High-voltage power transformation and direct-current fast charging integrated system

Abstract

The invention discloses a high-voltage power transformation and direct-current fast charging integrated system, and relates to the technical field of electric vehicle charging equipment. The system comprises a physical double-bin unit, a thermal management isolation unit, a layered electromagnetic shielding unit and an integrated grounding unit, through the double-bin integrated design, a high-voltage power transformation module is arranged in a high-voltage bin, a power module and a control module are integrated in an integrated bin, and the whole process integration from 10 kV / 35 kV high-voltage input to direct-current charging output is achieved. The high-voltage bin and the integrated bin adopt an independent heat dissipation system to cut off thermal pollution, electromagnetic protection is formed through a Q235 metal shielding layer and board-level shielding, and the EMI problem is solved in cooperation with a low-impedance equipotential grounding system. The system is high in integration level and compact in structure, can be prefabricated in factories for standardized production, greatly simplifies the installation process, saves the field, improves the working stability and the operation and maintenance efficiency of equipment, and effectively overcomes many defects of traditional discrete equipment.

Description

Technical Field

[0001] This invention relates to the field of electric vehicle charging equipment technology, specifically to an integrated system combining high-voltage power conversion and DC fast charging. Background Technology

[0002] In the field of electric vehicle charging infrastructure, traditional solutions present high-voltage prefabricated substations and DC charging piles as separate devices. This separate approach has several drawbacks: 1. It requires separate site planning and civil construction, and wiring needs to be done separately during installation, which is complicated and time-consuming. 2. The dispersed nature of the equipment results in a large footprint and low space utilization. 3. The heat dissipation of the transformer in the box-type substation and the heat dissipation of the power module of the charging pile affect each other, which can easily lead to thermal pollution and reduce the working stability and lifespan of the power module. 4. Electromagnetic interference (EMI) generated by high-voltage equipment such as transformers can easily enter the control and power circuits of the charging pile, affecting system reliability.

[0003] Therefore, there is an urgent need for an integrated architecture that can highly integrate systems such as high-voltage power substation and DC fast charging, while solving thermal management and electromagnetic compatibility issues. Summary of the Invention

[0004] The purpose of this invention is to provide an integrated system that combines high-voltage power conversion and DC fast charging.

[0005] To achieve the above objectives, the present invention provides the following technical solution: An integrated system for high-voltage power substation and DC fast charging includes a physical dual-compartment unit, a thermal management isolation unit, a layered electromagnetic shielding unit, and an integrated grounding unit, with the following specific structure: Physical dual-compartment unit The equipment is physically isolated into two independent compartments: 1. High-voltage compartment: Independently enclosed, housing transformers, high-voltage switchgear, and transformer AC input copper busbars, used to realize the substation function of 10kV / 35kV high-voltage input.

[0006] 2. Integrated Compartment: Independently enclosed, integrating the functions of the power sub-compartment and the control sub-compartment, including: The power sub-compartment houses AC / DC modules, DC contactors, DC fuses, and charging pile split units, enabling the conversion of AC to DC and DC output. The control sub-compartment houses the control board, switching power supply, AC contactor, 2P switch, intermediate relay, terminal block, etc., to realize intelligent control and power distribution of the system.

[0007] Thermal management isolation unit The high-voltage compartment uses a forced air cooling system to directly exhaust the heat generated by the transformer outside the compartment through a dedicated air duct, thus preventing heat accumulation.

[0008] The integrated compartment adopts an independent heat dissipation system, and its heat dissipation channel is completely physically isolated from the high-pressure compartment's air-cooling system, ensuring that power devices such as AC / DC modules and control components operate in a cool and stable environment.

[0009] Layered electromagnetic shielding unit Chamber-level shielding: The inner walls of both the high-voltage chamber and the integrated chamber are made of Q235 metal shielding material, forming a Faraday cage effect to achieve physical isolation of electromagnetic interference between the high-voltage chamber and the integrated chamber.

[0010] Board-level shielding: Local metal shielding covers are added to key circuit boards such as control boards and communication interfaces to further suppress electromagnetic interference from entering sensitive circuits.

[0011] Integrated grounding unit Design a common, low-impedance equipotential grounding system to reliably connect the shielding layers of the high-voltage compartment and the integrated compartment, the equipment housing, and the cable shielding layers to the system, providing a discharge path for interference currents and preventing them from affecting control and power circuits.

[0012] The beneficial effects of this invention are as follows: This application physically integrates the transformer substation, charging pile power modules, and intelligent control systems into two compartments, reducing site planning, civil engineering, and installation workload, and significantly improving space utilization. Through dual-compartment physical isolation and an independent heat dissipation system, thermal contamination from the high-voltage compartment to the integrated compartment is completely eliminated, ensuring long-term stable operation of the power modules and control components and extending equipment lifespan. Layered electromagnetic shielding and an integrated grounding system form a "dual-compartment" electromagnetic defense, confining electromagnetic interference from high-voltage equipment within the high-voltage compartment and ensuring the reliability of control and power circuits. The system can be prefabricated in the factory as a standardized product, significantly improving production efficiency while facilitating rapid on-site installation and subsequent maintenance.

[0013] The above description is merely an overview of the technical solution of the present invention. In order to better understand the technical means of the present invention and to implement it in accordance with the contents of the specification, the preferred embodiments of the present invention are described in detail below with reference to the accompanying drawings. Attached Figure Description

[0014] Figure 1 This is a schematic diagram of the overall structure of an integrated system for high-voltage power substation and DC fast charging as shown in this application; Figure 2 This is a schematic diagram of the layout of the control sub-compartment within the integrated compartment of a high-voltage substation and DC fast charging integrated system shown in this application; Figure 3This is a schematic diagram of the high-voltage compartment layout of an integrated high-voltage substation and DC fast charging system shown in this application.

[0015] Reference numerals: 1. Integrated compartment; 2. High voltage compartment; 101. AC / DC module; 102. DC contactor; 103. DC fuse; 104. Charging pile split unit; 201. Electricity meter; 202. Control board; 203. Intermediate relay; 204. Wiring terminal; 205. AC contactor; 206. 2P switch; 207. Switching power supply. Detailed Implementation

[0016] The technical solution of the present invention will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0017] In the description of this invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing the invention and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the invention. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0018] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0019] Furthermore, the technical features involved in the different embodiments of the present invention described below can be combined with each other as long as they do not conflict with each other.

[0020] See Figures 1-3 The present invention provides an integrated system for high-voltage power substation and DC fast charging. In this embodiment, the working process of the integrated system is as follows: 1. A 10kV / 35kV high-voltage input is sent to the transformer in the high-voltage compartment 2, and after transformation, it is transmitted to the AC / DC module 101 in the integrated compartment 1 through the AC contactor 205; 2. The AC / DC module 101 converts AC power into DC power, which is then output to the charging pile split unit 104 via DC contactor 102 and DC fuse 103, and finally supplies power to the electric vehicle through the charging gun. 3. The control board 202 inside the integrated chamber 1 collects the status of each module and intelligently regulates the forced air cooling of the high-pressure chamber 2 and the independent heat dissipation of the integrated chamber 1. At the same time, it realizes logic control and signal transmission through intermediate relays 203 and terminal blocks 204.

[0021] During thermal management, the air-cooling system of high-voltage compartment 2 continuously dissipates heat from the transformer, while the heat dissipation system of integrated compartment 1 independently dissipates heat from the AC / DC module 101 and control components. The airflow paths of the two do not intersect, thus completely avoiding thermal interference.

[0022] In terms of electromagnetic shielding, the Q235 metal inner walls of the high-voltage chamber 2 and the integrated chamber 1 together form an electromagnetic barrier, which confines most of the electromagnetic interference generated by the transformer within the high-voltage chamber 2; the local shielding cover on the control board 202 further filters the remaining interference; all metal shielding layers and equipment shells are reliably grounded through an integrated grounding system, and the interference current is quickly discharged through the grounding system.

[0023] This embodiment achieves a high degree of integration between high-voltage substation and DC fast charging through a collaborative design of dual-compartment physical isolation, thermal management isolation, layered electromagnetic shielding, and integrated grounding, significantly improving the system's stability, reliability, and operation and maintenance efficiency.

[0024] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0025] The embodiments described above are merely illustrative of several implementations of the present invention, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the invention patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these all fall within the protection scope of the present invention. Therefore, the protection scope of this invention patent should be determined by the appended claims.

Claims

1. A high-voltage power transformation and direct-current fast charging integrated system, characterized in that, Physical double-warehouse unit, thermal management isolation unit, layered electromagnetic shielding unit and integrated grounding unit are included, and the specific structure is as follows: The physical double-warehouse unit includes two independently closed warehouses, i.e. a high-voltage warehouse and an integrated warehouse; the high-voltage warehouse contains a transformer, a high-voltage switch cabinet and a transformer AC input copper bar; the integrated warehouse integrates a power sub-warehouse and a control sub-warehouse; the power sub-warehouse contains an AC / DC module, a DC contactor, a DC fuse and a charging pile split machine; the control sub-warehouse contains a control board, a switching power supply, an AC contactor, a 2P switch, an intermediate relay and a wiring terminal; The thermal management isolation unit includes a high-voltage warehouse forced air cooling system and an integrated warehouse independent heat dissipation system; the high-voltage warehouse forced air cooling system directly discharges the heat of the transformer outside the warehouse through a special air duct; the integrated warehouse independent heat dissipation system is physically isolated from the high-voltage warehouse forced air cooling system; The layered electromagnetic shielding unit includes a warehouse-level shielding and a board-level shielding; the warehouse-level shielding is made of Q235 metal shielding material and laid on the inner wall of the high-voltage warehouse and the integrated warehouse to form a Faraday cage effect; the board-level shielding is a local metal shielding cover added to the control board and the communication interface; The integrated grounding unit is a common ground, low impedance equipotential grounding system; the shielding layers of the high-voltage warehouse and the integrated warehouse, the equipment shell and the cable shielding layer can be reliably connected to the system.

2. The high-voltage power transformation and DC fast charging integrated system according to claim 1, characterized in that, The forced air cooling system of the high-voltage warehouse includes an axial flow fan and an independent exhaust air duct; the air inlet of the exhaust air duct is arranged on the side of the high-voltage warehouse close to the transformer, and the air outlet extends to the outside of the equipment. 3.The high-voltage power transformation and DC fast charging integrated system of claim 1, wherein, The independent heat dissipation system of the integrated warehouse is one of a forced air cooling system and a liquid cooling heat dissipation system.

4. The high-voltage power transformation and DC fast charging integrated system of claim 1, wherein, The metal shielding cover of the board-level shielding is reliably connected to the integrated grounding system through a grounding wire.

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