Integrated direct current charging pile

Abstract

The invention relates to an integrated direct-current charging pile which comprises a shell, a direct-current power module, a charging pile controller and an auxiliary power circuit, the direct-current power module, the charging pile controller and the auxiliary power circuit are arranged in the shell, the input end of the auxiliary power circuit is connected with the direct-current power module, and the output end of the auxiliary power circuit supplies power to the charging pile controller. The charging pile controller is integrated on the DC power supply module. According to the invention, the built-in power taking and charging pile controller of the auxiliary power supply circuit is integrated into the DC power supply module, so that the design of a traditional plug-in independent module is abandoned. And under the same power condition, the size of the whole equipment is effectively reduced, and the transportation and storage cost is reduced.

Description

Technical Field

[0001] This invention relates to the field of electric vehicle charging equipment technology, and in particular to a DC charging pile that highly integrates a power module, a charging pile controller, and an auxiliary power supply. Background Technology

[0002] With the rapid development of the new energy vehicle industry, DC charging piles, as core energy replenishment facilities, have attracted much attention regarding their performance, cost, and reliability. However, existing traditional DC charging piles have the following significant design flaws: Low integration and large size: In traditional designs, DC power modules, charging pile controllers, and auxiliary power supplies are usually purchased and assembled as independent units. In particular, auxiliary power supplies often require a separate power module to be connected to the mains power to convert it into low-voltage electricity. This results in low utilization of the internal space of the equipment and makes it difficult to compress the overall size.

[0003] The manufacturing process is complex, and the wiring harnesses are numerous: because the power modules, controller modules, and auxiliary power modules are separate, they must be connected by a large number of external wiring harnesses during assembly. This "building block" assembly method not only results in messy production harnesses and complex wiring processes, making it difficult to achieve automated production, but also leads to high manual wiring costs and poor consistency.

[0004] High failure rate and severe electromagnetic interference: The complex external wiring harness is not only prone to loosening or wear during transportation and operation, leading to poor contact or short circuits, but long-distance wiring transmission also easily introduces electromagnetic interference, affecting signal stability. Furthermore, compatibility issues often arise when matching independent modules from different suppliers, further increasing the overall failure rate.

[0005] Heat dissipation difficulties and high noise levels: Traditional charging piles suffer from poor heat dissipation efficiency due to the losses of silicon-based devices and their dispersed layout. To address the temperature rise issue, multiple high-speed, high-power fans are often required, which directly results in significant noise during operation and severely impacts the user experience.

[0006] High costs: The material costs of independent modules, the labor costs of complicated assembly, and the high transportation and warehousing costs due to their large size put traditional charging piles at a disadvantage in market competition.

[0007] Therefore, there is an urgent need for an integrated DC charging pile solution that is highly integrated in structure, simple in manufacturing process, has high heat dissipation efficiency, and is low in cost. Summary of the Invention

[0008] This invention addresses the problems of the existing technology by providing an integrated DC charging pile. The core of this invention lies in redefining the architecture of the charging pile: DC power module + charging pile controller + auxiliary power supply = integrated DC charging pile. Through a highly integrated internal power supply scheme and a wiring harness-free design, it achieves size reduction, cost reduction, and improved reliability.

[0009] To achieve the above objectives, the technical solution of the present invention is as follows: An integrated DC charging pile includes a housing and a DC power module, a charging pile controller, and an auxiliary power circuit within the housing. The input terminal of the auxiliary power circuit is connected to the DC power module, and the output terminal of the auxiliary power circuit supplies power to the charging pile controller. The charging pile controller is integrated on the DC power module.

[0010] Preferably, the DC power module includes a PFC power board and a DC / DC converter board, wherein the PFC power board and the DC / DC converter board are disposed opposite to each other and a heat dissipation duct gap is provided between them.

[0011] Preferably, the PFC power board is equipped with an EMC filter circuit and a three-phase VIENNA rectifier; the DC / DC converter board is equipped with a full-bridge inverter, a high-frequency transformer and an LLC resonant converter.

[0012] Preferably, the auxiliary power supply circuit is connected to the PFC power board.

[0013] Preferably, the charging pile controller includes a PCB board, and the charging pile controller is connected to the main board of the DC power module through its PCB board.

[0014] Preferably, the gap between the components on the PFC power board and the components on the DC / DC converter board is greater than or equal to 4 mm.

[0015] Preferably, a fan is provided on the top of the PFC power board and the DC / DC converter board, and heat dissipation holes are provided on the bottom of the housing.

[0016] Preferably, a fan is provided at the bottom of the PFC power board and the DC / DC converter board, and heat dissipation holes are provided at the top of the housing.

[0017] Preferably, it also includes a fixing plate, and three fans are provided, with the fans fixed on the fixing plate.

[0018] Preferably, the fixing plate is provided with a handle.

[0019] The integrated DC charging pile of the present invention has the following advantages compared with the prior art: Ultimate integration, 50% size reduction: By integrating the auxiliary power circuit and charging pile controller into the DC power module, the traditional external independent module design is eliminated. Under the same power conditions, the overall size of the equipment is effectively reduced, lowering transportation and storage costs.

[0020] Eliminating wire harnesses, simplifying processes, and reducing costs: This invention replaces all external control and power supply wire harnesses with internal PCB wiring, completely eliminating cumbersome manual or mechanical wiring processes. This not only reduces material costs (eliminating wire harnesses and connectors) but also significantly improves production automation and lowers manufacturing costs.

[0021] Significantly improved stability: It eliminates compatibility issues caused by inconsistent supplier matching in traditional solutions, as well as frequent failures due to loose or aging wiring harnesses. The internal wiring scheme avoids electromagnetic interference between wiring harnesses, greatly reducing the overall failure rate.

[0022] Efficient heat dissipation and low noise: Optimized airflow clearance and a 3-fan design ensure smooth airflow. Reduced heat generation necessitates only low-speed fans to meet cooling requirements, solving the problem of excessive noise in traditional charging stations.

[0023] EMC performance optimization: The integrated design shortens the transmission path of high-frequency signals, and together with the built-in filtering circuit, it effectively suppresses electromagnetic interference and improves the electromagnetic compatibility of the equipment. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of an integrated DC charging pile provided in an embodiment of the present invention; Figure 2 This is a schematic diagram of the structure of a DC power supply module provided in an embodiment of the present invention; Figure 3 This is an exploded view of a DC power supply module provided in an embodiment of the present invention. Detailed Implementation

[0025] The following detailed description illustrates the specific implementation method: The reference numerals in the accompanying drawings include: housing 1, DC power module 2, PFC power board 3, DC / DC converter board 4, fan 5, heat dissipation hole 6, fixing plate 7, handle 8, charging pile controller 9, auxiliary power circuit 10.

[0026] As attached Figure 1-3As shown in the figure, this embodiment demonstrates an integrated DC charging pile, which includes a housing 1 and a DC power module 2, a charging pile controller 9, and an auxiliary power circuit 10 disposed within the housing 1. The input terminal of the auxiliary power circuit 10 is electrically connected to the high-voltage side inside the DC power module 2, directly obtaining and converting electrical energy from the DC power module 2. Its output terminal provides a stable low-voltage power supply to the charging pile controller 9 and the external BMS system. The charging pile controller 9 is physically and electrically directly integrated with the main board of the DC power module 2 through its own PCB board. The two are connected via board-to-board connectors or soldering, completely eliminating the need for traditional external wiring harnesses.

[0027] Furthermore, the DC power module 2 includes a PFC power board 3 and a DC / DC converter board 4, which are arranged in a left-right facing configuration. A ventilation gap is intentionally maintained between them, serving as the main airflow channel for the heat dissipation system. Preferably, the gap between the components on the PFC power board 3 and the components on the DC / DC converter board 4 is greater than or equal to 4mm, preferably 5mm, to ensure sufficient airflow and effective heat removal.

[0028] In terms of circuit composition, the PFC power board 3 integrates an EMC filter circuit and a three-phase VIENNA rectifier, responsible for filtering and power factor correction of the input three-phase AC power, and boosting it to the high-voltage DC bus. The DC / DC converter board 4 is equipped with a full-bridge inverter, a high-frequency transformer, and an LLC resonant converter, used to convert the high-voltage DC power into an adjustable DC voltage that can charge the electric vehicle battery. The auxiliary power supply circuit 10 is integrated into the PFC power board 3, which draws power directly from the internal high-voltage bus or transformer auxiliary winding of the DC power module 2, realizing the internal integration of the auxiliary power supply.

[0029] To achieve efficient heat dissipation, a set of fans 5 is installed on the air intake or exhaust side of the air duct formed by the PFC power board 3 and the DC / DC converter board 4. Specifically, the fans 5 can be arranged on the top of the power board, in which case heat dissipation holes 6 are opened at the bottom of the housing 1 to form an upward airflow path. Alternatively, the fans 5 can also be arranged at the bottom of the power board, in which case heat dissipation holes 6 are opened at the top of the housing 1 to form a downward airflow path. In a preferred embodiment, three fans 5 are arranged side by side, and these fans 5 are installed and fixed by a common fixing plate 7. The fixing plate 7 can also be equipped with a handle 8 to facilitate assembly and maintenance.

[0030] Furthermore, the DC power module 2 fully utilizes third-generation silicon carbide power devices, significantly reducing switching and conduction losses and minimizing heat generation at the source. The PCB board of the charging pile controller 9 is directly mounted on the main board of the DC power module 2 using vertical insertion or parallel stacking, with all signal and power transmission completed through internal wiring, achieving complete elimination of wiring harnesses. The auxiliary power supply no longer relies on an independent module connected to external AC power but is instead powered internally, further saving space and cost. The cooling system, with its fluid dynamics-optimized interlayer airflow and low-speed fan 5, significantly reduces operating noise while ensuring effective heat dissipation.

[0031] In traditional designs, DC power modules, charging pile controllers, and auxiliary power supplies are typically procured and assembled as independent units. Auxiliary power supplies, in particular, often require a separate module connected to the mains to convert to low-voltage electricity, resulting in low internal space utilization and difficulty in compressing the overall size. However, the integrated DC charging pile of this embodiment, through its integrated design, elimination of wiring harnesses, use of low-loss components, and optimized airflow, demonstrates significant technical advantages in terms of size reduction, simplified manufacturing process, improved stability, and efficient, quiet heat dissipation.

[0032] The above descriptions are merely embodiments of the present invention, and common knowledge regarding specific structures and characteristics is not elaborated upon here. It should be noted that those skilled in the art can make various modifications and improvements without departing from the structure of the present invention, and these should also be considered within the scope of protection of the present invention. These modifications will not affect the effectiveness of the implementation of the present invention or the practicality of the patent. The scope of protection claimed in this application should be determined by the content of its claims, and the specific embodiments described in the specification can be used to interpret the content of the claims.

Claims

1. An integrated DC charging pile, characterized in that: The device includes a housing and a DC power module, a charging pile controller, and an auxiliary power circuit within the housing. The input terminal of the auxiliary power circuit is connected to the DC power module, and the output terminal of the auxiliary power circuit supplies power to the charging pile controller. The charging pile controller is integrated on the DC power module.

2. The integrated DC charging pile according to claim 1, characterized in that: The DC power module includes a PFC power board and a DC / DC converter board. The PFC power board and the DC / DC converter board are arranged opposite to each other, and a gap for heat dissipation is provided between them.

3. An integrated DC charging pile according to claim 2, characterized in that: The PFC power board is equipped with an EMC filter circuit and a three-phase VIENNA rectifier; the DC / DC converter board is equipped with a full-bridge inverter, a high-frequency transformer and an LLC resonant converter.

4. An integrated DC charging pile according to claim 2, characterized in that: The auxiliary power supply circuit is connected to the PFC power board.

5. An integrated DC charging pile according to claim 1, characterized in that: The charging pile controller includes a PCB board, and the charging pile controller is connected to the main board of the DC power module through its PCB board.

6. An integrated DC charging pile according to claim 2, characterized in that: The gap between the components on the PFC power board and the components on the DC / DC converter board is greater than or equal to 4 mm.

7. An integrated DC charging pile according to claim 6, characterized in that: The PFC power board and DC / DC converter board are equipped with fans on top, and the housing is equipped with heat dissipation holes on the bottom.

8. An integrated DC charging pile according to claim 6, characterized in that: The bottom of the PFC power board and the DC / DC converter board are equipped with fans, and the top of the housing is equipped with heat dissipation holes.

9. An integrated DC charging pile according to claim 7 or 8, characterized in that: It also includes a mounting plate, and three fans are provided, which are fixed on the mounting plate.

10. An integrated DC charging pile according to claim 9, characterized in that: A handle is provided on the fixing plate.

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