Modular high voltage distribution box and control method thereof

Abstract

The application discloses a modular high-voltage distribution box and a control method thereof, and relates to the technical field of container-type energy storage systems.The application comprises the following steps: power-on initialization is performed; a control unit identifies all connected charge-discharge circuit modules through a detection unit, and assigns a number to each charge-discharge circuit module; the running state of the charge-discharge circuit module is monitored based on the detection unit; when it is monitored that the charge-discharge circuit module is in a fault state, the charge-discharge circuit module in the fault state is recorded as a fault module, and the control unit controls a relay inside the fault module to be disconnected; in the state that other normal modules continue to run, the fault module is replaced through hot plugging based on the fault information.The application can replace the charge-discharge circuit module without replacing the main body when a high-voltage distribution box fails by monitoring the independently pluggable charge-discharge circuit module and the multi-interface substrate.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of container energy storage systems, in particular to a modular high-voltage distribution box and a control method thereof. BACKGROUND

[0002] In the field of energy storage system and equipment energy saving, such as elevator energy recovery system, the high-voltage distribution box (high-voltage box) as the core power distribution and management unit connecting the energy storage battery and the load directly affects the efficiency, reliability and maintainability of the whole system.

[0003] There are existing solutions using modular ideas in the prior art. For example, Chinese patent document CN220984701U discloses a modular and combined energy storage system, which mechanically splices multiple independent battery cabinets through bolts, and each battery cabinet is fixedly installed with a battery module and a high-voltage box; when it is necessary to expand the system power or capacity, the complete battery cabinet containing the high-voltage box is added to realize it, and this solution realizes the modularization and capacity expansion of the system level, that is, the system scale is adjusted by increasing or decreasing the standardized cabinet.

[0004] However, the above prior art still has the following limitations: its "modularization" is limited to the cabinet level, and the high-voltage box in each cabinet is still a fixed structure. The number, layout and device configuration of the charge and discharge circuits inside the high-voltage box are fixed at the factory, and cannot be flexibly adjusted according to the actual application scenario. When the same energy storage system needs to access different numbers or power levels of loads, different specifications of high-voltage boxes still need to be customized. In addition, when a certain circuit or device inside the high-voltage box fails, the entire high-voltage box still needs to be shut down for maintenance, and the maintenance process is complex, time-consuming and affects the continuous operation of the system. At the same time, the internal space of the high-voltage box is limited, which restricts the expansion of its monitoring and control functions. SUMMARY

[0005] The main purpose of the present application is to provide a modular high-voltage distribution box and a control method thereof, which aims to solve the problems of fixed and unchangeable charge and discharge circuits inside the high-voltage box, whole machine shutdown for maintenance, and limited control scale due to the physical space of the cabinet.

[0006] To achieve the above purpose, the present application provides a control method of a modular high-voltage distribution box, which comprises the following steps:

[0007] S10, power-on initialization is performed, and the connected charge and discharge circuit module is identified by a detection unit;

[0008] S20, the running state of the charge and discharge circuit module is monitored based on the detection unit;

[0009] S30, when the charging and discharging circuit module is monitored to be in a fault state, the charging and discharging circuit module in the fault state is recorded as a fault module, and the relay of the fault module is disconnected by the control unit;

[0010] S40, the fault module is replaced by hot plugging.

[0011] Further, the operation state of the charging and discharging circuit module is monitored, and whether the charging and discharging circuit module is faulty is judged, including: monitoring the voltage and current values in the operation of the charging and discharging circuit module, and judging the operation state of the charging and discharging circuit module whose voltage and current values exceed the set safety range as a fault state.

[0012] Further, the operation state of the charging and discharging circuit module is monitored, and whether the charging and discharging circuit module is faulty is judged, including: monitoring the temperature of the heating device of the charging and discharging circuit module, and judging the operation state of the charging and discharging circuit module whose temperature exceeds the set threshold as a fault state.

[0013] Further, the replacement of the fault module includes: after removing the fault module, the replacement charging and discharging circuit module is installed to the base plate structure, and then the control unit automatically identifies and registers the new module.

[0014] A modular high-voltage distribution box includes: a base plate structure, a charging and discharging circuit module, a control unit, and a detection unit.

[0015] The base plate structure is provided with a battery interface and a charging and discharging circuit interface;

[0016] The charging and discharging circuit module includes a positive electrode module and a negative electrode module, and both are modularly packaged and detachably connected to the charging and discharging circuit interface of the base plate structure through a high-current quick connector;

[0017] The control unit is of plug-in type structure, installed in a separate plug-in box, and the plug-in box is provided with a plurality of slots for controlling the on-off of the module by controlling the relays in the charging and discharging circuit module;

[0018] The detection unit is used to collect current and voltage signals from the charging and discharging circuit module and is in communication connection with the control unit.

[0019] Further, the positive electrode module is sequentially integrated with a positive electrode charging and discharging interface, a fuse, a circuit breaker and a positive electrode relay; and the negative electrode module is sequentially integrated with a negative electrode charging and discharging interface, a shunt and a negative electrode relay.

[0020] Further, the face plate of the positive electrode module is provided with a control signal interface, and the face plate of the negative electrode module is provided with a signal acquisition interface, and the positive electrode module and the negative electrode module lead the internal circuit to the face plate interface through a wall-penetrating terminal.

[0021] Further, among the plurality of charge-discharge circuit interfaces provided on the substrate structure, part of the interfaces are connected with the charge-discharge circuit module, and the rest of the interfaces are plugged by the insulating plugs.

[0022] Further, the substrate structure is of a non-standard shape that is adapted to the installation space.

[0023] Further, the temperature sensor is further arranged on the heat generating component of the charge-discharge circuit module, and the temperature sensor is in communication connection with the control unit.

[0024] The present application divides the high-voltage box into standardized and independently pluggable charge-discharge modules and optional substrate structures with multiple interfaces. Users can select the corresponding number of charge-discharge modules and substrate structures according to the actual application requirements, and when the system capacity needs to be expanded later, new charge-discharge modules can be directly added at the reserved redundant interfaces of the substrate structure, without the need to replace the high-voltage box main body, so as to flexibly adapt to different system requirements on the same high-voltage box platform, and improve the application range and resource utilization efficiency of the product. BRIEF DESCRIPTION OF DRAWINGS

[0025] The accompanying drawings, which are incorporated into and form part of the specification, illustrate embodiments consistent with the present application and, together with the description, serve to explain the principles of the application.

[0026] In order to more clearly illustrate the technical solutions in the embodiments of the present application or the prior art, the accompanying drawings needed to be used in the embodiments or prior art description will be briefly introduced. Obviously, for those skilled in the art, other drawings can also be obtained based on these drawings without creative labor.

[0027] Figure 1 The flowchart provided for the control method embodiment of the modular high-voltage distribution box of the present application;

[0028] Figure 2 The structural diagram of the control device of the modular high-voltage distribution box of the embodiment of the present application;

[0029] Figure 3 The substrate structure structural diagram of the control device of the modular high-voltage distribution box of the embodiment of the present application;

[0030] Figure 4 The substrate structure structural diagram of the control device of the modular high-voltage distribution box of another embodiment of the present application;

[0031] The purpose of the present application, functional characteristics and advantages will be further described with reference to the embodiments and the accompanying drawings. DETAILED DESCRIPTION

[0032] It should be understood that the specific embodiments described herein are merely illustrative of the technical solutions of the present invention and are not intended to limit the present invention.

[0033] To better understand the technical solution of the present invention, a detailed description will be provided below in conjunction with the accompanying drawings and specific embodiments.

[0034] like Figure 1 As shown, Figure 1 This is a flowchart illustrating the control method for the modular high-voltage distribution box of the present invention, provided in Embodiment 1.

[0035] refer to Figure 1 In this embodiment, the control method for the modular high-voltage distribution box includes the following steps:

[0036] S10, perform power-on initialization, and identify the connected charging and discharging circuit modules through the detection unit.

[0037] In this embodiment, after the system's low-voltage control power supply is powered on, the control unit enters the initialization program. The program drives the multi-channel analog input module in the detection unit to scan and measure the voltage of all charging and discharging circuit interfaces on the substrate structure to the common terminal at a sampling frequency of 100 times per second. In this embodiment, these are interfaces 1 to 4.

[0038] In this embodiment, the detection unit transmits the measured analog voltage value to the control unit in real time via the communication bus. The control unit has a preset effective voltage threshold, for example, 320V in this embodiment. The scan reveals that the voltage of interface 1 is 398V and the voltage of interface 2 is 397V, both higher than the threshold; while the voltages of interfaces 3 and 4 are 0.5V and 0.3V respectively, far below the threshold.

[0039] In this embodiment, the logic processing unit of the control unit determines, based on the scan result, that interfaces 1 and 2 are connected to a functional charging / discharging circuit module and battery load, thus identifying them as valid physical connections. The system assigns a unique identifier, Loop-01, to the first valid interface and Loop-02 to the second valid interface according to a preset enumeration logic. This identifier is then written into the non-volatile memory of the control unit and bound to all subsequent monitoring, control, and alarm information.

[0040] In this embodiment, after initialization, the human-machine interface of the control unit or the host computer monitoring system will display: The system has detected two loops: Loop-01 and Loop-02.

[0041] By performing power-on initialization, the control unit identifies all connected charge-discharge circuit modules through the detection unit, and assigns a unique number to each charge-discharge circuit module, achieving plug-and-play and automatic topology discovery. Compared with the traditional high-voltage box which requires manual jumper or software to set the circuit parameters, the application automatically identifies the module through the electrical characteristics of the detection unit, which realizes automatic identification and registration of the module, reducing the manual configuration link.

[0042] S20, monitoring the running state of the charge-discharge circuit module based on the detection unit.

[0043] In this embodiment, the current sensor of the detection unit continuously collects the current flowing through Loop-01 and Loop-02 circuits, and the temperature sensor collects the contactor contact temperature, all data are refreshed and uploaded to the control unit at a period of t time (for example, 10 ms).

[0044] In this embodiment, during the operation of the high-voltage box, the elevator connected to Loop-01 experiences mechanical stall, resulting in short circuit on the motor side, causing the circuit current to rise sharply to Ith (for example, 280A) within t1 time (for example, 1 ms), and the current continues to exceed the upper limit of the safety current of Ith, the large current generates Joule heat at the contactor contact, causing the temperature sensor on the positive module of Loop-01 to rise from T0 (for example, 40°C) to T1 (for example, 85°C) within t2 time (for example, 3 seconds), exceeding the alarm threshold of Tth (for example, 75°C);

[0045] The fault diagnosis algorithm of the control unit receives the alarm signals of Loop-01 current overrun and Loop-01 temperature overrun at the same time, and the control unit judges this situation as a serious fault of the first level—overload and overheating fault according to the preset fault tree logic.

[0046] S30, when the charge-discharge circuit module is in a fault state, the charge-discharge circuit module in the fault state is recorded as a fault module, and the relay of the fault module is disconnected through the control unit.

[0047] In this embodiment, the control unit immediately interrupts the current control cycle of Loop-01, and calls a fault handling subroutine, which sends a "disconnect" instruction to the control Loop-01 circuit digital output channel, and the instruction is transmitted to the relay control coil in the aviation plug of the positive and negative module panels of Loop-01 through the cable;

[0048] The control unit causes the relay coil in the positive and negative modules corresponding to Loop-01 to lose power, and the main contact is quickly disconnected under the action of the spring within t3 (for example, 5 ms), so that the Loop-01 circuit is completely disconnected from the system main bus and load in an electrical manner, realizing physical isolation.

[0049] In this embodiment, at the same time as the disconnect instruction is issued, the control unit generates a structured fault event record with the content: "Time stamp: 14:13; fault code: F101; fault loop: Loop-01; fault type: overcurrent, overheat; action: isolated." The record is immediately uploaded to the cloud monitoring platform through the Ethernet interface.

[0050] In another embodiment, the fault event record is uploaded to the local workstation through wireless transmission.

[0051] Through the implementation process of the above embodiments, precise, fast and active fault safety isolation can be achieved. Compared with the traditional scheme, which may only rely on the fuse to melt when short-circuiting, the reaction is fast but cannot be recovered, and cannot provide an early warning for overheating; relies on the inverse time or instantaneous tripping characteristics of the circuit breaker for protection, and the full breaking time is usually in the order of tens to hundreds of milliseconds, the response speed is limited; compared with the traditional scheme, the present application can make a judgment within milliseconds when the fault characteristics appear through real-time multi-parameter monitoring and intelligent algorithm, and drive the high-speed relay to complete the breaking within tens of milliseconds, realizing faster and more accurate active isolation of faults, thereby controlling the impact of the fault within the minimum range, greatly improving the dynamic safety and availability of the system, preventing the spread of the fault to other normal loops such as Loop-02, greatly improving the availability and safety of the entire system, and providing a data basis for predictive maintenance.

[0052] S40, hot swapping and replacing the fault module.

[0053] In this embodiment, after receiving the alarm information, the maintenance personnel arrive at the scene. By checking the monitoring screen, it is confirmed that Loop-01 has been isolated, Loop-02 is running normally, and the system total bus voltage is stable. In this state, the entire high-voltage box is still in a live working state except for the fault loop.

[0054] Further, in this embodiment, the maintenance personnel disconnect the Loop-01 panel aviation plug, and then operate the mechanical lock of the high-current quick plug, and sequentially pull out the positive and negative modules of Loop-01 from the base structure. Since the fault loop has been pre-electrically isolated, this plug-in operation only physically disconnects the connection without current, and does not generate an arc, nor does it affect the power supply of Loop-02.

[0055] Further, in this embodiment, the maintenance personnel align the pre-prepared, type-consistent spare positive and negative charge-discharge loop modules with the foolproof guide grooves of the original interface of the base plate, and insert them with force until the sound of the lock is heard. The high-voltage electrical connection is completed, and the panel aviation plug is connected.

[0056] Further, in the embodiment, after the new positive electrode charging and discharging circuit module and the negative electrode charging and discharging circuit module are inserted, the detection circuit inside the modules makes the interface present an effective voltage signal to the detection unit; after the control unit recognizes that the original fault interface reappears the effective module, a simplified identification and registration process is automatically executed: after verifying that the interface voltage is effective, the original number "Loop-01" is re- assigned to the new module, and the state is reset from fault isolation to standby readiness.

[0057] In the embodiment, the entire replacement process can be completed within 2 minutes; further, the system automatically re-enters Loop-01 into operation; during the entire process, the elevator connected to Loop-02 is not affected by any power interruption and continues to operate normally.

[0058] In another embodiment, the maintenance personnel can manually confirm that Loop-01 is re-entered into operation on the monitoring interface.

[0059] Compared with the high-voltage distribution box which must be powered off, opened, and the single device in the dense wire harness must be found and replaced, resulting in system downtime for hours, the embodiment makes the replacement of core power components as simple and fast as replacing a server power module through modular packaging, pre-fault isolation, and automatic identification, reduces unplanned downtime to almost zero, can greatly improve the continuous operation ability of the system, and reduces the technical threshold, time cost, and safety hazards of maintenance.

[0060] The application can replace the expansion and charging and discharging circuit module without replacing the main body when a high-voltage distribution box fails by monitoring the independently pluggable charging and discharging circuit module and the multi-interface substrate.

[0061] As shown in Figure 2 , it is a structural schematic diagram of the control device of the modular high-voltage distribution box of the embodiment of the application. Figure 2

[0062] Referring to Figure 2 , the application also proposes a modular high-voltage distribution box comprising: a substrate structural member 10, a charging and discharging circuit module 20, a control unit 30, and a detection unit 40.

[0063] As shown in Figure 3 , it is a structural schematic diagram of the substrate structural member of the control device of the modular high-voltage distribution box of the embodiment of the application. Figure 3

[0064] Referring to Figure 3 ​​The substrate structure 10 is provided with a battery interface 12 and a charge-discharge circuit interface 11; the charge-discharge circuit interface 11 is arranged on the front surface of the substrate structure 10, and the battery interface 12 is arranged on the back surface of the substrate structure 10, and the front and back surfaces are arranged in a partitioned manner so as to not interfere with each other in the wiring operation space, facilitating installation and maintenance, and facilitating separation of power lines and signal lines, and reducing interference.

[0065] In the embodiment, the charge-discharge circuit module 20 includes a positive electrode module and a negative electrode module, and both are modularly packaged and detachably connected to the charge-discharge circuit interface of the substrate structure 10 through a high-current quick connector; the modular packaging and quick connection design make each circuit become an independent functional unit, support quick plugging and replacement, greatly improve the maintenance efficiency and system maintainability, and allow flexible configuration of the number of circuits according to requirements.

[0066] In the embodiment, the control unit 30 is in a plug-in structure and is installed in a separate plug-in box, and the plug-in box is provided with a plurality of slots for controlling the on-off of the module by controlling the relays in the charge-discharge circuit module 20; the plug-in structure allows the control capacity to be expanded as needed, is not limited by the space of the main structure of the high-voltage box, improves the scalability and flexibility of the system, and facilitates independent maintenance and upgrading of the controller.

[0067] The detection unit 40 is used to collect current and voltage signals from the charge-discharge circuit module 20 and is in communication connection with the control unit 30.

[0068] In the embodiment, the positive electrode module is sequentially integrated with a positive electrode charge-discharge interface, a fuse, a circuit breaker and a positive electrode relay; the positive electrode module integrates the connection, short-circuit protection, overload protection and controlled opening of the positive electrode path, constitutes a complete safety protection and execution function package, simplifies the internal structure and improves the reliability.

[0069] The negative electrode module is sequentially integrated with a negative electrode charge-discharge interface, a shunt and a negative electrode relay; the negative electrode module integrates the connection, accurate current monitoring and controlled opening of the negative electrode path, constitutes a complete monitoring and circuit function package, and facilitates accurate power metering and state feedback.

[0070] In the embodiment, the panel of the positive electrode module is provided with a control signal interface, the panel of the negative electrode module is provided with a signal acquisition interface, and the positive electrode module and the negative electrode module lead the internal lines to the panel interfaces through the through-wall terminals; through the structural design, the standardization and quick docking of the internal low-voltage lines and external connection of the module can be realized, field wiring is simplified, connection reliability and electromagnetic compatibility are improved, and the overall replacement of a faulty module is facilitated.

[0071] In the embodiment, among the plurality of charge-discharge circuit interfaces provided on the substrate structure 10, part of the interfaces are connected with the charge-discharge circuit module 20, and the rest of the interfaces are plugged by the insulating plugs; the replacement of the charge-discharge circuit module can be realized without replacing the whole substrate or the box, and the safety insulation of the idle interfaces is ensured.

[0072] As shown in Figure 4 , Figure 4 the control device of the modular high-voltage distribution box is a schematic structural view of the substrate structure of another embodiment of the application.

[0073] Referring to Figure 4 , in another embodiment, the charge-discharge circuit interfaces 11 of the substrate structure 10 are arranged in a 2x2 square; a regular and compact interface layout can be provided, which is conducive to the regular installation of the modules and the organization of the heat dissipation air duct and improves the space utilization.

[0074] In another embodiment, the substrate structure 10 is a square structure, five surfaces of the substrate structure 10 are provided with the charge-discharge circuit interfaces 11, and one surface is provided with the battery interface 12; the multi-surface arrangement of the interfaces can greatly improve the circuit connection density and expansion potential of a single substrate to adapt to complex application scenarios with extremely high space utilization requirements or requiring a large number of concentrated circuits.

[0075] Further, a temperature sensor provided on the heat generating components of the charge-discharge circuit module 20 is further included, and the temperature sensor is in communication connection with the control unit 30; direct temperature monitoring of the key heat generating components can be realized, overheat protection function is provided for the system, and device damage or performance degradation caused by excessively high temperature rise is prevented.

[0076] The above only describes some embodiments of the application, and does not limit the patent scope of the application, and any equivalent structural transformation made under the technical concept of the application, or direct / indirect application in other related technical fields is included in the patent protection scope of the application.

Claims

1. A control method of a modular high-voltage distribution box, characterized in that, The modular high-voltage distribution box comprises a base plate structure, a charging and discharging circuit module, a control unit and a detection unit, the charging and discharging circuit module, the control unit and the detection unit being electrically connected through the base plate structure; the method comprises the following steps: carrying out power-on initialization, identifying the connected charging and discharging circuit module through the detection unit; monitoring the operating state of the charging and discharging circuit module based on the detection unit; when any charging and discharging circuit module is monitored to be in a fault state, recording the charging and discharging circuit module as a fault module, and the control unit immediately controls the positive and negative relays inside the fault module to perform a disconnection operation, so as to electrically isolate the fault module from the high-voltage DC bus; when the positive and negative relays inside the fault module have been disconnected and the current of the circuit in which the fault module is located has decreased to a state of no current connection, physically and hotly replacing the fault module, and during the replacement, other non-fault charging and discharging circuit modules in the modular high-voltage distribution box remain continuously operating; installing a replaced charging and discharging circuit module to the base plate structure, and the control unit automatically identifies and registers the replaced module.

2. The method of claim 1, wherein, The monitoring of the operating state of the charging and discharging circuit module comprises monitoring the voltage and current values in the operation of the charging and discharging circuit module, and judging the operating state of the charging and discharging circuit module whose voltage and current values exceed the set safety range as a fault state.

3. The method of claim 1, wherein, The monitoring of the operating state of the charging and discharging circuit module comprises monitoring the temperature of the heating device of the charging and discharging circuit module, and judging the operating state of the charging and discharging circuit module whose temperature exceeds the set threshold as a fault state.

4. A modular high voltage distribution box, characterized in that, The modular high-voltage distribution box comprises a base plate structure, a charging and discharging circuit module, a control unit and a detection unit; The base plate structure is provided with a battery interface and a charging and discharging circuit interface; The charging and discharging circuit module comprises a positive module and a negative module, and both are modularly packaged and detachably connected to the charging and discharging circuit interface of the base plate structure through a high-current quick connector; The control unit is of a plug-in type structure and is installed in a separate plug-in box, the plug-in box is provided with a plurality of slots for controlling the on-off of the modules by controlling the relays in the charging and discharging circuit module; The detection unit is used to collect current and voltage signals from the charging and discharging circuit module and is in communication connection with the control unit; when any charging and discharging circuit module is monitored to be in a fault state, the charging and discharging circuit module is recorded as a fault module, and the control unit immediately controls the positive and negative relays inside the fault module to perform a disconnection operation, so as to electrically isolate the fault module from the high-voltage DC bus; a replaced charging and discharging circuit module is installed to the base plate structure, and the control unit automatically identifies and registers the replaced module.

5. The modular high voltage distribution box of claim 4, wherein, The positive module is sequentially integrated with a positive charging and discharging interface, a fuse, a circuit breaker and a positive relay; and the negative module is sequentially integrated with a negative charging and discharging interface, a shunt and a negative relay.

6. The modular high voltage distribution box of claim 5, wherein, The panel of the positive electrode module is provided with a control signal interface, and the panel of the negative electrode module is provided with a signal acquisition interface.

7. The modular high voltage distribution box of claim 4, wherein, Among the plurality of charge-discharge circuit interfaces provided on the substrate structure, some interfaces are connected with the charge-discharge circuit module, and the rest of the interfaces are plugged by an insulating plug.

8. The modular high voltage distribution box of claim 4, wherein, The shape of the substrate structure is a non-standard shape that is adapted to the installation space.

9. The modular high voltage distribution box of claim 4, wherein, A temperature sensor is arranged on the heat generating component of the charge-discharge circuit module, and the temperature sensor is in communication connection with the control unit.

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