Method and device for controlling output state of high-power charging module

Abstract

The embodiment of the invention can be applied to the technical field of new energy automobiles, direct-current fast charging piles, energy storage systems and the like, and particularly provides an output state control method and device for a high-power charging module, and the method comprises the steps: obtaining real-time data of the high-power charging module, carrying out the threshold comparison after calculating a current state evaluation value, and if the current state evaluation value is smaller than a safety interval, stopping the operation of the high-power charging module; if yes, the high-power charging module is controlled to enter a low-power-consumption standby mode; if the impedance is larger than the safety interval, the output power is reduced according to a derating curve table, and the impedance change rate is monitored, and if the impedance is larger than a preset load threshold value, the output of the high-power charging module is cut off and controlled, and the output is recovered after preset delay time; and recording a timestamp of each output state switching and a corresponding state evaluation value so as to predict an output state trend in a future sampling period, and carrying out pre-regulation and control in advance. By means of the scheme, the problems that in the prior art, output state adjustment is not timely, and prediction control capacity is insufficient are solved.

Description

Technical Field

[0001] This application relates to the technical field of charging modules, and more specifically, to a method and apparatus for controlling the output state of a high-power charging module. Background Technology

[0002] With the rapid development of new energy vehicles, DC fast charging piles, and energy storage systems, high-power charging modules, as core units in power transmission systems, undertake energy conversion and steady-state control functions between the grid side and the load side. Their output power typically operates under high current, high frequency, and high thermal load conditions. Therefore, effective monitoring and dynamic adjustment of the module's real-time operating status are crucial for ensuring the system's safety, stability, and lifespan.

[0003] In related technologies, the operating status of the charging module is typically determined by collecting real-time operating parameters such as output voltage, current, and temperature, and output control is executed based on preset threshold logic. For example, when the output current exceeds a set limit, overload protection is achieved through current limiting or voltage reduction control; when the temperature exceeds a set threshold, the controller reduces the PWM duty cycle or temporarily stops the output to prevent thermal instability, thereby achieving adaptive adjustment of output power and safety protection of the module, ensuring the basic reliability of the charging process.

[0004] Although setting a fixed threshold can achieve output protection and derating control under overload and overtemperature conditions, traditional control methods based on single-sample threshold judgment cannot predict future state changes under complex load changes, high dynamic response, or long-term operating conditions. This can easily lead to delayed or over-triggered protection actions, thereby affecting system stability and output continuity. Summary of the Invention

[0005] The embodiments of this application provide an output state control method and apparatus for a high-power charging module, which can improve the problems of untimely output state adjustment and insufficient predictive control capability in the prior art.

[0006] Other features and advantages of this application will become apparent from the following detailed description, or may be learned in part from practice of this application.

[0007] According to one aspect of the embodiments of this application, an output state control method for a high-power charging module is provided, comprising: acquiring real-time data of the high-power charging module to calculate a current state evaluation value; performing a threshold comparison on the state evaluation value; if the state evaluation value is less than a preset safety range, controlling the high-power charging module to enter a low-power standby mode; if the state evaluation value is greater than the safety range, reducing the output power according to a preset derating curve table; while reducing the output power according to the preset derating curve table, monitoring the impedance change rate of the high-power charging module; if the impedance change rate is greater than a preset load threshold, cutting off the output of the high-power charging module and restoring the output after a preset delay time; recording the timestamp of each output state switch and the corresponding state evaluation value to predict the output state trend within future sampling periods and perform pre-adjustment in advance.

[0008] Optionally, the step of acquiring real-time data of the high-power charging module to calculate the current state evaluation value includes: collecting the output voltage value, output current value, and heat sink temperature value of the high-power charging module; using the ratio of the output voltage value to the rated voltage value as a voltage weight component, and the ratio of the output current value to the rated current value as a current weight component; using the ratio of the heat sink temperature value to the maximum allowable temperature value as a temperature weight component, and the ratio of the product of the output voltage value and the output current value to the rated power value as a power weight component; and multiplying the voltage weight component, the current weight component, the temperature weight component, and the power weight component by their respective preset weight coefficients and then performing a weighted summation to obtain the state evaluation value.

[0009] Optionally, the step of performing a threshold comparison on the state evaluation value, and determining an underload state if the state evaluation value is less than a preset safety range, and controlling the high-power charging module to enter a low-power standby mode, includes: comparing the state evaluation value with the lower limit of the preset safety range; when the state evaluation value is less than the lower limit of the safety range, starting the low-power standby mode and sending an underload state signal to the main controller of the high-power charging module; driving the main controller to turn off the drive signal of the power switch of the high-power charging module based on the underload state signal, and keeping the output relay of the high-power charging module in the closed state; providing maintenance power to the main controller and monitoring circuit through a preset auxiliary power supply circuit; continuously monitoring the state evaluation value in the low-power standby mode; and restarting the drive signal of the power switch to restore normal output when the state evaluation value recovers to within the safety range.

[0010] Optionally, the step of reducing the output power according to a preset derating curve table if the state assessment value is greater than the safe range includes: comparing the state assessment value with the upper limit of the safe range; when the state assessment value is greater than the upper limit of the safe range, calculating the difference between the state assessment value and the upper limit as an overload level parameter; inputting the overload level parameter into the preset derating curve table to find the corresponding target output power value; adjusting the duty cycle of the power switch of the high-power charging module to reduce the actual output power to be equal to the target output power value; during the process of reducing the output power, adjusting the power at a preset derating rate and continuously monitoring the state assessment value; when the state assessment value is reduced to within the safe range, stopping the derating operation and maintaining the current output power.

[0011] Optionally, the step of monitoring the impedance change rate of the high-power charging module when reducing the output power according to a preset derating curve, and cutting off the output of the high-power charging module and restoring the output after a preset delay time if the impedance change rate is greater than a preset load threshold, includes: continuously collecting the current load impedance value of the high-power charging module at a preset monitoring cycle when reducing the output power according to the preset derating curve, calculating the difference between the current load impedance value and the load impedance value of the previous monitoring cycle, and dividing the difference by the time length of the monitoring cycle to obtain the impedance change rate; wherein, the load impedance value is based on the output voltage value. The ratio of the impedance change rate to the output current value is calculated; the absolute value of the impedance change rate is compared with a preset load threshold. When the absolute value of the impedance change rate is greater than the load threshold, a cut-off command is sent to the main controller of the high-power charging module to control the electrical connection between the output relay of the high-power charging module and the load to be disconnected; after the preset delay time is reached, the output relay is closed, and after the output is restored, the load impedance value is re-acquired to calculate the impedance change rate; if the absolute value of the impedance change rate is still greater than the load threshold, the output is cut off again and the delay time is increased; if the absolute value of the impedance change rate is less than the load threshold, the output is maintained.

[0012] Optionally, the step of recording the timestamp and corresponding state evaluation value of each output state switch to predict the output state trend in future sampling periods and perform pre-adjustment includes: obtaining the current system time as a timestamp and recording the state evaluation value corresponding to the switch time each time the output state switches; storing the timestamp and the corresponding state evaluation value in a historical data storage to form a state switch record; when the number of state switch records reaches a preset minimum sample size, extracting the state switch records within the most recent preset time window, and identifying the output state trend of the state evaluation value changing over time in the extracted state switch records using a time series analysis algorithm, wherein the output state trend includes a trend coefficient and a fluctuation amplitude; predicting and calculating the state evaluation value in the next M sampling periods based on the trend coefficient and the fluctuation amplitude; and when it is predicted that the state evaluation value in the next Nth sampling period will exceed the safe range, pre-adjusting the output power of the high-power charging module in the current sampling period.

[0013] Optionally, the step of predicting and calculating the state assessment value for the next M sampling periods based on the trend coefficient and the fluctuation amplitude, and pre-regulating the output power of the high-power charging module in the current sampling period when it is predicted that the state assessment value will exceed the safe range in the Nth sampling period, includes: calculating the state assessment value for the next M sampling periods using the following formula: S pi =S1+K i; Among them, S pi Let S1 be the state evaluation value for the i-th future sampling period, K be the trend coefficient, and i be the index of the i-th future sampling period, where 1≤i≤M; S is constructed based on the fluctuation amplitude. pi Confidence interval: [S pi -α H,S pi +α H]; Where α is a preset safety factor, and H is the fluctuation amplitude; when the Nth sampling period in the future exists, the S pi If the confidence interval and the safety interval do not intersect or partially exceed the limit, it is determined that an over-limit will occur in the Nth sampling period in the future, and the output power of the high-power charging module will be actively adjusted in the current sampling period according to the preset pre-control strategy, where M>N≥1.

[0014] According to another aspect of the embodiments of this application, an output state control device for a high-power charging module is provided, comprising: an acquisition module for acquiring real-time data of the high-power charging module to calculate a current state evaluation value; a comparison module for performing a threshold comparison on the state evaluation value, wherein if the state evaluation value is less than a preset safety range, the high-power charging module is controlled to enter a low-power standby mode; a derating module for reducing the output power according to a preset derating curve table if the state evaluation value is greater than the safety range; a recovery module for monitoring the impedance change rate of the high-power charging module when reducing the output power according to the preset derating curve table, wherein if the impedance change rate is greater than a preset load threshold, the output of the high-power charging module is cut off and the output is restored after a preset delay time; and a regulation module for recording the timestamp and corresponding state evaluation value of each output state switch to predict the output state trend within future sampling periods and perform pre-regulation in advance.

[0015] Compared with existing technologies, this application has the following advantages: timely adjustment and strong predictive control. By introducing a state evaluation value as the core control parameter of the high-power charging module, and combining real-time data acquisition, threshold hierarchical control, dynamic adjustment of derating curve, impedance change rate protection, and time series predictive regulation, a complete output state management process from passive response to active pre-control is realized. This not only enables real-time monitoring and multi-level safety control of the output state of the high-power charging module, but also predicts future state trends based on historical state switching information, thereby performing output power pre-regulation in advance to avoid power overshoot or temperature over-limit, and improves the problems of untimely output state adjustment and insufficient predictive control capability in existing technologies. Attached Figure Description

[0016] Figure 1 This is a schematic flowchart of the output state control method for a high-power charging module provided in an embodiment of the present invention; Figure 2 This is a schematic block diagram of the output state control device for a high-power charging module provided in an embodiment of the present invention. Detailed Implementation

[0017] Exemplary embodiments will now be described in a more comprehensive manner with reference to the accompanying drawings. However, the exemplary embodiments can be implemented in various forms and should not be construed as limited to these examples; rather, these embodiments are provided so that this application will be more comprehensive and complete, and will fully convey the concept of the exemplary embodiments to those skilled in the art.

[0018] Furthermore, the features, structures, or characteristics described in this application can be combined in any suitable manner in one or more embodiments. Numerous specific details are provided in the following description to provide a full understanding of the embodiments of this application. However, those skilled in the art will recognize that when implementing the technical solutions of this application, not all the detailed features in the embodiments may be used, one or more specific details may be omitted, or other methods, elements, devices, steps, etc., may be employed.

[0019] The block diagrams shown in the accompanying drawings are merely functional entities and do not necessarily correspond to physically independent entities. That is, these functional entities can be implemented in software, in one or more hardware modules or integrated circuits, or in different network and / or processor devices and / or microcontroller devices.

[0020] The flowcharts shown in the accompanying drawings are merely illustrative and do not necessarily include all content and operations / steps, nor do they necessarily have to be performed in the described order. For example, some operations / steps can be broken down, while others can be combined or partially combined; therefore, the actual execution order may change depending on the specific circumstances.

[0021] It should be noted that "multiple" in this article refers to two or more. "And / or" describes the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent: A alone, A and B simultaneously, or B alone. The character " / " generally indicates that the preceding and following related objects have an "or" relationship.

[0022] The technical solution of the present invention will be further described below with reference to the accompanying drawings and specific embodiments.

[0023] like Figure 1 As shown, this application provides an example of a method for controlling the output state of a high-power charging module, which can realize real-time evaluation, hierarchical control and trend prediction regulation of the output state of the charging module to ensure the safety and stability of the system under high-power operation. The method specifically includes the following steps S100 to S500.

[0024] Step S100: Obtain real-time data from the high-power charging module to calculate the current state evaluation value.

[0025] A real-time monitoring unit, including a voltage sensor, a current sensor, and a temperature sensor, is configured at the output end of the high-power charging module to collect operating parameters such as output voltage, output current, and internal module temperature. The monitoring unit converts the collected analog signals into digital signals via an A / D converter and transmits them to the main controller. The main controller, according to preset calculation logic, inputs the real-time data into a state evaluation calculation module to calculate the current state evaluation value. This state evaluation value reflects the module's current comprehensive operating status, providing a quantitative basis for subsequent threshold determination.

[0026] For example, when the output current is 50A, the output voltage is 750V, and the module temperature is 65℃, the controller will calculate the status evaluation value according to the above data according to the preset weights. For example, the weighted sum is obtained by weighting the data with weight coefficients of 0.4 (voltage), 0.4 (current), and 0.2 (temperature) to reflect the load and thermal balance of the module.

[0027] Step S200: Compare the status evaluation value with a threshold. If the status evaluation value is less than the preset safe range, control the high-power charging module to enter the low-power standby mode.

[0028] The main controller retrieves the safety range parameters (consisting of an upper and lower limit) stored in internal memory and compares the current state assessment value with the lower limit. When the state assessment value is lower than the lower limit, the module is determined to be in an underload state. The main controller then sends a low-power standby command to the power control circuit to shut down the drive signals of some power switching transistors while keeping the control signal channel and auxiliary power module operational to maintain the monitoring function.

[0029] When the lower limit of the safety range is set to 0.35 and the calculated state evaluation value is 0.28, the control system immediately determines that it is in a low-load operating state and turns off the PWM signals of power switching transistors Q1~Q4 to put the module into a low-power standby state, so as to reduce energy loss and extend the device life.

[0030] Step S300: If the state assessment value is greater than the safe range, reduce the output power according to the preset derating curve table.

[0031] By comparing the state assessment value with the upper limit of the safe range, if the state assessment value is detected to exceed the upper limit, the corresponding target output power value is read from the derating curve table. The derating curve table is pre-stored in EEPROM, recording the correspondence between the state assessment value and the output power. The main controller adjusts the duty cycle of the power switching transistors according to the table lookup results, so that the output power decreases smoothly to prevent the module from overheating or overloading.

[0032] When the upper limit of the safe range is 0.85 and the current state evaluation value is 0.92, the system finds the corresponding target output power to be 85% of the rated power in the derating curve table. The controller adjusts the PWM duty cycle from 80% to 68% and gradually completes the adjustment within 10 sampling cycles to avoid current fluctuations caused by sudden power drops.

[0033] Step S400: When reducing the output power according to the preset derating curve table, monitor the impedance change rate of the high-power charging module. If the impedance change rate is greater than the preset load threshold, cut off the output of the high-power charging module and restore the output after the preset delay time.

[0034] The impedance change rate is calculated by comparing the load impedance changes between two adjacent sampling periods. When the absolute value of the impedance change rate exceeds the load threshold, the main controller sends a disconnect command to the relay control unit to immediately cut off the module output to prevent current surges caused by sudden load changes. The delay timing module recloses the relay and resumes output after reaching a preset delay time (e.g., 1.5 seconds). If the impedance change rate still exceeds the threshold after resumption, the delay time is extended further.

[0035] If the impedance in the previous sampling period was 15Ω, the current period is 12Ω, and the monitoring period is 0.5 seconds, then the impedance change rate is 6Ω / s. If the preset load threshold is 5Ω / s, the system will cut off the output and then restore the output after a 1.5-second delay.

[0036] Step S500: Record the timestamp and corresponding state evaluation value of each output state switch to predict the output state trend in the future sampling period and perform pre-adjustment in advance.

[0037] The system clock acquires the timestamp of the output state transition and synchronously records the corresponding state evaluation value. The main controller stores this data in the historical data storage area. When the number of recorded samples reaches the minimum sample threshold, a trend prediction program is executed. The trend prediction program calculates the trend coefficient and fluctuation amplitude using a linear recursive model or time series fitting to predict the future trend of the state evaluation value. When it is predicted that the state evaluation value in the Nth sampling period will exceed the safe range, the system performs pre-regulation of the output power in the current sampling period to prevent sudden over-limits.

[0038] When historical samples show that the state assessment value is increasing at a rate of +0.03 per cycle and the current value is 0.80, the system predicts that the state assessment value will reach 0.89 in the third cycle, exceeding the upper limit of the safe range of 0.85. Therefore, the system immediately reduces the output power by 5% in advance to achieve active adjustment.

[0039] In this embodiment, real-time data from the high-power charging module, including parameters such as output voltage, output current, and temperature, is acquired to calculate the current state assessment value. A threshold determination is then performed on the state assessment value. When the state assessment value is less than a preset safe range, the high-power charging module is controlled to enter a low-power standby mode to reduce energy consumption and prevent underload operation. When the state assessment value is greater than the safe range, the output power is gradually reduced according to a preset derating curve to achieve smooth adjustment of the output power. During the derating control process, the impedance change rate of the high-power charging module is continuously monitored. When the impedance change rate is detected to be greater than a preset load threshold, the output of the high-power charging module is immediately cut off to prevent abnormal surges, and the output is restored after a preset delay time. Simultaneously, the timestamp of each output state switch and the corresponding state assessment value are recorded throughout the entire operation. By analyzing historical switching data, the output state trend within future sampling periods is predicted, thereby enabling pre-regulation before the predicted future state assessment value exceeds the safe range, achieving proactive control and dynamic stability of the module output.

[0040] By introducing dynamic calculation of state evaluation values ​​and a safety range determination mechanism, real-time identification and hierarchical response control of the output state are achieved. By combining derating curve tables and impedance change rate monitoring, module instability and damage caused by sudden load changes or thermal stress are effectively prevented. By introducing timestamp recording and trend prediction mechanisms, the control system can proactively perform pre-regulation before the state evaluation value approaches the safety boundary, thereby significantly improving the foresight of output power regulation and the safety of system operation, and addressing the problems of untimely output state regulation and insufficient predictive control capabilities in existing technologies. This not only improves the operational stability and response speed of high-power charging modules but also reduces energy loss and hardware impact caused by frequent switching or delayed control, ultimately achieving intelligent, safe, and highly reliable operation of the high-power charging system.

[0041] As a preferred option, step S100 can preferably be the following: Collect the output voltage, output current, and heat sink temperature of the high-power charging module.

[0042] By setting voltage sampling circuits and current sampling circuits at the output end of the high-power charging module, the voltage and current values ​​at the output end can be collected in real time. The voltage sampling circuit realizes voltage drop ratio measurement through a resistor voltage divider module, and the current sampling circuit realizes non-contact current detection through a Hall sensor.

[0043] The ratio of the output voltage to the rated voltage is used as the voltage weighting component, and the ratio of the output current to the rated current is used as the current weighting component.

[0044] The voltage weighting component (V) is obtained by calculating the ratio of the collected real-time output voltage value (U1) to the rated voltage value (U0) of the high-power charging module. w =U1 / U0); simultaneously, the ratio of the output current value (I1) to the rated current value (I0) is calculated to obtain the current weight component (I). w =I1 / I0).

[0045] For example, if the module's rated voltage is 400V and rated current is 50A, and the actual detected voltage is 380V and current is 40A, the voltage weight component can be 0.95 and the current weight component can be 0.8, providing input parameters for subsequent calculation of the state evaluation value.

[0046] The ratio of the radiator temperature to the maximum allowable temperature is used as the temperature weighting component, and the ratio of the product of the output voltage and the output current to the rated power is used as the power weighting component.

[0047] The temperature value (T1) of the heat sink is collected by installing a temperature sensor on the heat sink of the high-power charging module, and compared with the maximum allowable temperature (T) set by the system. max The ratio is calculated to obtain the temperature weighted component (T). w =T1 / T max Simultaneously calculate the power weight component (P). w =(U1×I1) / P0), where (P0) is the rated output power of the high-power charging module.

[0048] When the radiator temperature is 60°C, the maximum allowable temperature is 85°C, the output voltage is 380V, the current is 40A, and the rated power is 20kW, the temperature weighting component is 0.71 and the power weighting component is 0.76.

[0049] The voltage weight component, current weight component, temperature weight component, and power weight component are multiplied by their respective preset weight coefficients and then summed to obtain the state evaluation value.

[0050] The state calculation module within the main controller multiplies each weight component by a weighting coefficient (K). v (K) i (K) t (K) p The values ​​are then weighted and summed to obtain the state evaluation value (S=K). v ×V w +K i ×I w +K t ×T w +K p ×P wThe total weighting coefficients are 1. These weighting coefficients are set during system initialization based on different module types and application environments. For example, temperature factors can be set to a high weight to prevent overheating damage.

[0051] For example, in a certain design, the weighting coefficient (K) v =0.25), (K i =0.25), (K t =0.30), (K p =0.20), and combining the aforementioned components, the state evaluation value is approximately 0.81. This value is subsequently compared with a preset safety range (e.g., 0.7–0.9) to determine whether the module's operating state is stable.

[0052] As a preferred option, step S200 can preferably be as follows: The status evaluation value is compared with the lower limit of the preset safe range. When the status evaluation value is less than the lower limit of the safe range, the low-power standby mode is activated and an underload status signal is sent to the main controller of the high-power charging module.

[0053] The state evaluation value is detected in real time by a threshold comparison module. When the state evaluation value is detected to be lower than the lower limit threshold (S), min When the load is low, an underload status signal is generated and sent to the main controller, triggering a low-power standby mode.

[0054] When the safety range is set to 0.7 to 0.9, and the current state evaluation value is only 0.65, the system automatically enters a low-power standby state to reduce ineffective energy consumption.

[0055] The underload status signal drives the main controller to turn off the drive signal of the power switch of the high-power charging module, and keeps the output relay of the high-power charging module in the closed state.

[0056] After receiving the underload status signal, the main controller immediately outputs a shutdown command to the drive unit to stop the PWM signal of the power switch, thereby cutting off the energy output in the main power path. At the same time, it keeps the output relay closed to maintain the detection continuity of the control loop.

[0057] When the power switch is an IGBT, the main controller can cancel its gate drive signal within 50ms after the underload signal is triggered, so that the module can quickly reduce the power to a safe level.

[0058] The main controller and monitoring circuit are provided with a maintenance power supply through a preset auxiliary power supply circuit.

[0059] The main controller and monitoring circuit are continuously powered by an independent auxiliary power supply module. This auxiliary power supply circuit adopts an isolated DC / DC converter. The input terminal is connected to the bus voltage of the high-power charging module, and the output terminal provides a stable 5V or 12V DC power supply, ensuring that the system can still maintain data acquisition and threshold detection functions in low-power standby mode.

[0060] For example, the auxiliary power module output power is set to 10W, which can continuously supply power to the main controller, communication module and sensor circuit, ensuring the detection reliability of the module in standby mode.

[0061] In low-power standby mode, the status evaluation value is continuously monitored. When the status evaluation value returns to the safe range, the drive signal of the power switch is restarted to restore normal output.

[0062] The monitoring circuit updates the status evaluation value at a fixed sampling period (e.g., 100ms). When the status evaluation value is detected to rise above the lower limit of the safe range, the main controller reactivates the drive signal and deactivates the low-power mode, allowing the module to resume normal operation.

[0063] When the status assessment value rises from 0.65 to 0.72, the system automatically resumes output within 1 second, avoiding human intervention and ensuring the continuity and efficiency of energy transmission.

[0064] As a preferred option, step S300 can preferably be as follows: The state assessment value is compared with the upper limit of the safe zone. When the state assessment value is greater than the upper limit of the safe zone, the difference between the state assessment value and the upper limit value is calculated as the overload level parameter.

[0065] The main controller's comparison and calculation module compares the status assessment value with the upper limit of the safe range in real time. When the status assessment value exceeds the upper limit, a difference calculation operation is immediately performed to obtain the overload level parameter. The overload level parameter reflects the extent to which the module's current output status exceeds the limit and is used for subsequent dynamic derating control decisions.

[0066] When the safety range is set to 0.7 to 0.9 and the current state assessment value is 0.95, the calculated overload level parameter is 0.05. When the state assessment value rises to 1.0, the overload level parameter increases to 0.1, indicating that the module is in a high load risk state.

[0067] Input the overload level parameter into the preset derating curve table to find the corresponding target output power value; the derating curve table stores the correspondence between the overload level parameter and the target output power value in advance, and the target output power value decreases as the overload level parameter increases.

[0068] By pre-setting a derating curve table in the main controller's storage unit, the overload level parameter and the target output power value can be correlated through a lookup table. This curve table can be generated based on experimental data or long-term operational statistics and has a non-linear decreasing characteristic, thereby ensuring the smoothness and reliability of derating adjustment.

[0069] When the overload level parameter is 0.05, the target output power value obtained from the table is 90% of the rated power; when the overload level parameter is 0.1, the corresponding target output power value drops to 75% of the rated power. Based on this, the system can dynamically adjust the output power to prevent the module from overheating or the device from exceeding its limits.

[0070] Adjust the duty cycle of the power switch transistor in the high-power charging module to reduce the actual output power to match the target output power value.

[0071] The PWM control module adjusts the duty cycle of the power switching transistors to regulate the output voltage and current, thereby achieving precise control of the actual output power. When the current output power is detected to be higher than the target output power value, the system automatically reduces the PWM duty cycle so that the actual output power gradually approaches and stabilizes within the target output power range.

[0072] When the target output power is 18kW and the current output power is 20kW, the control module can gradually reduce the duty cycle from 80% to 72%. After about 500ms of dynamic adjustment, the output power stabilizes at around 18kW.

[0073] During the process of reducing output power, power adjustment is performed at a preset derating rate to avoid sudden changes in output power, and the status evaluation value is continuously monitored. When the status evaluation value drops to within the safe range, the derating operation is stopped and the current output power is maintained.

[0074] By introducing a derating rate limit into the control strategy, power changes decrease in a fixed gradient, for example, the power decreases by no more than 2% of the rated power per sampling period, to avoid voltage fluctuations or load instability caused by sudden drops. Simultaneously, the status assessment value is continuously monitored in real time. When the status assessment value falls below the upper limit of the safe range, the derating process is automatically terminated and the current output power is locked.

[0075] When the initial output power is 20kW and the target power is 17kW, the adjustment is performed at a derating rate of 0.4kW per cycle. When the state assessment value drops to 0.89 (i.e., returning to the safe range), the derating operation stops and the output of 17.2kW is maintained, achieving a smooth transition and system stability.

[0076] As a preferred option, step S400 can preferably be as follows: When reducing the output power according to the preset derating curve, the current load impedance value of the high-power charging module is continuously collected at a preset monitoring cycle. The difference between the current load impedance value and the load impedance value of the previous monitoring cycle is calculated, and the difference is divided by the length of the monitoring cycle to obtain the impedance change rate. The load impedance value is calculated based on the ratio of the output voltage value to the output current value.

[0077] After the system control unit performs analog-to-digital conversion on the sampled signal and filters out high-frequency noise, it calculates the load impedance value according to the formula Z=U1 / I1, where Z represents the load impedance value, U1 represents the output voltage value, and I1 represents the output current value.

[0078] For example, in practical applications, when the output voltage of a high-power charging module is 380V and the current is 40A, the calculated load impedance value is 9.5Ω; when the current rises to 45A and the voltage drops to 370V, the load impedance value drops to 8.2Ω, thus reflecting the trend of power change at the load end, which can be used for subsequent state assessment calculations.

[0079] The load impedance value is collected once every monitoring cycle (e.g., 100ms or 200ms) by the impedance monitoring unit, and the difference between the current impedance value and the previous sampling result is calculated using the digital calculation module. The difference is divided by the length of the monitoring cycle to obtain the impedance change rate, thus reflecting the rate of change on the load side.

[0080] The current impedance value is 8.2Ω, and the current impedance value is 7.8Ω. The monitoring period is 0.1s. Therefore, the impedance change rate is (7.8Ω). 8.2) / 0.1= 4Ω / s. This indicator can be used to determine sudden load changes and to assist in the output protection control of auxiliary modules.

[0081] The absolute value of the impedance change rate is compared with a preset load threshold. When the absolute value of the impedance change rate is greater than the load threshold, a cut-off command is sent to the main controller of the high-power charging module to control the output relay of the high-power charging module to disconnect the electrical connection with the load.

[0082] The main controller's comparison module performs threshold determination on the absolute value of the impedance change rate. When it detects that the absolute value exceeds the preset load threshold (e.g., 3Ω / s), it immediately sends a cut-off command to the output control unit to disconnect the output relay, thereby preventing power surges or module overcurrent caused by sudden load changes.

[0083] When the calculated impedance change rate is When the current is 4Ω / s and the preset threshold is 3Ω / s, the control system will execute a disconnect command within 10ms to separate the high-power charging module from the load and prevent thermal breakdown or current surge of the device.

[0084] The output relay is closed after the preset delay time is reached, and the load impedance value is re-acquired after the output is restored in order to calculate the impedance change rate.

[0085] The timing module records the relay disconnection time and executes delay logic. When the delay time (e.g., 2 seconds) is reached, the main controller issues a closing command to reclose the output relay and restore the normal output process. The system then re-acquires the load impedance value to determine whether the load change is stable.

[0086] When the delay time is 2 seconds and the impedance value is detected to be stable at around 8.0Ω after the circuit is reopened, the control system considers the load to have returned to normal and continues to operate normally.

[0087] If the absolute value of the impedance change rate is still greater than the load threshold, the output is cut off again and the delay time is increased; if the absolute value of the impedance change rate is less than the load threshold, the output is maintained.

[0088] Load stability is determined through a cyclic detection logic. If the impedance change rate still exceeds the threshold after the relay is reclosed, the control system will perform the cut-off operation again and increase the delay time proportionally (e.g., by 50%) to avoid frequent switching; if the detection result is stable, normal output is maintained.

[0089] For example, if the first delay time is 2s and the impedance change rate is still 3.5Ω / s after the reset, the system will cut off for the second time and extend the delay time to 3s; if the impedance change rate drops to 2.1Ω / s after the second reset, which is lower than the load threshold of 3Ω / s, the system will maintain output and enter the stable operation stage.

[0090] As a preferred option, step S500 can preferably be as follows: Each time the output state changes, the current system time is obtained as a timestamp, and the state evaluation value corresponding to the time of change is recorded.

[0091] By calling the system clock module's time capture interface simultaneously with the output state switching event, millisecond-level timestamp acquisition can be achieved, and the latest calculation result in the state evaluation value cache register can be read synchronously, thereby realizing the synchronous binding of the output state switching event and the state evaluation value.

[0092] When the high-power charging module switches from normal output mode to low-power standby mode, the controller immediately records the system time t1 and the corresponding state evaluation value S1 at the moment of the switch, so as to analyze the dynamic characteristics of the state change later.

[0093] The timestamp and the corresponding state evaluation value are stored in the historical data storage to form a state transition record. When the number of state transition records reaches the preset minimum sample size, the state transition records within the most recent preset time window are extracted, and the output state trend of the state evaluation value changing over time in the extracted state transition records is identified by the time series analysis algorithm. The output state trend includes the trend coefficient and the fluctuation amplitude.

[0094] By setting up a historical data storage device with a ring cache structure, the records of the most recent state transitions can be continuously retained while ensuring that the storage capacity is controlled. Then, the timestamp and state evaluation value are paired and extracted using a sliding time window algorithm. Time series analysis algorithms such as linear regression or exponential smoothing are applied to calculate the slope of the state evaluation value change over time as the trend coefficient, and the fluctuation amplitude is calculated based on the standard deviation of the deviation.

[0095] When the state evaluation value of the output state switching record in the last ten times shows a continuous upward trend, the trend coefficient K takes a positive value; if it shows periodic fluctuations near the safe range, the fluctuation amplitude H is large.

[0096] Based on the trend coefficient and fluctuation amplitude, the state evaluation value is predicted and calculated for the next M sampling periods. When it is predicted that the state evaluation value will exceed the safe range in the next Nth sampling period, the output power of the high-power charging module is pre-regulated in the current sampling period.

[0097] By substituting the trend coefficient K and the current state assessment value S1 into the prediction formula, a sequence of state assessment values ​​for several future sampling periods can be obtained. Combined with the fluctuation amplitude H, a safe confidence interval can be constructed to identify potential over-limit risks in advance and achieve feedforward power control.

[0098] When the state assessment value S for the third future sampling period is predicted... p 3. When the power output exceeds the upper limit of the safe range, the main controller immediately reduces the output power in advance according to the preset pre-regulation strategy, thereby avoiding overload of the module due to delayed response.

[0099] The state assessment value for the next M sampling periods is calculated using the following formula: S pi =S1+K i; Among them, S pi Let S1 be the state evaluation value for the i-th future sampling period, K be the trend coefficient, and i be the index of the i-th future sampling period, where 1≤i≤M.

[0100] S is constructed based on the fluctuation amplitude. pi Confidence interval: [Spi -α H,S pi +α H]; Where α is the preset safety factor and H is the fluctuation range.

[0101] When the Nth sampling period exists, S pi If the confidence interval and the safety interval do not intersect or partially exceed the limit, it is determined that an over-limit will occur in the Nth sampling period in the future, and the output power of the high-power charging module will be actively adjusted in the current sampling period according to the preset pre-control strategy, where M>N≥1.

[0102] By calculating the confidence interval of the predicted sequence and comparing it with the safe interval, potential risks can be identified in advance. When the confidence interval exceeds the limit, the controller determines the adjustment strategy based on the direction of the over-limit trend. If the state assessment value shows an upward trend, the output power is reduced in advance; if there is a downward trend, the output power is maintained or the derating state is lifted.

[0103] When the trend coefficient K is positive, the fluctuation amplitude H is large, and the safety factor α is 1.2, the system predicts S for the second sampling period. p2 If the limit exceeds the upper limit of the safe range, pre-regulation will be triggered immediately, making the output power reduction ΔP proportional to the trend coefficient, thereby ensuring that the module remains in the safe operating range in future cycles.

[0104] like Figure 2 As shown, this application also provides an output state control device 10 for a high-power charging module, which specifically includes an acquisition module 11, a comparison module 12, a derating module 13, a recovery module 14, and a regulation module 15.

[0105] The acquisition module 11 is used to acquire real-time data from the high-power charging module in order to calculate the current state evaluation value.

[0106] The module 11 collects the output voltage, output current, and heat sink temperature of the high-power charging module in real time to obtain operating status information.

[0107] The comparison module 12 is used to perform threshold comparison on the status evaluation value. If the status evaluation value is less than the preset safety range, the high-power charging module is controlled to enter the low-power standby mode.

[0108] The comparison module 12 compares the calculated state evaluation value with the preset upper and lower limits of the safety range in real time. When the state evaluation value is lower than the lower limit of the safety range, it sends an underload status signal to the main controller of the high-power charging module to start the low-power standby mode. At the same time, it keeps the output relay closed and provides maintenance power to the main controller and monitoring circuit through the auxiliary power supply circuit.

[0109] The derating module 13 is used to reduce the output power according to the preset derating curve table if the state assessment value is greater than the safe range.

[0110] When the status assessment value is higher than the upper limit of the safe range, the derating module 13 searches the preset derating curve table based on the difference between the status assessment value and the upper limit of the safe range to obtain the target output power value, and reduces the actual output power by adjusting the duty cycle of the power switch at a preset derating rate to avoid sudden changes in output power, while continuously monitoring changes in the status assessment value.

[0111] The recovery module 14 is used to monitor the impedance change rate of the high-power charging module when the output power is reduced according to the preset derating curve table. If the impedance change rate is greater than the preset load threshold, the output of the high-power charging module is cut off and the output is restored after a preset delay time.

[0112] During the derating process, the recovery module 14 collects the load impedance value of the high-power charging module and calculates the impedance change rate according to the preset monitoring cycle. When the impedance change rate exceeds the load threshold, it cuts off the electrical connection between the output relay and the load, and closes the relay again after the delay time is reached. At the same time, it re-collects the load impedance value for calculation, so as to realize cyclic protection and fast recovery.

[0113] The control module 15 is used to record the timestamp of each output state switch and the corresponding state evaluation value, so as to predict the output state trend in the future sampling period and perform pre-control in advance.

[0114] The control module 15 continuously records the timestamp of each output state switch and the corresponding state evaluation value, stores the historical records in the state switch historical data storage, and calculates the output state trend, including the trend coefficient and fluctuation amplitude, through a time series analysis algorithm. In trend prediction, the state evaluation value of the next M sampling periods is predicted based on the trend coefficient and fluctuation amplitude, and a confidence interval is constructed. When the confidence interval of the predicted value does not intersect with the safety interval or partially exceeds the limit, the output power is immediately adjusted in advance according to the preset pre-control strategy, thereby realizing feedforward protection.

[0115] Through the coordinated control of the above modules, this embodiment can realize dynamic status assessment, intelligent power regulation, real-time overload protection and trend prediction and pre-regulation of high-power charging modules, thereby ensuring that the modules can work safely, stably and efficiently under various load and environmental conditions, and significantly improving the overall reliability and service life of the system.

[0116] It should be noted that although several modules or units of the system for executing actions have been mentioned in the detailed description above, this division is not mandatory. In fact, according to the embodiments of this application, the features and functions of two or more modules or units described above can be embodied in one module or unit. Conversely, the features and functions of one module or unit described above can be further divided and embodied by multiple modules or units.

[0117] From the above description of the embodiments, those skilled in the art will readily understand that the exemplary embodiments described herein can be implemented by software or by combining software with necessary hardware. Therefore, the technical solutions according to the embodiments of this application can be embodied in the form of a software product, which can be stored on a non-volatile storage medium (such as a CD). The method, which is contained in or on a ROM, USB flash drive, external hard drive, etc., includes several instructions to cause an electronic device (which may be a personal computer, server, touch terminal, or network device, etc.) to execute the method according to the embodiments of this application.

[0118] Other embodiments of this application will readily occur to those skilled in the art upon consideration of the specification and practice of the embodiments disclosed herein. This application is intended to cover any variations, uses, or adaptations of this application that follow the general principles of this application and include common knowledge or customary techniques in the art not disclosed herein.

[0119] It should be understood that this application is not limited to the precise structure described above and shown in the accompanying drawings, and various modifications and changes can be made without departing from its scope. The scope of this application is limited only by the appended claims.

Claims

1. A method for controlling the output state of a high-power charging module, characterized in that, include: Acquire real-time data from the high-power charging module to calculate the current state assessment value; The state evaluation value is compared with a threshold. If the state evaluation value is less than a preset safety range, the high-power charging module is controlled to enter a low-power standby mode. If the state assessment value is greater than the safe range, the output power is reduced according to the preset derating curve table; When reducing the output power according to the preset derating curve, the impedance change rate of the high-power charging module is monitored. If the impedance change rate is greater than the preset load threshold, the output of the high-power charging module is cut off and the output is restored after a preset delay time. Record the timestamp and corresponding state evaluation value for each output state transition to predict the output state trend within future sampling periods and perform pre-adjustment in advance.

2. The output state control method for a high-power charging module according to claim 1, characterized in that, The step of acquiring real-time data from the high-power charging module to calculate the current state evaluation value includes: Collect the output voltage, output current, and heat sink temperature of the high-power charging module; The ratio of the output voltage value to the rated voltage value is used as the voltage weighting component, and the ratio of the output current value to the rated current value is used as the current weighting component. The ratio of the radiator temperature value to the maximum allowable temperature value is used as the temperature weighting component, and the ratio of the product of the output voltage value and the output current value to the rated power value is used as the power weighting component. The voltage weight component, the current weight component, the temperature weight component, and the power weight component are multiplied by their respective preset weight coefficients and then summed to obtain the state evaluation value.

3. The output state control method for a high-power charging module according to claim 1, characterized in that, The step of comparing the state evaluation value with a threshold, and determining an underload state if the state evaluation value is less than a preset safety range, and controlling the high-power charging module to enter a low-power standby mode, includes: The state evaluation value is compared with the lower limit of the preset safety range. When the state evaluation value is less than the lower limit of the safety range, a low-power standby mode is activated, and an underload status signal is sent to the main controller of the high-power charging module. Based on the underload state signal, the main controller is driven to turn off the drive signal of the power switch tube of the high-power charging module, and the output relay of the high-power charging module is kept in the closed state. The main controller and monitoring circuit are provided with a maintenance power supply through a preset auxiliary power supply circuit; In the low-power standby mode, the status evaluation value is continuously monitored. When the status evaluation value returns to the safe range, the drive signal of the power switch is restarted to restore normal output.

4. The output state control method for a high-power charging module according to claim 1, characterized in that, The step of reducing the output power according to a preset derating curve table if the state assessment value is greater than the safe range includes: The state assessment value is compared with the upper limit of the safe range. When the state assessment value is greater than the upper limit of the safe range, the difference between the state assessment value and the upper limit is calculated as the overload level parameter. Input the overload level parameter into the preset derating curve table to find the corresponding target output power value; Adjust the duty cycle of the power switch transistor of the high-power charging module to reduce the actual output power to the same level as the target output power value; During the process of reducing output power, power adjustment is performed at a preset derating rate, and the status evaluation value is continuously monitored. When the status evaluation value drops to within the safe range, the derating operation is stopped and the current output power is maintained.

5. The output state control method for a high-power charging module according to claim 1, characterized in that, The step of monitoring the impedance change rate of the high-power charging module when reducing the output power according to a preset derating curve, and cutting off the output of the high-power charging module if the impedance change rate is greater than a preset load threshold, and restoring the output after a preset delay time, includes: When reducing the output power according to the preset derating curve, the current load impedance value of the high-power charging module is continuously collected at a preset monitoring cycle. The difference between the current load impedance value and the load impedance value of the previous monitoring cycle is calculated, and the difference is divided by the time length of the monitoring cycle to obtain the impedance change rate. The load impedance value is calculated based on the ratio of the output voltage value to the output current value. The absolute value of the impedance change rate is compared with a preset load threshold. When the absolute value of the impedance change rate is greater than the load threshold, a cut-off command is sent to the main controller of the high-power charging module to control the output relay of the high-power charging module to disconnect the electrical connection with the load. The output relay is closed after the preset delay time is reached, and the load impedance value is re-acquired after the output is restored in order to calculate the impedance change rate. If the absolute value of the impedance change rate is still greater than the load threshold, the output is cut off again and the delay time is increased; if the absolute value of the impedance change rate is less than the load threshold, the output is maintained.

6. The output state control method for a high-power charging module according to claim 1, characterized in that, The step of recording the timestamp and corresponding state evaluation value of each output state transition to predict the output state trend within future sampling periods and to perform pre-adjustment includes: Each time the output state changes, the current system time is obtained as a timestamp, and the state evaluation value corresponding to the time of change is recorded. The timestamp and the corresponding state evaluation value are stored in the historical data storage to form a state switching record. When the number of state switching records reaches the preset minimum sample size, the state switching records within the most recent preset time window are extracted, and the output state trend of the state evaluation value changing with time in the extracted state switching records is identified by a time series analysis algorithm. The output state trend includes a trend coefficient and a fluctuation amplitude. Based on the trend coefficient and the fluctuation amplitude, the state evaluation value for the next M sampling periods is predicted and calculated. When it is predicted that the state evaluation value for the next Nth sampling period will exceed the safe range, the output power of the high-power charging module is pre-regulated in the current sampling period.

7. The output state control method for a high-power charging module according to claim 6, characterized in that, The step of predicting and calculating the state assessment value for the next M sampling periods based on the trend coefficient and the fluctuation amplitude, and pre-regulating the output power of the high-power charging module in the current sampling period when it is predicted that the state assessment value in the Nth sampling period will exceed the safe range, includes: The state assessment value for the next M sampling periods is calculated using the following formula: S pi =S1+K in; Among them, S pi Let S1 be the state evaluation value for the i-th future sampling period, K be the trend coefficient, and i be the index of the i-th future sampling period, where 1≤i≤M; S is constructed based on the fluctuation amplitude. pi Confidence interval: [S pi -a H,S pi +a H]; Where α is the preset safety factor and H is the fluctuation range; When the Nth sampling period in the future exists, the S pi If the confidence interval and the safety interval do not intersect or partially exceed the limit, it is determined that an over-limit will occur in the Nth sampling period in the future, and the output power of the high-power charging module will be actively adjusted in the current sampling period according to the preset pre-control strategy, where M>N≥1.

8. An output state control device for a high-power charging module, characterized in that, include: The acquisition module is used to acquire real-time data from the high-power charging module in order to calculate the current state evaluation value; The comparison module is used to perform threshold comparison on the state evaluation value. If the state evaluation value is less than the preset safety range, the high-power charging module is controlled to enter the low-power standby mode. The derating module is used to reduce the output power according to a preset derating curve table if the state evaluation value is greater than the safe range. The recovery module is used to monitor the impedance change rate of the high-power charging module when the output power is reduced according to the preset derating curve table. If the impedance change rate is greater than the preset load threshold, the output of the high-power charging module is cut off and the output is restored after a preset delay time. The control module is used to record the timestamp of each output state switch and the corresponding state evaluation value in order to predict the output state trend in the future sampling period and perform pre-control in advance.

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