Direct current charging pile

Abstract

The invention provides a direct-current charging pile, and belongs to the technical field of charging piles, the direct-current charging pile comprises an aluminum alloy structural member and a charging assembly, the charging assembly comprises a power wire harness, a charging gun wire harness and the like, the power wire harness is used for supplying power to equipment and is electrically connected with a power supply, and a heat conduction structure is arranged on the inner bottom surface of the aluminum alloy structural member; the inner heat conduction structure is provided with a circuit board module, the outer bottom surface is provided with a heat dissipation structure, and the center of the heat dissipation structure is provided with a heat dissipation assembly. Heat conduction and heat dissipation structures on the inner side and the outer side of the bottom of an aluminum alloy structural part serve as the core of the whole heat conduction structure, the heat conduction structure on the inner side of the aluminum alloy structural part is provided with a boss capable of containing an inductor and a transformer, and main heating elements on a circuit board module are tightly pressed on the surface of the boss through pressing strips and ceramic pieces. By means of the heat conduction and heat dissipation structure which is arranged in a centralized mode, originally dispersed heat sources are gathered to an efficient heat conduction structure, and heat dissipation efficiency is effectively improved.

Description

Technical Field

[0001] This invention belongs to the field of charging pile technology, specifically a DC charging pile. Background Technology

[0002] A DC charging station is a charging device that provides DC power to electric vehicles. It converts AC power into DC power to directly charge the battery of the electric vehicle. The main core component of a DC charging station is the circuit board module. The circuit board module is used to convert AC power into DC power to provide a stable DC power supply for the electric vehicle. The circuit board module has a large number of electronic components, which are the main heat source inside the DC charging station. Due to its high power and high working intensity, it will generate a lot of heat, so it is necessary to dissipate heat quickly when the circuit board module is working.

[0003] However, existing charging piles typically install multiple independent cooling fans and circuit board modules in the same space. When working, the fans directly blow air into the circuit board modules to dissipate heat from the electronic components that generate a lot of heat. While this method can achieve a certain cooling effect, the airflow path is complex, and the circuit board modules are directly exposed to the external environment. During the cooling process, the airflow can easily bring dust and water vapor from the external environment into the circuit board modules, causing dust accumulation inside the charging pile and even short circuits in the circuit board modules. In severe cases, this can even lead to safety hazards. At the same time, the airflow generated by the fans may affect the stability of the internal electronic components.

[0004] Therefore, we propose a DC charging station to solve the problems mentioned above. Summary of the Invention

[0005] The purpose of this invention is to address the problems of existing commonly used charging piles, which typically have multiple independent cooling fans installed at the top inside the charging pile. External air is directly introduced into the charging pile through the air inlet at the top, and the airflow passes over the heat-generating components on the circuit board module before being discharged through the air outlet at the bottom of the charging pile. This method can dissipate the heat generated by the heat-generating components on the circuit board module and cool it down. Although this method can achieve a certain cooling effect, the airflow path is directly through the circuit board module. During the cooling process, the airflow can easily bring dust and water vapor from the external environment into the circuit board module, causing dust accumulation inside the charging pile and even short circuits in the circuit board module. In severe cases, this can even lead to safety hazards. At the same time, the airflow generated by the fans may affect the stability of the internal electronic components. Therefore, this invention proposes a DC charging pile.

[0006] The objective of this invention can be achieved through the following technical solution: It includes an aluminum alloy structural component and a charging assembly. The charging assembly includes at least a power harness and a charging gun harness. The power harness is used to supply power to the charging pile and is electrically connected to a power source. The bottom surface of the aluminum alloy structural component is a heat-conducting structure, and a circuit board module is disposed on the heat-conducting structure. The circuit board module is electrically connected to the charging gun harness. A heat dissipation structure is disposed on the outside of the aluminum alloy structural component, corresponding to the side of the internal heat-conducting structure. The heat dissipation structure includes heat dissipation fins and a heat dissipation fan. The internal heat-conducting structure and the external heat dissipation fins of the aluminum alloy structural component are integrally die-cast with other structures on the aluminum alloy structural component.

[0007] In a preferred embodiment of the present invention, the heat-generating electronic components are centrally arranged on the circuit board module. The heat-generating electronic components include diodes, MOSFETs, rectifier bridges, inductors, and transformers. A pressure strip is provided between the diodes and MOSFETs.

[0008] In a preferred embodiment of the present invention, a boss structure is provided on the heat-conducting structure inside the aluminum alloy structural component. The boss structure has an inductor placement cavity and a transformer placement cavity inside. The inductor is placed inside the inductor placement cavity, and the transformer is placed inside the transformer placement cavity. One side of the diode and the MOSFET are both abutted against the surface of the boss through a ceramic plate. A pressure strip is provided between the diode and the MOSFET to press the diode and the MOSFET firmly onto the ceramic plate. The rectifier bridge is directly abutted against the boss and fixed with screws.

[0009] In a preferred embodiment of the present invention, the heat dissipation structure includes heat dissipation fins distributed on the back of the aluminum alloy structural component. The heat dissipation fins are integrally die-cast with the aluminum alloy structural component and correspond to the internal heat conduction structure to increase the contact area with air. The heat dissipation fins are radially distributed, and a cooling fan is installed at the center of the heat dissipation fins.

[0010] In a preferred embodiment of the present invention, the radially distributed heat dissipation fins are perpendicular to the bottom back surface of the aluminum alloy structural component, and the gaps between the radially distributed heat dissipation fins serve as air outlet channels for gas outflow.

[0011] In a preferred embodiment of the present invention, wire harness through holes are provided on both the left and right sides of the bottom of the aluminum alloy structural component. One end of the power wire harness passes through the wire harness through hole on the left side and extends into the interior of the aluminum alloy structural component, and one end of the charging gun wire harness passes through the wire harness through hole on the right side and extends into the interior of the aluminum alloy structural component.

[0012] In a preferred embodiment of the present invention, a sheet metal front panel is provided at the front of the aluminum alloy structural component, and a rubber sealing strip is provided between the sheet metal front panel and the aluminum alloy structural component. A semi-transparent silicone button mounting hole is provided in the lower center of the sheet metal front panel. The semi-transparent silicone button corresponds to the button and indicator light part soldered on the circuit board. An equipment nameplate is provided on one side of the aluminum alloy structural component, and a hanging bolt is provided on the rear side of the aluminum alloy structural component. The hanging bolt is suspended in the hanging groove of the wall fixing plate. The wall fixing plate is pre-fixed to the wall at the charging pile installation position with expansion bolts.

[0013] Compared with the prior art, the beneficial effects of the present invention are as follows: (1) By using aluminum alloy structural components as the main structure of the entire charging pile, and using the protrusions set on the bottom surface of the aluminum alloy structural components, the heat conduction structure formed by the cavity surrounded by the protrusions, and the heat dissipation structure formed by the radially arranged heat dissipation fins on the outside of the aluminum alloy structural components as the core of the heat conduction structure, the protrusions on the heat conduction structure set on the bottom surface of the aluminum alloy structural components are tightly pressed with the main heat-generating components on the circuit board: diodes and MOSFETs through pressure strips and ceramic sheets. The rectifier bridge is directly pressed with the protrusions by screw fixing, thus achieving low thermal resistance contact between the heat source and the heat conduction structure. The cavity surrounded by the protrusions on the bottom surface of the aluminum alloy structural components surrounds the main heat-generating components on the circuit board: inductors and transformers, and thermal conductive glue is poured into the cavity so that the heat generated by the inductors and transformers can be quickly absorbed. This centralized heat conduction structure gathers the originally dispersed heat sources into a highly efficient heat conduction structure, fundamentally optimizing the heat dissipation path. (2) The radially distributed heat dissipation fins and cooling fan on the outside of the aluminum alloy structural component, which serves as the heat dissipation structure, constitute the internal heat source. The heat is conducted to the heat dissipation fins through the heat conduction structure inside the aluminum alloy structural component. Then, the airflow generated by the operation of the cooling fan quickly dissipates the heat to the outside, forming an efficient heat dissipation process. The heat dissipation fins greatly increase the heat exchange area with the air. The cooling fan realizes the directional, efficient and continuous absorption of heat by the air medium. Through the combined heat dissipation layout of internal concentrated heat absorption and heat conduction and external diffusion and efficient circulation, the overall heat dissipation efficiency is significantly improved. It can quickly and continuously dissipate internal heat, ensuring that the core components work at a suitable temperature, thereby improving the charging pile's continuous working capability and long-term operational reliability under high power. Attached Figure Description

[0014] To facilitate understanding by those skilled in the art, the present invention will be further described below with reference to the accompanying drawings.

[0015] Figure 1 This is a three-dimensional structural diagram of the present invention; Figure 2 This is a rear-view stereoscopic structural diagram of the present invention; Figure 3 This is a three-dimensional structural diagram of the sheet metal front panel of the present invention. Figure 4 This is a three-dimensional structural diagram of the rear side of the circuit board module of the present invention; Figure 5 This is a schematic diagram of the internal three-dimensional structure of the aluminum alloy structural component of the present invention.

[0016] In the diagram: 1. Sheet metal front panel; 2. Aluminum alloy structural component; 201. Boss structure; 202. Heat sink fins; 203. Inductor placement cavity; 204. Transformer placement cavity; 205. Wire harness via; 3. Circuit board module; 301. Diode; 302. MOSFET; 303. Pressure strip; 304. Ceramic plate; 305. Rectifier bridge; 306. Inductor; 307. Transformer; 4. Semi-transparent silicone button; 5. Cooling fan; 6. Wall mounting plate; 7. Equipment nameplate; 8. Power harness; 9. Charging gun harness; 10. Rubber sealing strip; 11. Wire harness sealing ring; 12. Wire harness sealing ring pressure plate; 13. Suspension bolt; 14. Expansion bolt. Detailed Implementation

[0017] The technical solution of the present invention will be clearly and completely described below with reference to the embodiments. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0018] Please see Figure 1 - Figure 5As shown, a DC charging pile includes an aluminum alloy structural component 2 and a charging assembly. The charging assembly includes at least a power harness 8 and a charging gun harness 9. The power harness 8 supplies power to the charging pile and is electrically connected to a power source. The aluminum alloy structural component 2 has a heat-conducting structure on its inner bottom surface, and a circuit board module 3 is mounted on the heat-conducting structure. The circuit board module 3 is electrically connected to the charging gun harness 9. The heat-generating electronic components on the circuit board module 3 are centrally arranged, including a diode 301, a MOSFET 302, a rectifier bridge 305, an inductor 306, and a transformer 307. A connection is provided between the diode 301 and the MOSFET 302. A pressure strip 303 is provided, which applies pressure to the diode 301 and the MOSFET 302. The pressure strip 303 has a certain degree of rigidity and elasticity, ensuring uniform and continuous pressure on the diode 301 and the MOSFET 302, guaranteeing tight contact between the contact surfaces, reducing contact thermal resistance, and ensuring that the diode 301 and the MOSFET 302 are always in contact with the heat transfer surface via the ceramic sheet 304. This allows the heat dissipated by the diode 301 and the MOSFET 302 during operation to be conducted to the heat-conducting structure via the ceramic sheet 304. The heat-conducting structure inside the aluminum alloy structural component 2 has a boss structure 201. The boss structure 201 has an inductor placement cavity 203 and a transformer placement cavity 204 inside. The inductor 306 is placed inside the inductor placement cavity 203, and the transformer 307 is placed inside the transformer placement cavity 204. The placement of the inductor placement cavity 203 and the transformer placement cavity 204 provides installation space for the inductor 306 and the transformer 307, allowing the heat from the inductor 306 and the transformer 307 to be absorbed by the aluminum alloy cavity wall and conducted to the heat dissipation fins on the back. Moreover, the boss structure 201 not only provides placement cavities, but its increased volume also expands the contact area with the internal heat source and enhances its heat absorption and conduction capabilities. The thermal capacity of the heat-conducting structure is increased, allowing for more complete heat absorption and preventing local overheating. One side of both diode 301 and MOSFET 302 abuts against the surface of boss structure 201 via ceramic sheet 304. The ceramic sheet 304 is used to insulate diode 301 and MOSFET 302, preventing current from being conducted to aluminum alloy structural component 2 during operation and causing safety hazards. At the same time, ceramic sheet 304 should be made of ceramic material with high thermal conductivity, such as alumina ceramic, so as to minimize thermal resistance while ensuring electrical safety, allowing heat to be quickly conducted to the heat-conducting structure through ceramic sheet 304. A heat dissipation structure is provided on the outer side of the aluminum alloy structural component 2, corresponding to the internal heat-conducting structure. The heat dissipation component includes heat dissipation fins 202 and a cooling fan 5. The cooling fan 5 accelerates the convective exchange of heat between the heat dissipation fins 202 and the air, allowing the heat conducted through the heat-conducting structure to be quickly dissipated to the outside. The heat dissipation fins on the heat dissipation structure are used to increase the contact area between the heat dissipation mechanism and the air. The cooling fan 5 is located at the center of the heat dissipation fins 202, and the structure of the heat dissipation fins 202 is radially distributed around the cooling fan 5. The heat dissipation fins 202 and the aluminum alloy The outer side of the aluminum alloy structural component 2 is vertically arranged, and an air outlet channel is formed between adjacent heat dissipation fins 202. All the heat conducted to the heat dissipation structure is quickly diffused to the outer heat dissipation fins through the heat dissipation structure. When the cooling fan 5 is working, the airflow passes through the channel between the heat dissipation fins 202, absorbs and carries away the heat on the heat dissipation fins 202, and achieves the heat dissipation function. The heat dissipation fins 202, the boss structure 201, and other structures on the aluminum alloy structural component 2 are integrally formed by die casting process, which ensures the overall structural strength, thermal conductivity and protection function. Both the left and right sides of the bottom of the aluminum alloy structural component 2 are provided with wire harness through holes 205. One end of the power wire harness 8 passes through the left wire harness through hole 205 and extends into the interior of the rear aluminum alloy structural component 2. One end of the charging gun wire harness 9 passes through the right wire harness through hole 205 and extends into the interior of the aluminum alloy structural component 2. The wire harness through holes 205 provide installation space for the power wire harness 8 and the charging gun wire harness 9, so that the power wire harness 8 and the charging gun wire harness 9 can be firmly connected to the circuit board module inside the device. A rubber sealing strip 11 is also provided inside the wire harness through hole 205. The rubber sealing strip 11 is pressed by the external wire harness sealing ring pressure plate 12 to seal the gap between the wire harness and the wire harness through hole 305, preventing external dust, impurities and water vapor from entering the housing through the wire harness through hole 305, and ensuring the realization of the sealing and protection function. The charging pile has a sheet metal front panel 1 on its front side, which is fixedly installed on the front end of the aluminum alloy structural component 2. The side wall of the sheet metal front panel 1 is fixedly connected to the aluminum alloy structural component 2 by bolts, and a rubber sealing strip 10 is provided at the connection between the sheet metal front panel 1 and the aluminum alloy structural component 2, achieving a sealing effect between the sheet metal front panel 1 and the aluminum alloy structural component 2. This keeps the charging pile's interior in a closed state, ensuring that the equipment meets dustproof, moisture-proof, and waterproof standards. After testing, the protection level reaches the IP66 standard. During equipment operation, this prevents dust, impurities, moisture, etc., from entering and contaminating or damaging the circuit board module 3, thus protecting the internal circuitry. A button is welded to the side of the circuit board module 3 facing the front panel, and indicator lights are welded around the button. The sheet metal front panel 1 corresponds to the button and indicator lights on the circuit board module 3. A semi-transparent silicone button 4 is installed on the indicator light area. The flashing status and light color of the indicator light on the circuit board module 3 can be observed through the semi-transparent silicone button 4 to identify the working status of the charging pile (start-up, charging, charging complete, fault). During use, the machine can be stopped by pressing the semi-transparent silicone button 4. A device nameplate 7 is set on one side of the aluminum alloy structural component 2. The device nameplate 7 displays relevant information of the charging equipment, such as: input voltage, input current, output voltage, output current, output power, operating temperature, protection level, etc., so as to use it in a targeted manner. A hanging bolt 13 is set on the rear side of the aluminum alloy structural component 2. When the charging pile is installed, the hanging bolt 13 is installed in the groove of the wall fixing plate 6, which is pre-fixed to the wall with expansion bolts 14.

[0019] When using this invention, if it is necessary to charge equipment such as electric vehicles, the charging gun harness 9 is removed and plugged into the charging port of the electric vehicle for charging. During the operation of the charging gun harness 9, the heat-generating components on the circuit board module 3 will generate heat. The generated heat is conducted to the heat dissipation fins 202 on the back through the boss structure 201 on the aluminum alloy structural component 2. The airflow blown out by the cooling fan 5 during operation flows through the heat dissipation fins 202, allowing the air to absorb the heat on the heat dissipation fins 202 and quickly dissipate the heat through the air outlet channels between the heat dissipation fins 202, avoiding heat accumulation near the shell, effectively reducing the operating temperature of the core components, and improving the continuous working stability of the charging pile.

[0020] The preferred embodiments of the present invention disclosed above are merely illustrative of the invention. These preferred embodiments do not exhaustively describe all details, nor do they limit the invention to any specific implementation. Clearly, many modifications and variations can be made based on the content of this specification. This specification selects and specifically describes these embodiments to better explain the principles and practical applications of the invention, thereby enabling those skilled in the art to better understand and utilize the invention. The invention is limited only by the claims and their full scope and equivalents.

Claims

1. A DC charging pile, comprising an aluminum alloy structural component (2) and a charging assembly, the charging assembly comprising at least a power harness (8) and a charging gun harness (9), the power harness (8) being used to supply power to the charging pile, the power harness (8) being electrically connected to a power source, characterized in that, The aluminum alloy structural component (2) has a heat-conducting structure on its inner bottom surface, and a circuit board module (3) is provided on the heat-conducting structure. The circuit board module (3) is electrically connected to the charging gun harness (9). The aluminum alloy structural component (2) has a heat dissipation structure on its outer side corresponding to the inner heat-conducting structure. A cooling fan (5) is installed in the center of the heat dissipation structure. The aluminum alloy structural component (2) has a boss and a cavity structure on its inner heat-conducting structure.

2. The DC charging pile according to claim 1, characterized in that, The circuit board module (3) is provided with heat-generating electronic components, including diodes (301), MOSFETs (302), rectifier bridges (305), inductors (306) and transformers (307), and a pressure bar (303) is provided between the diodes (301) and the MOSFETs (302).

3. A DC charging pile according to claim 2, characterized in that, The aluminum alloy structural component (2) has a boss structure (201) on its internal heat-conducting structure. The boss structure (201) has an inductor placement cavity (203) and a transformer placement cavity (204) inside. The inductor (306) is placed inside the inductor placement cavity (203), and the transformer (307) is placed inside the transformer placement cavity (204). One side of the diode (301) and the MOS transistor (302) are both abutted against the surface of the boss (202) by a ceramic sheet (304) and pressed with a pressure strip.

4. A DC charging pile according to claim 1, characterized in that, The heat dissipation structure includes heat dissipation fins (206), which are integrally cast with the aluminum alloy structural component and are radially distributed on the back of the aluminum alloy structural component to increase the contact area with air and improve heat dissipation efficiency. The heat dissipation fan (5) is installed in the center of the radially distributed heat dissipation fins.

5. A DC charging pile according to claim 4, characterized in that, The heat dissipation fins (206) are arranged radially from the center to the surrounding area. The heat dissipation fan (5) is installed in the center of the radially arranged heat dissipation fins. An air outlet channel is formed between adjacent heat dissipation fins (206). During the rotation of the heat dissipation fan (5), the airflow flows to the surrounding area through the channel between the heat dissipation fins (206) and absorbs the heat on the heat dissipation fins (206) and discharges the heat.

6. A DC charging pile according to claim 1, characterized in that, The aluminum alloy structural component (2) has wire harness through holes (205) on both the left and right sides at the lower end. One end of the power wire harness (8) passes through the wire harness through hole (205) on the left side and extends into the interior of the aluminum alloy structural component (2). One end of the charging gun wire harness (9) passes through the wire harness through hole (205) on the right side and extends into the interior of the aluminum alloy structural component (2).

7. A DC charging pile according to claim 1, characterized in that, The aluminum alloy structural component (2) is provided with a sheet metal front panel (1) at the front. A rubber sealing strip (10) is provided between the sheet metal front panel (1) and the aluminum alloy structural component (2). A semi-transparent silicone button (4) mounting hole is provided in the lower center of the sheet metal front panel (1). The semi-transparent silicone button (4) corresponds to the button and signal light welded on the circuit board (3). An equipment nameplate (7) is provided on one side of the aluminum alloy structural component (2). A hanging bolt (13) is provided on the rear side of the aluminum alloy structural component (2). The hanging bolt (13) is suspended in the hanging groove of the wall fixing plate (6). The wall fixing plate (6) is pre-fixed to the wall of the charging pile installation location with expansion bolts (14).

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