Integrated full liquid cooling charging pile equipment and intelligent temperature control method thereof

Abstract

The invention relates to integrated full liquid cooling charging pile equipment and an intelligent temperature control method thereof, the equipment comprises a cold plate heat exchanger, a circulating pump, a liquid cooling charging gun, a liquid storage tank and a liquid supply pump, and the liquid storage tank is communicated with the liquid cooling charging gun and an immersed power module cooling box; a liquid supply pump is arranged on the pipeline of the liquid storage tank and the liquid cooling charging gun; a liquid supply pump is arranged on a pipeline of the liquid storage tank and the immersed power module cooling box; the input end of the circulating pump is communicated with the liquid cooling charging gun and the immersed power module cooling box; the circulating pump is communicated with the cold plate heat exchanger; the cold plate heat exchanger is communicated with the liquid storage tank through a pipeline. A circulating pump parallel cooling framework is adopted, a power module and a charging gun are cooled in parallel, cooling liquid is pumped into the same cold plate heat exchanger after being mixed and finally returns to a liquid storage tank to form a closed loop, and heat carried by the cooling liquid is rapidly transferred to an external cold source; the efficient heat dissipation capability allows the power module to work stably at higher temperature and power, and the service life of the charging gun and the power module is prolonged.

Description

Technical Field

[0001] This application relates to the field of electric vehicle charging equipment technology, specifically to an integrated fully liquid-cooled charging pile device and its intelligent temperature control method. Background Technology

[0002] With the increasing popularity of electric vehicles, users' demands for charging efficiency continue to escalate. High-power, ultra-fast charging technology has become a core track in the development of the new energy vehicle industry. It not only achieves a charging experience similar to refueling, but also represents a technological breakthrough across the entire chain, from batteries and vehicles to charging stations and infrastructure. Liquid-cooled supercharging and megawatt-level fast charging have become mainstream directions. Simultaneously, ultra-fast charging technologies for passenger and commercial vehicles are developing in parallel, driving the leap of new energy vehicles from simply being usable to being truly user-friendly. With the increasing popularity of electric vehicles, high-power, ultra-fast charging technology has become a development trend.

[0003] However, the existing technology has obvious defects: the increase in charging power leads to a large amount of heat generated in the power module and charging gun inside the charging pile. The traditional air cooling method can no longer meet the heat dissipation requirements and has the following drawbacks: (1) The air cooling heat transfer coefficient is low and the heat dissipation efficiency is low. It is difficult to cope with the heat density generated by continuous high power operation, which can easily lead to overheating and derating or damage of power devices. (2) High power heat dissipation requires a high-power fan, which generates significant noise pollution. (3) Air cooling requires openings, which can easily lead to dust and moisture entering, affecting electrical safety and equipment life. The charging gun head has a small space and a complex structure, and air cooling is difficult to directly and effectively cool its internal conductors and contact points. At present, some solutions use liquid-cooled charging guns, but their cooling circuit is independent of the cooling system of the power module inside the pile. There are two sets of circulation, complex structure and high cost. There are also solutions that use cold plate liquid cooling for power modules, but the cold plate usually only contacts the device substrate, and thermal resistance still exists.

[0004] Therefore, this invention proposes an integrated fully liquid-cooled charging pile device and its intelligent temperature control method. Summary of the Invention

[0005] To overcome the shortcomings of the prior art, this application provides an integrated fully liquid-cooled charging pile device and its intelligent temperature control method, specifically adopting the following technical solution.

[0006] An integrated fully liquid-cooled charging pile device includes: a cold plate heat exchanger, a circulating pump, an immersion power module cooling box, a liquid-cooled charging gun, a liquid storage tank, a liquid supply pump A, and a liquid supply pump B.

[0007] The liquid storage tank is connected to the liquid-cooled charging gun and the immersion power module cooling box via pipelines; a liquid supply pump B is installed on the pipeline between the liquid storage tank and the liquid-cooled charging gun; and a liquid supply pump A is installed on the pipeline between the liquid storage tank and the immersion power module cooling box.

[0008] The input end of the circulating pump is connected to the liquid-cooled charging gun and the immersion power module cooling box via a T-junction and other piping. The output end of the circulating pump is connected to the cold plate heat exchanger via piping; the cold plate heat exchanger is connected to the liquid storage tank via piping.

[0009] As an optional embodiment of the present invention, a filter, a pressure sensor, a flow control valve, and a flow meter are installed on the pipeline between the liquid storage tank and the liquid-cooled charging gun. A 50-mesh filter screen is detachably and fixedly installed on the filter.

[0010] A filter, pressure sensor, flow control valve, and flow meter are fixedly installed on the pipeline between the circulating pump and the immersion power module cooling box.

[0011] As an optional solution of the present invention, temperature sensors are fixedly installed on the outside of the immersion power module cooling box and at the position of the liquid-cooled charging gun head. The temperature sensors directly collect the real-time temperature of the heat-generating components. Temperature sensors are installed on the inlet and outlet pipes of the cold plate heat exchanger to monitor the temperature difference of the coolant before and after heat exchange. Pressure sensors, temperature sensors and flow meters are installed on the pipe between the circulating pump and the cold plate heat exchanger to achieve comprehensive monitoring of the pressure, temperature and flow of the main circulation loop.

[0012] As an optional embodiment of the present invention, a high-level liquid level gauge and a low-level liquid level gauge are respectively installed on the upper and lower positions of the inner wall of the liquid storage tank. The high-level liquid level gauge is used to monitor the highest liquid level threshold of the coolant to prevent excessive liquid replenishment from causing the pipeline to overflow. The low-level liquid level gauge is used to monitor the lowest liquid level threshold of the coolant to avoid the circulation pump from running dry and being damaged due to the liquid level being too low. An automatic air vent valve is also installed on the top of the liquid storage tank.

[0013] As an optional embodiment of the present invention, the immersion power module cooling box adopts a sealed and pressure-resistant structural design. A liquid inlet connector and a data transmission connector are fixedly installed on the upper rear side of the box. The liquid inlet connector is used to connect the low-temperature coolant from the liquid supply pump A, and the data transmission connector is used to connect the power module and the charging pile controller to realize the real-time transmission of the power module's operating data. A liquid return connector is installed on the lower rear side of the box to discharge the heated coolant after heat exchange.

[0014] Between the liquid inlet and return connectors on the rear side of the immersion power module cooling box, there are multiple three-phase AC input connectors and DC output connectors. The three-phase AC input connectors are located above the DC output connectors for easy identification of wiring. A rotatable handle is installed on the top of the box; a transparent window is embedded in the upper front of the box.

[0015] The immersion power module cooling box is equipped with a detachable metal mounting bracket, and the charging pile power module is fixed to the bracket with bolts.

[0016] As an optional embodiment of the present invention, the immersion power module cooling box is provided with an internal flow guiding structure, which guides the coolant to flow through the hot spot area of ​​the power module.

[0017] All monitoring components, such as pressure sensors, temperature sensors, and flow meters, are electrically connected to the main controller of the charging pile to form an intelligent monitoring and control system.

[0018] As an optional embodiment of the present invention, a liquid collection section and a gas-liquid separation structure are provided in the low-position area before the input end of the circulating pump. The liquid collection section adopts a conical design, which allows impurities in the coolant to settle and collect under the action of gravity. The gas-liquid separation structure further separates the air bubbles mixed in the coolant, ensuring that the flow of coolant entering the circulating pump is stable and avoiding cavitation in the pump body.

[0019] The gas-liquid separation structure is a sealed cavity made of stainless steel, which is seamlessly connected to the cooling pipeline. It contains three core functional areas: a cone-shaped liquid collection and sedimentation area, a flow guiding and defoaming separation area, and a gas chamber exhaust area.

[0020] Conical Settling Zone: The bottom of the cavity is designed with a conical structure, integrated with the liquid collection section. The heated coolant flowing from the liquid-cooled charging gun and the immersion power module cooling box first enters the conical settling zone, where the flow rate slows down within the conical cavity. Impurities such as metal debris and small particles detached from the filter screen carried in the coolant settle along the conical surface under gravity, accumulating at the bottom of the cavity. A manual drain valve is also provided at the bottom of the cavity, allowing maintenance personnel to periodically open the valve to drain the deposited impurities without disassembling the entire structure.

[0021] Defoaming and defoaming separation zone: Above the conical zone is the main body of the cavity, inside which two arc-shaped flow guide baffles are vertically installed. When the coolant bypasses the flow guide baffles, the flow channel is deflected, further reducing the flow velocity; at the same time, a layer of 100-mesh polyester fiber defoaming net is laid between the baffles, and the defoaming net is arranged in a wavy shape to increase the contact area with the coolant.

[0022] Air Chamber Exhaust Area: The top of the cavity is a reserved air chamber. The separated air will gather in the air chamber, forming a stable air cushion layer, and will not flow into the circulation pump with the coolant. A miniature automatic exhaust valve is installed on the top of the air chamber, which is linked to the automatic exhaust valve on the top of the liquid storage tank; when the air pressure in the air chamber reaches 0.02MPa, the exhaust valve will automatically open to release the air into the atmosphere; when the air pressure is lower than the threshold, it will automatically close to prevent coolant leakage.

[0023] The gas-liquid separation structure has an inlet and an outlet on the side of the cavity.

[0024] As an optional embodiment of the present invention, the liquid-cooled charging gun includes a gun head section, a grip section, and a gun wire section. The internal liquid cooling channels of the gun head section, grip section, and gun wire section are seamlessly connected. The coolant flows in from the liquid inlet of the grip section, flows through the gun wire section and the gun head section in sequence, absorbs heat, and then flows out from the liquid return port of the grip section, and merges into the three-way pipe in front of the circulation pump.

[0025] The technical solution of this application has achieved the following beneficial effects.

[0026] 1. This invention employs a parallel cooling architecture with circulating pumps, simultaneously connecting the cooling power module and charging gun in parallel. This is not a simple stacking of components, but a highly integrated and optimally efficient thermal management topology. The cold plate heat exchanger, circulating pump, liquid storage tank, and dual liquid supply pumps form a closed-loop circuit. The cold plate heat exchanger, as the core heat dissipation component, can quickly transfer the heat carried by the coolant to an external cold source. The liquid supply pumps supply liquid independently to two branches, allowing for flow rate adjustment based on the heat load. Combined with the fluid distribution advantages of the integrated topology, energy waste is avoided, ensuring precise matching of heat dissipation at each terminal as needed.

[0027] 2. The efficient heat dissipation capability allows the power module to operate stably at higher temperatures and power levels, supports continuous high-power charging without derating, and extends the service life of the charging gun and power module. Attached Figure Description

[0028] Figure 1 This is a schematic diagram of the integrated liquid-cooled charging pile device in the embodiments of this application.

[0029] Figure 2 This is a schematic diagram of the immersion power module cooling box of the integrated liquid-cooled charging pile device in the embodiments of this application.

[0030] Figure 3 This is a schematic diagram of the top of the immersion power module cooling box of the integrated liquid-cooled charging pile device in the embodiments of this application.

[0031] Figure 4 for Figure 3 Sectional view along the AA direction.

[0032] Figure 5 This is a schematic diagram of the intelligent temperature control method for the integrated liquid-cooled charging pile device in the embodiments of this application.

[0033] Reference numerals: 1. Cold plate heat exchanger; 2. Circulating pump; 3. Immersion power module cooling box; 4. Liquid-cooled charging gun; 5. Storage tank; 6. Supply pump A; 7. Supply pump B; 8. Power module; 9. Level gauge; 10. Filter; 11. Pressure sensor; 12. Temperature sensor; 13. Flow meter; 31. Inlet connector; 32. Return connector; 33. Three-phase AC input connector; 34. DC output connector; 35. Data transmission connector; 36. Handle; 37. Transparent window; 51. High-level level gauge; 52. Low-level level gauge; 53. Automatic air vent valve. Detailed Implementation

[0034] The present application will now be further described with reference to the accompanying drawings. The following embodiments are only used to more clearly illustrate the technical solutions of the present application and should not be construed as limiting the scope of protection of the present application. It should be noted that the following detailed descriptions are exemplary and intended to provide further explanation of the present application.

[0035] like Figure 1 As shown, the present invention discloses an integrated fully liquid-cooled charging pile device, including a cold plate heat exchanger 1, a circulating pump 2, an immersion power module cooling box 3, a liquid-cooled charging gun 4, a liquid storage tank 5, a liquid supply pump A6, and a liquid supply pump B7.

[0036] The liquid storage tank 5 is connected to the liquid-cooled charging gun 4 and the immersion power module cooling box 3 through pipelines; a liquid supply pump B7 is installed on the pipeline between the liquid storage tank 5 and the liquid-cooled charging gun 4; and a liquid supply pump A6 is installed on the pipeline between the liquid storage tank 5 and the immersion power module cooling box 3.

[0037] The input end of the circulating pump 2 is connected to the liquid-cooled charging gun 4 and the immersion power module cooling box 3 via a three-way pipe and other piping. The output end of the circulating pump 2 is connected to the cold plate heat exchanger 1 via piping; the cold plate heat exchanger 1 is connected to the liquid storage tank 5 via piping.

[0038] Both supply pumps A6 and B7 are speed-regulating pumps, linked with circulation pump 2 for control. Circulation pump 2 is the main power source for circulation, while supply pumps A6 and B7 serve as auxiliary flow regulators for branch circuits. The head and flow parameters of the three pumps are matched, with the head of circulation pump 2 being greater than or equal to the sum of the heads of supply pumps A6 and B7, to avoid pressure rushing. The inflow and outflow of liquid in storage tank 5 are dynamically balanced to ensure stable liquid level. A return booster pump is installed between the three-way pipe and the input end of circulation pump 2 to provide power for return liquid, avoiding problems such as poor gravity return and liquid accumulation. The return booster pump is linked with circulation pump 2, and their speeds are adjusted synchronously.

[0039] The cold plate heat exchanger 1 is equipped with a cold plate air-cooled heat dissipation component, which includes a cooling fan and a guide air duct. The cooling fan is linked to the temperature sensor at the liquid inlet of the cold plate heat exchanger 1. When the liquid inlet temperature exceeds a preset threshold, the speed of the cooling fan is automatically increased to enhance heat dissipation.

[0040] In this technical solution, the cold plate heat exchanger 1, circulating pump 2, immersion power module cooling box 3, liquid-cooled charging gun 4, liquid storage tank 5, liquid supply pump A6, and liquid supply pump B7 are connected to form a closed cooling circulation loop. The immersion power module cooling box 3 houses a power module 8. The immersion power module cooling box 3 contains coolant, which is an insulating, inert liquid with good thermal properties, preferably silicone oil. Silicone oil can directly contact the power module casing and pins for heat exchange, while avoiding the risk of electrical short circuits and ensuring safe equipment operation. The cold plate heat exchanger 1 is the core of the entire system's heat dissipation. When the heated coolant flows through the cold plate heat exchanger 1, the heat it carries is efficiently transferred to an external cold source through the cold plate, completing the heat exchange and cooling down to form a low-temperature coolant. The cryogenic coolant flows through pipelines into the storage tank 5 for buffering and pressure stabilization, and then is delivered to different heat dissipation terminals via two routes: one route is pressurized and driven by the supply pump A6, delivering it to the immersion power module cooling box 3; the other route is pressurized and driven by the supply pump B7, delivering it to the liquid-cooled charging gun 4. The two routes are independently supplied, and the flow rate can be adjusted according to the heat load of different terminals. The cryogenic coolant entering the liquid-cooled charging gun 4 flows through the preset liquid cooling channel inside the gun body, directly and directionally cooling the gun wire conductor and the internal terminals of the gun head that generate serious heat under high current conditions, and promptly removing the heat generated during fast charging; the cryogenic coolant entering the immersion power module cooling box 3 directly immerses the power module 8 inside the box, and through a combination of natural convection and forced flow, it fully wraps the hot areas of the power module such as the IGBT and rectifier bridge, quickly dissipating the heat generated by the operation of the components. After heat exchange, the heated coolant flows out from the return port of the liquid-cooled charging gun 4 and the return connector of the immersion power module cooling tank 3. With the assistance of the return booster pump, it converges into a three-way pipe to avoid gravity-induced sluggish return and liquid accumulation, ensuring smooth return. The coolant then enters the input of the circulation pump 2, where it is pressurized and sent back to the cold plate heat exchanger 1 for cooling, thus completing the entire liquid cooling cycle. The contact points between the power module 8 pins and the coolant are coated with a high-temperature resistant, silicone oil-resistant insulating coating and a sealing sleeve to improve insulation performance and prevent leakage.

[0041] Example 1.

[0042] This embodiment 1 discloses an integrated fully liquid-cooled charging pile device, wherein a filter 10, a pressure sensor 11, a flow control valve, and a flow meter 13 are installed on the pipeline between the liquid storage tank 5 and the liquid-cooled charging gun 4. A 50-mesh filter screen is detachably fixed on the filter 10. The filter screen of the filter 10 is made of 304 stainless steel, which is resistant to temperature ≥100℃ and silicone oil corrosion, and the filter screen can be removed for cleaning.

[0043] On the pipeline between the liquid storage tank 5 and the immersion power module cooling box 3, after the liquid supply pump A6 and before the immersion power module cooling box 3, a filter 10, a pressure sensor 11, a flow control valve, and a flow meter 13 are installed. These components are consistent with the specifications of the charging gun circuit components, achieving a symmetrical arrangement of the two branches. This ensures that impurities are filtered before the coolant enters the terminal, avoiding blockage of the terminal liquid cooling channel.

[0044] In this technical solution, the filter effectively filters metal debris, particulate matter, and other impurities from the coolant, preventing them from clogging the internal liquid cooling channels of the gun body. The pressure sensor 11 monitors the pipeline pressure of the branch in real time, the flow meter 13 monitors the coolant flow rate of the branch, and the flow control valve adjusts the branch flow rate based on the monitoring data. Data from the pressure sensor 11 and flow meter 13 of both branches are transmitted to the intelligent control system. When the pressure exceeds the safety threshold, the system automatically adjusts the opening of the flow control valve and reduces the speed of the corresponding branch's supply pump to prevent overpressure in the pipeline. When the flow rate deviates from the target value, the system synchronously adjusts the speed of the supply pump and the opening of the flow control valve to achieve precise regulation of the branch flow rate.

[0045] Example 2.

[0046] This embodiment 2 discloses an integrated fully liquid-cooled charging pile device. Temperature sensors 12 are fixedly installed on the outside of the immersion power module cooling box 3 and at the head of the liquid-cooled charging gun 4. These temperature sensors 12 directly collect the real-time temperature of the heat-generating components. Temperature sensors 12 are also installed on the inlet and outlet pipes of the cold plate heat exchanger 1 to monitor the temperature difference before and after heat exchange, thereby determining the heat exchanger's heat dissipation efficiency. Pressure sensors 11, temperature sensors 12, and flow meters 13 are also installed on the pipe between the circulating pump 2 and the cold plate heat exchanger 1 to achieve comprehensive monitoring of the pressure, temperature, and flow rate of the main circulation loop. The priority of each sensor is as follows: main circulation loop sensor data serves as the basis for overall system control; branch loop sensor data serves as the basis for branch loop adjustment. If multiple sensors of the same type are installed on the same pipe, the data from the sensor closest to the terminal is used to avoid data redundancy and acquisition conflicts. All sensors adopt industrial-grade protection with a protection level ≥ IP67, suitable for outdoor charging pile conditions.

[0047] Example 3.

[0048] This embodiment 3 discloses an integrated fully liquid-cooled charging pile device, wherein a high-level liquid level gauge 51 and a low-level liquid level gauge 52 are respectively installed on the upper and lower positions of the inner wall of the liquid storage tank 5. The high-level liquid level gauge 51 is used to monitor the highest liquid level threshold of the coolant to prevent excessive liquid replenishment from causing the pipeline to overflow. The low-level liquid level gauge 52 is used to monitor the lowest liquid level threshold of the coolant to avoid the circulation pump from running dry and being damaged due to the liquid level being too low. An automatic exhaust valve 53 is also installed on the top of the liquid storage tank 5, which can discharge the air generated in the cooling circuit due to temperature changes in real time and eliminate the influence of air resistance on the flow of coolant.

[0049] This technical solution achieves precise liquid level control and avoids circulation anomalies. The high and low level gauges of the storage tank monitor the liquid level thresholds to prevent excessive liquid replenishment and overflow or damage to the circulation pump due to excessively low liquid level. In conjunction with the automatic air vent valve, it further ensures stable circuit pressure and continuous circulation.

[0050] Example 4.

[0051] Reference Figure 2 , Figure 3 and Figure 4 This embodiment discloses an integrated fully liquid-cooled charging pile device, wherein the immersion power module cooling box 3 adopts a sealed and pressure-resistant structure design. The sealing rating of the immersion power module cooling box 3 is ≥IP68, and the sealing components are made of silicone oil-resistant and high-temperature-resistant fluororubber. The box body and the box cover are sealed with bolts to ensure no coolant leakage. The box body is made of 304 stainless steel, which meets the dual requirements of efficient heat dissipation and convenient maintenance. A liquid inlet connector 31 and a data transmission connector 35 are fixedly installed on the upper rear side of the box body. The liquid inlet connector 31 is used to connect the low-temperature coolant from the liquid supply pump A6, and the data transmission connector 35 is used to connect the power module 8 and the charging pile controller to realize the real-time transmission of power module operation data. A return connector 32 is installed on the lower rear side of the box body to discharge the heated coolant after heat exchange.

[0052] Between the inlet and outlet connectors on the rear side of the immersion power module cooling box 3, multiple three-phase AC input connectors 33 and DC output connectors 34 are arranged. The three-phase AC input connectors 33 are located above the DC output connectors 34, making it easier to distinguish wiring and reducing the wiring error rate during on-site installation. A rotatable handle 36 is installed on the top of the box for easy handling and installation by staff. A transparent window 37 is embedded in the upper front of the box, allowing staff to directly observe the coolant level and the installation status of the power modules without opening the cover, improving inspection efficiency. The transparent window 37 is made of high-temperature resistant and impact-resistant tempered glass and is sealed with sealant to prevent coolant leakage.

[0053] The immersion power module cooling box 3 is equipped with a detachable metal bracket. The charging pile power module 8 is fixed to the bracket with bolts and is in direct contact with the coolant inside the immersion power module cooling box 3. During subsequent maintenance, the power module can be directly disassembled without draining the coolant inside the box, which greatly shortens the maintenance time.

[0054] To further improve heat dissipation efficiency, the immersion power module cooling box 3 is also equipped with a flow guiding structure, which consists of a flow guide plate and a flow turbulence column. The flow guide plate guides the coolant to flow along the power module arrangement direction and forces it to flow through hot spots such as the IGBT chips and busbars of the power module. The flow turbulence column is arranged in the gaps between the power modules to break the laminar boundary layer of the coolant, enhance the convective heat transfer effect, ensure uniform temperature in all parts of the power module, and avoid local overheating.

[0055] In this technical solution, the immersion power module cooling box has a built-in detachable metal bracket, which allows the power module to be disassembled and installed without draining the coolant during maintenance, greatly shortening maintenance time; the transparent window of the box makes it easy to inspect the liquid level and module status, and the top handle improves the efficiency of handling and installation.

[0056] Example 5.

[0057] Reference Figure 5 This embodiment discloses an integrated fully liquid-cooled charging pile device, wherein the immersion power module cooling box 3 is provided with an internal flow guiding structure, which guides the coolant to flow through the hot spot area of ​​the power module.

[0058] All monitoring components, including pressure sensor 11, temperature sensor 12, and flow meter 13, are electrically connected to the main controller of the charging pile, forming an intelligent monitoring and control system. For temperature control, a PID closed-loop regulation strategy is adopted. When the temperature sensor detects that the temperature of the power module or charging gun terminal exceeds a preset threshold, the controller automatically issues a command to increase the speed of the corresponding branch's liquid supply pump and adjust the opening of the flow control valve to increase the coolant flow and enhance heat dissipation. When the temperature drops back to a safe range, the controller reduces the speed of the liquid supply pump and decreases the coolant flow, achieving on-demand heat dissipation and reducing system energy consumption.

[0059] Leakage detection sensors are installed on the immersion power module cooling box 3, the liquid-cooled charging gun 4, and the coolant return pipeline to monitor the leakage of the coolant and the equipment casing in real time. When the leakage current exceeds the preset threshold, the system immediately cuts off the power supply to the charging and cooling system and issues a leakage alarm to prevent operators from being electrocuted.

[0060] In terms of fault diagnosis and protection, the system judges the operating status in real time based on the monitoring data of each sensor: when the pressure sensor detects that the pipeline pressure exceeds the safety threshold, it determines that the pipeline is blocked or the pump is abnormal, and the system immediately issues an alarm signal and shuts down for protection; when the flow meter detects that the branch flow is lower than 50% of the set value, it determines that the filter is blocked, and the system issues a maintenance reminder; when the low-level liquid level gauge detects that the liquid level in the storage tank is too low, it immediately cuts off the power supply to the charging and cooling systems to prevent the circulating pump from running dry and being damaged. Through the above intelligent control and protection measures, the equipment can achieve stable operation without human intervention, significantly reducing operation and maintenance costs.

[0061] This technical solution achieves precise temperature control and energy saving. Temperature, pressure, and flow sensors fully cover the core pipelines and heat-generating components, enabling real-time acquisition of branch parameters, coolant heat exchange temperature difference, and main circuit status. Based on a PID closed-loop regulation strategy, it automatically matches the speed of the liquid supply pump with the opening of the flow control valve. When the temperature exceeds the standard, heat dissipation is enhanced, and when the temperature reaches the standard, energy consumption is reduced, achieving on-demand heat dissipation and significantly reducing the system's operating power consumption.

[0062] Example 6.

[0063] This embodiment discloses an integrated fully liquid-cooled charging pile device, wherein a liquid collection section and a gas-liquid separation structure are set in the low-position area before the input end of the circulating pump 2. The liquid collection section adopts a conical design, which allows impurities in the coolant to settle and collect under the action of gravity. The gas-liquid separation structure further separates the air bubbles mixed in the coolant, ensuring that the coolant entering the circulating pump has a stable flow state and avoiding cavitation in the pump body.

[0064] Furthermore, the gas-liquid separation structure is a small, sealed cavity device integrated into the low-lying area before the inlet of the circulating pump 2. It is integrated with the conical liquid collecting section and its function is to separate air bubbles and sediment impurities mixed in the coolant, ensuring that the coolant entering the circulating pump is a single-phase fluid free of bubbles and impurities. This prevents pump cavitation and wear, and ensures the stability of the cooling cycle. The cavity wall thickness of the gas-liquid separation structure is greater than six millimeters, with a pressure resistance rating of ≥2.0 MPa. The connection to the pipeline is sealed by welding to ensure no leakage.

[0065] The gas-liquid separation structure is a sealed cavity made of 304 stainless steel, which is seamlessly connected to the cooling pipeline. It contains three core functional areas: a cone-shaped liquid collection and sedimentation area, a flow guiding and defoaming separation area, and a gas chamber exhaust area.

[0066] Conical Settling Zone: The bottom of the cavity is designed with a 30° inclined conical structure, integrated with the liquid collection section. The heated coolant flowing from the liquid-cooled charging gun 4 and the immersion power module cooling box 3 first enters the conical settling zone, where the flow rate slows down within the conical cavity. Impurities such as metal debris and small particles detached from the filter screen carried in the coolant settle along the conical surface under gravity, accumulating at the bottom of the cavity. A manual drain valve is also provided at the bottom of the cavity, allowing maintenance personnel to periodically open the drain valve to remove the deposited impurities without disassembling the entire structure. The draining cycle is once a month. During draining, the system automatically reduces the speed of the supply pumps A6 and B7, decreases the return flow, and simultaneously shuts down the circulation pump 2 and the return booster pump to prevent pressure drop and coolant leakage during draining. After draining is completed, the system automatically initiates an venting procedure to remove air mixed in during the draining process before resuming normal operation.

[0067] Defoaming and defoaming separation zone: Above the conical zone is the main body of the cavity, inside which two arc-shaped flow guide baffles are vertically installed, with a baffle spacing of 1.5 times the pipe diameter. When the coolant bypasses the flow guide baffles, the flow channel is deflected, further reducing the flow velocity; at the same time, a layer of 100-mesh polyester fiber defoaming net is laid between the baffles, with the defoaming net arranged in a wavy shape to increase the contact area with the coolant.

[0068] Bubbles with a diameter greater than 0.1 mm will gradually rise to the surface as the flow rate slows down.

[0069] Tiny bubbles with a diameter of less than 0.1 mm will be captured and adsorbed by the defoaming net, and will then gather into larger bubbles and detach from the liquid surface.

[0070] The combination of the flow guide baffle and the defoaming net can achieve a bubble separation efficiency of over 95%.

[0071] Air Chamber Exhaust Area: The top of the cavity is a reserved air chamber, accounting for approximately 15% of the total cavity volume. The separated air will gather in the air chamber, forming a stable air cushion layer, and will not flow into the circulation pump with the coolant. A miniature automatic exhaust valve is installed on the top of the air chamber, which is linked to the automatic exhaust valve 53 on the top of the liquid storage tank 5; when the air pressure in the air chamber reaches 0.02MPa, the exhaust valve automatically opens to release air into the atmosphere; when the air pressure is below the threshold, it automatically closes to prevent coolant leakage.

[0072] The gas-liquid separation structure has an inlet and an outlet on the side of the cavity.

[0073] Liquid inlet: Located in the lower part of the cavity, it is connected to the manifold. Coolant enters the cavity tangentially from the liquid inlet, forming a weak swirling flow to enhance the gas-liquid separation effect.

[0074] Liquid outlet: Located in the upper part of the cavity, it is connected to the input end of the circulation pump 2. The height of the liquid outlet is higher than the top of the conical sedimentation zone, ensuring that only the separated pure coolant can flow into the circulation pump, while avoiding the intake of impurities deposited at the bottom.

[0075] The specific workflow of the gas-liquid separation structure is as follows.

[0076] Merging and liquid inlet: After the heated coolant flows from the two branches, it enters the gas-liquid separation chamber through the tangential liquid inlet, where it is slowed down and deflected by the flow guide baffle.

[0077] Impurity sedimentation: Solid impurities in the coolant settle in the cone-shaped sedimentation zone and accumulate at the bottom of the cavity.

[0078] Bubble separation: After being captured and gathered by the defoaming net, the bubbles in the coolant float to the top air chamber.

[0079] Exhaust pressure stabilization: When the air pressure in the air chamber reaches the threshold, the top automatic exhaust valve opens to exhaust the air and maintain the pressure inside the chamber.

[0080] Pure coolant exits pump: The pure coolant, after gas-liquid and solid-liquid separation, flows from the outlet into the circulation pump 2 and enters the cooling process of the cold plate heat exchanger 1.

[0081] The automatic vent valve 53 of the liquid storage tank 5 and the automatic vent valve of the gas-liquid separation structure work together as follows: the automatic vent valve 53 of the liquid storage tank is responsible for venting the air released during the buffering process in the liquid storage tank, and the automatic vent valve of the gas-liquid separation structure is responsible for venting the air separated during the return liquid flow. Both are linked to the system pressure, and the vent pressure threshold is set to 0.02MPa to avoid a sudden drop in pipeline pressure caused by simultaneous venting. The liquid storage tank 5 is equipped with a convenient liquid replenishment interface and adopts a quick-connect sealing joint for easy replenishment of coolant.

[0082] This technical solution eliminates the need for additional motors and sensors, achieving gas-liquid separation solely through the fluid's own gravity and velocity changes, resulting in energy savings and high reliability. The bottom drain valve allows for periodic manual drainage, while the top exhaust valve operates automatically, eliminating the need for dedicated personnel on-site daily. It boasts strong impact resistance, maintaining stable separation even under the instantaneous fluctuations in coolant flow and pressure during fast charging, thus adapting to the intermittent high-power operation mode of charging piles.

[0083] Example 7.

[0084] This embodiment discloses an integrated fully liquid-cooled charging pile device, wherein the liquid-cooled charging gun 4 includes a gun head section, a grip section, and a gun wire section. The internal liquid-cooling channels of the gun head section, grip section, and gun wire section are seamlessly connected. Coolant flows in from the inlet of the grip section, flows through the gun wire section and the gun head section in sequence, absorbs heat, and flows out from the return port of the grip section, flowing into the three-way pipe in front of the circulation pump 2. The overall pressure resistance rating of the liquid-cooled charging gun 4 is ≥1.6MPa. The connection parts of the gun wire section, grip section, and gun head section are all sealed with double fluororubber O-rings to ensure no leakage. The gun body insulation material is made of high-temperature resistant material with a temperature resistance of ≥150℃, which is suitable for the high-temperature environment under fast charging conditions. The flexible stainless steel liquid-cooled sleeve of the gun wire section has a bending fatigue life of ≥10,000 times, which is suitable for frequent bending and dragging conditions.

[0085] The nozzle tip section employs a surrounding liquid-cooled cavity, a liquid inlet adapter, and a terminal base with a thermally conductive embedded structure. The nozzle tip section contains an annular sealed liquid-cooled cavity and an integrated liquid inlet adapter. This adapter serves as a transitional connection between the liquid inlet channel of the grip section and the annular liquid-cooled cavity of the nozzle tip. Located at the end of the nozzle tip section near the grip section, it is integrally formed with the nozzle tip section shell and made of copper alloy, balancing thermal conductivity and structural strength. The inner wall of the liquid-cooled cavity fits tightly against the outer wall of the terminal base, with the contact surface filled with high thermal conductivity silicone grease to reduce contact thermal resistance. The terminal base is made of thermally conductive copper alloy. After the terminal leads pass through the base, they indirectly contact the coolant in the liquid-cooled cavity. At the insertion / removal terminal area at the front of the nozzle tip, three to four axial flow guide ribs are evenly distributed to guide the coolant to flow axially along the terminal, flushing the outer wall of the terminal and preventing localized heat buildup. The liquid inlet adapter has radially radiating distribution grooves on its end face near the grip section. These grooves radiate outwards from the center of the adapter, with rounded corners to reduce fluid resistance and prevent eddies and bubble buildup. The number of distribution grooves perfectly matches the number of nozzle terminals, ensuring equal coolant flow into each terminal's cooling chamber. Coolant from the grip section flows into the distribution grooves of the liquid inlet adapter after entering through the nozzle inlet. These grooves divide the coolant into multiple streams, each flowing to the surrounding cooling chamber of its respective terminal, ensuring uniform cooling flow to each terminal. A confluence groove is located near the front of the nozzle section. The heated coolant, after heat exchange, is collected in the confluence groove and returns to the return channel of the grip section. The connection between the nozzle and grip sections uses a composite sealing structure of double-ringed fluororubber and end-face gaskets, with a pressure rating ≥1.6MPa, meeting the coolant circulation pressure requirements. A dustproof sealing lip is provided inside the terminal protective cover at the nozzle tip to prevent dust from entering the liquid cooling chamber during insertion and removal.

[0086] Grip Section: Employing a channel transition and sealed maintenance structure, the grip section balances operator comfort with stable connection to the liquid cooling pipeline. It features a dual-channel independent arrangement, with parallel inlet and return channels within the grip section. These channels do not interfere with each other, and the inner walls of the channels are decorated with spiral flow guides to reduce coolant flow resistance and extend coolant residence time within the gun. Each end of the channel connects to the liquid cooling sleeve of the gun line section and an external pipeline connector. The pipeline connector uses a quick-connect threaded connector for rapid connection to the B7 supply pump, and includes a built-in one-way valve that automatically seals the coolant during pipe removal to prevent leakage. The grip section outer shell is made of fiberglass-reinforced nylon with an internal heat-insulating foam layer to isolate heat transfer between the coolant and the shell, preventing burns to the operator's hands. The outer surface features anti-slip textures to enhance stability during insertion and removal. The grip section's inlet channel has a removable 100-mesh stainless steel filter to further intercept minute impurities and prevent clogging of precision flow channels such as the flow divider and axial guide ribs.

[0087] Gun segment: This is the main path for current transmission. The multi-strand copper core conductor generates significant heat under high current conditions, and a coaxial liquid-cooled bushing structure is adopted.

[0088] The gun-type conductor segment adopts a coaxial structure of an inner conductor bundle and a liquid-cooled bushing: the inner layer is a multi-strand stranded silver-plated copper core conductor, suitable for high currents above 500A, and the outer layer is a flexible stainless steel liquid-cooled bushing; the gap between the conductor bundle and the bushing is filled with insulating and thermally conductive coolant, forming a liquid-cooling channel surrounding the conductor. An axial groove is provided on the inner wall of the bushing, and the conductor bundle is embedded in the groove, increasing the contact area between the conductor and the coolant, while preventing the conductor from shaking inside the bushing and improving structural stability.

[0089] The liquid cooling sleeve adopts a corrugated stainless steel flexible structure, combined with an outer wear-resistant rubber sheath, to meet the working conditions of frequent bending and dragging of the charging gun; the connection between the two ends of the sleeve and the grip section and the gun head section adopts a vulcanization bonding process to achieve a unified flexible connection and sealing, with no leakage.

[0090] A miniature thermistor temperature sensor is embedded in the inner wall of the liquid cooling cavity of the charging head section. It is electrically connected to the main controller of the charging pile and directly collects the temperature of the coolant in the terminal area as a real-time feedback signal for PID regulation to achieve precise temperature control. The sensor is fixed by potting process and is in direct contact with the coolant, with a response time of ≤0.5s.

[0091] Example 8.

[0092] Reference Figure 5This embodiment discloses an integrated fully liquid-cooled charging pile device, wherein an intelligent control system is fixedly installed on the outside of the immersion power module cooling box 3. Based on the power module temperature and charging gun temperature collected by temperature sensors, the system dynamically adjusts the rotation speed of liquid supply pump A and liquid supply pump B, as well as the opening degree of the flow control valve of the corresponding branch, to achieve precise heat dissipation as needed. The intelligent control system includes...

[0093] Data Acquisition Module: Collects real-time and historical data from the following components: cold plate heat exchanger 1, circulating pump 2, immersion power module cooling box 3, liquid-cooled charging gun 4, liquid storage tank 5, liquid supply pump A 6, liquid supply pump B 7, power module 8, pressure sensor 11, temperature sensor 12, flow meter 13, high-level liquid level gauge 51, low-level liquid level gauge 52, and leakage current detection sensor. Historical data includes fault data, which is annotated and used as a reference sample. Real-time data acquisition includes power module temperature, charging gun head temperature, cold plate heat exchanger inlet and outlet liquid temperatures, pressure and flow data, and ambient temperature. Ambient temperature data is collected to provide environmental reference for the intelligent analysis module's heat dissipation parameter adjustment, avoiding deviations in heat dissipation control due to ambient temperature differences, and ensuring stable heat dissipation under different environmental conditions, such as high-temperature summers and low-temperature winters.

[0094] Data preprocessing module: preprocesses all collected data, including filtering and noise reduction, time synchronization, data verification, and normalization.

[0095] Noise Reduction Processing: The Kalman filter algorithm is used to denoise the original data and remove abnormal noise data caused by electromagnetic interference and sensor fluctuations.

[0096] Time synchronization processing: The main controller clock synchronization mechanism is adopted. The system clock of the main controller is used as the reference to calibrate the timestamps of all collected data to ensure that the timestamp error of all parameters does not exceed 10ms, so as to achieve accurate matching of multiple parameters at the same time.

[0097] Normalization: To address the issue of large differences in the magnitude of different parameters, a min-max normalization algorithm is used to map all preprocessed parameters to the standardized interval [0,1], thereby eliminating the impact of differences in parameter magnitude.

[0098] Data verification: The data, after filtering, noise reduction, time synchronization, and normalization, undergoes secondary verification to select data that conforms to the normal operating logic of the equipment and remove data that does not conform to the logic. The standardized data that passes the verification is directly transmitted to the intelligent analysis module for subsequent comprehensive analysis and control decisions.

[0099] Intelligent Analysis Module: Based on preprocessed standardized data, a comprehensive analysis model is established. The inputs to the intelligent analysis model include: power module temperature, charging gun head temperature, cold plate heat exchanger inlet temperature T_in, outlet temperature T_out, ambient temperature, charging gun circuit pressure, power module branch circuit pressure, flow rate; charging gun circuit flow rate, power module branch circuit flow rate, supply pump A speed, and supply pump B speed. The outputs are the optimal speeds of supply pumps A6 and B7, and the optimal opening degree of the corresponding branch flow control valves, providing precise control basis for the instruction generation module to achieve on-demand heat dissipation and precise energy saving. Combined with historical fault data from the data collection module, abnormal situations are identified. When the ambient temperature is below -10℃, the system automatically starts the coolant preheating program, using slight heat release from the power module to preheat and prevent increased coolant viscosity that could cause pump starting difficulties. Simultaneously, the pipes are wrapped with insulation cotton with a thickness greater than 20 mm to prevent coolant freezing and pipe rupture.

[0100] Command Generation Module: Based on the analysis results of the intelligent analysis module, it generates adjustment commands for supply pump A and supply pump B, as well as the flow control valve. The correspondence between commands and executing components is as follows: the speed command of supply pump A6 and the opening command of the flow control valve in the power module branch correspond to the control of heat dissipation in the power module branch; the speed command of supply pump B7 and the opening command of the flow control valve in the charging gun branch correspond to the control of heat dissipation in the charging gun branch; the speed commands of circulation pump 2 and return booster pump are dynamically generated based on the sum of the flow rates of the two branches.

[0101] Alarm Module: Includes an alarm that promptly issues a warning when any abnormality is detected. A tiered alarm system is used: minor anomalies trigger a yellow audible and visual alarm, such as slight filter blockage or a slight decrease in heat exchange efficiency, prompting maintenance personnel to address the issue periodically; serious anomalies trigger a red audible and visual alarm, such as pipeline leaks, pump malfunctions, power module temperatures exceeding the limit by more than 10°C, low-level liquid gauge triggering, and electrical leakage, simultaneously triggering shutdown protection and emergency cooling measures.

[0102] Main Controller: Employs a PLC intelligent control module, preferably the Siemens S7-1200 series, suitable for industrial-grade outdoor environments with an IP67 protection rating. Its core function is to coordinate the operation of all modules, receive input signals from each module, issue control commands, and achieve closed-loop operation of the entire intelligent control system. It also integrates with the charging pile's charging control system to ensure coordinated heat dissipation and charging process. The main controller uses an embedded microprocessor with the aforementioned intelligent temperature control program built-in. After system startup, the controller initializes all sensors and actuators, entering a self-test and cyclic standby state.

[0103] This invention provides a temperature control method for an integrated fully liquid-cooled charging pile device, comprising the following steps.

[0104] S1. The data acquisition module collects core parameters such as power module temperature, nozzle temperature, pressure, and flow rate in real time at a fixed frequency. The ambient temperature acquisition module collects the ambient temperature, and all component operating data and historical data are collected simultaneously. When the main controller is powered on, all modules are started, and communication links and hardware self-tests are performed. During the self-test, if a pump or sensor fault is detected, the system issues an alarm and disables the charging function. For coolant status monitoring, the data acquisition and collection module collects the coolant's moisture content and impurity content in real time. When the moisture content exceeds 0.5% or the impurity content exceeds 1%, a coolant replacement reminder is issued.

[0105] The data acquisition module collects the following core operating parameters in real time at a fixed sampling frequency, including...

[0106] Temperature: power module temperature, charging gun head temperature, cold plate heat exchanger inlet temperature, outlet temperature.

[0107] Pressure: Power module branch pressure, charging gun branch pressure.

[0108] Flow rate: Power module branch flow rate, charging gun branch flow rate.

[0109] Actuator status: speed of supply pump A, speed of supply pump B, opening degree of corresponding flow control valve, speed of circulation pump 2, and speed of return booster pump.

[0110] S2, the data preprocessing module filters and denoises the collected raw data, synchronizes the time, and normalizes it to output standardized data.

[0111] S3. The intelligent analysis module establishes a comprehensive analysis model. Based on standardized data, it comprehensively analyzes the equipment's operating status and heat dissipation requirements, identifies abnormal situations, and calculates the target speed of the liquid supply pump and the target opening of the flow control valve.

[0112] 3.1 Establish a comprehensive analysis model: The objective function is to minimize the system's operating energy consumption, and the comprehensive analysis model is as follows.

[0113] .

[0114] ; .

[0115] The constraints include...

[0116] Thermal safety constraints: ; .

[0117] Traffic generation constraints: ; .

[0118] Actuator limiting constraints: ; .

[0119] In the formula, It is the rotational speed of the liquid supply pump A; It is the rotational speed of the liquid supply pump B; It is the opening degree of the flow control valve in the power module branch, with a value range of [0,1]. It is the opening degree of the flow control valve for the charging gun circuit, with a value range of [0,1]. This is the operating power consumption of the liquid supply pump A; This is the operating power consumption of the liquid supply pump B; , These are the power characteristic constants of pump A and pump B, determined by the pump's mechanical efficiency and hydrodynamic characteristics, and can be obtained through fitting experimental data. It is the real-time temperature of the power module, which is directly measured by the temperature sensor installed on the power module 8. It is the real-time temperature of the charging gun head, which is directly measured by the temperature sensor installed on the liquid-cooled charging gun 4. It is the highest permissible operating temperature of the power module, defined by the material and packaging specifications of the semiconductor devices in the power module. It is the maximum permissible operating temperature of the charging gun, defined by the charging gun's insulation materials, connectors, and user safety standards. It is the volumetric flow rate of the coolant flowing through the power module branch, i.e., the immersion power module cooling box 3, which is measured by the flow meter 13 installed on the power module branch. It is the volumetric flow rate of the coolant flowing through the charging gun circuit, i.e., the liquid-cooled charging gun 4; It is the flow gain coefficient of the power module branch, reflecting the situation when the valve is fully open and there is no back pressure. Under ideal conditions (=0), the speed of the supply pump A affects the flow rate. The ability to contribute. It is the flow gain coefficient of the charging gun circuit, reflecting the effect of the speed of the supply pump B on the flow rate under ideal conditions of fully open valve and no back pressure. The ability to contribute. It is the pressure sensitivity coefficient of the power module branch, reflecting the flow rate. pressure on branch lines Sensitivity to change, i.e., the change in flow rate caused by a unit change in pressure. It is the pressure sensitivity coefficient of the power module branch; it reflects the flow rate. pressure on branch lines Sensitivity to change. It is the operating pressure of the power module branch. It is the operating pressure of the charging gun circuit; , These are the minimum and maximum operating speeds of the liquid supply pump A, determined by the performance of the pump's motor driver and its mechanical structure. , These are the minimum and maximum operating speeds of the liquid supply pump B, determined by the performance of the pump's motor driver and its mechanical structure.

[0120] 3.2 Status Prediction and Comprehensive Judgment: Based on the current system status, quickly and reliably determine the level of heat dissipation demand and generate preliminary control objectives. 3.2.1: Thermal state assessment.

[0121] 1) Calculate the temperature deviation.

[0122] Calculate the temperature deviation of the power module : .

[0123] Calculate the temperature deviation of the charging gun : .

[0124] In the formula, This is the safe target temperature for the power module; It is the safe target temperature for the charging gun.

[0125] 2) Calculate the rate of temperature change.

[0126] Power module temperature change rate : .

[0127] Charging gun temperature change rate : .

[0128] In the formula, To control the cycle, such as 1.0 second. It is the real-time temperature of the power module at time k in the current control cycle, which is collected by the temperature sensor installed on the power module; It is the real-time temperature of the charging gun head at time k in the current control cycle, which is collected by the temperature sensor installed on the charging gun head; It is the real-time temperature of the power module at time k-1 of the previous control cycle, which is historical data. It is the real-time temperature of the charging gun head at time k-1 of the previous control cycle, which is historical data.

[0129] 3.2.2: Demand Level Classification: Based on the values ​​of temperature deviation and temperature change rate, the heat dissipation requirements of each heat-generating component are classified into the following levels.

[0130] Emergency Status - Level E: This level is triggered when the current temperature of a component reaches or exceeds a safe threshold, or when its rate of temperature change is greater than +0.5°C per second. This level indicates that the component is in a critical dangerous state of impending overheating, or that the temperature is rising at an abnormally rapid rate, posing an immediate risk of overheating. The system must activate the highest level of cooling response.

[0131] High Load Condition - Level H: This level is triggered when the component temperature deviation exceeds +5.0°C, meaning the temperature is significantly higher than the target value, and the rate of temperature change is greater than 0, indicating that the temperature is still rising. This level indicates that the component's heat generation exceeds its current heat dissipation capacity, the temperature has deviated from the target, and continues to rise. Significantly enhanced cooling is required to suppress the temperature rise and bring the temperature back to the normal range.

[0132] Normal Regulation State - Level N: This level is triggered when the component temperature deviation is between -2.0°C and +5.0°C, meaning the temperature fluctuates within a small range near the target value. This level represents the ideal state for stable equipment operation. The temperature is within a well-controlled range, and the control objective is to perform fine, small-amplitude adjustments to maintain temperature stability and optimize system energy efficiency.

[0133] Low Load Condition - Level L: This level is triggered when the component temperature deviation is less than -5.0°C (significantly lower than the target value) and the rate of temperature change is less than 0 (the temperature continues to drop). This level indicates that the current cooling capacity is excessive, the component temperature is too low and continues to decrease. To save energy and prevent overcooling, the cooling intensity should be appropriately reduced.

[0134] Hibernation Standby State - Level S: This level is triggered when the current temperature of the component is below a preset hibernation temperature threshold (a very low temperature value), and the charging system has no power output (charging power is zero). This level indicates that the device is in idle or deep standby mode with minimal heat generation. The system should switch to the lowest power consumption operating state, maintaining only necessary monitoring and basic cycles.

[0135] The control system will execute the above rules in parallel, outputting the power module demand level and the charging gun demand level respectively. These two levels are the direct inputs for querying the joint decision table and performing independent PID control in subsequent steps.

[0136] Step 3.2.3: Feedforward compensation calculation.

[0137] 1) Calculate the ambient temperature compensation coefficient : .in k t1 To compensate for the gain, the preset value is 0.01 / ℃, which can be dynamically optimized and adjusted based on the actual environmental adaptability, equipment operating conditions, and historical data. It is the real-time ambient temperature, which is collected synchronously by the data acquisition module and serves as the basic input parameter for feedforward compensation calculation.

[0138] 2) Calculation of load feedforward.

[0139] Basic flow requirements of power module branches: .

[0140] Basic flow requirements for charging gun circuit: .

[0141] Simplify the flow model through inverse solution. ;Calculate the feedforward speed increment required to meet the basic flow rate .

[0142] In the formula, It is the basic flow requirement of the power module branch, that is, the basic coolant flow required to dissipate heat from the power module under the current charging load; It is the power module branch flow rate-load ratio coefficient, which is obtained by fitting experimental data and reflects the correspondence between charging power and the basic flow rate of the power module branch. It is the real-time charging power of the charging pile, which is the core input parameter for calculating the load feedforward quantity. It is synchronously transmitted to the intelligent analysis module by the charging pile charging control system. It is the basic flow requirement of the charging gun circuit, that is, the basic coolant flow required to dissipate heat from the liquid-cooled charging gun under the current charging load; It is the charging gun circuit flow rate-load ratio coefficient, which is derived from the fitting of experimental data and reflects the correspondence between charging power and the basic flow rate of the charging gun circuit. This is the actual flow rate of the coolant in the branch circuit; It is the flow coefficient, which is determined by the model of the liquid supply pump and the characteristics of the pipeline, and is a preset constant. It refers to the basic speed of the liquid supply pump, which is the core variable for inverse solution calculation; is the feedforward speed increment of the liquid supply pump A in the power module branch, which is obtained by simplifying the flow model through inverse solution and superimposed on the base speed of the liquid supply pump A to meet the base flow requirements of the power module branch; k is the pipeline resistance coefficient, which is determined by the pipeline length, diameter and roughness; I is the real-time charging current of the charging gun circuit.

[0143] Step 3.2.4: Query the decision rule base: Based on the determined power module demand level and charging gun demand level, a basic control strategy for the current operating condition is determined by querying a preset two-dimensional decision rule base. This rule base uses the combination of the state levels of the two heat-generating components as an index, and clearly defines the initial control actions that the power module branch and the charging gun branch should take under different conditions.

[0144] The core logic of the rule base is as follows.

[0145] When the power module is in the highest level of emergency, the system must prioritize ensuring the absolute safety of the power module regardless of the charging gun's status. Therefore, the rule base stipulates that once the power module's level is emergency, the power module branch immediately implements the strongest cooling strategy, which means controlling the liquid supply pump A to run at its highest speed and simultaneously adjusting its flow control valve opening to the maximum possible coolant flow.

[0146] When both components are under high load simultaneously, it indicates that the overall system is overheating. In this case, the rule base instructs the system to adopt an enhanced cooling strategy for both branches, namely, setting a higher reference speed value for liquid supply pump A and liquid supply pump B, and setting the opening of the flow control valves of both branches to a larger position, in order to synergistically improve the overall heat dissipation capacity.

[0147] If the power module is under high load while the charging gun is in normal adjustment mode, the control strategy needs to be differentiated. The rule base requires immediate implementation of the enhanced cooling measures described above for the power module branch to quickly curb its temperature rise; for the charging gun branch with controllable temperature, no aggressive preset actions are taken, but instead a fine PID feedback adjustment mode is adopted, making small and stable adjustments only based on its own temperature deviation, thereby solving the main problem while avoiding energy waste.

[0148] When both components are in normal adjustment mode, it indicates that the system is operating smoothly and the temperature control is good. The rule base stipulates that at this time, neither branch uses a fixed strong control strategy; instead, the PID controller performs closed-loop fine-tuning. The PID controller dynamically calculates and outputs the optimal pump speed and valve opening adjustment based on the real-time temperature deviation of each branch, aiming to maintain the temperature precisely within the target range with minimal energy consumption.

[0149] The rule base fully defines the basic control strategies corresponding to all other possible combinations of state levels, forming a comprehensive decision matrix. Example of a decision matrix: When the power module level is L and the charging gun level is L, the speeds of supply pumps A and B are adjusted to the lowest possible speed, such as 500 r / min, and the flow control valve opening is adjusted to 0.2. When the power module level is S and the charging gun level is S, the system shuts down supply pumps A and B, maintaining only circulation pump 2 and return booster pump running at low speeds, such as 800 r / min, to achieve basic circulation.

[0150] By querying this rule base, the system will obtain a set of preliminary, qualitative basic control quantities, including the basic speed setpoints of supply pump A and supply pump B, as well as the basic opening setpoints of the two branch flow control valves. These basic control quantities provide a clear starting point for subsequent compensation calculations and fine-tuning.

[0151] 3.2.5: PID feedback fine-tuning: For branches with normal demand levels, a PID controller is used for fine-tuning to eliminate steady-state errors.

[0152] .

[0153] U PID =K p e+K i ∑e+K d r.

[0154] Final control quantity synthesis.

[0155] For the power module branch: .

[0156] n A* =(n A-base k atm )+△n A-ff +u pid-mod .

[0157] For charging gun path: .

[0158] n B* =(n B-base k atm )+△n B-ff +u pid-gun .

[0159] In the formula, This is a proportionality coefficient, preferably 5.0-10.0. The integral coefficient is preferably 0.1-0.5. The differential coefficient is preferably between 0.5 and 2.0; dynamic optimization is performed using historical fault data and real-time operational data. , and Parameters are set to ensure adjustment accuracy. It is the output adjustment quantity of the PID controller, which has no unit and corresponds to the reference value of the pump speed adjustment quantity. Its core purpose is to eliminate the steady-state error of the system and realize the fine control of the branch temperature. Real-time temperature deviation, which is the difference between the actual temperature of the heating component and the target safe temperature at the current moment. This refers to the rate of temperature change, i.e. how quickly the temperature of the heating component changes over time, corresponding to the rate of temperature change of the power module mentioned earlier. Charging gun temperature change rate ; The final target rotational speed of the liquid supply pump B for the charging gun circuit is the core control parameter for the actual operation of the liquid supply pump B; The base speed of the liquid supply pump B for the charging gun circuit is obtained by the intelligent analysis module by querying the decision rule base, and serves as the benchmark value for the speed of the liquid supply pump B. The dedicated PID output adjustment for the power module branch is calculated by the PID control algorithm and is used for fine-tuning based on the temperature deviation of the power module. The feedforward speed increment of the liquid supply pump A in the power module branch is consistent with the feedforward speed increment in the load feedforward calculation, and is used to meet the basic heat dissipation requirements under the current load. The feedforward speed increment of the liquid supply pump B for the charging gun circuit is consistent with the feedforward speed increment in the load feedforward calculation, and is used to meet the basic heat dissipation requirements under the current charging current load. The dedicated PID output adjustment for the charging gun circuit is calculated by the PID control algorithm and is used for fine-tuning to address temperature deviations in the charging gun.

[0160] 3.3 Output Decision: Solve the above optimization problem and calculate the optimal target speeds of pump A and pump B. , And the optimal target opening of the corresponding flow control valve , Valve opening degree , It is usually adjusted in conjunction with the rotational speed according to a preset ratio, or kept at the base value in the decision table.

[0161] 3.4 Anomaly Identification: Based on the changing patterns of the model input parameters and combined with historical fault data in the data collection module, anomalies are identified, such as: (1) Flow rate or Below 50% of the minimum demand, and under pressure or (1) If the flow rate is not 0 but the speed of the liquid supply pump is not 0, it is determined that the pump body is running dry or the pipeline is blocked. (2) If the low level gauge is triggered and the liquid level in the storage tank continues to drop, it is determined that the pipeline is leaking. (3) If the pressure of any branch is continuously higher than the safety threshold or the flow rate is continuously lower than 50% of the minimum threshold, it is determined that the pipeline is blocked or the filter is blocked. (4) If the leakage current detected by the leakage current detection sensor exceeds 30mA, it is determined that the leakage is abnormal. (5) If the temperature of the coolant exceeds 50℃ and continues to rise, it is determined that the heat dissipation of the cold plate heat exchanger is abnormal. (6) If the exhaust volume of the gas-liquid separation structure is continuously greater than the normal range, preferably ≥100mL / h, it is determined that the air intake of the circuit is abnormal.

[0162] 3.5 Classification of abnormalities: minor abnormalities and serious abnormalities; minor abnormalities include slight filter blockage and slight decrease in heat exchange efficiency; serious abnormalities include pipeline leakage, leakage current abnormality, pump body abnormality, power module temperature exceeding the standard by more than 10°C, and low level gauge triggering.

[0163] 3.6 Anomaly Analysis Output: After identifying the anomaly type and level, the system synchronously outputs temporary control commands. For example, in the event of a severe anomaly, it immediately reduces the liquid supply pump speed and closes the flow control valve to prevent the fault from escalating. When the low-level gauge triggers, it synchronously outputs commands to shut down the charging function and cooling system, and transmits the anomaly information to the alarm module and command generation module. Temporary Control for Minor Anomalies: When the filter is slightly clogged, the system automatically increases the speed of the corresponding branch liquid supply pump, increases the branch pressure, attempts to clear the filter, and simultaneously issues a maintenance reminder. When the heat exchange efficiency decreases slightly, it increases the fan speed of the cold plate air-cooled heat dissipation component to enhance heat dissipation.

[0164] S4. The instruction generation module converts the analysis results into control instructions that can be recognized by the execution components, and outputs them after verification.

[0165] S4.1 Command Conversion: Converts the target speed and valve opening into control signals and valve positioning signals that can be recognized by the pump driver.

[0166] S4.2 Logic and Safety Verification: Verifies the rationality of the instructions, such as whether they are within the hardware's allowable range and whether the rate of change is too large, to prevent misoperation. After successful verification, a final set of control instructions that can be issued is generated. Verification includes whether the liquid supply pump speed is within preset upper and lower limits, whether the flow control valve opening is within the [0,1] interval, and whether the instruction rate of change exceeds the maximum response capability of the executing component, to avoid instructions exceeding the hardware's tolerance and causing component damage. If verification fails, the instruction generation module returns to the intelligent analysis module to recalculate the optimal control parameters and generate instructions until verification passes.

[0167] S5. The main controller sends control commands to the liquid supply pump A6, liquid supply pump B7, flow control valve and other actuators to perform heat dissipation regulation operations, and at the same time receives execution feedback signals.

[0168] 5.1 Command Issuance: The main controller issues verified control commands to the actuators via the fieldbus: liquid supply pump A6, liquid supply pump B7, and each flow control valve. The fieldbus adopts the RS485 protocol, consistent with the sensor data transmission protocol, to ensure communication compatibility. The command issuance response time is ≤0.1s, ensuring timely control. Encryption is used during command transmission to prevent signal interference from causing erroneous command execution.

[0169] 5.2 Execution and Control: Each actuator responds to commands, adjusting its speed and opening to precisely regulate the coolant flow rate in both branches, achieving on-demand cooling of the power module and charging gun. The response time of coolant supply pumps A6 and B7, along with the flow control valve, is ≤0.3s, enabling rapid response to the instantaneous heat generated during fast charging and ensuring timely temperature control. During execution, each actuator provides real-time feedback on its operating status, facilitating real-time monitoring by the main controller.

[0170] 5.3 Feedback Acquisition: The data acquisition module collects the system status in real time after the command is executed, such as actual speed, pressure, and flow rate, forming an execution feedback signal. Acquired parameters include the actual speed of liquid supply pump A6 and liquid supply pump B7, the actual pressure and flow rate of the power module branch and charging gun branch, and the actual temperature of the coolant, ensuring that the feedback data is synchronized with command execution and providing accurate data for subsequent closed-loop control.

[0171] S6. If an abnormal situation is detected, the alarm module issues a tiered alarm. The main controller sends the execution feedback signal and alarm information back to the intelligent analysis module. Based on the feedback information and new operating data, the model dynamically optimizes the control parameters to form a closed-loop control. The intelligent analysis module combines the feedback signal and newly collected operating data to compare the deviation between the command target value and the actual execution value, such as speed deviation and flow rate deviation. It then recalculates and optimizes the control parameters, adjusting the liquid supply pump speed and valve opening until the system state returns to the target range. In abnormal situations, the closed-loop control prioritizes emergency measures, such as shutdown protection in case of leakage or overheating. After the abnormality is alleviated, the control parameters are gradually optimized to restore normal heat dissipation operation.

[0172] The intelligent control system and supporting intelligent temperature control method in this embodiment achieve intelligent, precise, and energy-saving operation of the charging pile liquid cooling system through multi-module collaborative work and closed-loop control. It can not only effectively solve the problems of lagging heat dissipation control, excessive energy consumption, and complex operation and maintenance of traditional liquid-cooled charging piles, but also significantly improve the stability and safety of equipment operation through anomaly identification and safety protection mechanisms, adapting to the long-term operation requirements of high-current fast charging conditions. At the same time, the intelligent temperature control method has clear steps and strong operability. Relying on PID control algorithm and multi-parameter linkage control, it takes into account both temperature control accuracy and system energy efficiency, further optimizing the equipment operation performance.

[0173] The above description is only a preferred embodiment of this application. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the technical principles of this application, and these improvements and modifications should also be considered within the scope of protection of this application.

Claims

1. An integrated, fully liquid-cooled charging pile device, comprising: The cold plate heat exchanger, circulating pump, immersion power module cooling box, liquid-cooled charging gun, liquid storage tank and liquid supply pump are characterized by: The liquid storage tank is connected to the liquid-cooled charging gun and the immersion power module cooling box via pipelines; a liquid supply pump is installed on the pipeline between the liquid storage tank and the liquid-cooled charging gun; a liquid supply pump is installed on the pipeline between the liquid storage tank and the immersion power module cooling box. The input end of the circulating pump is connected to the liquid-cooled charging gun and the immersion power module cooling box through a three-way pipe and other pipelines; the output end of the circulating pump is connected to the cold plate heat exchanger through pipelines; and the cold plate heat exchanger is connected to the liquid storage tank through pipelines.

2. The integrated fully liquid-cooled charging pile equipment according to claim 1, characterized in that... A filter, pressure sensor, flow control valve, and flow meter are installed on the pipeline between the liquid storage tank and the liquid-cooled charging gun; a filter, pressure sensor, flow control valve, and flow meter are fixedly installed on the pipeline between the circulating pump and the immersion power module cooling box.

3. The integrated fully liquid-cooled charging pile equipment according to claim 1, characterized in that... Temperature sensors are fixedly installed on the outside of the immersion power module cooling box and at the head of the liquid-cooled charging gun; pressure sensors, temperature sensors and flow meters are installed on the pipeline between the circulating pump and the cold plate heat exchanger; high-level and low-level liquid level gauges are installed on the inner wall of the liquid storage tank, and an automatic vent valve is installed on the top of the liquid storage tank.

4. The integrated fully liquid-cooled charging pile equipment according to claim 1, characterized in that... The immersion power module cooling box has an internal flow guiding structure, which includes a flow guide plate and a flow turbulence column. The flow guide plate guides the coolant to flow along the power module arrangement direction, and the flow turbulence column is set in the gap between the power modules.

5. The integrated fully liquid-cooled charging pile equipment according to claim 1, characterized in that... A liquid collection section and a gas-liquid separation structure are set in the low-position area before the inlet of the circulating pump. The liquid collection section adopts a conical design. The gas-liquid separation structure is a sealed cavity made of stainless steel. The interior of the gas-liquid separation structure includes: a conical liquid collection and sedimentation zone, a flow guiding and defoaming separation zone, and a gas chamber exhaust zone; the side of the gas-liquid separation structure is provided with a liquid inlet and a liquid outlet.

6. The integrated fully liquid-cooled charging pile equipment according to claim 1, characterized in that... The liquid-cooled charging gun includes a head section, a grip section, and a cable section, with seamless internal liquid cooling channels connecting the head section, grip section, and cable section. The head section adopts a surround liquid cooling cavity, a liquid inlet adapter, and a terminal base heat-conducting embedded structure. The grip section adopts a channel transition and sealed maintenance structure; the gun line section adopts a coaxial structure of inner conductor bundle and liquid-cooled sleeve.

7. The integrated fully liquid-cooled charging pile equipment according to claim 1, characterized in that... The immersion power module cooling box has a liquid inlet connector and a data transmission connector fixedly installed on the upper rear side, and a liquid return connector installed on the lower rear side. Multiple three-phase AC input connectors and DC output connectors are installed on the rear side of the immersion power module cooling box. A transparent window is embedded in the upper front side of the box. A metal fixing bracket is detachably fixed inside the immersion power module cooling box.

8. A smart temperature control method for the integrated fully liquid-cooled charging pile equipment described in claims 1-7, characterized in that, include: After the main controller starts up, it completes hardware and communication self-tests. If the self-test fails, an alarm is triggered and charging is prohibited. It also collects core operating parameters of the equipment, ambient temperature, coolant status, and component operating and historical data simultaneously. The collected raw data is filtered, denoised, synchronized with time, and normalized to output standardized data. A comprehensive analysis model is established based on standardized data to complete the judgment of heat dissipation requirements, feedforward compensation, decision query and PID fine-tuning, calculate the target parameters of the execution components, and identify anomalies and output temporary control commands. The analysis results are converted into execution control signals. After passing the security check, the final instruction set is generated. If the check fails, the calculation is recalculated. The main controller sends instructions to each execution component to perform heat dissipation regulation and collects the system status after execution to form a feedback signal; Feedback signals and alarm information are fed back to the intelligent analysis module to dynamically optimize control parameters. In case of abnormalities, emergency measures are executed first to achieve closed-loop temperature control.

9. The intelligent temperature control method for the integrated fully liquid-cooled charging pile equipment according to claim 8, characterized in that... Establishing a comprehensive analysis model includes: Establish a comprehensive analysis model: The objective function is to minimize the system's operating energy consumption, and the parameters of the objective function are set in combination with the power consumption characteristics of the liquid supply pump. The constraints include thermal safety constraints, flow generation constraints, and actuator limiting constraints. Among them, the thermal safety constraints must ensure that the real-time temperature of the power module and the charging gun head does not exceed their respective maximum allowable operating temperatures. Status prediction and comprehensive judgment: Based on the current system status, determine the level of heat dissipation demand and generate preliminary control objectives; Feedforward compensation calculation: Calculate the ambient temperature compensation coefficient based on the real-time ambient temperature and the preset compensation gain, then calculate the basic flow requirements of the power module branch and the charging gun branch, simplify the flow model through inverse solution, and obtain the feedforward speed increment required to meet the basic flow. Decision rule base query: Based on the combination of power module and charging gun demand level, query the preset two-dimensional decision rule base, determine the basic control strategy, and obtain the basic speed of the liquid supply pump and the basic opening of the flow control valve. For branches with demand levels in normal adjustment state, a controller is used for adjustment. The adjustment is achieved by combining the proportional coefficient, integral coefficient, and derivative coefficient with the real-time temperature deviation, the historical temperature deviation accumulation value, and the temperature change rate, and finally synthesizing the target control quantity of the liquid supply pump of the power module branch and the charging gun branch.

10. The intelligent temperature control method for the integrated fully liquid-cooled charging pile equipment according to claim 9, characterized in that... Status prediction and comprehensive judgment: Thermal status assessment is completed by calculating temperature deviation and temperature change rate. Based on temperature deviation and temperature change rate, heat dissipation requirements are divided into different levels, and the requirement levels of power modules and charging guns are output respectively.

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