. The limiting slider is arranged on the inner wall of the guide plate on the side adjacent to the bullet block. The spring block includes: a block body, a spring guide cavity, a limiting slide groove and an insertion guide surface. After one end of the block body is inserted into the inner cavity of the shell, the insertion guide surface is set at the other end; the spring guide cavity is opened at one end of the block body located in the inner cavity of the shell, one end of the spring is inserted into the spring guide cavity, and the other end is pressed against the bottom plate; the limiting slide groove is opened on the two side walls adjacent to the block body and the guide plate, and the position and groove width of the limiting slide groove are adapted to the position and size of the limiting slider.

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