Preassembled safety island device for charging station

Abstract

The invention relates to the technical field of charging station corollary equipment, in particular to a preassembled safety island device for a charging station, which comprises a modularized steel frame main body, an anti-skid insulating composite platform, an intelligent safety monitoring system and a self-adaptive mounting assembly. The modularized steel frame body is formed by splicing a plurality of standardized module units through connecting pieces, the supporting frame is provided with supporting angle iron and a supporting plate in a matched mode, and a charging pile mounting hole and a cable threading hole are reserved. The anti-skid insulation composite platform is laid on the top of the steel frame body and matched with the rubber buffer pad. The intelligent safety monitoring system integrates a state indication module, an electric leakage monitoring module and an anti-collision early warning module to realize multi-dimensional safety protection; the self-adaptive installation assembly completes installation and grounding through the adjustable supporting legs and the grounding connecting pieces. The device solves the problems that a traditional safety island is long in construction period, poor in adaptability and insufficient in safety protection, has the advantages of being convenient to construct, safe, reliable and high in adaptability, and can be widely applied to various charging station scenes.

Description

Technical Field

[0001] This application relates to the field of charging station supporting equipment technology, and in particular to a pre-installed safety island device for charging stations. Background Technology

[0002] With the rapid development of the new energy vehicle industry, the construction scale and coverage of charging stations continue to expand. As a core supporting facility of charging stations, the safety island's main functions are to separate charging areas, fix charging pile equipment, protect underground cable lines, and provide users with a safe charging operation space. It plays a decisive role in the operational safety and service quality of charging stations.

[0003] Currently, charging station safety islands on the market are mainly divided into two categories: one is the traditional on-site cast-in-place concrete safety island. Although this type of safety island has a certain load-bearing capacity, it has many inherent defects: First, the construction cycle is long, requiring multiple stages such as formwork, pouring, and curing. A single construction usually takes 7-15 days to complete, which cannot meet the needs of rapid construction of charging stations; Second, it has extremely poor adaptability. Once the concrete is poured, the size is fixed. If the charging station is expanded or the equipment is upgraded later, the original safety island needs to be demolished and rebuilt, which is costly and destructive; Third, it is significantly affected by the environment. In the low temperature environment of winter, the concrete solidification speed is greatly slowed down, and even frost heave and cracking problems may occur, making construction in northern regions extremely difficult in winter; Fourth, its self-weight is too large, requiring high load-bearing capacity of the installation ground, making it unsuitable for scenarios with limited load-bearing capacity, such as the renovation of old parking lots.

[0004] Another type is the simple prefabricated safety island, which mostly uses an integrated steel frame or a simple splicing structure. Although it improves the convenience of construction, it still has many technical shortcomings: the structural design is rough, the support stability is insufficient, and most of them do not have a dedicated load-bearing reinforcement structure, which is prone to deformation after long-term use; the installation adaptability is poor, and it is impossible to make fine adjustments according to the flatness of the ground, which can easily lead to tilting problems after installation; the safety protection function is limited, which can only achieve basic physical separation and lacks key safety protection mechanisms such as leakage monitoring and collision warning, and cannot cope with the electrical safety and equipment collision risks during charging; the surface protection is insufficient, and ordinary steel plates or cement boards are mostly used, which are easy to slip, have poor insulation performance, and pose a risk of electric shock; the wiring is not well organized, and no dedicated cable passage is set up, resulting in messy and disorderly wiring and high maintenance difficulty. Summary of the Invention

[0005] The present invention addresses the aforementioned problems in the prior art by providing a pre-installed safety island device for charging stations.

[0006] The objective of this invention is primarily achieved through the following approach: The prefabricated safety island device for charging stations includes: a modular steel frame body, an anti-slip and insulated composite platform, an intelligent safety monitoring system, and adaptive installation components; The modular steel frame is assembled from multiple standardized modular units through connectors. Each standardized modular unit has pre-drilled holes for charging pile installation and cable threading. The anti-slip and insulating composite platform is laid on the top of the modular steel frame body, and its upper surface is provided with anti-slip texture; The intelligent safety monitoring system includes a status indication module, a leakage current monitoring module, and an anti-collision warning module. The status indication module is electrically connected to the charging pile control unit, the leakage current monitoring module is connected in series in the charging circuit, and the anti-collision warning module is set on the outer edge of the modular steel frame body. The adaptive installation component includes adjustable support feet and grounding connectors. The adjustable support feet are located at the four corners of the bottom of the modular steel frame body, and the grounding connectors are located on one side of the adjustable support feet and connected to the charging station grounding grid.

[0007] Preferably, the modular steel frame body includes a support frame, with assembly holes on all four sides of the support frame, and support angle irons installed at the four bottom corners of the support frame. The support angle irons are L-shaped, and a fixing hole is provided on one side of the support angle irons. The adjustable support feet are L-shaped and vertically fitted to the inner side of the support angle irons. A vertical adjustment elongated hole is provided on one side of the adjustable support feet to cooperate with the fixing hole.

[0008] Preferably, two support plates are symmetrically installed on the middle of the upper surface of the support frame. The support plates are provided with the charging pile mounting holes, and the cable threading holes are formed between the support plates and the support frame, as well as between the two support frames.

[0009] Preferably, the status indication module includes a multi-color LED light strip and an audible and visual alarm. The LED light strip is arranged along the top edge of the modular steel frame body and can switch between three display modes: green light, yellow light, and red light, depending on the working status of the charging pile. The audible and visual alarm is linked with the leakage current monitoring module.

[0010] Preferably, the leakage current monitoring module includes a current transformer, a signal processor, and a power-off actuator. The current transformer detects the current difference between the live wire and the neutral wire in the charging circuit. When the difference exceeds a preset threshold, the signal processor triggers the power-off actuator to cut off the power supply circuit of the charging pile and simultaneously activates the red light display and audible and visual alarm of the status indicator module.

[0011] Preferably, the collision avoidance warning module includes an infrared distance sensor and a buzzer. The infrared distance sensor detects the distance between the vehicle and the safety island in real time. When the distance is less than a preset safety threshold, the buzzer emits a graded warning sound, with the frequency of the warning sound increasing as the distance gets closer.

[0012] Preferably, the anti-slip insulating composite platform is made of epoxy resin-based composite insulating material, and a buffer pad is provided between it and the modular steel frame body. The buffer pad is made of rubber and has a thickness of 5-10mm.

[0013] In summary, compared with the prior art, the present invention has the following beneficial technical effects: (1) The construction efficiency of this invention is greatly improved. It adopts a standardized modular unit assembly design, which eliminates the need for on-site pouring and curing. The installation time of a single standardized modular unit is ≤30 minutes, and the overall construction cycle is shortened by more than 90% compared with the traditional concrete safety island. The modular units can be flexibly combined according to the scale of the charging station to meet the installation requirements of 1-8 charging piles. Later expansion only requires adding modular units without destroying the original structure, which greatly reduces the transformation cost. (2) In this invention, the adjustable support feet achieve height fine adjustment through the adjustment elongated holes, which can be adapted to different flatness of the ground. After installation, the horizontal error of the safety island is small, which solves the problem of easy tilting of simple pre-installed safety islands. (3) The present invention constructs a triple protection system of electrical protection, physical protection and intelligent early warning. The anti-slip insulation composite platform fundamentally eliminates the risk of electric shock and slipping. The leakage current monitoring module achieves a 30mA level leakage current fast response and cuts off the power supply within 0.1s, which is 5 times faster than the response speed of traditional leakage current protectors. The anti-collision early warning module avoids vehicle collisions with equipment through graded early warning, effectively reducing equipment maintenance costs. (4) In this invention, the multi-color LED light strip realizes the visualization of the charging pile status, and the operation and maintenance personnel can quickly judge the equipment status by the light; the fault signal remote upload function supports the background system to locate the faulty equipment without having to check them one by one, and the operation and maintenance efficiency is improved by more than 60%. Attached Figure Description

[0014] Figure 1 This is a schematic diagram of a standardized module unit in this invention; Figure 2 This is another structural diagram of the standardized module unit in this invention; Figure 3 This is a schematic diagram of the system structure of the intelligent safety monitoring system in this invention.

[0015] Attached reference numerals: 1-Charging pile mounting hole; 2-Cable threading hole; 3-Adjustable support foot; 4-Grounding connector; 5-Support frame; 6-Assembly hole; 7-Support angle iron; 8-Fixing hole; 9-Adjustable elongated hole; 10-Support plate; 11-Anti-slip insulating composite platform. Detailed Implementation

[0016] The technical solution of the present invention will be further described in detail below through specific embodiments and in conjunction with the accompanying drawings. It should be understood that the implementation of the present invention is not limited to the following embodiments, and any modifications and / or alterations made to the present invention will fall within the protection scope of the present invention.

[0017] like Figure 1 , 2 As shown in Figure 3, the present invention discloses a technical solution for a pre-installed safety island device for charging stations, comprising: a modular steel frame body, an anti-slip and insulating composite platform 11, an intelligent safety monitoring system, and an adaptive installation component; The modular steel frame, serving as the load-bearing core of the device, is assembled from multiple standardized modular units via connectors, enabling flexible size combinations and rapid installation. The core of each standardized modular unit is a support frame 5, welded from Q235B high-strength steel to ensure overall structural strength. It has assembly holes 6 around its perimeter, allowing adjacent modular units to be tightly connected via bolts through these holes, with an assembly gap ≤2mm to ensure connection stability. Supporting angle irons 7 are welded to the four corners of the bottom of the support frame 5. These L-shaped angle irons fit snugly against the side walls of the support frame 5, effectively enhancing the frame's bottom resistance to deformation. A fixing hole 8 is located on one side of each supporting angle iron 7 for installing adjustable support feet 3.

[0018] Two support plates 10 are symmetrically welded or bolted to the middle of the upper surface of the support frame 5. The support plates 10 are made of 10mm thick steel plates and have multiple charging pile mounting holes 1 of different specifications adapted to different models of charging piles. The hole diameter ranges from 16-24mm to meet the bolt fixing requirements. Through cable passage holes 2 are formed between the side walls of the support plates 10 and the support frame 5, as well as at the splicing points of two adjacent support frames 5, which facilitates the neat installation of charging cables and signal lines and avoids exposed and worn lines.

[0019] The anti-slip, insulated composite platform 11 serves as an operating and protective platform, laid on top of the modular steel frame body. It is fixedly connected to the support frame 5 using countersunk bolts, preventing tripping hazards caused by exposed bolts. Its material is an epoxy resin-based composite insulation material, composed of epoxy resin, glass fiber, and flame retardant. It has an insulation resistance ≥10¹²Ω, a flame retardant rating of V0, and a high temperature resistance range of -40℃ to 80℃, making it suitable for various extreme outdoor environments. The platform's surface features a 2mm deep diamond-shaped anti-slip texture with a friction coefficient ≥0.8, effectively preventing slips in rainy or oily environments. A 5-10mm thick rubber buffer pad with a Shore hardness of 50-60 is installed between the platform and the modular steel frame body to absorb vibrations generated during charging pile operation, reducing equipment noise and structural fatigue.

[0020] The intelligent safety monitoring system integrates a status indication module, a leakage current monitoring module, and an anti-collision warning module to build a comprehensive safety protection system. The modules work together to achieve the functions of status visualization, risk warning, and rapid fault disconnection. The status indicator module includes a multi-color LED light strip and an audible and visual alarm. The LED light strip adopts a low-power surface-mount structure with a power of 12W / m and a brightness of ≥300cd / m². It is continuously arranged along the top edge of the modular steel frame and is electrically connected to the charging pile control unit via a CAN bus. It can automatically switch the display mode according to the charging pile's working status: a solid green light indicates that the equipment is ready for standby, a flashing yellow light indicates that it is charging, and a flashing red light indicates that the equipment is faulty or there is a risk of leakage. The audible and visual alarm adopts an integrated design and is installed in a prominent position on the side of the steel frame. It is linked with the leakage monitoring module and simultaneously emits an alarm sound of more than 100dB and a red flashing signal when a fault occurs. The leakage current monitoring module includes a 0.5-level precision current transformer, an ARM architecture signal processor, and a fast power-off actuator. The current transformer is connected in series in the power supply circuit of the charging pile to detect the current difference between the live wire and the neutral wire in real time. The signal processor has a preset leakage current threshold of 30mA. When the detected current difference exceeds the threshold, it triggers the power-off actuator to cut off the power supply circuit of the charging pile within 0.1s. At the same time, the fault signal is uploaded to the charging station management platform through the communication module, and the red light flashing and audible and visual alarm functions of the status indicator module are activated simultaneously. The collision avoidance warning module consists of an infrared distance sensor and a tiered buzzer. The infrared distance sensor uses TOF technology, with a detection range of 0-2m and an accuracy of ±5mm. It is evenly distributed on the outer edge of the modular steel frame body, with one sensor every 1m. The buzzer is installed next to the sensor. When the sensor detects that the distance between the vehicle and the safety island is less than 30cm (first-level warning threshold), it emits a low-frequency warning sound of 500Hz. When the distance is less than 15cm (second-level warning threshold), it automatically switches to a high-frequency warning sound of 1000Hz. The closer the distance, the shorter the interval between warning sounds, thus realizing tiered warning reminders.

[0021] The adaptive installation component includes adjustable support feet 3 and grounding connector 4, solving installation adaptability issues under different ground conditions. The adjustable support feet 3 are L-shaped and made of stainless steel. Their upper part fits snugly against the inner side of the support angle iron 7. One side has a vertical adjustment hole 9 that mates with the fixing hole 8. The adjustment hole 9 is 50mm long. A bolt passes through the fixing hole 8 and the adjustment hole 9 to fix the position. Loosening the bolt allows the support foot height to be adjusted up and down along the hole, with an adjustment range of 0-50mm, suitable for installation scenarios with ground flatness errors ≤5mm. The bottom of the horizontal section of the support foot has an anti-slip pad to increase friction with the ground. The grounding connector 4 uses a copper busbar with a cross-sectional area ≥25mm². One end is welded to the adjustable support feet 3, and the other end is connected to the charging station's grounding grid via a grounding wire, ensuring a grounding resistance ≤4Ω and forming reliable grounding protection.

[0022] This embodiment provides a pre-installed safety island device that can be adapted to two charging piles. The specific structural parameters are as follows: Modular steel frame main structure: It is assembled from two standardized modular units. The dimensions of a single modular unit are 1.2m×0.8m×0.5m (length×width×height). The support frame 5 is welded with 8mm thick Q235B steel plate; the support angle iron 7 is 50×50×5mm L-shaped angle steel, welded to the four corners of the bottom of the frame; the support plate 10 is 10mm thick steel plate with dimensions of 0.6m×0.2m, and has four 20mm diameter charging pile installation holes 1 on it. The spacing between adjacent support plates 10 is 0.4m; the assembly holes 6 on the side of the modular unit are 16mm diameter threaded holes, and adjacent modules are connected and fixed by M16 bolts. Anti-slip and insulated composite platform: The overall dimensions are 2.4m×0.8m×0.015m. It is made of epoxy resin and glass fiber composite. The surface has a diamond anti-slip texture with a depth of 2mm. The insulation resistance test value is 1.5×10¹²Ω and the flame retardant rating is V0. An 8mm thick natural rubber cushioning pad is laid between the platform and the steel frame. The cushioning pad is fixed to the steel frame with glue. The platform is connected to the support frame 5 with M8 countersunk bolts. The top of the bolts is flush with the platform surface. Intelligent safety monitoring system: Status indicator module: LED light strip with a total length of 6.4m (arranged around the top edge of the safety island), power of 12W / m, connected to the charging pile BMS system via CAN bus; audible and visual alarm model is LTE-1101J, alarm volume is 110dB, installed in the center of the front of the safety island; Leakage monitoring module: The current transformer is model BH-0.66 / 50, with an accuracy of 0.5 class and a leakage threshold set to 30mA; the signal processor uses an STM32F103 chip, the power-off actuator is a 100A AC contactor, and the response time is 0.08s; the fault signal is uploaded to the charging station cloud management platform via a 4G module. Collision avoidance warning module: The infrared distance sensor model is VL53L0X, with a total of 4 sensors installed at the midpoints of the four outer edges of the safety island, front, back, left, and right; the buzzer model is HXD-BZ-12V, with a 500Hz alarm sound at 1s interval for the first-level warning (30-15cm) and a 1000Hz alarm sound at 0.2s interval for the second-level warning (<15cm). Adaptive installation components: The adjustable support foot 3 is a stainless steel L-shaped piece with a 50mm long adjustment hole 9 on one side, which is connected to the fixing hole 8 of the support angle iron 7 by M12 bolts. The bottom of the support foot is equipped with a 5mm thick rubber anti-slip pad; the grounding connector 4 is a 25mm² copper busbar, one end of which is welded to the support foot, and the other end is connected to the charging station grounding grid through a 16mm² grounding wire. The grounding resistance test value is 3.2Ω.

[0023] The device in this embodiment was tested and found to have the following characteristics: the overall construction time was 2 hours, which is 95% shorter than that of traditional concrete safety islands; in the load-bearing test, the platform uniformly carried a 10t weight without deformation; in the leakage test, when simulating a 30mA leakage current, the power-off actuator responded in 0.08s, and the audible and visual alarm was activated simultaneously; in the collision avoidance test, when a vehicle approached at a speed of 5km / h, a low-frequency warning was issued at a distance of 30cm, and a high-frequency warning was issued at a distance of 15cm, with timely and effective warnings.

[0024] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. A pre-installed safety island device for charging stations, characterized in that: include: Modular steel frame main body, anti-slip and insulated composite platform (11), intelligent safety monitoring system and adaptive installation components; The modular steel frame is assembled from multiple standardized modular units through connectors. Each standardized modular unit has a pre-drilled charging pile installation hole (1) and a cable threading hole (2) on its surface. The anti-slip insulating composite platform (11) is laid on the top of the modular steel frame body, and its upper surface is provided with anti-slip texture; The intelligent safety monitoring system includes a status indication module, a leakage current monitoring module, and an anti-collision warning module. The status indication module is electrically connected to the charging pile control unit, the leakage current monitoring module is connected in series in the charging circuit, and the anti-collision warning module is set on the outer edge of the modular steel frame body. The adaptive installation component includes adjustable support feet (3) and grounding connectors (4). The adjustable support feet (3) are located at the four corners of the bottom of the modular steel frame body, and the grounding connectors (4) are located on one side of the adjustable support feet (3) and connected to the charging station grounding network.

2. The pre-installed safety island device for charging stations according to claim 1, characterized in that: The modular steel frame body includes a support frame (5), and the support frame (5) has assembly holes (6) on all four sides. Support angle irons (7) are installed at the four corners of the bottom of the support frame (5). The support angle irons (7) are L-shaped and have fixing holes (8) on one side. The adjustable support feet (3) are L-shaped and are vertically fitted to the inside of the support angle irons (7). The adjustable support feet (3) have vertical adjustment holes (9) on one side that cooperate with the fixing holes (8).

3. The pre-installed safety island device for charging stations according to claim 2, characterized in that: Two support plates (10) are symmetrically installed on the middle of the upper surface of the support frame (5). The support plate (10) has the charging pile installation hole (1), and the cable threading hole (2) is formed between the support plate (10) and the support frame (5) and between the two support frames (5).

4. The pre-installed safety island device for charging stations according to claim 1, characterized in that: The status indication module includes a multi-color LED light strip and an audible and visual alarm. The LED light strip is arranged along the top edge of the modular steel frame body and can switch between three display modes: green, yellow, and red, depending on the working status of the charging pile. The audible and visual alarm is linked with the leakage monitoring module.

5. The pre-installed safety island device for charging stations according to claim 1, characterized in that: The leakage current monitoring module includes a current transformer, a signal processor, and a power-off actuator. The current transformer detects the current difference between the live wire and the neutral wire in the charging circuit. When the difference exceeds a preset threshold, the signal processor triggers the power-off actuator to cut off the power supply circuit of the charging pile and simultaneously activates the red light display and audible and visual alarm of the status indicator module.

6. The pre-installed safety island device for charging stations according to claim 1, characterized in that: The collision avoidance warning module includes an infrared distance sensor and a buzzer. The infrared distance sensor detects the distance between the vehicle and the safety island in real time. When the distance is less than a preset safety threshold, the buzzer emits a graded warning sound, with the frequency of the warning sound increasing as the distance gets closer.

7. The pre-installed safety island device for charging stations according to claim 1, characterized in that: The anti-slip insulating composite platform (11) is made of epoxy resin-based composite insulating material and has a buffer pad between it and the modular steel frame body. The buffer pad is made of rubber and has a thickness of 5-10mm.

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