Direct current charging pile universal power control device and control method

Abstract

The invention discloses a universal power control device and control method for a direct current charging pile. Relates to the technical field of new energy charging, and solves the problems that a traditional DC charging pile power regulation and control device is insufficient in compatibility, hardware transformation and software joint debugging are difficult, and a regulation and control strategy is difficult to consider power distribution operation safety and user charging requirements. The intelligent regulation and control terminal junction box is arranged in the mobile charging and discharging pile, one end of the intelligent regulation and control terminal junction box is connected with a communication loop of a main control board of the mobile charging and discharging pile and a charging gun, and the other end of the intelligent regulation and control terminal junction box is connected with the intelligent socket. Power output can be optimized in real time according to dynamic changes of loads of a power distribution network, the positions and power output of the mobile charging and discharging piles can be dynamically allocated according to charging demand distribution of different areas based on centralized power scheduling of intelligent sockets and flexible deployment of the mobile charging and discharging piles, and the problems caused by fixed positions of traditional fixed charging piles are solved.

Description

Technical Field

[0001] This application relates to the field of new energy charging technology, and in particular to a general-purpose power control device and control method for DC charging piles. Background Technology

[0002] With the rapid increase in the popularity of electric vehicles, the demand for charging services has shown a surge in regional and time-specific characteristics. In some areas, problems such as charging queues and uneven utilization of charging piles frequently occur during peak electricity consumption periods.

[0003] Traditional DC charging piles are mostly fixed installations, relying on fixed parking spaces and dedicated power lines. This results in long installation cycles, poor mobility, and an inability to flexibly adapt to temporary charging needs. Furthermore, existing DC charging piles primarily use a single-pile independent adjustment mode for power control, lacking a cluster-based collaborative control mechanism. This makes it difficult to optimize power output based on dynamic changes in the distribution network load, potentially leading to grid safety risks such as transformer overload and voltage fluctuations. In special scenarios, such as planned power outages or sudden power failures, traditional charging piles cannot provide emergency power support for critical loads. Moreover, upgrading existing charging piles often requires large-scale modifications to the charging pile's hardware and software, resulting in high costs, poor compatibility, and disruption to normal operation during construction. Meanwhile, cluster control schemes for new charging piles lack standardized interfaces and rapid networking capabilities, making it difficult to achieve flexible deployment and collaborative control within minutes.

[0004] Therefore, it is evident that there is an urgent need for a DC charging pile power control device that is versatile, easy to install, and supports cluster collaboration and dynamic power adjustment. This is a technical problem that needs to be solved by those in the field. Summary of the Invention

[0005] The purpose of this application is to provide a universal power control device and control method for DC charging piles, which solves the problems of insufficient compatibility of traditional DC charging pile power regulation equipment, difficulty in hardware modification and software integration, and difficulty in balancing power distribution operation safety and user charging needs with regulation strategies.

[0006] To address the aforementioned technical problems, this application provides a universal power control device for DC charging piles, comprising: Smart sockets, mobile charging piles, and smart control terminal junction boxes; The intelligent control terminal junction box is built into the mobile charging and discharging pile. One end is connected to the communication circuit between the main control board of the mobile charging and discharging pile and the charging gun, and the other end is connected to the smart socket through an aviation connector in the form of power line carrier, for bidirectional power transmission and data interaction. The smart socket is used to establish a communication connection with the main meter of the distribution area, collect real-time load information of the power grid and rated capacity parameters of the distribution transformer, generate a power regulation strategy based on the real-time load information, rated capacity parameters of the distribution transformer and current charging demand, and issue power control commands; the smart regulation terminal junction box is used to receive the power regulation commands and convert them into control signals for the mobile charging and discharging pile to adjust the output power of the charging pile, and at the same time collect the operating data of the mobile charging and discharging pile and feed it back to the smart socket.

[0007] Optionally, in the above-mentioned general-purpose power control device for DC charging piles, the smart socket includes a main controller, a load acquisition module, and multiple external communication modules; The load acquisition module is connected to the main meter of the transformer area and is used to collect the power distribution load data of the transformer area in real time and upload it to the main controller. Each of the aforementioned external communication modules is connected to multiple mobile charging and discharging piles via a standard charging interface; The main controller has a built-in power regulation strategy unit that calculates and allocates the allowable output power to each of the mobile charging and discharging piles based on the rated capacity of the power distribution area and real-time load data.

[0008] Optionally, in the above-mentioned general-purpose power control device for DC charging piles, the smart socket further includes: an environmental monitoring module and a surge protection switch; The environmental monitoring module integrates a temperature sensor, a humidity sensor, and a barometric pressure sensor, which are used to collect environmental parameters and trigger early warnings. The surge protection switch adopts a two-stage surge protection design and is connected in series in the power input circuit; The external communication module is a dual-mode communication module that supports PLC carrier communication and 4G / 5G wireless communication, and automatically switches to the backup link when a single communication link is interrupted.

[0009] Optionally, in the above-mentioned general-purpose power control device for DC charging piles, the power regulation strategy unit includes at least a power distribution capacity adaptation strategy and a load priority regulation strategy. The power distribution capacity adaptation strategy is based on the total load of the distribution area and the rated capacity of the distribution transformer to determine the remaining capacity of the distribution transformer and allocate it to the maximum allowable output power of each connected mobile charging and discharging pile. The load priority control strategy dynamically sorts the charging priorities of each connected mobile charging and discharging pile and adjusts the power allocation based on user charging demand information. The main controller can automatically switch between two strategies or manually select them based on the power grid operating status or preset configuration.

[0010] Optionally, in the above-mentioned general-purpose power control device for DC charging piles, the intelligent control terminal junction box includes: a CAN series bridge module and an intelligent bypass module; The CAN serial bridge module has dual functions of signal pass-through and command injection. It is used to pass through the communication signal between the charging gun and the main control board, and to insert the control command frame into the pass-through signal when the main controller of the smart socket issues a power control command. The intelligent bypass module includes: a bypass relay and a fault detection module; When the fault detection module detects an abnormality, it controls the bypass relay to engage, so that the main control board of the charging pile is directly connected to the charging gun.

[0011] Optionally, in the above-mentioned general-purpose power control device for DC charging piles, the smart socket further includes: a load prediction module; The load forecasting module is used to predict the load change trend of the transformer area within a preset time period based on historical load data, environmental parameters collected by the environmental monitoring module, and time series analysis algorithms, and to feed back the load change trend of the transformer area to the main controller.

[0012] Optionally, in the above-mentioned general-purpose power control device for DC charging piles, the smart socket is connected to the mobile charging pile via a pluggable aviation connector; the aviation connector has built-in three-phase power pins and two sets of communication pins, which are used for three-phase power transmission, PLC carrier communication, and operation data feedback, respectively. The aviation connector adopts an anti-misinsertion design, with matching guide grooves and positioning pins on the mechanical structure, and power pins and communication pins of different diameters on the electrical interface, and the power circuit and communication circuit are isolated by an insulating partition.

[0013] This application also provides a universal power control method for DC charging piles, applied to a universal power control device for DC charging piles. The universal power control device includes: a smart socket, a mobile charging pile, and a smart control terminal junction box. The smart control terminal junction box is built into the mobile charging pile, with one end connected to the communication circuit between the mobile charging pile's main control board and the charging gun, and the other end connected to the smart socket via a power line carrier connection through an aviation connector for bidirectional power transmission and data interaction. The smart socket is used to establish a communication connection with the main meter of the distribution area, collect real-time load information and transformer rated capacity parameters from the power grid, generate a power control strategy based on the real-time load information, transformer rated capacity parameters, and current charging demand, and issue power control commands. The smart control terminal junction box receives the power control commands and converts them into control signals for the mobile charging pile to adjust the output power of the charging pile, while simultaneously collecting the mobile charging pile's operating data and feeding it back to the smart socket. The method includes: Establish a communication connection with the main meter of the distribution area to collect real-time load information and rated capacity parameters of the distribution transformers on the power grid side; Based on real-time power distribution load information, transformer rated capacity parameters, and current charging demand, a power regulation strategy is generated and a power control command is sent to the intelligent control terminal junction box of the mobile charging and discharging pile. Receives mobile charging and discharging pile operation data fed back from the intelligent control terminal junction box.

[0014] Optionally, in the above-mentioned general power control method for DC charging piles, the step of generating a power regulation strategy includes: The remaining capacity of the distribution transformer is determined based on the rated capacity parameters of the distribution transformer and the total load in the real-time load information of the power grid. Based on the current control objectives, either the transformer capacity adaptation strategy or the load priority control strategy can be implemented. If the distribution transformer capacity adaptation strategy is implemented, the maximum allowable output power of each pile is allocated proportionally according to the number of connected mobile charging and discharging piles and the current power demand of each mobile charging and discharging pile, so that the total power of all connected mobile charging and discharging piles does not exceed the remaining capacity of the distribution transformer. If a load priority control strategy is implemented, the user charging demand information of each mobile charging and discharging pile is obtained and the charging priority is dynamically sorted. The output power is then allocated to the mobile charging and discharging piles of different priorities in sequence based on the remaining capacity of the distribution transformer. The output power of the mobile charging and discharging pile with higher priority is higher than that of the mobile charging and discharging pile with lower priority.

[0015] Optionally, in the above-mentioned general power control method for DC charging piles, the user charging demand information includes at least: the current SOC value of the vehicle to be charged, the expected SOC value, and the estimated departure time.

[0016] The universal power control device for DC charging piles provided in this application features an intelligent control terminal junction box built into the mobile charging pile. This junction box is connected in series between the main control board of the pile and the communication circuit of the charging gun. Only a few existing communication terminals inside the pile need to be connected; the original hardware structure and communication logic of the mobile charging pile remain unchanged, enabling command intervention and data acquisition. The intelligent socket and the mobile charging pile are bidirectionally connected via an aviation connector to achieve bidirectional power transmission and data interaction. The intelligent socket generates a power control strategy by collecting real-time load information from the power grid, transformer rated capacity parameters, and current charging demand. It can optimize power output in real-time according to dynamic changes in the power grid load, avoiding transformer overload and voltage fluctuations caused by disordered high-power charging, thus ensuring the safe operation of the power grid. Furthermore, based on the centralized power scheduling of the intelligent socket and the flexible deployment of the mobile charging pile, the location and power output of the mobile charging pile can be dynamically allocated according to the charging demand distribution in different areas. This solves the problem that traditional fixed charging piles, due to their fixed location, cannot meet temporary charging needs while ensuring power grid safety.

[0017] In addition, this application also provides a general power control method for DC charging piles, which corresponds to the above-mentioned general power control device for DC charging piles and has the same effect. Attached Figure Description

[0018] To more clearly illustrate the embodiments of this application, the accompanying drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0019] Figure 1 A schematic diagram of a universal power control device for DC charging piles provided in an embodiment of this application; Figure 2 This is a flowchart of a general power control method for DC charging piles provided in an embodiment of this application.

[0020] The annotations in the attached figures are explained as follows: 11-Smart socket; 12-Mobile charging pile; 13-Smart control terminal junction box. Detailed Implementation

[0021] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of this application.

[0022] The core of this application is to provide a universal power control device and control method for DC charging piles.

[0023] To enable those skilled in the art to better understand the present application, the present application will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0024] This application provides a universal power control device for DC charging piles, such as... Figure 1 As shown, it includes: 11. Smart socket; 12. Mobile charging and discharging pile; 13. Smart control terminal junction box; The intelligent control terminal junction box 13 is built into the mobile charging and discharging pile 12. One end is connected to the communication circuit between the main control board of the mobile charging and discharging pile 12 and the charging gun, and the other end is connected to the intelligent socket 11 through an aviation connector in the form of power line carrier, for bidirectional power transmission and data interaction. The smart socket 11 is used to establish a communication connection with the main meter of the distribution area, collect real-time load information of the power grid and rated capacity parameters of the distribution transformer, generate a power regulation strategy based on the real-time load information of the power grid and rated capacity parameters of the distribution transformer and the current charging demand, and issue power control commands. The smart control terminal junction box 13 is used to receive the power regulation commands and convert them into control signals for the mobile charging and discharging pile 12 to adjust the output power of the charging pile, and at the same time collect the operating data of the mobile charging and discharging pile 12 and feed it back to the smart socket 11.

[0025] The universal power control device for DC charging piles provided in this application is mainly used in electric vehicle charging service scenarios. Specifically, it can cover various environments such as residential areas, commercial districts, industrial parks, outdoor temporary charging points, and emergency power supply locations, and is particularly suitable for scenarios where electric vehicle charging demand experiences regional and temporal surges. It should be noted that the implementation of this device does not rely on fixed parking spaces and dedicated power supply lines, and can be flexibly deployed within the coverage area of ​​the distribution network. It is suitable for the supporting control of newly added mobile DC charging piles, as well as for the upgrading and transformation of existing mobile DC charging piles. Simultaneously, its implementation environment must meet the conditions of having a main distribution meter in the distribution area to realize distribution load data collection and the distribution network having basic power supply capacity. This embodiment does not strictly limit the capacity of the distribution transformer or the power specifications of the charging piles, and can adapt to mobile DC charging piles of different power levels and distribution transformers of different capacities.

[0026] The three core components—smart socket 11, mobile charging and discharging pile 12, and smart control terminal junction box 13—build a collaborative control system of perception, decision-making, and execution through standardized interfaces and communication protocols.

[0027] First, the smart socket 11 is the core control node of this device. It is not a traditional basic socket that simply controls power on and off, but rather a multi-functional intelligent control unit integrating communication, data processing, strategy generation, and command issuance. It's important to note that its core function is to serve as the interface between the device and the power distribution network. On one hand, it establishes a communication connection with the main meter in the distribution area; on the other hand, it achieves a bidirectional connection with the mobile charging pile 12 via an aviation connector. Specifically, this structure has two aspects: first, it has a power transmission interface, enabling bidirectional power transmission between the power grid and the mobile charging pile 12, overcoming the limitation of traditional sockets' unidirectional power supply; second, it has a data interaction interface, capable of collecting real-time load information and transformer rated capacity parameters from the power grid side, while simultaneously receiving operational feedback data from the mobile charging pile 12, serving as the decision-making core for the entire device's power regulation strategy. Because it integrates power distribution data acquisition and control command issuance functions, there is no need to deploy an additional independent control terminal, simplifying the overall architecture of the device.

[0028] The mobile charging / discharging pile 12 is the charging execution carrier of the device, that is, a DC charging device with mobile attributes. It does not represent a traditional fixed DC charging pile. Its core feature is that it can be flexibly deployed, freeing it from the limitations of fixed installation locations. It can also be a regular DC charging pile or a regular DC charging / discharging pile. It should be noted that this structure has both the charging function of a conventional DC charging pile, which can provide DC charging services for electric vehicles through the charging gun, and the discharging function due to its bidirectional connection design with the smart socket 11, which can realize reverse energy output in special scenarios. At the same time, it has reserved installation space for the intelligent control terminal junction box 13, providing a hardware foundation for the access of power control functions. Generally speaking, this structure can be flexibly deployed according to the regional distribution of charging demand, adapting to diverse needs such as temporary charging and emergency charging.

[0029] The intelligent control terminal junction box 13 is built into the mobile charging and discharging pile 12. It is an intermediate transfer module connected in series between the main control board of the mobile charging and discharging pile 12 and the communication circuit of the charging gun. Without destroying the original communication logic of the charging pile, it builds a control bridge between the intelligent socket 11 and the mobile charging and discharging pile 12. Since the series access method is adopted, there is no need to modify the software and hardware of the main control board, charging gun and other core components of the mobile charging and discharging pile 12. The power control function can be superimposed simply by the series intervention of the communication circuit.

[0030] The aviation connector is a standardized connection component between the smart socket 11 and the mobile charging pile 12. On one hand, it enables bidirectional power transmission between the power grid and the mobile charging pile 12 through the power transmission pin; on the other hand, it enables bidirectional transmission of power control commands and operating data through the data interaction pin. Due to the standardized design of the aviation connector, it has a plug-and-play rapid networking capability, which can realize the rapid connection of multiple mobile charging piles 12 with the smart socket 11, and adapt to the minute-level deployment requirements of temporary scenarios.

[0031] The communication loop is the link between the main control board of the mobile charging pile 12 and the charging gun for signal transmission. This step refers to the core path in the original control logic of the charging pile, where the main control board sends control signals to the charging gun and the charging gun feeds back status signals to the main control board. Through the series intervention of the intelligent control terminal junction box 13, the injection of power control commands and the acquisition of operating data are realized.

[0032] The smart socket 11 first achieves comprehensive data collection from the power distribution network side. Through communication with the main meter of the distribution area, it obtains real-time load information and rated capacity parameters of the distribution transformer, providing a data foundation for power dispatch. Secondly, based on the collected data and current charging demand, it generates an appropriate power control strategy to avoid problems such as transformer overload and voltage fluctuations caused by disordered charging of single charging piles. Finally, it sends power control commands to the mobile charging pile 12 to achieve centralized power control, while receiving operational feedback data to form a control closed loop.

[0033] The mobile charging and discharging pile 12 provides DC charging services for electric vehicles through a charging gun, meeting the charging needs of vehicles. At the same time, thanks to its mobile nature, it enables flexible allocation of charging resources, solving the problems of uneven utilization and inability to adapt to temporary charging needs of traditional fixed charging piles. In addition, through bidirectional power transmission capabilities, it provides emergency power supply for critical loads in special scenarios such as power outages, expanding the application scenarios of charging facilities.

[0034] The intelligent control terminal junction box 13 has four main functions: First, it performs protocol conversion of power control commands, transforming the commands issued by the smart socket 11 into control signals recognizable by the main control board of the mobile charging pile 12, ensuring effective execution of the commands; second, it precisely adjusts the output power of the charging pile, responding to the control strategy of the smart socket 11; third, it collects real-time operating data of the charging pile and feeds it back to the smart socket 11, providing a basis for strategy optimization; and fourth, it achieves non-destructive modification of existing charging piles through series connection, reducing modification costs and construction difficulty.

[0035] The aviation connector enables a fast and stable connection between the smart socket 11 and the mobile charging pile 12, while carrying bidirectional power and data transmission, replacing the traditional separate wiring design and simplifying the installation and deployment process of the device; in addition, the standardized aviation connector design can improve the versatility of the device and adapt to different models of mobile charging piles 12 and smart sockets 11.

[0036] The universal power control device for DC charging piles provided in this application has an intelligent control terminal junction box 13 built into the mobile charging pile 12 and connected in series between the main control board of the pile and the communication circuit of the charging gun. This does not change the original hardware structure and communication logic of the mobile charging pile 12; it only achieves command intervention and data acquisition through series connection. The intelligent socket 11 and the mobile charging pile 12 are bidirectionally connected via an aviation connector to achieve bidirectional power transmission and data interaction. The intelligent socket 11 generates a power control strategy by collecting real-time load information from the power grid side, transformer rated capacity parameters, and current charging demand. It can optimize power output in real time according to the dynamic changes in the power grid load, avoiding problems such as transformer overload and voltage fluctuations caused by disordered high-power charging, thus ensuring the safe operation of the power grid. Furthermore, based on the centralized power scheduling of the intelligent socket 11 and the flexible deployment of the mobile charging pile 12, the location and power output of the mobile charging pile 12 can be dynamically allocated according to the charging demand distribution in different areas, solving the problem of uneven utilization caused by the fixed location of traditional fixed charging piles.

[0037] According to the above embodiments, specifically, the smart socket 11 includes a main controller, a load acquisition module, and multiple external communication modules; The load acquisition module is connected to the main meter of the transformer area for real-time acquisition of the power distribution load data of the transformer area and uploading it to the main controller; Each of the external communication modules is connected to multiple mobile charging and discharging piles 12 via a standard charging interface; The main controller has a built-in power regulation strategy unit that calculates and allocates the allowable output power to each mobile charging and discharging pile 12 based on the rated capacity of the power distribution area and real-time load data.

[0038] The load acquisition module is not an independent acquisition unit, but establishes a direct communication connection with the main meter of the transformer area. It acquires the distribution load data of the transformer area in real time through a standardized communication protocol and uploads the data synchronously to the main controller.

[0039] Each external communication module corresponds one-to-one with the mobile charging and discharging pile 12, and is physically connected through a dedicated aviation connector, forming a multi-channel independent communication architecture to ensure the stability of data interaction with multiple piles; the main controller, as the core processing unit, has a built-in power regulation strategy unit, which calculates and allocates the allowable output power of each mobile charging and discharging pile 12 through strategy calculation based on the rated capacity of the power distribution area and the real-time load data uploaded by the load acquisition module.

[0040] First, the load acquisition module obtains real-time load and capacity parameters from the power grid side, preventing power dispatch from deviating from the actual carrying capacity of the power grid and mitigating the risk of transformer overload from the source. Multiple external communication modules enable parallel connection and independent interaction between the smart socket 11 and multiple mobile charging / discharging piles 12. On the one hand, power control commands can be issued synchronously; on the other hand, feedback from each pile can be received separately, supporting the realization of multi-pile cluster collaborative control. Compared with a single communication module design, this effectively improves the control coverage and response efficiency of the device. The main controller and built-in power regulation strategy unit optimize the allocation of power resources based on power grid side data, rationally distributing the total capacity of the distribution area to each mobile charging / discharging pile 12. This ensures the safe operation of the power grid while maximizing the satisfaction of charging demand, achieving dynamic matching between charging power and power grid load.

[0041] This embodiment further enhances the cluster collaborative control capability of the device. Through modular functional decomposition and collaboration, it not only ensures the accuracy of data acquisition and the efficiency of command issuance, but also realizes the dynamic adaptation of grid capacity and charging power. At the same time, the multi-channel communication design also improves the stability of device operation.

[0042] The smart socket 11 supports multiple version customizations. It can adjust the power distribution cabinet parameters (such as the rated current of the circuit breaker and the cross-sectional area of ​​the copper busbar), the number of aviation connectors, and the number of programmable logic controller (PLC) carrier communication modules according to the charging power requirements of the application scenario and the number of connected charging piles, forming four standardized versions to meet the needs of different scenarios.

[0043] The "SuperCharging One-to-One" version is designed for ultra-fast charging scenarios. It is equipped with one set of aviation connectors (supporting a maximum current of 300A), one PLC carrier communication module, and one 250A circuit breaker. It is compatible with a single supercharging mobile charging pile 12 (maximum output power of 480kW) and is mainly used in scenarios with high charging speed requirements, such as highway service areas and large commercial districts. The internal power circuit of this version of the smart socket 11 uses copper busbars (cross-sectional area of ​​120mm²) for connection to ensure good heat dissipation when running at full power. The surface of the copper busbars is tin-plated to prevent oxidation and corrosion.

[0044] The "Supercharging + Fast Charging One-to-Two" version is designed for mixed charging scenarios. It is equipped with two sets of aviation connectors (one 300A for supercharging piles and one 150A for fast charging piles), two PLC carrier communication modules, and one 400A circuit breaker. It can simultaneously connect one supercharging pile (maximum 480kW) and one fast charging pile (maximum 120kW), with the total power controlled within 600kW. It is suitable for integrated charging stations that have both supercharging and fast charging requirements. This version supports independent control of supercharging piles and fast charging piles. The main controller can limit the power output of the two piles separately according to the transformer capacity, so that they do not interfere with each other.

[0045] The "One-to-Two Fast Charging" version is designed for conventional fast charging scenarios. It is equipped with two 150A aviation connectors, two PLC carrier communication modules, and one 250A circuit breaker. It can connect to two fast charging piles (maximum 120kW per unit, total power 240kW), and is suitable for scenarios with moderate charging needs such as communities and office buildings. The smart socket 11 in this version is small in size and can be installed in a standard power distribution cabinet, making it suitable for mass deployment.

[0046] The "one-to-four fast charging" version is designed for high-density charging scenarios. It is equipped with four 150A aviation connectors, four PLC carrier communication modules, and one 400A circuit breaker, and can connect to four fast charging piles (maximum 120kW per unit, total power 480kW). It is suitable for scenarios such as large parking lots and bus stations where multiple vehicles are charged simultaneously. This version adopts a modular design, with the power circuit and communication circuit of each aviation connector being independent. The failure of one pile will not affect the operation of other piles, and it supports future expansion (up to six aviation connectors).

[0047] The circuit breaker is a molded case circuit breaker with triple functions of overload protection, short circuit protection, and leakage protection. The overload protection current can be set according to the total power of the connected charging piles (e.g., when connecting 4 120kW fast charging piles, the overload protection current is set to 200A). When the actual current exceeds the set value and the duration is ≥5s, the circuit breaker will automatically trip. The short circuit protection current is set to 10 times the overload protection current. When a short circuit fault occurs, the circuit breaker will trip quickly within 0.1s to cut off the power circuit. The leakage protection current is set to 30mA. When the leakage current in the circuit exceeds 30mA, the circuit breaker will trip immediately to ensure personnel safety. The circuit breaker also has a status indication function, which displays the status of "closed", "tripped", and "leakage" through light-emitting diodes (LEDs) to facilitate maintenance personnel to quickly determine the type of fault.

[0048] The intelligent control terminal junction box 13 has independent operation capability and can realize power control of existing charging piles without relying on the intelligent socket 11, meeting the needs of cluster transformation of existing charging piles. During the transformation, the junction box only needs to be connected to the communication circuit between the original main control board of the charging pile and the charging gun through the controller area network (CAN) bus, and power is drawn from the inside of the charging pile through the power interface of the junction box (supporting 12V-24VDC wide voltage input), without the need to lay additional power supply lines.

[0049] According to the above embodiments, specifically, the smart socket 11 also includes: an environmental monitoring module and a surge protection switch; The environmental monitoring module integrates a temperature sensor, a humidity sensor, and a barometric pressure sensor, which are used to collect environmental parameters and trigger early warnings. The surge protector adopts a two-stage surge protection design and is connected in series with the power input circuit; The external communication module is a dual-mode communication module that supports PLC carrier communication and 4G / 5G wireless communication. It automatically switches to the backup link when a single communication link is interrupted.

[0050] Specifically, this embodiment adds an environmental monitoring module and a surge protection switch to the original structure of the smart socket 11, and specifies the communication mode of the external communication module.

[0051] It should be noted that the environmental monitoring module is not a single sensor, but a composite monitoring unit integrating three types of sensors: temperature, humidity, and air pressure. Each sensor collects corresponding environmental parameters, and an alarm is triggered when a parameter exceeds a preset threshold. This step refers to achieving comprehensive perception of the device's operating environment, providing environmental data for safety protection. Real-time monitoring of the smart socket 11 and its surrounding environment, through multi-dimensional environmental parameter collection, proactively identifies abnormal operating conditions such as high temperature, high humidity, and sudden changes in air pressure, triggering alarms to avoid equipment failures or safety hazards caused by environmental factors. Compared to designs without environmental monitoring, this significantly improves the device's environmental adaptability and safety.

[0052] The temperature measurement range is -40℃ to 85℃, with a measurement accuracy of ±0.5℃; the humidity measurement range is 0% to 100%RH, with a measurement accuracy of ±3%RH; the air pressure measurement range is 50kPa to 110kPa, with a measurement accuracy of ±0.5kPa. The sensor is connected to the main controller via an I2C bus, and the data update cycle is 10s / time. When the temperature is ≥70℃, humidity is ≥95%RH, or air pressure changes suddenly (change ≥10kPa within 10 minutes), the main controller immediately triggers a local audible and visual alarm and sends the alarm information to the upper-level platform.

[0053] The surge protector adopts a two-stage surge protection design and is connected in series to the power input circuit. This series connection directly integrates into the main power supply path of the grid, achieving graded protection against lightning surges. The two-stage surge protector discharges lightning overvoltages and surge currents in stages through its tiered surge protection design, preventing damage to the core modules inside the smart socket 11 from abnormal grid impacts such as lightning strikes. Simultaneously, its series connection to the power input circuit provides protection from the power supply head, ensuring the stability of power transmission throughout the device. The first stage is a zinc oxide surge arrester (nominal discharge current 10kA, maximum discharge current 20kA), and the second stage is a surge circuit breaker (operating current 500A, operating time ≤25ns), connected in series in the power input circuit of the smart socket 11. When encountering lightning strikes or grid surges, it can quickly clamp overvoltages and cut off overcurrents, protecting the internal modules from overvoltage damage. The surge protector also has a status monitoring function, providing real-time feedback on the health status of the surge protection components. When a surge protection component fails, the main controller triggers a fault alarm and prohibits the connection of new charging piles.

[0054] The external communication module is limited to PLC carrier and 4G / 5G (fourth-generation mobile communication technology / fifth-generation mobile communication technology) wireless dual-mode communication. In the event of a single link failure, it can automatically switch to a backup link, forming a "primary and backup dual-link" communication redundancy architecture, ensuring communication continuity without manual intervention. PLC carrier communication complies with communication standards and can utilize existing power lines for data transmission, eliminating the need for additional wiring. 4G / 5G communication supports all network frequency bands and features data encryption to ensure data transmission security. When the PLC communication link is interrupted, the module automatically switches to 4G / 5G communication with a switching time of ≤3 seconds, ensuring communication continuity with the upper-level control platform.

[0055] In addition, the socket body is made of cold-rolled steel plate with an IP54 protection level, which can adapt to outdoor semi-open-air installation environment. It has independent power and communication chambers inside to avoid power circuit interference with communication signals.

[0056] The 380V three-phase power supply is connected to the power chamber of the socket body through the distribution phase circuit breaker (the rated current is configured according to the number of access piles; a 100A circuit breaker is selected when a single pile is accessed, and a 250A circuit breaker is selected when four piles are accessed). After that, the power is distributed to the power pins of each aviation connector through the copper busbar. The cross-sectional area of ​​the shunt copper busbar is designed according to the maximum current carrying capacity to ensure that the temperature rise of the copper busbar is ≤30K when running at full load (under an ambient temperature of 25℃).

[0057] The socket body also includes a 24V DC power module. The 24V DC power module adopts a switching power supply design, with an input voltage range of 110V-240V and an output voltage stable at 24V±0.5V. The maximum output current can reach 10A, which can provide stable power supply for all control modules in the smart socket 11, such as the main controller, environmental monitoring module, and communication module. The power module has overvoltage protection (protection threshold 28V), overcurrent protection (protection threshold 12A) and short circuit protection functions. When the input voltage is abnormal or the output circuit is short-circuited, it can quickly cut off the power supply to avoid damage to downstream modules.

[0058] The main controller uses an industrial-grade ARM chip with a main frequency >1GHz, memory >512MB, and storage capacity >4GB, supporting multi-task concurrent processing. It connects to the main meter of the distribution area via an RS485 communication interface (using shielded twisted-pair cable, communication distance ≤100m) to collect load data such as active power, reactive power, power factor, and cumulative power consumption in real time. The collection cycle can be configured through the upper-level platform, with a default setting of 1s / time. The main controller has a built-in data caching function. When communication with the upper-level platform is interrupted, it can locally cache at least 72 hours of load data and control records, which will be automatically retransmitted after communication is restored.

[0059] The junction box has a reserved 4G / 5G communication interface, which can be used to insert an IoT SIM card to access the control cloud platform and support two-way data interaction with the platform. The cloud platform can send power control commands to the junction box (such as peak and off-peak power limits, emergency load reduction commands, etc.). After receiving the commands, the junction box controls the charging pile to adjust the output power through the CAN interface. For example, during the peak period of the power grid (18:00-22:00), the cloud platform sends a command to "limit the maximum output power to 70% of the rated power". The junction box will limit the maximum output power of the charging pile from 120kW to 84kW to participate in the peak shaving of the power grid. During the off-peak period of the power grid (0:00-6:00), the platform cancels the power limit and the charging pile resumes full power operation.

[0060] The junction box also features local manual control, allowing maintenance personnel to set power limit parameters, view operating status, and check fault records via buttons and a display screen. The display screen uses an OLED screen (2.4 inches) that supports Chinese display and can show real-time information such as current output power, power limit value, and communication status. The buttons include "Confirm," "Cancel," and "Add / Decrease" buttons for easy on-site operation, allowing basic parameter configuration to be completed without connecting to a computer or platform.

[0061] The charging and discharging station also has V2G dispatch response function, which can receive discharge commands from the upper-level power grid dispatch center. When the power grid frequency is low (≤49.5Hz) or the voltage is low (≤0.9pu), it actively discharges to the power grid to provide frequency and voltage regulation services. The discharge power can be flexibly adjusted according to the dispatch command, with an adjustment range of 10kW-100kW and a response time of ≤100ms, meeting the requirements of power grid auxiliary services. During the discharge process, the BMS monitors the battery status in real time. When the battery SOC is ≤20%, it automatically stops discharging to avoid damage from deep discharge of the battery.

[0062] According to the above embodiments, specifically, the power regulation strategy unit includes at least a power distribution capacity adaptation strategy and a load priority regulation strategy; The power distribution capacity matching strategy is based on the total load of the distribution area and the rated capacity of the distribution transformer to determine the remaining capacity of the distribution transformer and allocate it to the maximum allowable output power of each connected mobile charging and discharging pile 12. The load priority control strategy dynamically sorts the charging priorities of each connected mobile charging and discharging pile 12 and adjusts the power allocation based on user charging demand information. The main controller can automatically switch between the two strategies or manually select them based on the power grid operating status or preset configuration.

[0063] The distribution capacity adaptation strategy is based on grid-side parameters. It calculates the remaining capacity of the distribution transformer by the difference between the real-time total load of the distribution area and the rated capacity of the distribution transformer, and uses this capacity as the total constraint to allocate the maximum allowable output power of each connected mobile charging and discharging pile 12. This step refers to the power allocation logic based on the grid carrying capacity to ensure that the total output does not exceed the grid safety boundary.

[0064] The load priority control strategy shifts to user-side demand, dynamically prioritizing each mobile charging pile 12 based on user charging demand information, and adjusting the power allocation quota differently according to the ranking results, while also ensuring that the total output does not exceed the grid safety boundary.

[0065] In addition, the main controller has the ability to switch strategies, which can be automatically switched according to the real-time power grid operation status, or manually selected to enable any strategy according to the preset configuration. This does not mean that the strategy is fixed, but rather forms a flexible and adjustable dual scheduling mechanism.

[0066] According to the above embodiments, specifically, the intelligent control terminal junction box 13 includes: a CAN serial bridge module and an intelligent bypass module; The CAN serial bridge module has dual functions of signal pass-through and command injection. It is used to pass through the communication signal between the charging gun and the main control board, and to insert the control command frame into the pass-through signal when the main controller of the smart socket 11 issues the power control command. The intelligent bypass module includes: bypass relay and fault detection module; When the fault detection module detects an anomaly, it controls the bypass relay to engage, directly connecting the charging pile's main control board to the charging gun.

[0067] The CAN serial bridge module is not simply a signal conversion component, but has the dual functions of signal transmission and command injection. On the one hand, it transmits the original CAN communication signal between the charging gun and the main control board under normal conditions without changing the original control logic of the charging pile. On the other hand, when the main controller of the smart socket 11 issues a power control command, it inserts the corresponding control command frame into the transmitted signal stream. This step refers to realizing the intervention of external power control commands without damaging the original communication link.

[0068] Two CAN interfaces are set on the control wiring side, labeled "Main Control Board End" and "Charging Gun End" respectively. They are connected to the CAN output interface of the original main control board of the charging pile and the CAN input interface of the charging gun through CAN bus cables, and connected in series to the main control-gun communication loop. The CAN interface supports CAN2.0A / B protocol, and the baud rate can be set through DIP switch (selectable 250kbps, 500kbps, default 500kbps) to match the communication parameters of different brands of charging piles.

[0069] The intelligent bypass module consists of a bypass relay and a fault detection module. The fault detection module monitors the power supply status (24V DC input), CAN communication status (communication link with the smart socket 11 and the charging pile main control board) and its own circuit status (such as chip temperature and power supply voltage) of the junction box in real time. When it detects that the charging pile is not connected to the smart socket 11 (no response from PLC communication for 30 consecutive seconds), the junction box power supply is interrupted (input voltage ≤18V), CAN communication fails (no valid data for 10 consecutive communication cycles), or its own circuit fails (chip temperature ≥85℃), the fault detection module immediately controls the bypass relay to engage, directly connecting the CAN interface between the charging pile main control board and the charging gun, bypassing the CAN series bridge module. The bypass switching time is ≤100ms, ensuring that the charging pile can restore its original independent charging function without affecting the user's normal charging use. In the bypass state, the junction box alerts the maintenance personnel through an LED indicator (solid yellow) and simultaneously uploads the fault status to the smart socket 11 main controller.

[0070] The CAN serial bridge module is used to achieve non-intrusive power regulation intervention. It retains the original communication functions of the charging pile through signal pass-through and issues power scheduling commands to the smart socket 11 through command injection. Compared to directly modifying the charging pile's main control program, this approach achieves both power control function overlay and maximum compatibility with the existing architecture of existing charging piles, reducing modification costs and compatibility risks. The intelligent bypass module ensures the basic operational capability of the charging pile under extreme scenarios such as junction box failure and communication anomalies. The fault detection module enables real-time identification of abnormal states, while the bypass relay provides a direct physical layer conduction path, preventing complete charging pile failure due to junction box malfunction and improving the operational reliability and safety of the entire power control device. In the real-time and reliability design of the collaborative control link, the end-to-end transmission delay of power regulation commands is defined. The formula for calculating the total time from when the instruction is issued by the smart socket 11 controller, transmitted via the communication link to the smart control terminal junction box 13, and then parsed and converted by the junction box before being sent to the charging pile actuator is as follows: ; In the formula, The delay in sending commands to the main controller is affected by the computational load of the main controller and must meet the following requirements. (Under the condition that CPU utilization is ≤80%) ); To reduce the delay in command parsing and format conversion of the intelligent control terminal junction box 13, the Modbus protocol commands sent by the main controller need to be converted into CAN protocol commands that the charging pile can recognize (compliant with GB / T27930-2015 standard). ; For the action delay of the charging pile actuator (such as IGBT module), And it must meet the following requirements: To ensure timely power regulation in scenarios with rapid fluctuations in distribution transformer load and to prevent distribution transformer overload, the data collection scope covers the output power of charging piles in the charging status data feedback dimension. Charging voltage (Including DC bus voltage and charging grid terminal voltage), charging current (Including main charging circuit current and auxiliary circuit current), vehicle battery state of charge (SOC), battery temperature, and charging pile operation status flags. (e.g., normal operation, fault alarm, standby, etc.); Define data acquisition integrity indicators. The formula used to measure the proportion of valid data per unit of time is: ; In the formula, The theoretical number of data collections per unit time (data collection cycle) Within 1 minute ), The number of times valid data was actually collected (valid data must have values ​​within a reasonable range, such as...). (etc.), and must meet the following requirements. This is to avoid biased regulatory decisions due to data loss. At the same time, to ensure data accuracy, a data measurement error is defined. The deviation rate between the measured value and the true value of each collected parameter is used to calculate the comprehensive error using a weighted average algorithm. The formula is as follows: ; In the formula, These are the error weights for each parameter (set according to the degree of influence of the parameter on the control decision). These represent the measured value, the actual value, and the maximum value of the output power, respectively. These are the measured value, the actual value, and the maximum value of the charging voltage, respectively. These are the measured value, the actual value, and the maximum value of the charging current, respectively. These are the measured and actual values ​​of the state of charge, respectively. These are the maximum ranges for charging voltage and current, respectively. These represent the measured and true values, maximum and minimum values ​​of the state of charge, respectively. These are the upper and lower limits of the battery temperature measurement range; and they must meet the following requirements. This ensures that the main controller formulates control strategies based on accurate data.

[0071] In addition, the collaborative control link also has fault tolerance capabilities, defining the link fault tolerance rate. The probability that the link can still maintain core functions (power regulation, data feedback) when a single component (such as an aviation connector or communication module) fails is calculated using the following formula: ; In the formula, n is the number of key components in the link (n=4 in this device, including aviation connector, PLC communication module, intelligent control terminal junction box 13, and CAN interface). For the single-point reliability of the i-th component (aviation connector) PLC communication module 13 Intelligent control terminal junction box CAN interface ), and must meet By using component redundancy design (such as PLC communication modules supporting dual-link backup) and automatic fault switching mechanism, stable operation of the link is ensured.

[0072] According to the above embodiments, specifically, the smart socket 11 also includes a load prediction module; The load forecasting module is used to predict the load change trend of the transformer area within a preset time period based on historical load data, environmental parameters collected by the environmental monitoring module, and time series analysis algorithms, and to feed back the load change trend of the transformer area to the main controller.

[0073] The input data for the load forecasting module includes three categories: first, historical load data of the transformer area, reflecting the historical patterns of load changes; second, environmental parameters such as temperature, humidity, and air pressure collected by the environmental monitoring module, reflecting the impact of environmental factors on the load; and third, data modeling and calculation through time series analysis algorithms, inputting multi-dimensional data into the algorithm model, outputting the trend of load changes in the transformer area within a preset time period, and synchronously feeding this trend result back to the main controller to provide a forward-looking basis for power dispatch.

[0074] The load forecasting module is used to proactively predict the load in the distribution area, overcoming the limitations of traditional real-time load scheduling which relies solely on lag. By combining historical patterns, environmental influences, and algorithmic analysis, it predicts the timing and magnitude of load peaks and troughs in advance. Compared to scheduling methods that rely solely on real-time data, this allows power regulation to shift from "passive response" to "proactive prediction." It provides advance data support for the main controller's strategy decisions. Based on predicted load change trends, the main controller can adjust distribution capacity adaptation strategies or load priority control strategies in advance. For example, when a load increase is predicted, the allowable output power of each mobile charging / discharging pile 12 can be reduced in advance; when a load decrease is predicted, power quotas can be gradually released, achieving dynamic advance optimization of power scheduling.

[0075] For example, based on historical operating data and real-time monitoring information, the load change trend of the transformer area in the next 15-30 minutes can be predicted to provide forward-looking support for power regulation strategies. The data sources for load prediction include the load data of the transformer area in the same period of the past 30 days (such as the load data of Monday 14:00-14:30 in the past 4 weeks), the current load data of the transformer area, the date type (weekday / holiday / weekend), the weather data (temperature, humidity, rainfall) and special event information (such as large-scale events nearby, power outage plans, etc.).

[0076] The main controller uses a time series analysis algorithm for load forecasting. First, it preprocesses historical load data to remove outliers (such as sudden increases or decreases in load due to equipment failure) and trend terms (such as seasonal load changes). Then, it smooths data fluctuations using a moving average method. Finally, based on the preprocessed historical data and real-time influencing factors, it establishes a forecasting model. The forecasting model self-corrects in real time. When the deviation between the actual load and the forecasted load exceeds 10%, it automatically adjusts the model parameters to improve subsequent forecast accuracy. The forecast results are output in the form of a load curve. The main controller adjusts the power allocation scheme in advance based on the forecast curve. For example, if it predicts that the load in the distribution area will increase by 50kW in the next 20 minutes, it will reduce the total power limit of each charging pile by 50kW in advance to prevent the transformer load from exceeding the rated capacity.

[0077] The load forecasting function also supports data interaction with the upper-level platform. The main controller can upload the forecast results to the platform, and the platform can combine the forecast data of multiple transformer areas in the region to formulate a global scheduling plan. At the same time, the platform can also send regional load warning information to the main controller (such as the prediction that the total regional load will exceed the power supply capacity in the next hour). The main controller can further optimize the local control strategy based on the warning information and cooperate with the platform to achieve regional load balance.

[0078] According to the above embodiment, specifically, the smart socket 11 and the mobile charging pile 12 are connected by a pluggable aviation connector; the aviation connector has built-in three-phase power pins and two sets of communication pins, which are used for three-phase power transmission, PLC carrier communication, and operation data feedback, respectively. The aviation connector features a design to prevent mis-insertion. The mechanical structure is equipped with matching guide grooves and positioning pins, and the electrical interface uses power pins and communication pins of different diameters. The power circuit and communication circuit are isolated by an insulating partition.

[0079] This aviation connector integrates a composite interface for power transmission and multi-channel data interaction. It features built-in three-phase power pins (corresponding to L1, L2, and L3 phases) and two sets of communication pins (corresponding to PLC carrier communication and status monitoring), each independently handling three-phase power transmission, PLC carrier communication, and operational data feedback. This means that a single physical connector enables bidirectional transmission of electrical energy and multiple signals simultaneously. It supports power transmission up to 300A and 400V, meeting the access requirements of charging piles with different power levels.

[0080] In addition, the aviation connector adopts an anti-misinsertion design. Mechanically, it achieves physical positioning and error prevention through matching guide grooves and positioning pins. Electrically, it distinguishes between power pins and communication pins by their different diameters and uses an insulating partition to physically isolate the power circuit and the communication circuit. This does not mean that power and communication signals share a path or have no protective isolation, but rather that a safe connection mechanism is constructed from both mechanical and electrical dimensions.

[0081] The female aviation plug is matched with the male aviation plug of the smart socket 11. It connects to the 24VDC power supply and PLC communication signal provided by the smart socket 11 through the aviation plug. The junction box integrates a PLC carrier communication module. This module uses the same communication protocol and frequency band as the PLC communication module of the smart socket 11. It can receive power control commands (such as maximum output power limit, power adjustment step size, etc.) issued by the main controller of the smart socket 11, and convert the commands into control signals in CAN protocol format and send them to the main control board of the charging pile to realize the accurate transmission of power control commands.

[0082] Thanks to its pluggable integrated connector, rapid network deployment can be achieved within minutes. The independent and isolated power and communication pins ensure stable and reliable electrical-to-communication transmission without interference. Furthermore, its dual mechanical and electrical anti-misplugging and anti-crosstalk design effectively mitigates various safety risks during connection and operation. This solution addresses the problems of cumbersome wiring and low deployment efficiency associated with traditional charging pile interfaces. Multiple safety designs ensure the safe and coordinated transmission of high-voltage power and sensitive communication signals. It also adapts to the frequent plugging and unplugging and flexible movement scenarios of mobile charging piles, further enhancing the versatility, convenience, and operational safety of the entire device.

[0083] The intelligent control terminal junction box 13 has a built-in fault self-diagnosis module, which can monitor its own hardware circuit, communication link and connection status in real time, detect and report faults in a timely manner, and reduce operation and maintenance costs. The fault monitoring scope includes the junction box power supply circuit (24VDC input voltage and current), CAN communication circuit (CAN bus voltage and communication frame error rate), PLC communication circuit (communication signal strength and data transmission rate), bypass relay status (engagement / disengagement feedback) and chip temperature (main chip and communication chip temperature).

[0084] The fault self-diagnosis module adopts a periodic monitoring method with a monitoring cycle of 1 second per monitoring. After each monitoring, a monitoring report is generated. If an abnormality is found (such as power supply voltage ≤18V, CAN bus error rate ≥5%, chip temperature ≥85℃), it is determined to be a fault, and a corresponding fault code is generated according to the fault type (such as "E01" for power supply fault, "E02" for CAN communication fault, "E03" for PLC communication fault, etc.). The fault code is uploaded to the main controller of the smart socket 11 or the control cloud platform via PLC communication or 4G / 5G communication. At the same time, the LED fault light (red) on the junction box will flash alarm, and the flashing frequency corresponds to the fault code (such as flashing once per second for E01 fault, and flashing twice per second for E02 fault), which makes it easy for maintenance personnel to identify the fault type on site.

[0085] The fault self-diagnosis module also has a fault recording function, which can store the most recent 100 fault records, including fault code, fault occurrence time, operating parameters at the time of the fault (such as voltage, current, temperature) and fault recovery time. Maintenance personnel can read the fault records through the display screen of the junction box or by connecting to a computer, analyze the cause of the fault, and formulate targeted maintenance plans. For faults that can be automatically recovered (such as momentary communication interruption), the module will attempt to recover automatically. If the recovery is successful, the fault alarm will be cleared; if the recovery fails, the alarm will continue and be reported.

[0086] Specifically, the smart socket 11 also includes an alarm and fire extinguishing device. This device uses a perfluorohexanone fire extinguishing system, including a 2L extinguishing agent tank, sufficient to extinguish fires in a 10m³ space. It is equipped with temperature-sensing nozzles with an activation temperature set at 70℃. When the internal temperature of the smart socket 11 reaches this threshold, the nozzles automatically activate and release the extinguishing agent. The accompanying audible and visual alarm has a volume of at least 85dB and a red flashing light at a frequency of 2Hz, simultaneously triggering an audible and visual alarm to alert nearby personnel. When the main controller detects overcurrent, short circuit, or other faults, it will also actively trigger the fire extinguishing device. The extinguishing agent spraying time is at least 10 seconds, with a fire extinguishing efficiency of over 99%. Furthermore, there is no residue or pollution after extinguishing the fire, and it will not cause secondary damage to electronic equipment.

[0087] This application also provides a universal power control method for DC charging piles, applied to a universal power control device for DC charging piles. The universal power control device for DC charging piles includes: a smart socket 11, a mobile charging pile 12, and a smart control terminal junction box 13. The smart control terminal junction box 13 is built into the mobile charging pile 12, with one end connected to the communication circuit between the main control board of the mobile charging pile 12 and the charging gun, and the other end connected to the smart socket via an aviation connector using power line carrier communication for bidirectional power transmission and data interaction. The smart socket 11 is used to establish a communication connection with the main meter of the distribution area, collect real-time load information of the power grid and the rated capacity parameters of the distribution transformer, generate a power control strategy based on the real-time load information of the power grid, the rated capacity parameters of the distribution transformer, and the current charging demand, and issue power control commands. The smart control terminal junction box 13 is used to receive power control commands and convert them into control signals for the mobile charging pile 12 to adjust the output power of the charging pile, while simultaneously collecting the operating data of the mobile charging pile 12 and feeding it back to the smart socket 11. like Figure 2 As shown, the method includes: S11: Establish a communication connection with the main meter of the distribution area to collect real-time load information and rated capacity parameters of the distribution transformers on the power grid side; S12: Based on the real-time load information of the power distribution and the rated capacity parameters of the distribution transformer, and the current charging demand, a power regulation strategy is generated and a power control command is sent to the intelligent control terminal junction box 13 of the mobile charging and discharging pile 12. S13: Receives the operation data of the mobile charging and discharging pile 12 fed back by the intelligent control terminal junction box 13.

[0088] S11 establishes a communication connection with the main distribution meter of the distribution area to collect real-time load information and transformer rated capacity parameters from the power grid. This step refers to obtaining core operating parameters of the power grid through the communication link between the smart socket 11 and the main distribution meter of the distribution area. It does not only collect single data, but also simultaneously obtains real-time load status and transformer carrying capacity limits to provide basic data support for subsequent power dispatching. This embodiment does not impose strict restrictions on communication protocols or data collection frequencies and can be adapted to the communication specifications of different distribution areas.

[0089] S12 generates a power control strategy based on real-time power distribution load information, transformer rated capacity parameters, and current charging demand, and sends a power control command to the intelligent control terminal junction box 13. At this time, the intelligent socket 11, as the core decision-making unit, generates an adaptation strategy with the power grid's safety carrying capacity as the core constraint, and then sends the command to the pile-end execution unit through the communication link of the aviation connector, which can be compatible with multiple strategies and adapt to different scenarios.

[0090] S13 receives the operating data of the mobile charging and discharging pile 12 from the intelligent control terminal junction box 13, and collects the actual operating status of the pile end through the communication link to form a closed loop of the process. This step refers to obtaining the execution result of power control, providing feedback basis for strategy optimization and anomaly monitoring, rather than one-way command issuance without response.

[0091] First, S11 collects real-time load information and transformer rated capacity parameters from the power grid to understand the real-time load status and rated upper limit of the power distribution network. This clarifies the safety boundary of power dispatch from the source, preventing grid risks such as transformer overload and voltage fluctuations caused by disorderly charging of charging piles. Compared to the traditional single-pile control method without grid awareness, this achieves linkage and adaptation between charging power and grid load. Second, S12 generates a power control strategy and issues commands to optimize the allocation of charging power based on grid constraints. Through the intelligent control terminal junction box 13, it intervenes in the original control logic of the charging pile to achieve cluster collaborative control, solving the problems of independent adjustment and uneven utilization of traditional single piles. At the same time, it adapts to the transformation needs of different models of mobile charging piles 12 through standardized command issuance. Finally, S13 receives pile-end operation data to: 1) verify the execution effect of power control commands to ensure that the output power of the charging pile meets the dispatch requirements; 2) form closed-loop control, and correct the control strategy in real time based on feedback data to adapt to the dynamic changes in grid load and charging demand; and 3) monitor the equipment operation status, promptly detect pile-end anomalies, and ensure the stable operation of the entire system.

[0092] According to the above embodiments, the specific steps for generating a power regulation strategy include: The remaining capacity of the distribution transformer is determined based on the rated capacity parameters of the distribution transformer and the total load in the real-time load information of the power grid. Based on the current control objectives, either the transformer capacity adaptation strategy or the load priority control strategy can be implemented. If the distribution transformer capacity adaptation strategy is implemented, the maximum allowable output power of each pile is allocated proportionally according to the number of connected mobile charging and discharging piles 12 and the current power demand of each mobile charging and discharging pile 12, so that the total power of all connected mobile charging and discharging piles 12 does not exceed the remaining capacity of the distribution transformer. If the load priority control strategy is implemented, the user charging demand information of each mobile charging and discharging pile 12 is obtained and the charging priority is dynamically sorted. Combined with the remaining capacity of the distribution transformer, the output power of the mobile charging and discharging piles 12 with different priorities is allocated in sequence, and the output power of the mobile charging and discharging piles 12 with higher priority is higher than that of the mobile charging and discharging piles 12 with lower priority.

[0093] First, the remaining capacity of the distribution transformer is calculated based on its rated capacity and the total load on the grid. This step refers to setting a rigid safety upper limit for power dispatch, which does not mean directly allocating power equally according to the number of charging piles. Instead, the total power available for charging in the entire distribution area is determined first. This sets an inviolable safety bottom line for power dispatch, preventing the power of multiple charging piles from exceeding the transformer's carrying capacity from the source, and preventing grid safety issues such as transformer overload and voltage drop. Compared with dispatch methods without capacity constraints, this achieves a rigid match between charging power and grid capacity.

[0094] Subsequently, based on the current control objective, either a transformer capacity adaptation strategy or a load priority control strategy is selected. This embodiment does not strictly limit the determination conditions of the control objective, and can be flexibly triggered by grid load status, preset rules, etc. When the grid load and capacity are tight, priority is given to ensuring grid safety; when the grid capacity is sufficient, priority is given to optimizing charging experience and resource efficiency, taking into account both safety and practicality, and avoiding the inability of a single strategy to adapt to dynamically changing operational needs.

[0095] If a transformer capacity adaptation strategy is implemented, the maximum allowable output power is allocated proportionally based on the number of charging piles connected and the current power demand (i.e., charging demand) of each pile. The core constraint is that the total power does not exceed the transformer's remaining capacity, which is a balanced allocation logic with the grid's carrying capacity as the sole core. In capacity-constrained scenarios, fair and safe power allocation is achieved. Allocating power according to the ratio of the number of charging piles to demand avoids some piles monopolizing power resources, while the total power constraint ensures grid safety and solves the problem of disorderly competition among multiple charging piles under peak load. For example, when the transformer's rated active power is 500kW, the current total load of the distribution area is 300kW, and four charging piles are connected with a current power demand of 60kW for each pile, the transformer's remaining capacity is 200kW. The main controller will limit the maximum allowable output power of each pile to 50kW, keeping the total power within 200kW to avoid transformer overload.

[0096] If a load priority control strategy is implemented, user charging demand information is first obtained and dynamically prioritized. Then, power is allocated sequentially based on remaining capacity, with higher priority charging piles receiving more power than lower priority piles. This means that, while ensuring grid safety, the allocation logic shifts to a user-demand-centric differentiated approach. In scenarios with ample capacity, resource allocation efficiency is optimized by dynamically prioritizing user charging needs (such as urgency and remaining power), allowing high-demand charging piles to receive more power first, improving overall charging efficiency and user experience. This reduces power resource waste compared to average allocation. For example, users with an estimated departure time ≤ 1 hour and current SOC ≤ 30% are given the highest priority, receiving sufficient power to meet fast charging needs. Users with an estimated departure time ≥ 4 hours and current SOC ≥ 60% are given lower priority, with power output appropriately limited, allocating remaining capacity to higher priority users. The priority ranking results are updated in real time. When user needs change (such as modifying the estimated departure time), the main controller recalculates the priorities and adjusts the power allocation scheme.

[0097] Specifically, user charging demand information should include at least: the current SOC value of the vehicle to be charged, the expected SOC value, and the estimated departure time.

[0098] First, the current SOC (State of Charge, remaining battery percentage) directly reflects the urgency of a vehicle's charging needs. Generally, the lower the current SOC, the more urgent the vehicle's charging requirement, and the higher its weight in priority ranking. Compared to ranking methods that don't consider battery level, this provides a quantitative assessment of urgency. Second, the expected SOC clarifies the user's charging goals (e.g., charging to 80% or full charge), avoiding misjudgments based solely on the current SOC. For example, two vehicles with the same current SOC might have different expected SOC values; the vehicle with the higher expected SOC requires longer charging time and more power resources. Therefore, priority allocation must be tailored to these goals to ensure that charging resources are allocated more align with the user's actual needs. Finally, the estimated departure time considers the urgency of the user's time frame. Even if a vehicle's current SOC is not low, a very short estimated departure time (e.g., in 10 minutes) significantly increases its urgency compared to vehicles with ample departure time. Ranking based on this information avoids long queues for highly urgent users, improving the fairness and user experience of the charging service. In practice, other dimensions of information can be added according to the needs of the scenario; this embodiment does not impose strict limitations.

[0099] In summary, by collecting three core types of information—current SOC value, expected SOC value, and estimated departure time—the load priority control strategy's ranking criteria have been upgraded from a "single-dimensional" approach to a multi-dimensional quantitative system encompassing "power capacity + target + time." Because these three types of information comprehensively depict the urgency and resource requirements of users' charging needs, the priority ranking is more accurate and reasonable. Furthermore, by allocating power based on this information, high-urgency demands can receive sufficient power first, while low-urgency demands can be allocated power more appropriately. This improves charging resource utilization efficiency and ensures a better user experience. Therefore, this information structure design addresses the pain points of traditional priority ranking criteria being vague and lacking adaptability, providing accurate and quantifiable core support for the implementation of load priority control strategies and making differentiated power allocation more targeted.

[0100] The foregoing provides a detailed description of the universal power control device and control method for DC charging piles provided in this application. The various embodiments in the specification are described in a progressive manner, with each embodiment focusing on its differences from other embodiments. Similar or identical parts between embodiments can be referred to interchangeably. For the devices disclosed in the embodiments, since they correspond to the methods disclosed in the embodiments, the descriptions are relatively simple; relevant parts can be referred to in the method section. It should be noted that those skilled in the art can make several improvements and modifications to this application without departing from the principles of this application, and these improvements and modifications also fall within the protection scope of this application.

[0101] It should also be noted that, in this specification, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

Claims

1. A universal power control device for DC charging piles, characterized in that, include: Smart sockets, mobile charging piles, and smart control terminal junction boxes; The intelligent control terminal junction box is built into the mobile charging and discharging pile. One end is connected to the communication circuit between the main control board of the mobile charging and discharging pile and the charging gun, and the other end is connected to the smart socket through an aviation connector in the form of power line carrier, for bidirectional power transmission and data interaction. The smart socket is used to establish a communication connection with the main meter of the distribution area, collect real-time load information of the power grid and rated capacity parameters of the distribution transformer, generate a power regulation strategy based on the real-time load information, rated capacity parameters of the distribution transformer and current charging demand, and issue power control commands; the smart regulation terminal junction box is used to receive the power regulation commands and convert them into control signals for the mobile charging and discharging pile to adjust the output power of the charging pile, and at the same time collect the operating data of the mobile charging and discharging pile and feed it back to the smart socket.

2. The universal power control device for DC charging piles according to claim 1, characterized in that, The smart socket includes a main controller, a load acquisition module, and multiple external communication modules; The load acquisition module is connected to the main meter of the transformer area and is used to collect the power distribution load data of the transformer area in real time and upload it to the main controller. Each of the aforementioned external communication modules is connected to multiple mobile charging and discharging piles via a standard charging interface; The main controller has a built-in power regulation strategy unit that calculates and allocates the allowable output power to each of the mobile charging and discharging piles based on the rated capacity of the power distribution area and real-time load data.

3. The universal power control device for DC charging piles according to claim 2, characterized in that, The smart socket also includes: an environmental monitoring module and a surge protection switch; The environmental monitoring module integrates a temperature sensor, a humidity sensor, and a barometric pressure sensor, which are used to collect environmental parameters and trigger early warnings. The surge protection switch adopts a two-stage surge protection design and is connected in series in the power input circuit; The external communication module is a dual-mode communication module that supports PLC carrier communication and 4G / 5G wireless communication, and automatically switches to the backup link when a single communication link is interrupted.

4. The universal power control device for DC charging piles according to claim 2, characterized in that, The power regulation strategy unit includes at least a power distribution capacity adaptation strategy and a load priority regulation strategy. The power distribution capacity adaptation strategy is based on the total load of the distribution area and the rated capacity of the distribution transformer to determine the remaining capacity of the distribution transformer and allocate it to the maximum allowable output power of each connected mobile charging and discharging pile. The load priority control strategy dynamically sorts the charging priorities of each connected mobile charging and discharging pile and adjusts the power allocation based on user charging demand information. The main controller can automatically switch between two strategies or manually select them based on the power grid operating status or preset configuration.

5. The universal power control device for DC charging piles according to claim 1, characterized in that, The intelligent control terminal junction box includes: a CAN series bridge module and an intelligent bypass module; The CAN serial bridge module has dual functions of signal pass-through and command injection. It is used to pass through the communication signal between the charging gun and the main control board, and to insert the control command frame into the pass-through signal when the main controller of the smart socket issues a power control command. The intelligent bypass module includes: a bypass relay and a fault detection module; When the fault detection module detects an abnormality, it controls the bypass relay to engage, so that the main control board of the charging pile is directly connected to the charging gun.

6. The universal power control device for DC charging piles according to claim 3, characterized in that, The smart socket also includes: a load prediction module; The load forecasting module is used to predict the load change trend of the transformer area within a preset time period based on historical load data, environmental parameters collected by the environmental monitoring module, and time series analysis algorithms, and to feed back the load change trend of the transformer area to the main controller.

7. The universal power control device for DC charging piles according to claim 2, characterized in that, The smart socket is connected to the mobile charging and discharging pile via a pluggable aviation connector; the aviation connector has built-in three-phase power pins and two sets of communication pins, which are used for three-phase power transmission, PLC carrier communication, and operation data feedback, respectively. The aviation connector adopts an anti-misinsertion design, with matching guide grooves and positioning pins on the mechanical structure, and power pins and communication pins of different diameters on the electrical interface, and the power circuit and communication circuit are isolated by an insulating partition.

8. A universal power control method for DC charging piles, characterized in that, A general-purpose power control device for DC charging piles includes: a smart socket, a mobile charging pile, and a smart control terminal junction box. The smart control terminal junction box is built into the mobile charging pile, with one end connected to the communication circuit between the mobile charging pile's main control board and the charging gun, and the other end connected to the smart socket via a power line carrier connection through an aviation connector for bidirectional power transmission and data interaction. The smart socket establishes a communication connection with the main meter of the distribution area, collects real-time load information and transformer rated capacity parameters from the power grid, generates a power control strategy based on the real-time load information, transformer rated capacity parameters, and current charging demand, and issues power control commands. The smart control terminal junction box receives the power control commands and converts them into control signals for the mobile charging pile to adjust the output power of the charging pile, while simultaneously collecting the mobile charging pile's operating data and feeding it back to the smart socket. The method includes: Establish a communication connection with the main meter of the distribution area to collect real-time load information and rated capacity parameters of the distribution transformers on the power grid side; Based on real-time power distribution load information, transformer rated capacity parameters, and current charging demand, a power regulation strategy is generated and a power control command is sent to the intelligent control terminal junction box of the mobile charging and discharging pile. Receives mobile charging and discharging pile operation data fed back from the intelligent control terminal junction box.

9. The universal power control method for DC charging piles according to claim 8, characterized in that, The steps of the power generation regulation strategy include: The remaining capacity of the distribution transformer is determined based on the rated capacity parameters of the distribution transformer and the total load in the real-time load information of the power grid. Based on the current control objectives, either the transformer capacity adaptation strategy or the load priority control strategy can be implemented. If the distribution transformer capacity adaptation strategy is implemented, the maximum allowable output power of each pile is allocated proportionally according to the number of connected mobile charging and discharging piles and the current power demand of each mobile charging and discharging pile, so that the total power of all connected mobile charging and discharging piles does not exceed the remaining capacity of the distribution transformer. If a load priority control strategy is implemented, the user charging demand information of each mobile charging and discharging pile is obtained and the charging priority is dynamically sorted. The output power is then allocated to the mobile charging and discharging piles of different priorities in sequence based on the remaining capacity of the distribution transformer. The output power of the mobile charging and discharging pile with higher priority is higher than that of the mobile charging and discharging pile with lower priority.

10. The universal power control method for DC charging piles according to claim 9, characterized in that, The user charging demand information includes at least: the current SOC value of the vehicle to be charged, the expected SOC value, and the estimated departure time.

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