Water cooling control method of charging pile system

Abstract

The invention provides a water-cooling control method for a charging pile system. The charging pile system comprises a pile body, a control mainboard, a water-cooling unit, a high-voltage loop and a water-cooling gun head. The control mainboard, the water cooling unit and the high-pressure loop are all located in the pile body. The water-cooling gun head is located on the outer side of the pile body and connected with the water-cooling unit and the output end of the high-voltage loop through a water-cooling pipeline and a water-cooling gun line, and the input end of the high-voltage loop is used for being connected with the mains supply. A temperature sensor is arranged at the water-cooling gun head; the water cooling gun head and the water cooling unit are both in communication and control connection with the control mainboard, and the control mainboard is used for being in communication and control connection with a vehicle BMS. Through the water-cooling gun head and the corresponding water-cooling control strategy, the safety problem caused by the increase of the charging current of the high-power charging pile is solved.

Description

[0001] This case is a divisional application based on the invention patent filed on October 18, 2022, with application number 202211272253.5 and titled "A Water-Cooled Charging Pile System and Its Water-Cooling Control Method". Technical Field

[0002] This invention relates to the field of charging pile technology, and in particular to a water-cooling control method for a charging pile system. Background Technology

[0003] With the development of the new energy industry, electric vehicles are becoming increasingly popular in the market, and the number of charging stations for electric vehicles is also increasing. However, despite the widespread adoption of electric vehicles, charging time has not improved significantly, mainly due to limitations in charging power. According to current national standards, most charging stations on the market currently have a maximum single-gun charging current of 250A, a charging voltage that generally does not exceed 750V, and a power of a single charging station that generally does not exceed 180kW.

[0004] To increase the charging power of charging stations, either the charging voltage or the charging current must be increased. Currently, the maximum charging voltage of 750V for charging stations is already considered relatively high, and most electric vehicles on the market do not reach 750V, so the effect of increasing the charging voltage is relatively limited. However, the charging current can be increased significantly, for example, from 250A to 500A, the power can reach 350kW or even higher.

[0005] With the increasing charging current of these high-power charging piles, implementing safety protection strategies is crucial. How to provide a sound protection mechanism to safeguard the safety of personnel and equipment has gradually become an urgent issue to be addressed. Summary of the Invention

[0006] The technical problem to be solved by the present invention is to provide a water-cooling control method for a charging pile system, providing a water-cooled charging gun head for the charging pile, and combining it with a corresponding water-cooling control strategy to solve the safety problems caused by high-power charging piles.

[0007] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is as follows: A water-cooled charging pile system includes a charging pile body, a control motherboard, a water-cooling unit, a high-voltage circuit, and a water-cooled charging gun head; The control motherboard, the water-cooled unit, and the high-voltage circuit are all located inside the pile body; The water-cooled nozzle is located outside the pile body and is connected to the output end of the water-cooled unit and the high-voltage circuit through water-cooled pipes and water-cooled gun wires, respectively. The input end of the high-voltage circuit is used to connect to the mains power. A temperature sensor is installed at the water-cooling nozzle; Both the water-cooled nozzle and the water-cooled unit are connected to the control motherboard for communication and control. The control motherboard is used for communication and control with the vehicle's BMS.

[0008] To solve the above-mentioned technical problems, another technical solution adopted by the present invention is as follows: A water-cooling control method for a charging pile system, applied to the aforementioned water-cooled charging pile system, includes the following steps: S1. When the vehicle is charging, the control board inside the charging pile obtains the temperature from the temperature sensor located at the water-cooled gun head in real time. S2. The control motherboard sends corresponding operating instructions to the water-cooled unit based on the temperature collected by the temperature sensor and the power parameters fed back by the vehicle BMS. S3. The water-cooled unit receives the working command and controls the flow rate of the coolant in the water-cooled pipeline.

[0009] The beneficial effects of this invention are as follows: This invention provides a water-cooling control method for charging piles. Traditional high-power charging piles often experience overheating of the charging gun head during charging, leading to charging safety hazards. This invention transforms the traditional charging gun head into a water-cooled gun head. Water-cooled pipes and water-cooled gun wires are connected to a water-cooling unit and high-voltage circuit located within the charging pile body. A temperature sensor is installed at the water-cooled gun head to collect the temperature at the gun head in real time during vehicle charging and feed it back to the charging pile's control board. The control board, based on the charging temperature of the gun head and the charging amount fed back by the vehicle's BMS, issues working instructions to the water-cooling unit. The water-cooling unit then adjusts the coolant flow rate in the water-cooling pipes in real time, thereby regulating the operating temperature of the water-cooled gun head, effectively solving the safety problems caused by high-power charging piles. Attached Figure Description

[0010] Figure 1 This is an overall structural diagram of a water-cooled charging pile system according to an embodiment of the present invention; Figure 2 This is a schematic diagram of water cooling control for a water-cooled charging pile system according to an embodiment of the present invention. Figure 3 This is a cross-sectional view of a water-cooled charging gun wire in a water-cooled charging pile system according to an embodiment of the present invention. Figure 4 This is a communication block diagram of a water-cooled charging pile system according to an embodiment of the present invention. Figure 5 This is an overall flowchart of a water-cooling control method for a water-cooled charging pile system according to an embodiment of the present invention. Figure 6 This is a flowchart illustrating a water-cooling control method for a water-cooled charging pile system according to an embodiment of the present invention.

[0011] Label Explanation: 1. Pile body; 2. Control main board; 3. Water-cooled unit; 4. Water-cooled nozzle; 5. High-voltage circuit; 6. Water-cooled pipeline; 7. Water-cooled nozzle wire; 71. Positive cable; 72. Negative cable; 73. Internal environment of nozzle wire. Detailed Implementation

[0012] To explain in detail the technical content, objectives, and effects of the present invention, the following description is provided in conjunction with the embodiments and accompanying drawings.

[0013] Please refer to Figures 1 to 4 A water-cooled charging pile system includes a charging pile body, a control motherboard, a water-cooling unit, a high-voltage circuit, and a water-cooled charging gun head; The control motherboard, the water-cooled unit, and the high-voltage circuit are all located inside the pile body; The water-cooled nozzle is located outside the pile body and is connected to the output end of the water-cooled unit and the high-voltage circuit through water-cooled pipes and water-cooled gun wires, respectively. The input end of the high-voltage circuit is used to connect to the mains power. A temperature sensor is installed at the water-cooling nozzle; Both the water-cooled nozzle and the water-cooled unit are connected to the control motherboard for communication and control. The control motherboard is used for communication and control with the vehicle's BMS.

[0014] As described above, the beneficial effects of this invention are as follows: Traditional high-power charging stations often experience overheating during charging, leading to safety hazards. This invention addresses this by transforming the traditional charging gun into a water-cooled gun. Water-cooled pipes and wires are connected to a water-cooling unit and high-voltage circuit within the charging station. A temperature sensor is installed at the water-cooled gun to collect the temperature in real-time during vehicle charging and feed it back to the charging station's control board. Based on the gun's charging temperature and the charging amount reported by the vehicle's BMS, the control board issues operating commands to the water-cooling unit. The water-cooling unit then adjusts the coolant flow rate in the water-cooling pipes in real-time, thereby regulating the operating temperature of the water-cooled gun and effectively solving the safety issues associated with high-power charging stations.

[0015] Furthermore, the water-cooled gun wire includes a positive cable and a negative cable; The portion of the water-cooled pipeline located outside the pile body is located inside the water-cooled gun line; The input terminals of the positive and negative cables are respectively connected to the positive and negative output terminals of the high-voltage circuit. The output ends of the positive and negative cables are respectively connected to the DC+ and DC- of the water-cooling nozzle.

[0016] As described above, the water-cooled gun wire integrates positive and negative cables connected to the positive and negative output terminals of the high-voltage circuit, thus forming an integrated structure of the water-cooled gun head and water-cooled gun wire outside the charging pile. This facilitates vehicle charging while effectively protecting the positive and negative cables and water-cooling pipes running outside the charging pile.

[0017] Furthermore, a temperature sensor is provided at both the DC+ and DC- terminals of the water-cooling nozzle; The positive electrode cable and the negative electrode cable are each provided with a temperature sensor at a position outside the pile body and away from the water-cooling gun head; A pair of temperature sensors are disposed opposite each other in the water-cooled gun line, except for the positive cable, the negative cable and the water-cooling pipeline.

[0018] As described above, a temperature sensor is installed at both the DC+ and DC- terminals of the water-cooled nozzle, a key component for charging, to accurately monitor its charging temperature in real time. Simultaneously, the positive and negative cables, as current-carrying wires, also significantly impact the charging performance of the charging station. Therefore, temperature sensors are also installed at these cables, taking into account not only the temperature of the water-cooled nozzle but also the temperature of the cables, enabling more intelligent control of the water cooling system. Furthermore, in addition to considering the temperatures of the water-cooled nozzle and cables, two additional temperature sensors are installed within the water-cooled nozzle's internal environment (besides the cables and water-cooling piping) to collect and consider the ambient temperature. Combining the temperatures from all three locations further enhances the accuracy of water cooling control.

[0019] Furthermore, voltage samplers are provided at the DC+ and DC- terminals of the water-cooling gun head, as well as at the positive and negative output terminals of the high-voltage circuit. The voltage sampler is communicatively connected to the control motherboard, and the high-voltage circuit is controlled by the control motherboard.

[0020] As described above, in addition to temperature sensors, voltage samplers are also installed at the DC+ and DC- terminals of the water-cooling gun head to collect the charging voltage at the water-cooling gun head in real time. At the same time, voltage samplers are also installed at the positive and negative output terminals of the high-voltage circuit inside the charging pile to collect the voltage output of the high-voltage circuit. This allows the control board to calculate the line resistance of the positive and negative cables by comparing the voltages at the high-voltage circuit terminal and the water-cooling gun head terminal (the line resistance will change due to temperature or line aging). Based on the line resistance, the heat generation of the cables can be further determined, thereby further controlling the cooling capacity of the water cooling system and enabling timely derating or protection of the charging pile.

[0021] Furthermore, the water-cooling nozzle and the water-cooling unit communicate and are connected to the control motherboard via the first CAN bus; The control board is used for communication and control connection with the vehicle BMS via the second CAN bus.

[0022] As described above, a CAN bus is used to realize the communication and control between the water-cooling nozzle and the water-cooling unit and the control motherboard. At the same time, a CAN bus is also used to realize the communication between the BMS of the vehicle being charged and the control motherboard, so as to ensure the effectiveness and timeliness of the water-cooling control strategy.

[0023] Furthermore, it also includes a leakage sensor; The leakage sensor is built into the water-cooling gun line and communicates with the control motherboard to detect whether leakage has occurred in the water-cooling pipeline.

[0024] As described above, a leakage sensor is added to the water-cooling gun line to detect whether leakage occurs in the water-cooling pipeline in real time. When leakage occurs, the sensor can promptly provide feedback to the control board, which can then issue commands to stop the charging pile and the water-cooling unit, thus preventing damage to the charging pile and the charging vehicle.

[0025] Furthermore, it also includes electronic locks; The electronic lock is built into the water-cooling nozzle and is used to lock the water-cooling nozzle to the vehicle's charging socket when the water-cooling nozzle is charging the vehicle.

[0026] As described above, the water cooling nozzle is equipped with an electronic lock to lock the water cooling nozzle during charging, preventing personnel from unplugging or plugging the water cooling nozzle while it is powered on, thus avoiding safety hazards.

[0027] Please refer to Figure 5 and Figure 6 A water-cooling control method for a water-cooled charging pile system, applied to the aforementioned water-cooled charging pile system, includes the following steps: S1. When the vehicle is charging, the control board inside the charging pile obtains the temperature from the temperature sensor located at the water-cooled gun head in real time. S2. The control motherboard sends corresponding operating instructions to the water-cooled unit based on the temperature collected by the temperature sensor and the power parameters fed back by the vehicle BMS. S3. The water-cooled unit receives the working command and controls the flow rate of the coolant in the water-cooled pipeline.

[0028] As described above, the beneficial effects of this invention are as follows: Based on the same technical concept, using the aforementioned water-cooled charging pile system, a water-cooling control method for the water-cooled charging pile system is provided. Since the charging gun heads of traditional high-power charging piles often experience overheating during charging, leading to charging safety hazards, this invention transforms the traditional charging gun head into a water-cooled gun head. Water-cooled pipes and water-cooled gun wires are connected to a water-cooling unit and high-voltage circuit located within the charging pile body. A temperature sensor is installed at the water-cooled gun head to collect the temperature at the gun head in real time during vehicle charging and feed it back to the charging pile's control board. The control board, based on the charging temperature of the gun head and the charging amount fed back by the vehicle's BMS, issues working instructions to the water-cooling unit. The water-cooling unit then adjusts the coolant flow rate in the water-cooling pipes in real time, thereby regulating the operating temperature of the water-cooled gun head, effectively solving the safety problems caused by high-power charging piles.

[0029] Furthermore, a temperature sensor is provided at both the DC+ and DC- terminals of the water-cooling nozzle.

[0030] Furthermore, in step S2, the control motherboard issues corresponding operating instructions to the water-cooled unit based on the temperature collected by the temperature sensor and the power parameters fed back by the vehicle BMS, specifically as follows: When the temperature Tdc of the DC+ or DC- of the water-cooling nozzle is ≤30℃, the control motherboard sends a working instruction to the water-cooling unit to control the water-cooling pipeline to maintain a low-flow self-circulation state. When 30℃<Tdc≤45℃ or (△Tdc / △t)<V1 and lasts for 3s, the control motherboard sends a working command to the water-cooled unit to control the coolant flow rate F=0.5Fmax in the water-cooled pipeline, where F is the real-time flow rate of the coolant in the water-cooled pipeline, Fmax is the maximum flow rate of the coolant, △Tdc is the temperature change value of the DC+ or DC- of the water-cooling nozzle in time △t, and V1 is the first preset temperature rise rate in time △t. When 45℃<Tdc≤60℃ or V1<(△Tdc / △t)<V2 and this continues for 3s, the control motherboard sends a working instruction to the water-cooled unit to control the flow rate of the coolant in the water-cooled pipeline F=0.75Fmax, where V2 is the second preset temperature rise rate within the time △t. When 60℃<Tdc≤90℃ or (△Tdc / △t)>V2 and lasts for 3s, the control motherboard sends a working command to the water-cooled unit to control the flow rate of the coolant in the water-cooled pipeline F=Fmax. When the control motherboard receives feedback from the vehicle's BMS that the vehicle battery is fully charged, it controls the charging station to stop charging.

[0031] As described above, a temperature sensor is installed at both the DC+ and DC- terminals of the water-cooling gun head, which is a key component for charging, to collect the charging temperature of the water-cooling gun head in real time, ensuring accuracy.

[0032] The present invention discloses a water-cooled charging pile system and its water-cooling control method, which solves the safety problems caused by increasing the charging current of high-power charging piles from 250A to 500A through water-cooled gun heads and corresponding water-cooling control strategies. The following is a description in conjunction with specific embodiments.

[0033] Please refer to Figure 1 and Figure 4 Embodiment 1 of the present invention is as follows: A water-cooled charging station system, such as Figure 1 As shown, it includes pile body 1, control main board 2, water-cooled unit 3, high-voltage circuit 5, and water-cooled gun head 4.

[0034] In this embodiment, the control motherboard 2, the water-cooled unit 3, and the high-voltage circuit 5 are all located inside the pile body 1; the water-cooled gun head 4 is located outside the pile body 1 and is connected to the output end of the water-cooled unit 3 and the high-voltage circuit 5 (not shown in the figure) through the water-cooled pipe 6 and the water-cooled gun wire 7, respectively, while the input end of the high-voltage circuit 5 is used to connect to the mains power.

[0035] Meanwhile, in this embodiment, temperature sensors are installed at four locations on the water-cooling gun head; such as Figure 4 As shown, both the water-cooled nozzle 4 and the water-cooled unit 3 are connected to the control motherboard 2 for communication and control. The control motherboard 2 is also used to communicate and control the BMS of the vehicle being charged.

[0036] In this embodiment, since the charging gun head of a traditional high-power charging pile often overheats during charging, leading to charging safety hazards, this embodiment modifies the traditional charging gun head into a water-cooled gun head 4. This gun head is connected to the water-cooling unit 3 and high-voltage circuit 5 located inside the charging pile body 1 via water-cooling pipes 6 and water-cooling gun wires 7. A temperature sensor is installed at the water-cooled gun head 4 to collect the temperature at the gun head in real time during vehicle charging and feed it back to the charging pile's control board 2. The control board 2 then issues operating commands to the water-cooling unit 3 based on the charging temperature of the gun head and the charging amount fed back by the vehicle's BMS. The water-cooling unit 3 adjusts the flow rate of the coolant in the water-cooling pipes 6 in real time, thereby regulating the operating temperature of the water-cooled gun head 4, effectively solving the safety problems caused by high-power charging piles.

[0037] It's worth noting that the water-cooled charging gun cable 7 integrates liquid cooling piping within a conventional charging gun cable, extending from the charging head to the inside of the charging pile and connecting to the heat exchanger's piping internally. Existing charging gun cables and heads generate significant heat during high-current operation. Due to limitations in cable specifications and the size of the connection points between the charging head and the vehicle, conventional charging cables cannot meet the power density requirements of supercharging. Therefore, a heat exchange device must be incorporated within the cable. The water-cooled charging gun cable 7 provides a heat dissipation pathway for the power cable and the internal connection terminals of the charging head. The water-cooled charging head 4 is compatible with the interface logic of current conventional charging guns and supports charging vehicles with high-current supercharging capabilities.

[0038] Furthermore, in this embodiment, for example... Figure 4 As shown, the water-cooled nozzle 4 and the water-cooling unit 3 communicate and are controlled by the control motherboard 2 via the first CAN bus; the control motherboard 2 communicates and is controlled by the vehicle's BMS via the second CAN bus. That is, through two CAN buses, one for communication between the water-cooled nozzle 4 and the water-cooling unit 3 and the control motherboard 2, and the other for communication between the vehicle's BMS and the charging pile's control motherboard 2, the control of various devices within the charging pile and the information exchange between the charging pile and the vehicle are realized, ensuring the effectiveness and timeliness of the water-cooling control strategy.

[0039] Please refer to Figure 2 and Figure 3 Embodiment two of the present invention is as follows: A water-cooled charging pile system, based on the above embodiment one, in this embodiment, as follows: Figure 3 As shown, the water-cooled gun wire 7 includes a positive cable 71 and a negative cable 72.

[0040] In this embodiment, the portion of the water-cooled pipe 6 located outside the pile body 1 is located inside the water-cooled gun line 7. Meanwhile, the input ends of the positive cable 71 and the negative cable 72 are respectively connected to the positive output end and the negative output end of the high-voltage circuit 5, and the output ends of the positive cable 71 and the negative cable 72 are respectively connected to the DC+ and DC- of the water-cooled gun head 4.

[0041] It is worth noting that, in this embodiment, the positive and negative output terminals of the high-voltage circuit 5 are not explicitly labeled, nor are the various devices within the high-voltage circuit 5 explicitly labeled. However, those skilled in the art should understand that the AC power input to the charging pile needs to be rectified, transformed, and converted into DC power suitable for electric vehicle charging via the high-voltage circuit 5. This DC power is then output through the positive and negative output terminals of the high-voltage circuit 5 to the positive cable 71 and negative cable 72, respectively. The positive and negative cables 71 and 72 then transmit the DC power to the DC+ and DC- terminals of the water-cooled nozzle 4 to charge the external electric vehicle. Meanwhile, in this embodiment… Figure 2The high voltage circuit only displays simple components on the positive and negative circuits. Specifically, a shunt is connected in series in the circuit between the positive cable 71 and the charging pile input +. This shunt can be used to collect the current magnitude of the high voltage circuit 5. By collecting the current magnitude of the high voltage circuit 5, the charging power and heat generation can be calculated, providing a basis for the calculation of the controller system strategy. In contrast, a fuse FU is connected in series in the circuit between the negative cable 72 and the charging pile input -. This fuse can melt in time when a short circuit or leakage occurs in the high voltage circuit 5, protecting the charging pile and the electric vehicle being charged. In addition, a relay, K1 and K2, is connected in series in both the positive and negative circuits. This relay can be connected to the control board 2, and the opening and closing state of its contacts can be controlled by the control board 2. In the event of an abnormality in the charging pile, the charging circuit can be disconnected in time to further protect the charging pile itself and the electric vehicle being charged.

[0042] In this embodiment, the water-cooled gun wire 7 integrates the positive cable 71 and the negative cable 72, which are connected to the positive and negative output terminals of the high-voltage circuit 5, thereby making the water-cooled gun head 4 and the water-cooled gun wire 7 outside the pile body 1 form an integrated structure. At the same time, the water-cooled pipe 6 can be made of FEP heat shrink tubing, which facilitates charging of the vehicle while effectively protecting the wiring of the positive cable 71, the negative cable 72, and the water-cooled pipe 6 outside the pile body 1.

[0043] In this embodiment, a temperature sensor is installed at both the DC+ and DC- terminals of the water-cooling nozzle 4. As a crucial part of the charging process, the presence of a temperature sensor at both the DC+ and DC- terminals of the water-cooling nozzle 4 allows for real-time monitoring of its charging temperature. This facilitates the control panel in issuing water-cooling control commands to the water-cooling unit 3 to accurately control the flow rate of the coolant in the water-cooling pipes 6.

[0044] Meanwhile, in this embodiment, a temperature sensor is also installed on both the positive cable 71 and the negative cable 72 outside the charging pile 1 and away from the water-cooled nozzle 4. Since the positive cable 71 and the negative cable 72 are current-carrying cables, their temperature has a significant impact on the charging performance of the charging pile. Therefore, temperature sensors are installed on both the positive cable 71 and the negative cable 72 to consider not only the temperature of the water-cooled nozzle 4 but also the temperature of the cables, enabling more intelligent control of the water cooling system.

[0045] In addition, in this embodiment, a pair of temperature sensors are also installed in locations other than the positive cable 71, negative cable 72, and water-cooling pipe 6 within the water-cooled gun line 7. That is, in addition to considering the temperature of the water-cooled gun head 4 and the cables, two temperature sensors are also installed in the internal environment 73 of the water-cooled gun line 7 (excluding the cables and water-cooling pipe 6) to collect and consider the ambient temperature of the water-cooled gun line 7. By combining the temperatures from these three locations, water cooling can be further controlled more accurately.

[0046] In summary, in this embodiment, by collecting six temperature data points from the water-cooled gun cable 7 (two gun head terminal temperatures at DC+ and DC- of the water-cooled gun head 4, two gun cable temperatures at the positive cable 71 and negative cable 72, and two ambient temperatures within the gun cable environment 73), under normal circumstances, the gun head terminal temperature > gun cable temperature > ambient temperature within the gun cable. The control panel compares the temperatures collected from different locations by the temperature acquisition device to determine whether any abnormalities have occurred, such as the relationship between each temperature and its abnormal threshold, and alarms for exceeding abnormal thresholds. By judging the temperature abnormalities at each temperature acquisition point, it determines whether a charging fault has occurred, providing a basis for the water-cooled unit 3 to control the flow rate of the coolant in the water-cooled pipeline 6. When the temperature is high, the flow rate is increased; when the temperature is low, the flow rate is decreased, so that the temperature inside the water-cooled gun head 4 is controlled within a constant range or at a constant value, thus achieving effective water-cooling control of the high-power charging pile charging process.

[0047] Embodiment 3 of the present invention is as follows: A water-cooled charging pile system, based on the above embodiment two, in this embodiment, voltage samplers are provided at the DC+ and DC- terminals of the water-cooled gun head 4 and the positive and negative output terminals of the high-voltage circuit 5.

[0048] Among them, the voltage sampler is connected to the control motherboard 2 for communication, and the high voltage circuit 5 is connected to the control motherboard 2 for control.

[0049] In this embodiment, in addition to temperature sensors, voltage samplers are also installed at the DC+ and DC- terminals of the water-cooling gun head 4 to collect the charging voltage at the water-cooling gun head 4 in real time. At the same time, voltage samplers are also installed at the positive and negative output terminals of the high-voltage circuit 5 located in the charging pile body 1 to collect the voltage output of the high-voltage circuit 5. This allows the mainboard 2 to calculate the line resistance of the positive cable 71 and the negative cable 72 by comparing the voltages at the high-voltage circuit 5 and the water-cooling gun head 4 (the line resistance will change due to temperature or line aging). Based on the line resistance, the heat generation of the cables can be further determined, thereby further controlling the cooling capacity of the water cooling system and timely derating or protecting the charging pile.

[0050] In this embodiment, a leakage sensor is also included. The leakage sensor is built into the water-cooling gun line 7 and communicates with the control motherboard 2 to detect whether leakage occurs in the water-cooling pipeline in real time. When leakage occurs, the sensor can promptly feed back to the control motherboard 2, which can then issue commands such as stopping the charging pile and stopping the water-cooling unit 3 to prevent damage to the charging pile and the electric vehicle being charged.

[0051] In addition, this embodiment also includes an electronic lock. The electronic lock is built into the water-cooling nozzle 4 and is used to lock the water-cooling nozzle 4 to the vehicle's charging socket when the water-cooling nozzle 4 is charging the vehicle, preventing personnel from unplugging or plugging the water-cooling nozzle 4 while it is energized, thus preventing safety hazards.

[0052] Please refer to Figure 5 and Figure 6 Embodiment four of the present invention is as follows: A water-cooling control method for a water-cooled charging pile system, employing a water-cooled charging pile system as described in Embodiment 3 above, such as... Figure 5 As shown, the steps include: S1. When the vehicle is charging, the control board inside the charging pile obtains the temperature from the temperature sensor located at the water-cooled gun head in real time.

[0053] S2. The control board sends corresponding operating instructions to the water-cooled unit based on the temperature collected by the temperature sensor and the power parameters fed back by the vehicle BMS.

[0054] S3. The water-cooled unit receives the working command and controls the flow rate of the coolant in the water-cooled pipeline.

[0055] In this embodiment, based on the same technical concept and in conjunction with the aforementioned water-cooled charging pile system, a water-cooling control method for a water-cooled charging pile system is provided. Since the charging gun heads of traditional high-power charging piles often experience overheating during charging, leading to charging safety hazards, this embodiment modifies the traditional charging gun head into a water-cooled gun head. Water-cooled pipes and water-cooled gun wires are connected to a water-cooling unit and high-voltage circuit located within the charging pile body. A temperature sensor is installed at the water-cooled gun head to collect the temperature at the gun head in real time during vehicle charging and feed it back to the charging pile's control board. The control board then issues operating commands to the water-cooling unit based on the charging temperature of the gun head and the charging amount fed back by the vehicle's BMS. The water-cooling unit adjusts the coolant flow rate in the water-cooling pipes in real time, thereby regulating the operating temperature of the water-cooled gun head and effectively solving the safety problems caused by high-power charging piles.

[0056] like Figure 6 As shown in the example, this embodiment illustrates the water cooling control process of a water-cooled charging pile system: First, when the vehicle needs to be charged, you can insert the water-cooling nozzle into the vehicle's socket, then connect the vehicle to the charging station via CAN bus and start the charging station.

[0057] The charging station is powered on and performs a self-check. If there are no problems, it waits to start charging. If there are problems, it reports the fault and stops using the charging station.

[0058] Before charging begins, the control board will first detect the insertion signal of the water-cooling gun head. After successful insertion, the charging pile can first output current to the vehicle's BMS to establish a communication connection. If the BMS cannot exchange information with the control board of the charging pile, an alarm will sound indicating BMS communication failure, and charging will stop.

[0059] Once communication between the charging station and the BMS is successfully established, the electronic lock of the water-cooling nozzle can be activated to lock the nozzle. The control panel then controls the high-voltage circuit relays K1 and K2 to close, and the charging station begins charging the vehicle.

[0060] During the charging process, the BMS provides real-time feedback on the battery's charging level to the control motherboard. At the same time, the temperature sensor also collects the temperature at each sampling point inside the water-cooling nozzle and feeds it back to the control motherboard.

[0061] like Figure 6 As shown, the temperatures at DC+ and DC- of the water-cooling nozzle are used as an example: When the temperature Tdc of the water-cooling nozzle's DC+ or DC- is ≤30℃, the water-cooling unit controls the water-cooling piping to maintain a low-flow self-circulation state; when 30℃ < Tdc ≤ 45℃ or (△Tdc / △t) < V1 and lasts for 3 seconds, the water-cooling unit controls the coolant flow rate in the water-cooling piping to F = 0.5Fmax, where F is the real-time flow rate of the coolant in the water-cooling piping, Fmax is the maximum flow rate of the coolant, and △Tdc is the temperature of the water-cooling nozzle's DC+ or DC-. The temperature change value within time Δt, where V1 is the first preset temperature rise rate within time Δt; when 45℃<Tdc≤60℃ or V1<(△Tdc / △t)<V2 and lasts for 3s, the coolant flow rate in the water-cooled pipeline of the water-cooled unit is controlled as F=0.75Fmax, where V2 is the second preset temperature rise rate within time Δt; when 60℃<Tdc≤90℃ or (△Tdc / △t)>V2 and lasts for 3s, F=Fmax is controlled.

[0062] Taking the temperature of the water-cooled gun head combined with the ambient temperature Te inside the gun wire and the cable resistance Rdcc as an example: When 90℃<Tdc≤100℃ or 80℃<Te≤85℃ or Rdcc≥Rmax, the water-cooled unit controls the coolant flow rate F=Fmax in the water-cooled pipeline and reduces the charging power by 50%, where Rmax is the maximum internal resistance of the positive and negative cables.

[0063] Taking the temperature of the water-cooled gun head combined with the cable temperature Tdcc and the ambient temperature Te inside the gun cable as an example: When Tdc > 100℃, Te > 85℃, Tdcc - Tdc > 5℃, Te > Tdcc, or |TDC+ - TDC| > 20℃, charging will stop and a fault will be reported. Here, TDC+ is the temperature at DC+ of the water-cooling gun head, and TDC- is the temperature at DC- of the water-cooling gun head.

[0064] When the leakage sensor detects leakage in the water-cooling nozzle, charging is stopped and a fault is reported.

[0065] Finally, the control board determines whether charging is complete based on the vehicle battery power level fed back by the BMS. If so, charging is stopped, the high-voltage circuit is disconnected, the electronic lock is engaged, the water cooling nozzle is removed, and the system waits for the next charging cycle.

[0066] In summary, the water-cooled charging pile system and its water-cooling control method provided by this invention have the following beneficial effects: 1. By using a water-cooling control method for the charging pile system, the use of high-power charging piles with water cooling and high current is made safer, providing a feasible solution for increasing the current charging current from 250A to 500A.

[0067] 2. A constant temperature control method is adopted. Before reaching the abnormal threshold, the coolant flow rate is adjusted by collecting data at the main temperature points, thereby stabilizing the temperature of the water-cooled gun head at a certain point, making full use of the charging pile's power, and minimizing the charging time within the allowable temperature.

[0068] 3. The above strategies can be applied not only to single-pile, single-gun charging piles, but also to single-pile, dual-gun or multi-gun charging piles sharing a single water-cooling unit. The water-cooling pipes between each water-cooled gun line and the water-cooling unit are independent and can be controlled individually. The charging pile's mainboard collects parameters such as temperature and water-cooling pipe flow rate for each individual circuit gun line. The safety protection strategies are universal, enabling independent control and operation of each water-cooling pipe, reducing the number of charging piles and mainboards, reducing costs, reducing the cost of liquid-cooled pile cooling units and charging piles, and reducing land occupation. This provides a new approach to the construction of a charging station and reduces construction costs.

[0069] 4. In addition to temperature, the water-cooling nozzle can also collect the voltage on the cable. By comparing it with the voltage at the output of the high-voltage circuit, the cable resistance can be calculated. When the resistance reaches a certain value, it can be determined that the heat generated by the line exceeds the cooling capacity, so as to reduce the rated or protect the line in time.

[0070] The above description is merely an embodiment of the present invention and does not limit the patent scope of the present invention. Any equivalent modifications made based on the content of the present invention specification and drawings, or direct or indirect applications in related technical fields, are similarly included within the patent protection scope of the present invention.

Claims

1. A water-cooling control method for a charging pile system, characterized in that, The charging pile system includes a charging pile body, a control main board, a water-cooled unit, a high-voltage circuit, and a water-cooled charging gun head. The control main board, the water-cooled unit, and the high-voltage circuit are all located within the charging pile body. The water-cooled charging gun head is located outside the charging pile body and is connected to the output terminals of the water-cooled unit and the high-voltage circuit via water-cooled pipes and a water-cooled charging gun wire, respectively. The input terminal of the high-voltage circuit is used to connect to the mains power. The water-cooled charging gun wire integrates liquid-cooled pipes within a conventional charging gun wire, extending from the water-cooled charging gun head to the interior of the charging pile body, and connects to the heat exchanger's pipes inside the charging pile body. A temperature sensor is installed at the water-cooled charging gun head, with one temperature sensor at each of its DC+ and DC- terminals. Both the water-cooled charging gun head and the water-cooled unit are connected to the control main board for communication and control. The control main board is used for communication and control with the vehicle's BMS (Battery Management System). Including the following steps: S1. When the vehicle is charging, the control board inside the charging pile obtains the temperature from the temperature sensor located at the water-cooled gun head in real time. S2. The control motherboard, based on the temperature collected by the temperature sensor and the power parameters fed back by the vehicle BMS, issues corresponding operating instructions to the water-cooled unit, specifically: When the temperature Tdc of the DC+ or DC- of the water-cooling nozzle is ≤30℃, the control motherboard sends a working instruction to the water-cooling unit to control the water-cooling pipeline to maintain a low-flow self-circulation state. When 30℃<Tdc≤45℃ or (△Tdc / △t)<V1 and lasts for 3s, the control motherboard sends a working command to the water-cooled unit to control the coolant flow rate F=0.5Fmax in the water-cooled pipeline, where F is the real-time flow rate of the coolant in the water-cooled pipeline, Fmax is the maximum flow rate of the coolant, △Tdc is the temperature change value of the DC+ or DC- of the water-cooling nozzle in time △t, and V1 is the first preset temperature rise rate in time △t. When 45℃<Tdc≤60℃ or V1<(△Tdc / △t)<V2 and this continues for 3s, the control motherboard sends a working instruction to the water-cooled unit to control the flow rate of the coolant in the water-cooled pipeline F=0.75Fmax, where V2 is the second preset temperature rise rate within the time △t. When 60℃<Tdc≤90℃ or (△Tdc / △t)>V2 and lasts for 3s, the control motherboard sends a working command to the water-cooled unit to control the flow rate of the coolant in the water-cooled pipeline F=Fmax. When the control motherboard receives feedback from the vehicle BMS that the vehicle battery is fully charged, it controls the charging pile to stop charging. S3. The water-cooled unit receives the working command and controls the flow rate of the coolant in the water-cooled pipeline.

2. The water-cooling control method for a charging pile system according to claim 1, characterized in that, The water-cooled gun cable includes a positive cable and a negative cable; The portion of the water-cooled pipeline located outside the pile body is located inside the water-cooled gun line; The input ends of the positive cable and the negative cable are respectively connected to the positive output end and the negative output end of the high voltage circuit, and a shunt is connected in series on the line connecting the positive cable and the positive output end of the high voltage circuit, and a fuse is connected in series on the line connecting the negative cable and the negative output end of the high voltage circuit. The output ends of the positive and negative cables are respectively connected to the DC+ and DC- of the water-cooling nozzle.

3. The water-cooling control method for a charging pile system according to claim 2, characterized in that, The positive electrode cable and the negative electrode cable are each provided with a temperature sensor at a position outside the pile body and away from the water-cooling gun head; A pair of temperature sensors are disposed opposite each other in the water-cooled gun line, except for the positive cable, the negative cable and the water-cooling pipeline.

4. The water-cooling control method for a charging pile system according to claim 2, characterized in that, Voltage samplers are provided at the DC+ and DC- terminals of the water-cooled gun head, as well as at the positive and negative output terminals of the high-voltage circuit. The voltage sampler is communicatively connected to the control motherboard, and the high-voltage circuit is controlled by the control motherboard.

5. The water-cooling control method for a charging pile system according to claim 1, characterized in that, The water-cooling nozzle and the water-cooling unit communicate and are connected to the control motherboard via the first CAN bus. The control board is used for communication and control connection with the vehicle BMS via the second CAN bus.

6. The water-cooling control method for a charging pile system according to claim 1, characterized in that, It also includes a leak sensor; The leakage sensor is built into the water-cooling gun line and communicates with the control motherboard to detect whether leakage has occurred in the water-cooling pipeline.

7. The water-cooling control method for a charging pile system according to claim 1, characterized in that, It also includes electronic locks; The electronic lock is built into the water-cooling nozzle and is used to lock the water-cooling nozzle to the vehicle's charging socket when the water-cooling nozzle is charging the vehicle.

8. The water-cooling control method for a charging pile system according to claim 1, characterized in that, Step S1 further includes: Insert the water-cooling nozzle into the vehicle's socket, connect the vehicle to the charging station via CAN bus, start the charging station, and the charging station will perform a self-test. If there are no problems, wait to start charging; if there are problems, report the fault and stop using the charging station.

9. The water-cooling control method for a charging pile system according to claim 8, characterized in that, Step S1 further includes: When the control motherboard detects the insertion signal of the water-cooling nozzle, the charging pile outputs current to the vehicle's BMS to establish a communication connection. If the vehicle's BMS cannot exchange information with the control motherboard, an alarm for BMS communication failure is triggered, and charging is stopped. Otherwise, the electronic lock of the water-cooling nozzle is activated, and the relay in the high-voltage circuit is closed, allowing the charging pile to charge the vehicle.

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