State self-sensing based charging interface plugging state confirmation and locking protection system

Abstract

The application discloses a charging interface plugging state confirmation and locking protection system based on state self-sensing, relates to the technical field of power transmission and distribution and control equipment manufacturing, and comprises a state sensing module, a plugging confirmation module, a locking protection module, a control core module, a communication interaction module, an environment adaptation module and a man-machine interaction module.The state sensing module comprises a variety of sensor arrays and a FPGA signal fusion unit, and collects physical parameters of interfaces in a global mode.The plugging confirmation module comprises a dynamic threshold generator and a fuzzy neural network decision maker, and automatically adapts to vehicle thresholds.The locking protection module comprises a multistage locking mechanism and a self-adaptive execution unit.The control core module adopts a heterogeneous architecture, defines seven states and conversion rules, supports a variety of communication modes, and realizes SM4 encrypted communication.The environment adaptation module monitors environmental parameters and actively adjusts the parameters.The man-machine interaction module comprises an OLED screen, a touch key, a voice prompt and an indicator light.The application improves plugging confirmation precision and locking reliability, adapts to multiple vehicle types and complex environments, reduces fault and maintenance costs, and guarantees charging safety.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of power transmission and control equipment manufacturing, and in particular to a charging interface plugging state confirmation and locking protection system based on state self-sensing. BACKGROUND

[0002] With the rapid growth of the number of new energy vehicles, the ground and underground alternating current charging piles as the core energy supplement facilities, their operation safety and reliability are directly related to user experience and equipment life. As the key node of energy transmission, the effectiveness of the plugging state of the charging interface and the reliability of the locking protection are the core links to prevent risks such as electric shock, electric arc burning, and equipment damage. In the current charging pile market, the plugging state confirmation of most products relies on a single mechanical contact or a simple displacement sensor, and the locking mechanism uses a fixed torque electromagnetic lock or a mechanical buckle, which is difficult to adapt to complex application scenarios and diversified use requirements, and the safety hazards and performance short boards are increasingly prominent.

[0003] The prior art has obvious limitations in the plugging state confirmation link. The traditional scheme only detects the insertion depth or a single pressure point to determine whether the plugging is in place, ignoring key parameters such as interface radial offset, uneven circumferential pressure distribution, and abnormal contact resistance. When the interface is slightly misaligned or partially poorly contacted, the system is prone to misjudgment as "plugging qualified" and starting charging, resulting in excessive current density at the contact point, causing local overheating, and even burning the interface in severe cases. At the same time, the physical size and contact characteristics of different vehicle interfaces differ, and the fixed threshold judgment logic cannot achieve precise adaptation, further reducing the reliability of the confirmation result, especially in humid and dusty environments such as underground charging piles, sensor signals are easily disturbed, and the misjudgment rate is significantly increased.

[0004] The lack of environmental adaptation capability of locking protection exacerbates the risk of operation. The existing locking mechanism uses a fixed locking force design, which can easily cause deformation of the plastic shell for new interfaces due to overlocking, and can cause loosening for worn and aged interfaces due to underlocking, which is prone to occur when the vehicle is accidentally dragged or vibrated. The harsh environment of low temperature, high humidity, and dust accumulation faced by underground charging piles also causes the locking tongue to freeze and jam, and the metal parts to rust, greatly increasing the failure probability of the locking mechanism. In addition, the existing system lacks dynamic monitoring and life cycle management during charging, and can only respond passively after failure occurs, which cannot predict potential problems such as contact state degradation and locking mechanism wear in advance, resulting in high maintenance costs, short average trouble-free operation time of equipment, and difficulty in meeting the safety needs of large-scale operation of charging piles. SUMMARY

[0005] The charging interface plugging state confirmation and locking protection system based on state self-sensing proposed by the present application solves the problems mentioned in the prior art.

[0006] In order to achieve the above object, the application adopts the following technical scheme: a charging interface plugging state confirmation and locking protection system based on state self-sensing, comprising the following modules:

[0007] The state sensing module is composed of a multi-dimensional sensing array and a signal fusion unit, the multi-dimensional sensing array includes three sensors of laser displacement, distributed pressure and fiber grating temperature and a high-frequency impedance detection unit; the signal fusion unit adopts an FPGA chip to output a fusion state vector after processing sensor data;

[0008] The plugging confirmation module includes a dynamic threshold generator and a multi-modal decision maker, the dynamic threshold generator has a built-in interface parameter model of a main vehicle type to automatically generate an adaptive threshold; the multi-modal decision maker adopts a fuzzy neural network algorithm to extract features from the fusion state vector and outputs a plugging qualified signal when a condition is met for 5 consecutive sampling periods;

[0009] The locking protection module is composed of a multi-stage locking mechanism and an adaptive execution unit, the multi-stage locking mechanism includes an electromagnetic lock tongue, a mechanical pawl and a Hall sensor array; the adaptive execution unit adjusts the locking force according to the pressure field distribution and controls the electromagnetic lock current through a PWM signal;

[0010] The control hub module adopts a heterogeneous computing architecture, integrates a Cortex-A76 processor and a neural network acceleration unit, runs an operating system, has a built-in state transition engine and defines 7 states of "initial-alignment-insertion-locking-charging-unlocking-reset" and transition rules; the control hub module is connected with each functional module through a high-speed bus;

[0011] The communication interaction module supports multi-protocol fusion communication and includes an industrial Ethernet interface, a 5G dual-mode communication unit and a near-field communication module; communication data is encrypted end-to-end, the encryption algorithm is SM4 and the key is dynamically updated every hour;

[0012] The environment adaptation module integrates multi-parameter environment monitoring and active adjustment units, the environment monitoring includes three sensors of temperature and humidity, dust concentration and corrosive gas, and the active adjustment unit includes a miniature heating sheet, an anti-condensation fan and a dustproof sealing ring, which are automatically started to adjust when the environment parameters exceed the threshold;

[0013] The man-machine interaction module adopts a multi-modal interaction mode and includes an OLED display screen, a capacitive touch key, a voice prompt unit and a three-color ring indicator light, which distinguish different states through flicker frequency.

[0014] Further, it further includes a pressure field uniformity correction module, which optimizes the contact pressure field by adjusting the force point distribution of the locking mechanism, and the uniformity correction adopts Wherein U is the non-uniformity of the pressure field; The detection value of the i th pressure sensor; The average value of all sensor detection values; n is the number of sensors; When the module controls the three fine adjustment motors of the locking mechanism to act respectively, each motor independently adjusts the locking force of the corresponding area until .

[0015] Further, it also includes a dynamic impedance-temperature coupling monitoring module, which analyzes the thermal-electric coupling characteristics of the contact state in real time, and the coupling coefficient is calculated as Where C is the coupling coefficient; The contact resistance change amount; The temperature change amount; I is the charging current, when The interface contact has a deterioration trend, and the module outputs a warning signal to the control center, which gradually reduces the charging current, while recording the coupling coefficient change curve.

[0016] Further, it also includes a predictive locking wear compensation module, which predicts the wear amount of the locking mechanism through historical data modeling and dynamically compensates. The module has a built-in wear model, which calculates the wear amount based on the cumulative locking times, average locking force, and environmental temperature: after each locking, the driving parameters for the next locking are corrected according to the difference between the current locking force and the preset standard locking force; when the cumulative wear amount prediction value exceeds 0.5mm, the bolt extension length is automatically increased by 0.1mm, and the maintenance is prompted through the human-computer interaction module.

[0017] Further, it also includes a multi-physical field interference suppression module, which includes: an electromagnetic shield covering the sensor and communication circuit; an adaptive filter that automatically adjusts the filter parameters according to the detected electromagnetic interference frequency; a common-mode interference suppression circuit that reduces the ground loop interference to below 5mV.

[0018] Further, it also includes an emergency forced unlocking module, which includes: a mechanical emergency pull rod connected to a secondary pawl mechanism, with a manual pulling force ≥50N to trigger unlocking; an electronic emergency drive unit that inputs an unlocking command through a special interface when the main power fails, drives the electromagnetic lock to release, and records the unlocking reason and timestamp synchronously during the unlocking process and stores them in the non-volatile memory.

[0019] Further, it also includes an AI-assisted plug-in guide module, which integrates a miniature TOF camera to capture interface alignment images; uses deep learning algorithms to identify the position and angle deviation of the socket, calculates the optimal insertion path; and through voice prompts and indicator light direction guidance, assists users to control the radial offset within 0.5mm.

[0020] Further, it also includes an arc suppression pre-judgment module, the module monitors the plug-in speed and the charging loop voltage, and triggers the arc suppression when the following conditions are detected: the plug-in speed < 0.05 m / s and the voltage > 300 V, or the unlocking action is started before the charging current is completely cut off, at this time, the module controls the pre-charge loop to be put into, limits the loop current to be <= 5 A through a soft start resistor, and delays the main loop on-off action by 50 ms.

[0021] Further, it also includes a modular function expansion platform, which supports expanding function modules on demand; the expansion platform contains standard slots, and accesses: an ultrasonic cleaning module for interface stain cleaning, a wireless charging coupler for supporting non-physical contact charging, and an infrared thermal imaging module for realizing interface global temperature distribution monitoring; the expansion module supports hot plugging, that is, plug and play without system restart.

[0022] Further, it also includes a full life cycle health management module, the module collects 128 key parameters, and establishes a health degree evaluation model: Wherein H is the health degree; is the weight coefficient of the i-th parameter; is the degradation degree of the i-th parameter; when H < 0.8, the system issues a maintenance warning; when H < 0.6, the charging power is limited to 50%; when H < 0.4, the use is prohibited and a repair instruction is triggered.

[0023] Compared with the prior art, the present application has the following advantages:

[0024] In terms of plug-in state confirmation accuracy, the present application realizes a leap from "single parameter judgment" to "multi-dimensional global verification". The state sensing module uses a multi-type sensor array of laser displacement, distributed pressure, optical fiber temperature, high-frequency impedance, etc., to synchronously collect key parameters such as insertion depth, radial offset, pressure field distribution, contact resistance, temperature, etc., in combination with a dynamic threshold generator and a fuzzy neural network decision algorithm, which can automatically adapt the judgment standard according to the interface type, accurately identify subtle problems such as slight misalignment and local poor contact, etc. The multi-dimensional plug-in verification and pressure field uniformity correction function further optimizes the confirmation logic, effectively avoids misjudgment caused by single sensor interference, ensures that charging is started only when the interface is fully attached and in good contact, and fundamentally reduces the risk of local overheating and arc burning, etc.

[0025] The reliability and adaptability of the locking protection are essentially enhanced. The multi-stage locking mechanism of the locking protection module forms an irreversible locking through the linkage of the electromagnetic lock tongue and the mechanical pawl, and cooperates with the adaptive execution unit to dynamically adjust the locking force according to the pressure field distribution, which can not only avoid the deformation of the new interface due to excessive locking, but also ensure the stable locking of the aging interface. The predictive wear compensation module predicts the wear of the locking mechanism based on historical data and realizes dynamic compensation through parameter correction, significantly prolonging the service life of mechanical components. The emergency forced unlocking module provides mechanical and electronic dual unlocking paths in extreme cases, taking into account the locking reliability and emergency operation convenience, solving the industry pain points of "poor adaptability and easy failure" in traditional fixed locking force design.

[0026] The environmental adaptation and safety protection capability are greatly improved, which can calmly cope with complex application scenarios. The environmental adaptation module monitors multiple parameters such as temperature, humidity, dust, and corrosive gas, and combines with active adjustment functions such as heating, condensation prevention, and dust sealing to ensure the normal operation of the system in the humid and dusty environment of underground charging piles and low temperature climate. The multi-physical field interference suppression module reduces the influence of strong electromagnetic environment on sensing and communication through electromagnetic shielding and adaptive filtering, ensuring the stability of data acquisition and command transmission. The arc suppression prediction module intervenes in advance during the plugging process, and effectively prevents the generation of arc through the pre-charge circuit and delay on-off control, further improving the operation safety.

[0027] The intelligent level and operation convenience are significantly optimized, reducing the operation cost. The AI-assisted plugging guide module assists users in accurately connecting the interface through visual recognition and voice guidance, especially improving the success rate and efficiency of novice operation. The full life cycle health management module monitors parameters such as sensor accuracy, motor torque, and circuit temperature drift, and realizes early warning of faults through health degree evaluation, avoiding downtime losses caused by passive maintenance. The modular function expansion platform supports the access of functions such as ultrasonic cleaning and wireless charging as needed, adapts to the individual needs of different scenarios, and enhances the expandability and reusability of the system.

[0028] Overall, the present application constructs a comprehensive charging interface safety protection system through the coordinated innovation of precise perception, intelligent confirmation, reliable locking, environmental adaptation, and full life cycle management, significantly improves the safety and stability of the charging pile operation, reduces the maintenance cost, and provides key technical support for the large-scale and high-quality operation of new energy vehicle charging facilities. BRIEF DESCRIPTION OF DRAWINGS

[0029] Figure 1 The schematic diagram of the charging interface plugging state confirmation and locking protection system based on state self-perception proposed by the present application is shown in the figure.

[0030] Figure 2For the key performance comparison group column chart of the traditional and the charging interface protection system of the application;

[0031] Figure 3 For the comparison line chart of system failure downtime frequency under different environments;

[0032] Figure 4 For the comparison line chart of system failure downtime frequency under different environments. DETAILED DESCRIPTION

[0033] The technical solutions in the embodiments of the application will be clearly and completely described below with reference to the drawings in the embodiments of the application. Obviously, the described embodiments are only part of the embodiments of the application, rather than all the embodiments of the application. Based on the embodiments in the application, all other embodiments obtained by a person of ordinary skill in the art without creative labor fall within the protection scope of the application.

[0034] In the description of the application, it should be understood that the orientations or positional relationships indicated by the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise" and the like are based on the orientations or positional relationships shown in the drawings, and are only for the purpose of facilitating the description of the application and simplifying the description, and do not indicate or imply that the devices or elements indicated must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as limiting the application.

[0035] In addition, the terms "first" and "second" are only for descriptive purposes, and cannot be understood as indicating or implying relative importance or implicitly indicating the number of the indicated technical features. Therefore, the features defined as "first" and "second" can explicitly or implicitly include one or more of the features. In the description of the application, the meaning of "multiple" is two or more, unless otherwise specifically limited. In addition, the terms "mounting", "connecting", "connection" should be broadly understood, for example, it can be fixed connection, or detachable connection, or integral connection; it can be mechanical connection, or electrical connection; it can be directly connected, or indirectly connected through an intermediate medium, or the communication between two elements. For a person of ordinary skill in the art, the specific meaning of the above terms in the application can be understood according to the specific circumstances, and the application will be further described in detail below with reference to the drawings.

[0036] Reference Figures 1 to 4 A state self-sensing based charging interface plugging state confirmation and locking protection system, comprising the following modules:

[0037] The state sensing module is composed of a multi-dimensional sensing array and a signal fusion unit, and realizes global collection of the physical state of the interface. The multi-dimensional sensing array includes: three groups of micro laser displacement sensors, which are distributed at 120° at the head of the charging gun, with a measurement range of 0-50 mm, an accuracy of ±0.05 mm, a sampling frequency of 200 Hz, and synchronous monitoring of the axial insertion depth and radial offset of the plug and the socket; 8-point distributed pressure sensors embedded in the annular groove of the mating surface, with a single sensor range of 0-30 N, a resolution of 0.05 N, and a sampling frequency of 150 Hz, forming a pressure field distribution map; a fiber optic grating temperature sensor with three detection points along the pin axis, with a temperature measurement range of -40°C to 150°C, an accuracy of ±0.3°C, and a response time of ≤50 ms; a high-frequency impedance detection unit using a 1 kHz test signal with a sampling interval of 20 ms, a measurement range of 0-50 mΩ, and an accuracy of ±0.5 mΩ. The signal fusion unit uses an FPGA chip to perform time and space registration and noise suppression on the sensor data, and outputs the fused state vector with a data update rate of 100 Hz.

[0038] The plug-in confirmation module includes a dynamic threshold generator and a multi-modal decision maker, and realizes intelligent determination of the plug-in state. The dynamic threshold generator has 15 built-in interface parameter models of mainstream vehicle types, and automatically generates adaptive thresholds according to the interface type identified by the laser displacement sensor: the axial insertion depth threshold is 90%-110% of the rated depth of the interface, the radial offset is ≤1.5 mm, the pressure field uniformity is ≥85%, the contact impedance is ≤3 mΩ, and the initial temperature is ≤35°C. The multi-modal decision maker uses a fuzzy neural network algorithm to extract features from the fused state vector, and outputs a "plug-in qualified" signal when the following conditions are met for 5 consecutive sampling periods: the depth is within the threshold interval, the pressure field standard deviation is ≤2 N, the impedance is stable and the temperature does not mutate, the delay of determination is ≤30 ms, and the misjudgment rate is ≤0.1%.

[0039] The locking protection module is composed of a multi-stage locking mechanism and an adaptive execution unit, and realizes reliable locking and safety protection. The multi-stage locking mechanism includes: a first electromagnetic lock tongue with a stroke of 8 mm, a driving voltage of 12 V, a locking force of 30 N, and a response time of ≤100 ms; a second mechanical pawl linked with the lock tongue to form an irreversible locking, which requires electromagnetic release and mechanical linkage double action for unlocking; the locking state monitoring uses a Hall sensor array with a positioning accuracy of ±0.1 mm to real-time feedback the position of the lock tongue. The adaptive execution unit adjusts the locking force according to the pressure field distribution, controls the electromagnetic lock current through a PWM signal, realizes continuous adjustment of the locking force from 0 to 50 N, and ensures that the interface with different degrees of wear can be stably locked.

[0040] The control center module adopts a heterogeneous computing architecture, integrates an ARM Cortex-A76 processor and a neural network acceleration unit, has a main frequency of 2.2 GHz and a memory of 1 GB, and runs a real-time operating system. A state transition engine is built-in, seven states of "initial, alignment, insertion, locking, charging, unlocking and reset" and transition rules are defined, and the state transition trigger condition is combined with the plug-in confirmation signal, locking feedback and charging parameters. The control center module is connected with each functional module through a high-speed bus, and the output control signal response time is less than or equal to 5 ms, and the module has a fault injection detection function, can simulate 20 typical faults and trigger corresponding protection mechanisms.

[0041] The communication interaction module supports multi-protocol converged communication, includes an industrial Ethernet interface, a 5G dual-mode communication unit and a near field communication module (NFC). The industrial Ethernet interface has a rate of 1000 Mbps, communicates with the charging pile main system by using a PROFINET protocol, the 5G dual-mode communication unit supports Sub-6GHz+millimeter wave and has an uplink rate of greater than or equal to 200 Mbps, can be directly connected with an edge computing node, and the near field communication module has a communication distance of 0-10 cm and is used for local parameter configuration. Communication data is encrypted by using an end-to-end encryption algorithm SM4, and the key is dynamically updated every hour, so that the transmission safety of state data and control instructions is ensured.

[0042] The environment adaptation module integrates a multi-parameter environment monitoring and active adjustment unit, and is suitable for complex application scenarios. The environment monitoring includes a temperature and humidity sensor, a dust concentration sensor and a corrosive gas sensor, wherein the temperature and humidity sensor has a measurement range of -40℃ to 85℃ and a relative humidity of 0-100%RH, the dust concentration sensor has a measurement range of 0-10 mg / m³, and the corrosive gas sensor can detect SO2 and H2S. The active adjustment unit includes a micro heating sheet, an anti-condensation fan and a dustproof sealing ring, the micro heating sheet has a power of 50 W and a temperature control accuracy of ±2℃, the anti-condensation fan has a wind volume of 50 L / min, the dustproof sealing ring is made of oil-resistant rubber material and has a Shore hardness of 60A; when the environment parameters exceed the threshold value, the adjustment is automatically started, so that the system can normally work in an environment of -30℃ to 60℃.

[0043] The man-machine interaction module adopts a multi-modal interaction mode, includes a 2.4-inch OLED display screen, a capacitive touch key, a voice prompt unit and a three-color ring indicator. The 2.4-inch OLED display screen has a resolution of 320x240, can display parameters such as plug-in state, locking force and temperature; the capacitive touch key supports single-point touch and sliding operation; the voice prompt unit is equipped with a TTS chip, has a volume range of 60-100 dB, and can broadcast plug-in steps and fault information; the three-color ring indicator has three colors of red, yellow and green, different states are distinguished by flashing frequency, and constant light indicates normal, 1 Hz flashing indicates abnormal, and 2 Hz flashing indicates waiting.

[0044] In the present application, a pressure field uniformity correction module is also included, which is linked with the state sensing module and the locking protection module, and optimizes the contact pressure field by adjusting the force point distribution of the locking mechanism. The uniformity correction adopts Wherein U is the pressure field non-uniformity, unit ; is the detection value of the i th pressure sensor, unit N; is the average value of all sensor detection values, unit N; n is the number of sensors, which is 8. When , the module controls the three fine adjustment motors of the locking mechanism to act respectively, and each motor can independently adjust the locking force of the corresponding area until to ensure that the pressure distribution on the interface contact surface is uniform, and to reduce the risk of local overheating.

[0045] In the present application, a dynamic impedance-temperature coupling monitoring module is also included, which is connected with the state sensing module and the control hub module, and analyzes the thermal-electric coupling characteristics of the contact state in real time. The coupling coefficient is calculated as Wherein C is the coupling coefficient, unit ; is the contact resistance change, unit , is the temperature change, unit ; I is the charging current, unit A. When , it is determined that the interface contact has a deterioration trend, and the module outputs a warning signal to the control hub, and the control hub gradually reduces the charging current, while recording the coupling coefficient change curve to provide data support for subsequent maintenance.

[0046] In the present application, a predictive locking wear compensation module is also included, which is connected with the locking protection module and the control hub module, and predicts the locking mechanism wear amount through historical data modeling and dynamically compensates. The module has a built-in wear model, which calculates the wear amount based on the cumulative locking times, the average locking force and the environmental temperature: after each locking, the driving parameters of the next locking are corrected according to the difference between the current locking force and the preset standard locking force; when the cumulative wear amount prediction value exceeds 0.5mm, the locking bolt extension length is automatically increased by 0.1mm, and the maintenance is prompted through the man-machine interaction module. The module can prolong the service life of the locking mechanism and reduce the locking failure caused by mechanical wear.

[0047] In the application, a multi-physical field interference suppression module is also included, which is integrated with the state sensing module and the communication interaction module to eliminate the interference of complex electromagnetic environment on sensing and communication. The module includes: an electromagnetic shield cover (using 0.3mm thick permalloy, shielding effectiveness ≥80dB) covering the sensor and the communication circuit; an adaptive filter automatically adjusting the filtering parameters according to the detected electromagnetic interference frequency (10kHz-1GHz); a common mode interference suppression circuit reducing the ground loop interference to below 5mV. In a strong electromagnetic interference environment such as an underground charging pile, the sensor measurement error can be ensured to be ≤2%, and the communication packet loss rate is ≤0.01%.

[0048] In the application, an emergency forced unlocking module is also included, which is connected with the locking protection module and the control hub module to realize mechanical and electronic double forced unlocking in extreme cases. The module includes a mechanical emergency pull rod and an electronic emergency driving unit. The mechanical emergency pull rod is made of 304 stainless steel with a tensile strength ≥500MPa, is connected to a secondary pawl mechanism, and can trigger unlocking by manual pulling force ≥50N. The electronic emergency driving unit is equipped with a 12V backup battery independent of the main power supply, which can input an unlocking command through a special interface when the main power supply fails, drive the electromagnetic lock to release, and the response time is ≤500ms. During the unlocking process, the module synchronously records the unlocking reason and timestamp and stores them in the non-volatile memory, ensuring that the operation is traceable.

[0049] In the application, an AI assisted plug-in guide module is also included, which is connected with the state sensing module and the human-computer interaction module to guide the user to accurately plug in through visual and sensing data. The module integrates a miniature TOF camera with a field of view angle of 90° and a ranging accuracy of ±2mm, which can collect interface alignment images. The module uses a deep learning algorithm to identify the position and angle deviation of the socket, and calculates the optimal insertion path. Through voice prompts (such as "adjust 3° to the left") and indicator light direction guidance, the user can control the radial offset within 0.5mm. For novice users, the plug-in success rate can be improved to more than 98%, and the average plug-in time can be shortened by 40%.

[0050] In the application, an arc suppression pre-judgment module is also included, which is linked with the control hub module and the plug-in confirmation module to prevent arc generation in advance during the plug-in process. The module monitors the plug-in speed (calculated by a laser displacement sensor, accuracy ±0.1m / s) and the charging circuit voltage, and triggers arc suppression when the following conditions are detected: plug-in speed <0.05m / s and voltage >300V, or unlocking action starts before the charging current is completely cut off. At this time, the module controls the pre-charging circuit to be put into operation, limits the circuit current to ≤5A through a soft start resistor, and delays the main circuit on-off action by 50ms, which can reduce the probability of arc generation to below 0.05%.

[0051] In the application, a modular function expansion platform is also included, which is connected with the control hub through a high-speed backplane bus, supports on-demand expansion of function modules. The expansion platform contains standard slots (compatible with PCIe3.0 protocol), which can access ultrasonic cleaning modules, wireless charging couplers and infrared thermal imaging modules. The ultrasonic cleaning module has a working frequency of 40 kHz and a cleaning time of 1-5 seconds, which can be adjusted, and is used for interface stain cleaning; the wireless charging coupler has a transmission power of 3.3 kW and an efficiency of ≥90%, supporting physical contact-free charging; the infrared thermal imaging module has a resolution of 160x120 and a temperature measurement range of-20℃ to 200℃, realizing global temperature distribution monitoring of the interface. The expansion module supports hot plugging, plug and play without system restart, and adapts to the functional needs of different scenes.

[0052] In the application, a full life cycle health management module is also included, which is connected with all function modules, realizing full-dimensional monitoring and life prediction of system state. The module collects 128 key parameters (including sensor accuracy drift, motor output torque attenuation, circuit element temperature drift, etc.), establishes a health degree evaluation model: wherein H is the health degree, taking a value of 0-1; is the weight coefficient of the i-th parameter (assigned according to importance 0.01-0.1); is the degradation degree of the i-th parameter (taking a value of 0-1, calculated based on historical data and threshold). When H<0.8, the system issues a maintenance warning; when H<0.6, the charging power is limited to 50%; when H<0.4, the use is prohibited and a repair instruction is triggered. The module can realize early fault warning, and prolong the average fault-free working time of the system by more than 60%.

[0053] The specific implementation of the system is further illustrated by two embodiments as follows:

[0054] Embodiment 1: Ground large-scale AC fast charging station special system (application scene of a charging station in a certain commercial district in Beijing)

[0055] This embodiment is aimed at the demand of a 120kW AC fast charging station on the ground in a certain commercial district in Beijing. The station serves 80 vehicles per day, adapts to 13 mainstream new energy vehicle models, and the original system causes 3 monthly interface overheating faults and 2 locking failures due to misjudgment of plug-in. The application scheme is used to realize precise protection, and the specific implementation process is as follows.

[0056] 1. System module selection and integration debugging

[0057] The state perception module selects three groups of Keyence LK-G5000 miniature laser displacement sensors, which are distributed at 120° on the head of the charging gun, with a measurement range of 0-50 mm and an accuracy of ±0.05 mm. The 8-point TE Connectivity distributed pressure sensor is embedded in the docking surface, with a single range of 0-30 N. The fiber Bragg temperature sensor is implanted along the pin, with a temperature measurement range of -40°C to 150°C. The high-frequency impedance detection unit uses a 1 kHz test signal with a sampling interval of 20 ms. The signal fusion unit uses Xilinx Artix-7 FPGA to complete data space registration with an update rate of 100 Hz.

[0058] The dynamic threshold generator of the plug-in confirmation module has built-in parameters for 15 types of vehicles. The multi-modal decision maker uses a fuzzy neural network algorithm, and the training samples contain 2000 plug-in data with a misjudgment rate of 0.08%. The primary electromagnetic lock of the lock protection module is a 12V DC type with a stroke of 8mm. The secondary mechanical pawl is made of 304 stainless steel, and the Hall sensor array has a positioning accuracy of ±0.1mm. The adaptive execution unit controls the PWM signal through STM32F407 to achieve a lock force of 0-50N adjustable.

[0059] The control center module uses NXP i.MX8MPlus processor (ARM Cortex-A76) with a main frequency of 2.2GHz and 1GB of memory, running VxWorks real-time system. The state transfer engine defines 7 states with a response time of ≤5ms. The communication interaction module integrates gigabit Ethernet, Huawei MH50005G module and NFC near field communication, with SM4 encryption algorithm and key update every hour.

[0060] The environmental adaptation module selects Sensirion SHT31 temperature and humidity sensor and Sharp GP2Y1010AU0F dust sensor. The active adjustment unit contains a 50W miniature heating sheet and a 50L / min anti-condensation fan. The human-machine interaction module is equipped with a 2.4-inch OLED screen, capacitive touch buttons and a Kedao Xunfei TTS voice chip, with three-color indicator lights to distinguish the state.

[0061] 2. Core function test and formula application

[0062] Pressure field uniformity correction test: When plugging into the interface of a certain vehicle, the 8-point pressure values are 22N, 21N, 18N, 23N, 20N, 17N, 24N and 21N, respectively. Calculate , according to U=(1.56+0.06+7.56+5.06+0.56+14.06+10.56+0.06) / 8≈5.18N²>5N². The module control 3 micro-adjustment motors, and the adjusted pressure values are all in the range of 19-22N, U=2.8N²≤3N², and the correction is completed.

[0063] Dynamic impedance-temperature coupling monitoring: initial resistance 2.1 mΩ, temperature 32℃, resistance 2.7 mΩ, temperature 40℃ after running for 30 minutes, ΔR=0.6 mΩ, ΔT=8℃, according to

[0064] Full life cycle health management: collect 128 parameters, weight coefficient is assigned according to importance (such as motor torque attenuation weight 0.1, sensor drift weight 0.05), after a device runs for 6 months, According to Normal state; after running for 12 months H=0.78, triggering maintenance warning.

[0065] AI-assisted plug-in guidance: integrate STMicroelectronics VL53L5CX TOF camera, field of view angle 90°, recognize plug position deviation 3.2°, voice prompt "adjust 3° to the left", indicator light synchronous guidance, user adjustment radial deviation 0.4mm, plug-in success.

[0066] 3. Full-process operation verification

[0067] Plug-in process: user holds gun and aims, TOF camera recognizes deviation and guides; laser sensor measures depth 18mm (rated depth 20mm, 90% threshold) during insertion, pressure field U=2.8N², impedance 2.1mΩ, temperature 32℃, continuous 5 cycles meet the conditions, output "plug-in qualified"; locking mechanism acts, locking tongue extends 8mm, locking force 35N, Hall sensor feedback in place, indicator light always on, voice prompt "locking complete"; control hub starts charging, dynamically monitors impedance and temperature.

[0068] Charging: coupling coefficient C stabilizes in a safe range, arc suppression module monitors speed 0.1m / s, voltage 220V, no arc risk. Charging complete: receive stop command, cut off current, electromagnetic lock releases, mechanical ratchet linkage unlocks, gun body pulls out, system resets to initial state, total time about 45 minutes.

[0069] 4. Operation effect data representation

[0070]

[0071] The data in Table 1 is from 6-month operation statistics. Due to single parameter judgment and fixed locking force design, the traditional system has an accurate rate of only 82% for multi-vehicle type adaptation, an error rate of 3.5%, and frequent interface overheating and locking failure, resulting in short maintenance intervals. The present application has an adaptation accuracy of 99.5% and an error rate of 0.08% through multi-dimensional sensing array and dynamic threshold generation; pressure field correction and coupling monitoring avoid local overheating, adaptive locking and wear compensation achieve 6-month locking failure-free; and full life cycle management extends the maintenance interval, completely solves the pain points of the traditional system such as poor adaptation, easy misjudgment and frequent failures, and meets the high-frequency use requirements of commercial circle fast charging stations.

[0072] Example 2: System in a humid and dusty environment of an underground parking lot (application scenario of an underground charging pile in a community in Shanghai)

[0073] This example is a 7kW AC charging pile project in an underground parking lot of a community in Shanghai. The environmental humidity is often as high as 85%RH, the dust concentration is 0.8mg / m³, the minimum temperature in winter is-8℃, and 8 types of household vehicles of residents need to be adapted. The specific implementation process is as follows.

[0074] 1. High environmental adaptability system construction

[0075] The sensors of the state perception module are all equipped with waterproof and dustproof housings (IP67), and the laser displacement sensor is provided with a lens blowing function; the pressure sensor adopts a moisture-resistant package, and the impedance detection unit optimizes the grounding design. The plug-in confirmation module supplements the humidity environment threshold correction, the radial offset threshold is widened to 1.8mm, and the pressure field uniformity is ≥80%.

[0076] The electromagnetic lock of the locking protection module is waterproof, and the lock tongue is coated with a Teflon coating for corrosion protection; the secondary pawl is provided with a lubricating grease filling port, and the grease is automatically supplemented every 3 months. The predictive wear compensation module inputs the underground environment wear coefficient, and automatically increases the lock tongue extension amount by 0.05mm after 500 times of locking.

[0077] The control center module is equipped with moisture-proof cooling fins, the Ethernet interface of the communication interaction module adopts a shielded crystal head, and the 5G antenna is externally enhanced. The environmental adaptation module adds a corrosive gas sensor, and the active adjustment unit is provided with an interface blowing device (air volume 30L / min), and the heating sheet power is increased to 60W.

[0078] The multi-physical field interference suppression module adopts a 0.3mm permalloy shield cover to cover the sensing and communication circuit; the adaptive filter is tuned to 10kHz-1GHz, and the common mode interference suppression circuit reduces the interference to 4.2mV. The mechanical pull rod of the emergency forced unlocking module is made of 304 stainless steel with a tensile strength of 520MPa; the electronic emergency unit is provided with a 12V lithium battery with a continuous running time of ≥72 hours.

[0079] 2. Core function and formula landing test

[0080] Low temperature environment adaptation: actual temperature -8℃, P=K t ×P0, K t =1+0.02×(25-(-8))=1.66, P=1.66×50=83W, heating sheet works at 83W power, 5 minutes later the temperature of the locking tongue area rises to 5℃, and the extension is normal.

[0081] Waterproof and dustproof monitoring: when the humidity is 86%RH and the dust concentration is 0.6mg / m³, the system delays locking, starts the purging device for 2 seconds, and the parameters decrease to 82%RH and 0.3mg / m³, and the locking is started. Dynamic impedance-temperature coupling: charging current 7A, after 1 hour of operation, ΔR=0.4mΩ, ΔT=6℃, C=0.4 / (6×49)≈0.00136mΩ / (℃・A²), normal state.

[0082] Fault self-diagnosis: simulate sensor disconnection, system detects fault within 1 second, acousto-optic alarm and upload fault code, maintain current locking state; simulate motor locked-rotor, immediately cut off the driving power supply to avoid burning. Modular extension accesses ultrasonic cleaning module, working frequency 40kHz, cleaning time 3 seconds, contact resistance decreases after removing interface stains.

[0083] 3. Full-process environmental adaptation verification

[0084] Low temperature insertion: environment -8℃, heating sheet starts, locking tongue extension is normal, TOF camera guides insertion, radial offset 0.5mm; pressure field U=3N², impedance 2.3mΩ, temperature 30℃, determine qualified and lock, locking force 32N.

[0085] High humidity and dust: humidity 85%RH, start locking after purging; charging coupling monitoring is normal, interference suppression module makes sensor error 1.8%, communication packet loss rate 0.008%. Emergency unlocking: simulate main power failure, electronic emergency unit responds 450ms to unlock; mechanical pull rod triggers unlocking with a pulling force of 55N, records unlocking time and reason.

[0086] Reset process: after charging is completed, the push plate is unhooked, the locking mechanism is reset, the purging device is started again, and the system is homed, with no jam throughout the process, suitable for underground humid and dusty environments.

[0087] 4. Running effect data representation

[0088]

[0089] Table 2 Data from 3 months of multi-environment testing, the traditional system has a failure frequency of 2 times / month in a high-humidity and dusty environment, the locking success rate drops to 85% at low temperature, and the sensor and communication are severely interfered. The application has a failure frequency of ≤0.1 times / month in each environment through moisture-proof heating, blowing and cleaning, electromagnetic shielding and other designs, and the locking success rate is 100% at low temperature and normal temperature dry environment; multi-physical field interference suppression makes the sensor error ≤1.8%, and the communication packet loss rate ≤0.008%. Even in the presence of corrosive gases, it can still maintain high reliability, perfectly adapt to the complex environment of underground parking lots, and solve the pain points of traditional systems such as "poor environmental adaptability and easy to be disturbed".

[0090] Reference Figure 2 The figure intuitively presents the breakthrough advantages of the application in adaptability, reliability and operability. The traditional system has a single parameter judgment and a fixed locking force design, and the multi-vehicle type adaptation accuracy is only 82%, and the insertion misjudgment rate is as high as 3.5%, which leads to frequent interface overheating and locking failure, and the maintenance interval is only 1.5 months. The application has a multi-dimensional sensing array and dynamic threshold generation, and the adaptation accuracy is improved to 99.5%, and the misjudgment rate is reduced to 0.08%; pressure field correction and coupling monitoring avoid local overheating, and adaptive locking realizes 6 months without failure; the whole life cycle management prolongs the maintenance interval to 6 months. Data confirms the effectiveness of multi-module collaborative innovation, and completely solves the pain points of traditional systems such as "poor adaptation, easy to fail and maintenance".

[0091] Reference Figure 3 The figure clearly shows the actual value of the strong environmental adaptation ability of the application. The traditional system is sensitive to the environment, and the failure frequency in a high-humidity and dusty environment rises to 2.1 times / month, and reaches 3.2 times / month in extreme hot and humid conditions, and cannot adapt to complex scenes such as underground parking lots. The application has a failure frequency of only 0.1 times / month in a high-humidity and dusty, corrosive gas environment, and does not exceed the threshold of 0.2 times / month in extreme hot and humid conditions. This reflects the synergistic effect of the environmental adaptation module and the anti-interference design, and solves the industry pain points of traditional devices such as "poor environmental tolerance and frequent failures", and ensures stable operation in complex scenes.

[0092] Reference Figure 4 The figure intuitively presents the core value of the whole life cycle management module. The traditional system lacks degradation prediction, and the health decreases rapidly with running time, dropping to 0.55 in 12 months, below the power limit threshold, and only 0.40 in 18 months, requiring forced shutdown. The application has a health decline that is slow through the collection of 128 parameters for modeling and evaluation, and is still 0.78 in 18 months, close to the warning threshold, and gives an early warning of potential failure after 6 months. This solves the problem of traditional systems such as "sudden failure and passive maintenance", and prolongs the service life of the device through predictive maintenance, reducing operating costs.

[0093] The above merely describes preferred embodiments of the present application, but the protection scope of the present application is not limited thereto, and any person skilled in the art can make equivalent replacements or changes within the technical scope disclosed by the present application and according to the technical solutions and inventive concept of the present application, which should be covered within the protection scope of the present application.

Claims

1. A charging interface plug-in status confirmation and locking protection system based on state self-sensing, characterized in that, Includes the following modules: The state perception module consists of a multi-dimensional sensor array and a signal fusion unit. The multi-dimensional sensor array includes three sensors: laser displacement, distributed pressure, and fiber optic temperature, as well as a high-frequency impedance detection unit. The signal fusion unit uses an FPGA chip to process the sensor data and output a fused state vector. The plug-in confirmation module includes a dynamic threshold generator and a multimodal decision maker. The dynamic threshold generator has a built-in interface parameter model of mainstream vehicle models and automatically generates the adaptation threshold. The multimodal decision maker uses a fuzzy neural network algorithm to extract features from the fused state vector and outputs a plug-in qualified signal when the conditions are met for 5 consecutive sampling cycles. The locking protection module consists of a multi-stage locking mechanism and an adaptive execution unit. The multi-stage locking mechanism includes an electromagnetic latch, a mechanical pawl, and a Hall sensor array. The adaptive execution unit adjusts the locking force according to the pressure field distribution and controls the electromagnetic lock current through a PWM signal. The control center module adopts a heterogeneous computing architecture, integrating a Cortex-A76 processor and a neural network acceleration unit, running an operating system, and has a built-in state transition engine that defines seven states and transition rules: "initialization-alignment-insertion-locking-charging-unlocking-reset". The control center module is connected to various functional modules through a high-speed bus. The communication module supports multi-protocol converged communication and includes: an industrial Ethernet interface, a 5G dual-mode communication unit, and a near-field communication module; communication data is encrypted end-to-end using the SM4 encryption algorithm, and the key is dynamically updated hourly. The environmental adaptation module integrates a multi-parameter environmental monitoring and active adjustment unit. The environmental monitoring includes three sensors: temperature and humidity, dust concentration, and corrosive gas. The active adjustment unit includes a miniature heating element, an anti-condensation fan, and a dustproof sealing ring. When the environmental parameters exceed the threshold, the adjustment is automatically activated. The human-computer interaction module adopts a multimodal interaction method, including: an OLED display screen, capacitive touch buttons, a voice prompt unit, and a three-color ring indicator light, which distinguishes different states by flashing frequency; The pressure field uniformity correction module optimizes the contact pressure field by adjusting the force application point distribution of the locking mechanism. Uniformity correction employs... , where U is the non-uniformity of the pressure field; The detected value of the i-th pressure sensor; The average value is the result of all sensor readings; n is the number of sensors; when At this time, the module controls the three fine-tuning motors of the locking mechanism to operate independently, with each motor adjusting the locking force of its corresponding area until... The predictive locking wear compensation module predicts and dynamically compensates for the wear of the locking mechanism by modeling historical data. The module has a built-in wear model that calculates the wear based on the cumulative number of locking attempts, the average locking force, and the ambient temperature. After each locking, the driving parameters for the next locking are adjusted based on the difference between the current locking force and the preset standard locking force. When the predicted cumulative wear exceeds 0.5mm, the bolt extension length is automatically increased by 0.1mm, and maintenance prompts are provided through the human-machine interaction module.

2. The charging interface plug-in status confirmation and locking protection system based on state self-sensing according to claim 1, characterized in that, It also includes a dynamic impedance-temperature coupling monitoring module to analyze the thermal-electric coupling characteristics of the contact state in real time, and the coupling coefficient is calculated as follows: Where C is the coupling coefficient; This represents the change in contact resistance. I is the temperature change; I is the charging current, when If the interface contact is found to be deteriorating, the module outputs a warning signal to the control center, which then gradually reduces the charging current and records the coupling coefficient change curve.

3. The charging interface plug-in status confirmation and locking protection system based on state self-sensing according to claim 1, characterized in that, It also includes a multi-physics interference suppression module, which includes: an electromagnetic shielding cover to cover the sensor and communication circuit; an adaptive filter that automatically adjusts the filtering parameters according to the detected electromagnetic interference frequency; and a common-mode interference suppression circuit that reduces ground loop interference to below 5mV.

4. The charging interface plug-in status confirmation and locking protection system based on state self-sensing according to claim 1, characterized in that, It also includes an emergency forced unlocking module, which consists of: a mechanical emergency pull rod connected to a secondary ratchet mechanism, which triggers unlocking with a manual pull force of ≥50N; and an electronic emergency drive unit that, in the event of a main power failure, inputs an unlocking command through a dedicated interface to drive the electromagnetic lock to release. During the unlocking process, the module simultaneously records the unlocking reason and timestamp and stores them in non-volatile memory.

5. The charging interface plug-in status confirmation and locking protection system based on state self-sensing according to claim 1, characterized in that, It also includes an AI-assisted insertion guidance module, which integrates a miniature TOF camera to capture images of the interface alignment; it uses deep learning algorithms to identify the position and angle deviation of the socket and calculate the optimal insertion path; and it assists users in controlling the radial offset within 0.5mm through voice prompts and indicator light directional guidance.

6. The charging interface plug-in status confirmation and locking protection system based on state self-sensing according to claim 1, characterized in that, It also includes an arc suppression prediction module, which monitors the insertion speed and charging circuit voltage. When the following conditions are detected, arc suppression is triggered: insertion speed < 0.05m / s and voltage > 300V, or the unlocking action is started before the charging current is completely cut off. At this time, the module controls the pre-charging circuit to be put into operation, limits the circuit current to ≤ 5A through the soft start resistor, and delays the main circuit switching action by 50ms.

7. The charging interface plug-in status confirmation and locking protection system based on state self-sensing according to claim 1, characterized in that, It also includes a modular functional expansion platform that supports on-demand expansion of functional modules. The expansion platform includes standard slots for connecting: an ultrasonic cleaning module for cleaning interface stains; a wireless charging coupler for charging without physical contact; and an infrared thermal imaging module for monitoring the temperature distribution across the entire interface area. The expansion modules support hot-swapping, allowing for plug-and-play functionality without requiring a system restart.

8. The charging interface plug-in status confirmation and locking protection system based on state self-sensing according to claim 1, characterized in that, It also includes a full life-cycle health management module, which collects 128 key parameters to establish a health assessment model. Where H represents health status; Let be the weight coefficient of the i-th parameter; H represents the degradation degree of the i-th parameter; when H < 0.8, the system issues a maintenance warning; when H < 0.6, the charging power is limited to 50%; when H < 0.4, use is prohibited and a maintenance command is triggered.

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