Charging module zero-power control system, method, device, and medium

Abstract

The application discloses a kind of charging module zero-power control system, method, equipment and medium, the system includes main control unit, and the pulse driving circuit electrically connected with main control unit, and for connecting or disconnecting the magnetic latching relay of charging module main loop, pulse driving circuit is used to generate driving pulse to control the state switching of magnetic latching relay, control system further includes: sensor, for monitoring at least one operating parameter.The application introduces sensor to monitor the operating state parameters such as ambient temperature, power grid voltage and cumulative operation number of magnetic latching relay of charging module, and the parameters of driving pulse are dynamically determined by main control unit based on these parameters, to ensure that magnetic latching relay can reliably switch state under complex working conditions such as low temperature, voltage fluctuation and equipment aging, so as to realize the true zero-power standby of charging module, while taking into account fast response and high reliability.

Description

Technical Field

[0001] This invention relates to the field of new energy technology, and in particular to a zero-power control system, method, device and medium for a charging module. Background Technology

[0002] With the booming development of the new energy vehicle industry, the energy consumption problem of charging infrastructure has become increasingly prominent. In particular, the standby power consumption of DC charging piles during non-charging periods has become a key bottleneck restricting the economic benefits and green operation of charging stations.

[0003] Currently, the standby power consumption of traditional DC charging modules is typically as high as 10-15W. For high-power charging piles equipped with multiple modules, the total standby power consumption can reach hundreds of watts, which increases the operating costs for operators. Deep sleep solutions have been designed to reduce power consumption, but these solutions generally suffer from excessively long wake-up times, typically exceeding 500ms, which negatively impacts the user experience.

[0004] To address these issues, some solutions attempt to use magnetic latching relays driven by pulses with fixed parameters. However, in complex environments, the pulse energy provided by such solutions may be insufficient to ensure reliable engagement or disengagement of the magnetic latching relay, leading to a significantly increased engagement failure rate.

[0005] In summary, existing technologies cannot simultaneously achieve ultra-low power consumption, fast response, and high reliability in complex environments. A new control scheme is urgently needed to achieve "true zero power consumption" for DC charging modules in standby mode, while ensuring that they can be quickly and reliably woken up under any operating conditions. Summary of the Invention

[0006] The main objective of this invention is to provide a zero-power control system, method, device, and medium for charging modules to solve the above-mentioned technical problems.

[0007] In a first aspect, the present invention provides a zero-power consumption control system for a charging module, comprising a main control unit, a pulse drive circuit electrically connected to the main control unit, and a magnetic latching relay for connecting or disconnecting the main circuit of the charging module. The pulse drive circuit is used to generate drive pulses to control the state switching of the magnetic latching relay. The control system further includes:

[0008] A sensor is used to monitor at least one operating status parameter, the operating status parameter including at least one of the ambient temperature where the charging module is located, the mains voltage input to the charging module, and the cumulative number of operations of the magnetic latching relay;

[0009] The main control unit is configured as follows:

[0010] In response to a preset triggering condition, the operating status parameters are acquired from the sensor; and based on the acquired operating status parameters, the pulse parameters of the driving pulse are dynamically determined, and the pulse driving circuit is controlled to generate a driving pulse having the pulse parameters.

[0011] Secondly, the present invention also provides a zero-power control method for a charging module. The method is applied to a control system, which includes a pulse drive circuit for generating drive pulses and a magnetic latching relay for connecting or disconnecting the main circuit of the charging module. The method includes the following steps:

[0012] In response to a preset triggering condition, operating status parameters are acquired, including at least one of the ambient temperature of the charging module, the mains voltage input to the charging module, and the cumulative number of operations of the magnetic latching relay;

[0013] Based on the acquired operating state parameters, the pulse parameters of the driving pulse are dynamically determined; and

[0014] The pulse drive circuit is controlled to generate a drive pulse with the pulse parameters to drive the magnetic latching relay to switch states.

[0015] Thirdly, the present invention also provides a computer device, comprising: a memory for storing a computer program; and a processor for executing the computer program to implement the method as described in the second aspect.

[0016] Fourthly, the present invention also provides a storage medium storing a computer program, the computer program including program instructions that, when executed by a processor, implement the method as described in the second aspect.

[0017] The beneficial technical effects of this invention are as follows: By introducing sensors to monitor the operating status parameters of the charging module, such as ambient temperature, mains voltage, and cumulative number of operations of the magnetic latching relay, and by having the main control unit dynamically determine the parameters of the drive pulse based on these parameters, this invention ensures that the magnetic latching relay reliably switches states under complex conditions such as low temperature, voltage fluctuation, and equipment aging. This achieves true zero-power standby for the charging module, while also ensuring fast response and high reliability. This solves the technical problems of high standby power consumption, slow wake-up response, and poor reliability under fixed parameter drive in the prior art. Attached Figure Description

[0018] To more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the following description of the embodiments will be briefly introduced. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0019] Figure 1 A schematic diagram of the control system provided in an embodiment of the present invention;

[0020] Figure 2 This is a schematic diagram of the control method provided in an embodiment of the present invention;

[0021] Figure 3 This is a schematic diagram of the control method provided in an embodiment of the present invention. Detailed Implementation

[0022] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0023] It should be understood that, when used in this specification and the appended claims, the terms "comprising" and "including" indicate the presence of the described features, integrals, steps, operations, elements and / or components, but do not exclude the presence or addition of one or more other features, integrals, steps, operations, elements, components and / or collections thereof.

[0024] It should also be understood that the terminology used in this specification is for the purpose of describing particular embodiments only and is not intended to limit the invention. As used in this specification and the appended claims, the singular forms “a,” “an,” and “the” are intended to include the plural forms unless the context clearly indicates otherwise.

[0025] It should also be further understood that the term "and / or" as used in this specification and the appended claims refers to any combination of one or more of the associated listed items and all possible combinations, and includes such combinations.

[0026] Please also refer to Figure 1This invention provides a zero-power control system for a charging module, applied to DC charging modules in charging piles, aiming to solve the problems of high standby power consumption and poor reliability of charging modules in complex environments in the prior art. The system includes a main control unit, a pulse drive circuit electrically connected to the main control unit, and a magnetic latching relay for connecting or disconnecting the main circuit of the charging module. The pulse drive circuit generates drive pulses to control the state switching of the magnetic latching relay. The control system further includes a sensor for monitoring at least one operating state parameter, including at least one of the ambient temperature of the charging module, the mains voltage input to the charging module, and the cumulative number of operations of the magnetic latching relay. The main control unit is configured to: acquire the operating state parameter from the sensor in response to a preset trigger condition; and dynamically determine the pulse parameter of the drive pulse based on the acquired operating state parameter, and control the pulse drive circuit to generate a drive pulse with the pulse parameter.

[0027] In this embodiment, the system includes a main control unit, a pulse drive circuit, and a magnetic latching relay.

[0028] The main control unit can be implemented using electronic units with data processing and control capabilities, such as microcontrollers (MCUs), digital signal processors (DSPs), or field-programmable gate arrays (FPGAs). It is responsible for executing preset control logic, monitoring system status, and generating corresponding control commands according to different operating conditions.

[0029] The pulse drive circuit is electrically connected to the main control unit and is used to receive control commands from the main control unit. Upon receiving a command, this circuit generates a drive pulse with specific pulse parameters. In this embodiment, the pulse drive circuit can be integrated into a pulse converter board, responsible for converting the logic level signal from the main control unit into a power pulse sufficient to drive the magnetic latching relay coil.

[0030] The magnetic latching relay is the actuator, and its switching contacts are connected in series in the main circuit of the charging module. Unlike traditional relays, the magnetic latching relay uses the magnetic force of a permanent magnet to maintain its contacts in a closed or open state, requiring no continuous power consumption, only a drive pulse at the moment of state switching. When the magnetic latching relay is open, it can physically isolate the main circuit power supply of the charging module, thereby reducing the standby power consumption of the charging module to near zero, achieving true zero-power standby.

[0031] To improve the system's reliability in various complex environments, the system also includes a sensor. This sensor monitors at least one operating status parameter that affects the reliable operation of the magnetic latching relay. The operating status parameter may include, but is not limited to: the ambient temperature of the charging module, the mains voltage input to the charging module, and the cumulative number of operations recording the mechanical and electrical wear of the magnetic latching relay. In a specific scenario of this embodiment, the sensor may be a collection of one or more sensing devices.

[0032] The main control unit is configured to execute a set of control strategies. Specifically, the workflow of the main control unit is as follows:

[0033] In response to a preset trigger condition, the operating status parameters are acquired from the sensor.

[0034] The "preset trigger condition" is a specific event that initiates the system's state judgment. For example, the trigger condition could be a signal detecting that the charging gun has been unplugged from the vehicle, or a signal detecting that the charging gun has been plugged into the vehicle's charging port. When these events occur, it means that the charging module needs to switch from an operating state to a standby state, or be woken up from a standby state to an operating state. This is precisely the moment when the magnetic latching relay needs to be driven to perform the state switching. When the trigger condition is met, the main control unit immediately reads one or more real-time operating status parameters collected by the sensors through its interface.

[0035] Based on the acquired operating status parameters, the pulse parameters of the driving pulse are dynamically determined.

[0036] After acquiring operating status parameters (such as the current ambient temperature, mains voltage, or the number of relay operations), the main control unit internally runs a preset compensation algorithm or queries a pre-stored lookup table. For example, if the acquired parameter is ambient temperature, the main control unit will determine whether the temperature will affect the relay coil's operating threshold; if the acquired parameter is mains voltage, the main control unit will determine whether voltage fluctuations will lead to insufficient or excessive drive energy. Based on these judgments, the main control unit dynamically calculates the pulse parameters of the drive pulse most suitable for the current operating conditions, such as the pulse width (duration) and / or the pulse voltage amplitude. This dynamic determination process ensures that the energy contained in the drive pulse is always just right, guaranteeing reliable relay driving under harsh conditions (such as extremely low temperatures) while avoiding damage to the relay due to excessive drive energy under normal conditions, thereby extending its service life.

[0037] The pulse driving circuit is controlled to generate a driving pulse with the pulse parameters.

[0038] After determining the optimal pulse parameters, the main control unit sends a control command containing these parameters to the pulse drive circuit. For example, the main control unit can output a PWM (Pulse Width Modulation) signal of a specific width, or send a digital command containing voltage and width settings via the communication bus. Upon receiving the command, the pulse drive circuit generates a drive pulse that meets the requirements (e.g., a +12V pulse for activation or a -12V pulse for deactivation) and applies it to the corresponding coil of the magnetic latching relay, thereby driving its contacts to reliably complete the state switching.

[0039] Through the above solution, the zero-power control system for the charging module described in this embodiment can adjust the pulse parameters of the magnetic latching relay in real time and dynamically according to the actual working conditions such as ambient temperature, grid voltage and the aging state of the relay itself. This solves the problem of high failure rate of traditional fixed pulse drive schemes under extreme working conditions such as low temperature and low voltage, improves the reliability and safety of the charging module entering and exiting the zero-power state, and also takes into account the service life of the magnetic latching relay.

[0040] In one embodiment, the sensor includes a temperature sensor, a voltage detection circuit, and an operation counter, and the main control unit is connected to the temperature sensor, the voltage detection circuit, and the operation counter respectively; the operating status parameters include the ambient temperature detected by the temperature sensor, the mains voltage detected by the voltage detection circuit, and the cumulative number of operations recorded by the operation counter.

[0041] In this embodiment, the sensor specifically includes a temperature sensor, a voltage detection circuit, and an operation counter. These components are used to monitor different operating status parameters and are electrically connected to the main control unit to achieve real-time data acquisition and transmission. The operating status parameters include the ambient temperature detected by the temperature sensor, the mains voltage detected by the voltage detection circuit, and the cumulative number of operations recorded by the operation counter.

[0042] The temperature sensor is a thermistor used to monitor the ambient temperature of the charging module. In this embodiment, the temperature sensor can be a thermistor or a PT100 platinum resistance thermometer, and its installation position is close to the magnetic latching relay or critical heat source parts of the charging module to accurately capture ambient temperature changes that may affect the relay's operation. The temperature sensor is connected to the main control unit via an analog signal line or a digital interface. The main control unit can periodically or under trigger conditions read its output value to obtain real-time ambient temperature parameters.

[0043] The voltage detection circuit is a voltage monitoring device used to monitor the mains voltage input to the charging module. In this embodiment, the voltage detection circuit may include a resistor divider network, an operational amplifier, and an analog-to-digital converter. It is connected to the input power line of the charging module and can sample the instantaneous or average value of the mains voltage in real time. The voltage detection circuit is connected to the main control unit through an analog or digital interface. The main control unit can obtain the mains voltage parameters by reading its output data, thereby understanding the stability of the power supply.

[0044] The operation counter is a counting device used to record the cumulative number of operations of the magnetic latching relay, that is, the number of times the relay switches from closed to open or from open to closed. In this embodiment, the operation counter can be integrated into the internal memory of the main control unit or used as a separate hardware counter. Each time the magnetic latching relay completes a state switch, the main control unit detects the switching event through its connected signal line and increments the counter value. The operation counter is directly connected to the main control unit, which can read the recorded cumulative number of operations at any time to assess the aging degree of the relay.

[0045] During system operation, the main control unit responds to preset trigger conditions, obtains the corresponding operating status parameters (i.e., ambient temperature, mains voltage, and cumulative number of operations) from these components, and dynamically determines the pulse parameters of the drive pulse based on these parameters. Then, it controls the pulse drive circuit to generate the corresponding drive pulse to drive the magnetic latching relay to switch states.

[0046] With the above configuration, the system described in this embodiment can comprehensively monitor key operating parameters that affect the reliable operation of the magnetic latching relay, ensuring that it can provide an accurate data basis under various operating conditions (such as temperature changes, voltage fluctuations, or aging caused by long-term use), thereby providing support for dynamically adjusting the drive pulse and realizing the stability and adaptability of zero-power control of the charging module.

[0047] In one embodiment, the pulse parameters include pulse width and pulse voltage; the main control unit is further configured to: increase the pulse width of the drive pulse when the ambient temperature is lower than a preset temperature threshold; adjust the pulse voltage of the drive pulse to compensate for the deviation of the grid voltage when the grid voltage deviates from a standard voltage range; and / or gradually increase the pulse width of the drive pulse as the cumulative number of operations increases.

[0048] In this embodiment, the pulse parameters dynamically determined by the main control unit specifically include pulse width and pulse voltage. The pulse width determines the duration of the driving energy applied to the relay coil, while the pulse voltage determines the intensity of the driving energy. The main control unit achieves precise control of the driving energy by coordinating the adjustment of these two parameters.

[0049] Specifically, the main control unit is further configured to execute one or more of the following control logic:

[0050] The main control unit is configured to increase the pulse width of the drive pulse when the ambient temperature obtained from the temperature sensor is lower than a preset temperature threshold. In low-temperature environments, the damping of the internal mechanical components of the magnetic latching relay increases, requiring more energy to operate. By increasing the pulse width, the energy delivery time can be extended, ensuring sufficient impulse to overcome the additional resistance caused by the low temperature, thereby guaranteeing reliable engagement or disengagement of the relay.

[0051] In one specific implementation, the preset temperature threshold can be set to -10℃. When the main control unit detects that the ambient temperature is below -10℃, it activates the pulse width compensation algorithm. For example, the base pulse width (at normal temperature) is 100ms, and the pulse width can increase by 2ms for every 1℃ decrease in temperature. To prevent the coil from overheating due to excessively long pulse widths, an upper limit can be set. In this way, the system can adaptively cope with low temperatures, reducing the pull-in failure rate in extreme low-temperature environments such as -40℃.

[0052] The main control unit is configured to adjust the pulse voltage of the drive pulse to compensate for the deviation of the grid voltage when the grid voltage obtained from the voltage detection circuit deviates from a standard voltage range. The energy of the pulse drive circuit comes from the grid side, and fluctuations in the grid voltage directly affect the final generated drive pulse voltage. When the grid voltage is too low, if no compensation is performed, the voltage amplitude of the drive pulse will also decrease accordingly, which may lead to insufficient drive energy; conversely, when the grid voltage is too high, excessively high drive voltage may be generated, impacting the relay coil and affecting its lifespan.

[0053] In one specific implementation, the standard voltage range can be set to ±15% of the standard input voltage (e.g., 400VAC). When the main control unit detects that the mains voltage exceeds this range, it controls the pulse drive circuit (e.g., by controlling the internal DC-DC conversion unit) to adjust the output drive pulse voltage. For example, when the standard mains voltage is 400V, the corresponding standard drive pulse voltage is 12V DC. If the mains voltage drops to 300V (below the standard range), the main control unit can instruct the pulse drive circuit to increase the drive voltage to 16V to ensure that the total drive energy remains constant. If the mains voltage rises to 500V (above the standard range), the drive voltage can be reduced accordingly to 9.6V to avoid overdrive. This dynamic voltage regulation ensures constant drive energy and improves the system's adaptability to mains fluctuations.

[0054] Pulse width compensation based on cumulative operation count (aging compensation):

[0055] The main control unit is configured to gradually increase the pulse width of the drive pulse as the cumulative number of operations increases. As an electromechanical component, the magnetic latching relay experiences fatigue in its internal contact springs and may also experience wear or oxidation on the contact surfaces after prolonged use, leading to increased contact resistance and a higher operating threshold. This aging phenomenon makes the relay less "sensitive" under the original drive pulse.

[0056] To compensate for this aging effect, the main control unit continuously tracks the cumulative number of relay operations using an operation counter. When the number of operations reaches a certain value, the main control unit appropriately increases the width of the drive pulse according to a preset aging compensation algorithm. For example, if the base pulse width is 100ms, it can be set to increase the pulse width by 0.1ms every 1000 operations. Thus, when the number of operations reaches 50,000, the pulse width will automatically adjust to 105ms; when it reaches 100,000, it will be adjusted to 110ms. This gradual compensation mechanism can effectively eliminate the risk of unreliable drive caused by relay aging and extend the effective service life of the entire system.

[0057] Through the above compensation configuration, the main control unit can dynamically determine the pulse parameters based on the acquired operating status parameters after responding to preset trigger conditions, and control the pulse drive circuit to generate corresponding drive pulses. This adjustment mechanism improves the reliability of the system under extreme environments (such as low temperature and low pressure) and long-term operation, ensuring reliable switching of the magnetic latching relay, thereby achieving zero-power control of the charging module.

[0058] In one embodiment, the preset triggering condition includes a delay condition after detecting that the charging gun has been unplugged or a signal that the charging gun has been plugged in.

[0059] In this embodiment, the preset triggering conditions specifically include two different situations, corresponding to the scenarios of the charging module entering a zero-power standby state and waking up from the zero-power state to enter the working state.

[0060] The trigger condition for entering zero-power mode is a delay condition after the charging gun is detected being unplugged.

[0061] This condition is used to control the charging module to safely and orderly switch from normal operating state to zero-power standby state:

[0062] First, the system monitors the connection status between the charging gun and the vehicle in real time through a status detection circuit connected to the charging gun interface. When the user finishes charging and unplugs the charging gun, the detection circuit immediately sends a "charging gun unplugged" signal to the main control unit.

[0063] Upon receiving the "charging gun unplugged" signal, the main control unit does not immediately drive the magnetic latching relay to disconnect the main circuit. Instead, it starts an internal delay timer. The purpose of setting this delay condition is to prevent the system from frequently switching states due to user misoperation (such as momentarily unplugging and then immediately plugging it back in).

[0064] This delay time can be configured according to actual operational needs; for example, it can be set to 5 minutes. During the delay period, the main control unit can continue to operate at low power.

[0065] When the delay timer finishes counting down, the "delay condition after detecting that the charging gun has been unplugged" is met. At this point, the event of the delay ending serves as a preset trigger condition, prompting the main control unit to execute subsequent operations: immediately acquiring real-time operating status parameters from the temperature sensor, voltage detection circuit, and operation counter, and dynamically determining the drive pulse parameters for disconnecting the magnetic latching relay based on these parameters (for example, generating a -12V pulse), and finally controlling the pulse drive circuit to output the pulse, causing the main circuit of the charging module to disconnect, and the system officially enters the zero-power state.

[0066] The trigger condition for exiting zero-power mode is: a charging gun insertion signal is detected.

[0067] This condition is used to quickly wake the charging module from zero-power standby state, restoring it to normal operating status in response to new charging requests:

[0068] When the charging module is in a zero-power state, most of its circuitry is powered off, but the most basic state detection circuit remains in a low-power standby state. This state detection circuit continuously monitors the status of the charging gun interface. When a user inserts the charging gun into the vehicle's charging port, this detection circuit immediately detects the establishment of a connection signal.

[0069] The establishment of the detected connection signal is considered as "charging gun insertion signal detected". This signal will immediately serve as a preset trigger condition to wake up the main control unit.

[0070] Once the main control unit is awakened, it immediately executes its preset wake-up program: first, it obtains the current operating status parameters from the temperature sensor, voltage detection circuit, and operation counter; then, based on these parameters, it dynamically determines the drive pulse parameters for engaging the magnetic latching relay (e.g., generating a +12V pulse) and controls the pulse drive circuit to output this pulse. Upon receiving the pulse, the magnetic latching relay quickly engages, connecting the main circuit of the charging module, supplying power to all system components, and enabling the charging module to quickly enter normal operating condition, ready to begin the charging process. This instantaneous response design ensures a plug-and-play experience for users and meets the charging standard's requirements for rapid response time.

[0071] Through the aforementioned preset triggering conditions, the system described in this embodiment can intelligently manage the state transitions of the charging module: the delay condition after unplugging ensures the smoothness and necessity of zero-power entry, while the immediate response to the insertion signal guarantees the efficiency of rapid wake-up. These conditions are closely integrated with the dynamic pulse determination logic of the main control unit, improving the reliability and user experience of the system in practical applications, such as adapting to frequent charging operations in scenarios like public charging stations or community charging piles.

[0072] like Figure 2 and 3 As shown, corresponding to the above-mentioned zero-power control system for a charging module, this embodiment of the invention also provides a zero-power control method for a charging module. The method is applied to a control system, which corresponds to the system in the aforementioned embodiment. This control system includes a pulse drive circuit for generating drive pulses and a magnetic latching relay for connecting or disconnecting the main circuit of the charging module. The purpose of this method is to improve the reliability of the magnetic latching relay under different operating conditions through an intelligent control process, thereby achieving safe and efficient zero-power management of the charging module. The method includes the following steps S1-S3:

[0073] Step S1: In response to the preset triggering conditions, obtain the running status parameters.

[0074] This step is the starting point of the entire control method. The control system continuously monitors specific system events, which are defined as "preset trigger conditions." When any preset trigger condition is met, the control system is activated and begins to execute subsequent control actions. These trigger conditions are related to the start and end of the charging process, such as detecting signals that the charging gun is inserted into or removed from the vehicle.

[0075] Once the triggering condition is met, the control system (specifically executed by the main control unit) immediately acquires one or more operating status parameters from various connected sensors. These parameters reflect the current state affecting the operating performance of the magnetic latching relay. In this embodiment, the operating status parameters include at least one of the following:

[0076] Ambient temperature of the charging module: This parameter is measured in real time by a temperature sensor deployed inside the charging module or near the magnetic latching relay;

[0077] The mains voltage input to the charging module: This parameter is obtained in real time by a voltage detection circuit monitoring the AC input terminal of the charging module. Fluctuations in the mains voltage directly affect the energy source of the pulse drive circuit;

[0078] The cumulative number of operations of the magnetic latching relay: This parameter is recorded and updated by an internal system counter. Each time the relay successfully completes a state switch, the count value increases, characterizing the mechanical and electrical aging of the relay.

[0079] Step S2: Based on the acquired operating status parameters, dynamically determine the pulse parameters of the driving pulse.

[0080] After acquiring real-time operating status parameters, the control system enters the decision-making stage. This step calculates the optimal drive pulse parameters based on the current specific operating conditions to ensure that the drive energy is "just right," neither too much nor too little.

[0081] The control system has a pre-set algorithm model or lookup table that establishes the correspondence between operating state parameters and drive pulse parameters. The pulse parameters include the pulse width (duration) and / or the pulse voltage amplitude.

[0082] For example, the control system will perform the following judgments and calculations:

[0083] If the acquired ambient temperature parameter is below a certain threshold, the pulse width is increased to provide a longer duration of action to overcome the resistance at low temperatures.

[0084] If the obtained grid voltage parameters deviate from the normal range, the pulse voltage is adjusted accordingly to compensate for the impact of voltage fluctuations on the driving energy and maintain the stability of the total energy output.

[0085] Based on the acquired cumulative number of operations, the pulse width is gradually increased to compensate for the aging effect of the relay due to long-term use.

[0086] Through this dynamic determination process, the control system can generate a set of customized pulse parameters that are best suited to the current operating conditions for each relay drive requirement.

[0087] Step S3: Control the pulse drive circuit to generate a drive pulse with the pulse parameters to drive the magnetic latching relay to switch states.

[0088] After determining the optimal pulse parameters, the control system sends these parameters as instructions to the pulse drive circuit.

[0089] Upon receiving a command, the pulse drive circuit generates a drive pulse that meets the requirements. For example, if the command requests a pulse with a width of 120ms and a voltage of +12V, the drive circuit will output such an electrical pulse and apply it to the "closing" coil of the magnetic latching relay. If the command requests a pulse with a width of 110ms and a voltage of -12V, the drive circuit will apply it to the "disconnecting" coil.

[0090] The energy of the drive pulse is sufficient to actuate the armature of the magnetic latching relay, causing its internal switching contacts to switch to the target state (on or off), thereby completing the control of the main circuit of the charging module. Because a magnetic latching relay is used, after the state switch is completed, no continuous power supply is required, and the system can enter a zero-power standby state or resume normal operation.

[0091] Through the steps described above, the method described in this embodiment can dynamically optimize the drive pulse based on actual operating state parameters, achieving intelligent management of zero-power control for the charging module. This method is applicable to various charging infrastructure scenarios, such as public charging stations or community charging piles, improving system reliability and energy efficiency, and solving the problem of unreliable drive under extreme conditions in traditional solutions.

[0092] In one embodiment, the step of acquiring the running status parameters in response to a preset triggering condition includes:

[0093] S11. After detecting the signal that the charging gun has been unplugged, start a preset delay timer.

[0094] In this embodiment, during the charging process, the control system continuously monitors the connection status between the charging gun and the electric vehicle through its interface circuit. When the user finishes charging and unplugs the charging gun from the vehicle's charging port, the interface circuit immediately detects the interruption of the connection and generates a "charging gun unplugging signal".

[0095] Upon receiving the "charging gun unplugged signal," the control system (e.g., the main control unit) does not immediately shut down the main circuit. Instead, it first starts an internal preset delay timer. This delay is designed to ensure smooth and reliable system state transitions, preventing frequent system starts and stops caused by momentary actions such as the user plugging the gun back in shortly after unplugging it.

[0096] In one specific implementation, the duration of the preset delay is configurable; for example, it can be set to 5 minutes based on the charging station's operational strategy. During the timing period, the charging module can remain in a low-power standby state, but the main circuit remains connected.

[0097] S12. After the preset delay ends, acquire at least one of the following operating status parameters: the ambient temperature of the charging module, the mains voltage input to the charging module, and the cumulative number of operations of the magnetic latching relay.

[0098] In this embodiment, when the preset delay timer expires, it signifies that the system has confirmed the charging process has officially ended and can safely enter a zero-power state. At this point, the event of the delay ending constitutes the time point that triggers subsequent actions.

[0099] The control system is triggered at this point in time and immediately executes a data acquisition task. It actively reads one or more real-time operating status parameters through communication interfaces with various sensors and counters. Specific parameters acquired may include:

[0100] Ambient temperature: acquired via a temperature sensor to assess the impact of the current temperature on relay operation;

[0101] Grid voltage: obtained through a voltage detection circuit to determine the current grid power supply conditions;

[0102] Cumulative number of operations: Read from the internally stored operation counter to assess the aging of the relay.

[0103] The control system can select to acquire all these parameters, or only one or a few, based on a preset strategy. For example, a simplified version might focus only on the ambient temperature parameter, which has the greatest impact on relay operation. A more comprehensive version would acquire all three parameters simultaneously for integrated compensation calculations.

[0104] After completing this step, the control system obtains all the necessary state information before the drive magnetic latching relay disconnects the main circuit, providing accurate data input for subsequent steps S2 (dynamically determining pulse parameters) and S3 (generating drive pulses).

[0105] Using the above method, the system can acquire key state parameters at a specific point in time (i.e., after the charging gun is unplugged and a delay occurs), ensuring that the decision to enter zero-power mode is based on the latest and most relevant environmental and device state information, thus guaranteeing the orderliness and safety of the zero-power entry process. This method is particularly suitable for high-frequency usage scenarios such as public charging stations or community charging piles, reducing energy waste and improving the overall stability of the system.

[0106] In one specific embodiment, the comprehensive compensation calculation scheme uses an algorithm that dynamically determines the final drive pulse parameters based on a multi-dimensional collaborative calculation model. Specifically, the final pulse width is linearly superimposed from a base width, a temperature-based compensation, and an aging compensation based on the number of operations, ensuring sufficient operating time to overcome the additional resistance caused by low temperature and mechanical aging. Simultaneously, the final pulse voltage is dynamically adjusted according to the inverse relationship between the current grid voltage and the nominal voltage to compensate for fluctuations in input energy and ensure constant drive power. All calculation results undergo a safety-range limiting check before output to prevent damage to components.

[0107] In one embodiment, the step of acquiring operating status parameters in response to a preset trigger condition includes: immediately acquiring at least one of the following operating status parameters after detecting a charging gun insertion signal: the ambient temperature of the charging module, the mains voltage input to the charging module, and the cumulative number of operations of the magnetic latching relay.

[0108] In this embodiment, when the charging module is in zero-power standby mode, its main circuit is disconnected by the magnetic latching relay, and most circuits are in a power-off or extremely low-power mode. However, the system retains a basic status detection circuit (e.g., a low-power signal monitoring module) that continues to operate. This status detection circuit is connected to the charging interface and is responsible for monitoring the connection status of the charging gun.

[0109] Once the user inserts the charging gun into the electric vehicle's charging port, the status detection circuit immediately detects the establishment of a connection signal. This connection signal detection is considered a "charging gun insertion signal," requiring a rapid system response to restore power.

[0110] Unlike the delayed mechanism for entering zero-power mode, the emphasis here is on immediacy. The control system (e.g., the main control unit) is immediately activated the moment a "charging gun insertion signal" is detected, without introducing any artificial delay. Upon activation, the control system immediately performs data acquisition tasks, actively reading one or more real-time operating status parameters through communication interfaces with various sensors and counters. Specific parameters acquired may include: ambient temperature, mains voltage, and cumulative number of operations.

[0111] The control system can select to acquire all these parameters, or only one or several of them, according to a preset strategy. For example, in a fast-response-first mode, the grid voltage parameter is acquired first to ensure immediate compensation of the drive voltage. In a more comprehensive mode, all three parameters are acquired simultaneously to support subsequent integrated dynamic adjustments.

[0112] After this immediate acquisition is completed, the control system obtains all the necessary state information before the drive magnetic latching relay engages the main circuit, providing real-time data input for subsequent steps S2 (dynamically determining pulse parameters) and S3 (generating drive pulses), thereby enabling the charging module to quickly switch from a zero-power state to a working state.

[0113] The above method enables the immediate acquisition of key status parameters upon detecting a charging gun insertion signal, ensuring the efficiency and reliability of the wake-up process. This design is particularly suitable for charging scenarios requiring rapid response, such as highway service areas or public fast-charging stations, thus improving the user experience.

[0114] In one embodiment, dynamically determining the pulse parameters of the drive pulse based on the acquired operating state parameters includes:

[0115] When the ambient temperature is lower than a preset temperature threshold, the pulse width of the driving pulse is increased;

[0116] When the mains voltage deviates from a standard voltage range, the pulse voltage of the drive pulse is adjusted to compensate for the deviation of the mains voltage; and

[0117] Based on the cumulative number of operations, the pulse width of the driving pulse is adjusted using an aging compensation algorithm.

[0118] In this embodiment, the process of dynamically determining pulse parameters specifically includes one or more of the following parallel compensation and adjustment logic:

[0119] After the control system obtains the ambient temperature parameter from the temperature sensor, it will execute the following logic: when the ambient temperature is lower than a preset temperature threshold, the pulse width of the drive pulse will be increased.

[0120] This logic aims to overcome the adverse effects of low temperatures on the mechanical operation of magnetic latching relays. In a specific implementation, the preset temperature threshold can be set to -10℃. The control system (executed by the main control unit) compares the acquired real-time temperature value with this threshold. If the temperature value is below -10℃, pulse width compensation is activated. For example, the system can employ a linear compensation strategy: with a base pulse width of 100ms, the pulse width increases by 2ms for every 1℃ decrease in temperature below -10℃. For example, at -20℃, the pulse width would be calculated as 100ms + ((-10) - (-20)) * 2ms / ℃ = 120ms. To prevent energy waste, the system also sets an upper limit for the pulse width, such as 150ms. If the temperature is not lower than this threshold, the pulse width remains at the base value or is determined by other compensation logic.

[0121] After the control system obtains the grid voltage parameters from the voltage detection circuit, it will execute the following logic: when the grid voltage deviates from a standard voltage range, the pulse voltage of the drive pulse will be adjusted to compensate for the deviation of the grid voltage.

[0122] This logic ensures that the drive energy applied to the relay coil remains stable regardless of fluctuations in the mains voltage. In one specific implementation, the standard voltage range can be set to ±15% of the rated voltage; for example, for a rated input of 400V, the range is 340V to 460V. The control system compares the real-time detected mains voltage with this range. If the voltage value is within this range, the drive pulse voltage is maintained at a standard reference value, such as 12V. If the voltage deviates from this range, voltage compensation is initiated. For example, the target drive voltage can be calculated using an inverse compensation formula: Target drive voltage = Reference drive voltage × (Rated mains voltage / Actual mains voltage). For example, when the mains voltage drops to 300V, the target drive voltage = 12V × (400V / 300V) ≈ 16V. Conversely, when the mains voltage rises to 500V, the target drive voltage = 12V × (400V / 500V) = 9.6V. The control system uses the calculated target voltage value as a command to control the power adjustment unit (such as a DC-DC converter) inside the pulse drive circuit to output the corresponding voltage pulse.

[0123] Once the control system obtains the cumulative number of operations parameter from the operation counter, it will execute the following logic: adjust the pulse width of the drive pulse according to the cumulative number of operations through an aging compensation algorithm.

[0124] This logic aims to compensate for the performance degradation of magnetic latching relays due to long-term use. The aging compensation algorithm is a function that gradually increases the pulse width with the number of operations. In a specific implementation, this algorithm can be a simple linear incrementing function. For example, setting the base pulse width to 100ms, and the compensation coefficient to increase by 0.1ms every 1000 operations, then the target pulse width is calculated as: Target pulse width = Base pulse width + (Cumulative number of operations / 1000) × 0.1ms. When the cumulative number of operations reaches 50,000, the target pulse width = 100ms + (50000 / 1000) × 0.1ms = 105ms. When the number of operations reaches 100,000, the pulse width is adjusted to 110ms. Similarly, for safety, a maximum pulse width limit can be set for the aging compensation.

[0125] In actual execution, the control system integrates the calculation results of the multiple compensation logics mentioned above. For example, the final pulse width is the result of the combined effect of temperature compensation and aging compensation, while the final pulse voltage is determined by the voltage compensation logic. Through this multi-dimensional dynamic adjustment, this method can ensure the generation of an optimized drive pulse under single or combined operating conditions such as low temperature, voltage fluctuation, or equipment aging, thereby improving the reliability, safety, and service life of the zero-power control of the charging module.

[0126] In this embodiment, an inverse proportional compensation formula is used to adjust the grid voltage compensation to ensure that the energy of the drive pulse remains constant during voltage fluctuations. Specifically, the formula is: Target drive voltage V = Reference drive voltage V × (Rated grid voltage V / Actual grid voltage V), where the reference drive voltage V is the reference value under standard operating conditions (e.g., 12V), the rated grid voltage V is the rated grid voltage (e.g., 400V), and the actual grid voltage V is the actual voltage value detected by the sensor in real time. For example, when the actual grid voltage V drops to 300V, the target drive voltage V = 12V × (400V / 300V) ≈ 16V, thereby increasing the voltage to compensate for energy loss; conversely, when the actual grid voltage V rises to 500V, the target drive voltage V = 12V × (400V / 500V) = 9.6V to avoid overdrive.

[0127] In one embodiment, the drive pulse includes a negative pulse for disconnecting the magnetic latching relay and a positive pulse for connecting the magnetic latching relay; the control of the pulse drive circuit to generate the drive pulse having the pulse parameters includes: generating the negative pulse under the condition triggered by the charging gun being pulled out; and generating the positive pulse under the condition triggered by the charging gun being inserted.

[0128] In this embodiment, the magnetic latching relay is a dual-coil or single-coil bistable relay, and its state switching depends on the polarity of the drive pulse. Therefore, the drive pulse is divided into two types:

[0129] Negative pulse: This is an electrical pulse with a specific negative voltage value, such as -12V. This pulse is used to drive the magnetic latching relay to perform a disconnect operation. When this negative pulse is applied to the corresponding coil of the relay, the generated magnetic field interacts with the magnetic field of the permanent magnet, driving the armature of the relay to move, causing its normally open contacts to separate, thereby cutting off the main circuit of the charging module;

[0130] Positive pulse: This is an electrical pulse with a specific positive voltage value, such as +12V. This pulse is used to drive the magnetic latching relay to perform the closing operation. When this positive pulse is applied to the relay coil, the generated magnetic field drives the armature to move in the opposite direction, causing its normally open contacts to close, thereby connecting the main circuit of the charging module.

[0131] Based on the above definition of pulse type, the step of controlling the pulse driving circuit to generate a driving pulse with the pulse parameters specifically comprises the following two control branches corresponding to the triggering conditions:

[0132] The negative pulse is generated when the charging gun is unplugged.

[0133] This control branch corresponds to the scenario where the charging module enters zero-power standby mode. When the system detects the "charging gun unplugged signal" and completes the preset delay, the trigger condition is met. At this time, after the control system (main control unit) has completed the dynamic calculation of pulse parameters (such as pulse width and voltage amplitude) based on ambient temperature, mains voltage, and cumulative number of operations, the final control command it generates is clear: generate a negative pulse.

[0134] The main control unit sends this instruction along with the calculated pulse parameters to the pulse drive circuit. The pulse drive circuit then generates a drive pulse with a specified width and a voltage amplitude of -12V and applies it to the "off" coil of the magnetic latching relay. Upon receiving this negative pulse, the relay's contacts open, the main circuit of the charging module is cut off, and the system successfully enters a zero-power state.

[0135] The positive pulse is generated when the charging gun insertion signal is triggered.

[0136] This control branch corresponds to the scenario where the charging module is woken up from a zero-power state. When the system detects a "charging gun insertion signal," the trigger condition is immediately met. At this time, the woken-up control system (main control unit) immediately acquires and analyzes the current operating status parameters, dynamically determines the optimal pulse parameters, and finally generates the control command: generate a positive pulse.

[0137] The main control unit sends this instruction and related parameters to the pulse drive circuit. The pulse drive circuit then generates a drive pulse with a specified width and a +12V voltage amplitude and applies it to the "on" coil of the magnetic latching relay. Upon receiving the positive pulse, the relay's contacts quickly close, the main circuit of the charging module is connected, the system is successfully woken up and enters normal operating mode, ready to respond to charging requests.

[0138] Through the aforementioned generation mechanism, this method closely links the polarity of the driving pulse with the specific triggering conditions, ensuring the accuracy of state switching. For example, a negative pulse is generated under the condition of gun removal triggering, avoiding the risk of improper closure; a positive pulse is generated under the condition of gun insertion triggering, achieving rapid response. This design further enhances the reliability and safety of the zero-power control method for the charging module, making it suitable for various practical scenarios such as public charging stations or highway service areas.

[0139] Corresponding to the above-described zero-power control method for a charging module, this embodiment of the invention also provides a computer device, including: a memory for storing a computer program; and a processor for executing the computer program to implement the method described in the foregoing embodiments. This computer device may be an integrated microcontroller unit (MCU) or a control circuit board including a processor and a memory.

[0140] In this embodiment, the computer device specifically includes:

[0141] Processor: An industrial-grade 32-bit ARM Cortex-M series microcontroller, such as the STM32 series chip, can be used. This processor integrates the computing core, multiple communication interfaces, and necessary peripherals such as timers. The processor's function is to execute the computer program stored in memory to achieve logical operations and timing control for zero-power control of the entire charging module;

[0142] Memory: Includes non-volatile memory and volatile memory.

[0143] Non-volatile memory: such as flash ROM embedded within the MCU. This flash memory is used to permanently store a computer program (firmware) that implements the methods of the foregoing embodiments. This computer program embeds a complete set of control logic, including but not limited to:

[0144] Trigger condition monitoring module: used to detect the "charging gun insertion / removal" signal;

[0145] Status parameter acquisition module: used to read the analog voltage of the temperature sensor through one interface and convert it into a temperature value; to sample the output of the grid voltage detection circuit through another interface and calculate the real-time grid voltage value; and to record the number of operations of the magnetic latching relay through internal counter logic;

[0146] The pulse parameter dynamic decision algorithm module includes a temperature-based pulse width compensation algorithm (e.g., when the temperature is below -10℃, the pulse width increases by 2ms for every 1℃ decrease), a mains voltage-based pulse voltage compensation algorithm (e.g., dynamically adjusting the output voltage of the DC-DC converter in the drive circuit using a lookup table or inverse proportional formula), and an aging compensation algorithm based on the cumulative number of operations (e.g., the pulse width increases by 0.1ms for every 1000 operations).

[0147] Pulse drive control module: Based on the results of the decision algorithm, it generates a control signal with a specific width and polarity (positive or negative) through the PWM (Pulse Width Modulation) peripheral and sends it to the pulse drive circuit.

[0148] Volatile memory: such as the static random access memory (SRAM) inside the MCU. This memory is used to temporarily store real-time operating status parameters obtained from sensors, intermediate calculation results of algorithms, and system operating status flags during device operation.

[0149] Corresponding to the above-described zero-power control method for a charging module, this embodiment of the invention also provides a storage medium storing a computer program. The computer program includes program instructions, which, when executed by a processor, implement the method described in the foregoing embodiments. This computer-readable storage medium can be any physical carrier capable of carrying or storing the computer program. Depending on the application scenario, it can be a non-volatile semiconductor chip or a portable storage device.

[0150] Regardless of the physical medium used, the computer program stored on it contains a series of program instructions. When these program instructions are loaded and executed by the processor of the computer device, they drive the processor to complete all the steps described in the foregoing embodiments. Specifically, these instructions cause the processor to: respond to triggers, acquire data, perform dynamic calculations, and generate control.

[0151] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any person skilled in the art can easily conceive of various equivalent modifications or substitutions within the technical scope disclosed in the present invention, and these modifications or substitutions should all be covered within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. A zero-power control method for a charging module, the method being applied to a control system, the control system comprising a main control unit, a pulse drive circuit electrically connected to the main control unit, and a magnetic latching relay for connecting or disconnecting the main circuit of the charging module, the pulse drive circuit being used to generate drive pulses to control the state switching of the magnetic latching relay, characterized in that, The method includes the following steps: The main control unit responds to a preset trigger condition and acquires operating status parameters, including the ambient temperature of the charging module, the mains voltage input to the charging module, and the cumulative number of operations of the magnetic latching relay. The main control unit dynamically determines the pulse parameters of the driving pulse based on a multi-dimensional collaborative computing model and the obtained operating status parameters. The pulse parameters include pulse width and pulse voltage. The main control unit controls the pulse drive circuit to generate a drive pulse with the pulse parameters to drive the magnetic latching relay to switch states. The step of obtaining running status parameters in response to a preset trigger condition includes: Upon detecting a charging gun being unplugged, a preset delay timer is initiated. After the preset delay ends, the ambient temperature, the mains voltage, and the cumulative number of operations are acquired. When the charging module is in zero-power standby mode, the magnetic latching relay is in the off state to physically isolate the main circuit power supply of the charging module. Most of the circuits of the charging module are in a power-off state, but the most basic state detection circuit is kept in a low-power standby state. The state detection circuit is connected to the charging gun interface and continuously monitors the connection status of the charging gun interface. When the state detection circuit detects that the connection signal of the charging gun insertion is established, the connection signal is immediately used as a preset trigger condition to wake up the main control unit. After being woken up, the main control unit immediately obtains the current ambient temperature, the mains voltage and the cumulative number of operations from the temperature sensor, the voltage detection circuit and the operation counter, and dynamically determines the pulse parameters of the positive pulse used to engage the magnetic latching relay based on the multi-dimensional collaborative calculation model. It then controls the pulse drive circuit to generate the positive pulse to turn on the magnetic latching relay, so that the charging module can quickly enter the normal working state. The method of dynamically determining the pulse parameters of the driving pulse based on a multi-dimensional collaborative computing model and the acquired operating state parameters includes: The pulse width is calculated by linear superposition based on the ambient temperature and the cumulative number of operations, wherein the pulse width is formed by linear superposition of a base width, a temperature-based compensation amount, and an aging compensation amount based on the number of operations. The pulse voltage is dynamically adjusted based on the inverse relationship between the grid voltage and the nominal voltage; and The pulse width and pulse voltage are subjected to a limit check within a safe range; The driving pulse includes a negative pulse for disconnecting the magnetic latching relay and a positive pulse for connecting the magnetic latching relay; the control of the pulse driving circuit to generate the driving pulse having the pulse parameters includes: generating the negative pulse under the condition of a charging gun being pulled out; and generating the positive pulse under the condition of a charging gun being inserted.

2. A computer device, characterized in that, Includes: memory, used to store computer programs; And a processor, for executing the computer program, to implement the method as described in claim 1.

3. A storage medium, characterized in that, The storage medium stores a computer program, which includes program instructions that, when executed by a processor, implement the method as described in claim 1.

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