High-conversion-efficiency automobile charging pile module adapting to severe environment

Abstract

The invention provides a high-conversion-efficiency automobile charging pile module adapting to a severe environment, belongs to the technical field of electric automobile charging equipment, and adopts an LLC topological structure combining a wide-temperature-range element and a GaN device, a resonant frequency self-adaptive adjusting method and a composite heat dissipation system containing liquid cooling, phase change heat dissipation and air duct back blowing. And a multi-mode automatic switching logic thereof. An environment parameter and power state linked fuzzy PID adjusting algorithm and a power limiting strategy under extreme conditions are adopted; a multi-sensor monitoring module and a cooperative control framework of the system are integrated, and efficient operation in a severe environment is achieved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of electric vehicle charging equipment, and particularly relates to a high-conversion-efficiency automobile charging pile module suitable for harsh environments. BACKGROUND

[0002] With the increasing popularity of electric vehicles, the deployment range of outdoor charging piles is expanding, and their working environment is becoming increasingly complex. Existing charging pile modules are mostly designed based on conventional indoor or mild outdoor environments. In harsh conditions such as high-temperature exposure, low-temperature coldness, high humidity and rain, or dust concentration (such as industrial areas, mining areas, coastal areas), the following problems are common:

[0003] Conversion efficiency drops sharply: high-temperature environments increase the switching loss of power semiconductor devices (such as IGBT, MOSFET), and low-temperature environments cause the parameter drift of capacitors, inductors, and other components, both of which can lead to a decrease in module conversion efficiency. Some traditional modules can have an efficiency of less than 85% at -20℃ or 50℃.

[0004] The heat dissipation system fails: traditional air-cooled heat dissipation is prone to blockage of the air duct in high-dust environments, and liquid-cooled heat dissipation is prone to cooling liquid freezing problems at low temperatures, further increasing the risk of module overheating or overcooling damage.

[0005] Poor stability: high humidity environments can cause a decrease in circuit insulation performance, leading to leakage or short circuit faults and shortening the service life of the module.

[0006] Existing technologies mostly use methods such as strengthening the shell protection (such as increasing the IP level) or adding heating / cooling elements, but the former cannot solve the efficiency problem caused by internal component parameter drift, and the latter increases additional energy consumption, which in turn reduces the overall energy utilization efficiency. Therefore, there is an urgent need for a charging pile module that is optimized in multiple dimensions such as circuit topology, heat dissipation system, and control algorithm to adapt to harsh environments and maintain high conversion efficiency. SUMMARY

[0007] To solve the above technical problems, the present application provides a high-conversion-efficiency automobile charging pile module suitable for harsh environments. In a harsh environment of -30℃ to 60℃ temperature range, relative humidity ≤95% (no condensation), and dust concentration ≤15mg / m 3 The conversion efficiency of the charging pile module is maintained at 94% or above, and the anti-interference ability and service life of the module are improved.

[0008] The technical solution of the present application is:

[0009] A high-efficiency electric vehicle charging pile module adapted to harsh environments includes a novel LLC resonant topology circuit, an environmentally adaptive composite heat dissipation system, a dynamic power adjustment unit, and an environmental monitoring module. The components work together to achieve high conversion efficiency and adaptability to harsh environments.

[0010] The environmental monitoring module collects temperature, humidity, and dust concentration data in real time and transmits them to the dynamic power regulation unit;

[0011] The dynamic power adjustment unit controls the environmental adaptive composite heat dissipation system to switch heat dissipation modes based on environmental data, and adjusts the switching frequency and output power of the new LLC resonant topology circuit.

[0012] The environmental adaptive composite heat dissipation system uses the control unit to determine the current environment type based on environmental data and switches to the corresponding heat dissipation mode.

[0013] The novel LLC resonant topology circuit features an adaptive adjustment module that adjusts the switching frequency and drive voltage based on temperature and load data.

[0014] in

[0015] 1. Novel LLC resonant topology circuit

[0016] To address the issue of resonant parameter drift in traditional LLC topologies over a wide temperature range, this invention makes the following optimizations: employing wide-temperature-range high-frequency capacitors and inductors: the capacitors are ceramic polymer composite dielectric capacitors that can withstand temperatures from -55℃ to 125℃, and the inductors use ferrite cores and high-temperature resistant enameled wires to ensure that the parameter drift rate is ≤5% under extreme temperatures.

[0017] Add a resonant frequency adaptive adjustment module: By real-time acquisition of module input voltage, output current and temperature signals, dynamically adjust the switching frequency of LLC topology (adjustment range: 50kHz-200kHz) so that the topology always works at the optimal resonant point and reduces switching losses.

[0018] Optimize the synchronous rectification circuit: replace the traditional Si device with GaN (gallium nitride) device, which increases the switching speed by 3 times and reduces the conduction loss by 40%. At the same time, it is combined with a temperature-compensated drive circuit to avoid conduction failure caused by insufficient drive voltage at low temperature.

[0019] 2. Environmentally Adaptive Composite Heat Dissipation System

[0020] This system integrates air cooling, liquid cooling, and phase change heat dissipation technologies, and automatically switches the heat dissipation mode based on temperature, humidity, and dust concentration data collected by the environmental monitoring module.

[0021] High temperature and high dust mode: Liquid cooling is activated (coolant is selected from -40℃ to 100℃ antifreeze), and the dust sensor monitors the air duct blockage. When the blockage rate is ≥30%, the air duct back-blowing cleaning function is automatically activated.

[0022] Low temperature mode: Active cooling is turned off, and the latent heat released by the phase change material (selected paraffin-based composite material with a phase change temperature of 0℃-5℃) is used to maintain the core temperature of the module and avoid component parameter drift during low temperature start-up.

[0023] High humidity mode: The dehumidification function of the heat dissipation system is activated. By heating the surface of the heat sink (temperature controlled at 5℃-10℃), condensation is prevented. At the same time, in conjunction with the humidity sensor inside the module, when the humidity is ≥90%, the module output power is automatically reduced by 10% to avoid the risk of insulation breakdown.

[0024] 3. Dynamic power regulation unit and environmental monitoring module

[0025] Environmental monitoring module: integrates a temperature sensor (accuracy ±0.5℃), a humidity sensor (accuracy ±3% RH), and a dust sensor (detection range 0-50mg / m³). 3 It includes vibration sensors to collect environmental parameters in real time and transmit them to the control unit.

[0026] Dynamic power regulation unit: Based on environmental parameters and module operating status (such as input voltage fluctuations and output current requirements), a fuzzy PID algorithm is used to dynamically adjust the module's output power.

[0027] When the ambient temperature is ≥50℃ or ≤-20℃, the output power will be automatically limited to 80%-90% of the rated power to avoid component overload;

[0028] When the input voltage fluctuates by ±15%, the output voltage is kept stable by adjusting the PWM duty cycle and LLC resonant frequency, while ensuring that the conversion efficiency is not less than 92%.

[0029] Working principle

[0030] Environmental monitoring phase: The environmental monitoring module collects temperature, humidity, and dust concentration data in real time and transmits them to the core control unit; Heat dissipation mode switching: The control unit determines the current environmental type based on the environmental data and switches to the corresponding heat dissipation mode (e.g., high temperature and high dust → liquid cooling + backflushing cleaning, low temperature → phase change heat dissipation).

[0031] Circuit parameter adjustment: The synchronous rectifier circuit and LLC resonant frequency adaptive adjustment module adjust the switching frequency and drive voltage according to temperature and load data to ensure that the topology works in the optimal state;

[0032] Dynamic power control: When environmental parameters exceed the normal range (such as temperature ≥55℃), the dynamic power adjustment unit activates the power limiting strategy to ensure charging needs while avoiding a sudden drop in efficiency.

[0033] The beneficial effects of this invention are

[0034] In extreme environments, the conversion efficiency reaches 94%-96%, which is 8%-13.2% higher than traditional modules, reducing energy waste by an average of 230kWh per year. It can adapt to high temperature, low temperature, high humidity, and high dust scenarios and can be deployed in many places such as mining areas in Northeast China, Hainan, and Northwest China. The module lifespan is extended to 5-6 years, and the operation and maintenance cost is reduced by more than 60%. The additional energy consumption accounts for less than 2%, balancing protection and energy saving. It is also compatible with existing charging pile sizes and interfaces, and the incremental cost can be recovered in 1.5 years, making it easy to promote. Attached Figure Description

[0035] Figure 1 This is a schematic diagram of the overall structure of the present invention; the diagram shows the linkage relationship of the four core units of the module. The environmental monitoring module is the data input source, the dynamic power adjustment unit is the control core, the novel LLC resonant topology circuit is the main body of power conversion, and the environmental adaptive composite heat dissipation system is the guarantee unit, forming a closed loop of "monitoring-control-execution-feedback".

[0036] Figure 2 This is a schematic diagram of a novel LLC resonant topology circuit. The diagram shows the specific structure of the circuit topology. The core optimization points are reflected in the application of GaN devices, the selection of wide-temperature-range resonant components, and the signal interaction between the resonant frequency adaptive adjustment module and the circuit, ensuring that the topology operates at the optimal resonant point under extreme temperatures.

[0037] Figure 3 This is a flowchart of the working mode switching of the environmental adaptive composite heat dissipation system. The flowchart clearly shows the switching logic of the four working modes of the heat dissipation system. With temperature, humidity and dust concentration as trigger conditions, it realizes the automatic switching of "high temperature and high dust - liquid cooling + backflushing", "low temperature - phase change", "high humidity - heating + power reduction" and "normal - air cooling", covering the harsh environmental scenarios described in the patent. Detailed Implementation

[0038] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, 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 some embodiments of the present invention, but not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0039] This invention provides a high-efficiency electric vehicle charging pile module adapted to harsh environments, including...

[0040] Circuit topology optimization: A novel LLC resonant topology with GaN devices for synchronous rectification is used, along with wide-temperature-range capacitors and inductors that can withstand temperatures from -55℃ to 125℃. Combined with an adaptive adjustment module for the resonant frequency of 50kHz to 200kHz, the optimal resonant point is dynamically matched, reducing switching losses.

[0041] Adaptive cooling system: It integrates liquid cooling (-40℃~100℃ antifreeze), phase change cooling (0℃~5℃ paraffin-based material) and air duct backflushing cleaning technology, and automatically switches the cooling mode according to environmental data to solve the heat dissipation problem in extreme environments.

[0042] Intelligent control strategy: The dynamic power regulation unit based on the fuzzy PID algorithm is linked with environmental monitoring data (temperature, humidity, dust) to achieve coordinated control of power and heat dissipation, balancing efficiency and safety.

[0043] I. Module Creation and Parameter Selection

[0044] 1. LLC resonant topology circuit:

[0045] Switching device: GaN HEMT device (model: TPH3205WS), rated voltage 650V, on-resistance 80mΩ; Resonant capacitor: X7R ceramic capacitor, capacitance 10nF, withstand voltage 1kV.

[0046] Resonant inductor: PC40 ferrite core, inductance 10μH, rated current 20A.

[0047] 2. Environmentally Adaptive Composite Heat Dissipation System:

[0048] Liquid cooling system: The coolant is an aqueous solution of ethylene glycol (concentration 40%), the heat pump power is 15W, and the heat sink material is 6061 aluminum alloy;

[0049] Phase change material: Paraffin-expanded graphite composite phase change material is selected, with a latent heat of phase change of 200 J / g and a filling amount of 500 g;

[0050] Duct backflushing device: Employs a miniature centrifugal fan with an air volume of 50m³ / h. 3 / h, backflushing cycle 30 minutes / time.

[0051] 3. Environmental Monitoring Module:

[0052] Temperature sensor: Model DS18B20, measuring range -55℃ to 125℃;

[0053] Humidity sensor: Model SHT30, measurement range 0%-100% RH;

[0054] Dust sensor: Model PMS5003, measurement accuracy ±10%.

[0055] II. Performance Testing and Results

[0056] The module of this invention was compared with a traditional module under simulated harsh environmental conditions in the laboratory. The results are shown in the table below:

[0057]

[0058]

[0059] Test results show that the module of this invention can maintain a conversion efficiency of over 94% under various harsh environments, which is significantly better than traditional modules. At the same time, in a continuous 1000-hour high humidity and high dust environment test, there were no short circuits or insulation failures, and the service life is expected to be increased by 2-3 times.

[0060] The following table compares the conversion efficiency of the module of this invention with that of the traditional module under different environmental conditions.

[0061] Data comparison and analysis:

[0062] Ambient conditions Module efficiency of the invention Module efficiency of the conventional Efficiency improvement Normal temperature (25°C / RH 50%) 96％ 92％ +4％ High temperature (60°C / RH 30%) 94％ 83％ +11％ Low temperature (-30°C / RH 40%) 94.2％ 81％ +13.2％ High humidity (30°C / RH 95%) 95％ 85％ +10％ High dust (25°C / 15 mg / m 3 )]]> 94.5％ 82％ +12.5％

[0063] This table presents a bar chart comparison, visually demonstrating the efficiency differences between the two modules in five typical environments. The module of this invention achieves an efficiency of ≥94% in all scenarios, while the traditional module experiences a significant decrease in efficiency (minimum 81%) under harsh environments, confirming the technical effect of "efficiency improvement of 8%-13.2%" described in this invention.

[0064] This technical solution can be extended to fields such as 5G base station power modules (extending from fixed to mobile networks) and photovoltaic energy storage PCS modules. The core technology logic is reused, requiring only scenario-specific adaptation.

[0065] 5G base station power module: The original LLC topology is adapted to the high power requirements of 3000W base stations. The high-frequency resistant PI thin film substrate is replaced to reduce signal loss. The heat dissipation system is designed to address the 100℃ hot spot of the power amplifier chip. The phase change temperature of the phase change material is adjusted to 60℃-70℃. Combined with liquid cooling dual circulation, the problem of high temperature frequency reduction is solved. A salt spray sensor has been added to the environmental monitoring system to adapt to outdoor coastal scenarios.

[0066] Photovoltaic energy storage PCS module: The topology has been upgraded to a three-level structure with SiC devices, reducing switching losses by 47%. The heat dissipation system is adapted to low temperatures of -40℃. A capacitor preheating circuit has been added. The dynamic adjustment algorithm has been optimized to a grid-connected current harmonic suppression strategy, keeping THD below 2.1%.

[0067] By retaining the core module structure and adapting component parameters and control logic, the scope of patent protection can be expanded to power supply fields such as communication and energy storage.

[0068] The above description is merely a preferred embodiment of the present invention and is used only to illustrate the technical solution of the present invention, and is not intended to limit the scope of protection of the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention are included within the scope of protection of the present invention.

Claims

1. A high-efficiency electric vehicle charging pile module adapted to harsh environments, characterized in that, include: The environmental monitoring module collects temperature, humidity, and dust concentration data in real time and transmits them to the dynamic power regulation unit; The dynamic power adjustment unit controls the environmental adaptive composite heat dissipation system to switch heat dissipation modes based on environmental data, and adjusts the switching frequency and output power of the new LLC resonant topology circuit. The environmental adaptive composite heat dissipation system uses the control unit to determine the current environment type based on environmental data and switches to the corresponding heat dissipation mode. The novel LLC resonant topology circuit features an adaptive adjustment module that adjusts the switching frequency and drive voltage based on temperature and load data.

2. The charging pile module according to claim 1, characterized in that, The novel LLC resonant topology circuit uses GaN devices as synchronous rectification elements, combined with wide-temperature-range high-frequency capacitors and inductors, and is equipped with a resonant frequency adaptive adjustment module with an adjustment range of 50kHz-200kHz.

3. The charging pile module according to claim 2, characterized in that, The capacitors are ceramic polymer composite dielectric capacitors that can withstand temperatures from -55℃ to 125℃, and the inductors use ferrite cores and high-temperature resistant enameled wires. The switching frequency of the LLC topology is dynamically adjusted by acquiring the module's input voltage, output current, and temperature signals in real time.

4. The charging pile module according to claim 1, characterized in that, The environmental adaptive composite heat dissipation system includes a liquid cooling device, a phase change heat dissipation device, and an air duct backflushing cleaning device, which can automatically switch to high temperature and high dust mode, low temperature mode, or high humidity mode according to environmental data.

5. The charging pile module according to claim 4, characterized in that, High temperature and high dust mode: Liquid cooling is activated, and the dust sensor monitors the air duct blockage. When the blockage rate exceeds the threshold, the air duct back-blowing cleaning function is automatically activated. Low temperature mode: Active cooling is turned off, and the latent heat released by the phase change material is used to maintain the core temperature of the module, so as to avoid component parameter drift during low temperature start-up; High humidity mode: The dehumidification function of the heat dissipation system is activated. By heating the surface of the heat sink, condensation is prevented. At the same time, in conjunction with the humidity sensor inside the module, when the humidity exceeds the threshold, the module output power is automatically reduced by 10%.

6. The charging pile module according to claim 1, characterized in that, The dynamic power regulation unit adopts a fuzzy PID algorithm, which automatically limits the output power to 80%-90% of the rated power when the ambient temperature is ≥50℃ or ≤-20℃.

7. The charging pile module according to claim 6, characterized in that, When the input voltage fluctuates by ±15%, the output voltage is kept stable by adjusting the PWM duty cycle and the LLC resonant frequency.

8. The charging pile module according to claim 1, characterized in that, The environmental monitoring module integrates a temperature sensor, a humidity sensor, a dust sensor, and a vibration sensor.

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