Device for adjusting output power of charging terminal of charging pile and charging pile

Abstract

This invention relates to the field of charging pile technology, specifically to a device for adjusting the output power of a charging terminal and a charging pile. The device includes: a temperature sensor disposed on the connection part of the output copper busbar of the charging terminal, used to collect the temperature of the output copper busbar in real time and send the analog signal corresponding to the temperature of the output copper busbar to an AD converter; an AD converter used to receive the analog signal corresponding to the temperature of the output copper busbar sent by the temperature sensor, convert the analog signal corresponding to the temperature of the output copper busbar into a digital signal and send it to a controller; a power adjustment module connected to the power output unit of the charging terminal, used to adjust the output power of the power output unit according to the instructions of the controller; and a controller connected to the power adjustment module used to receive the digital signal corresponding to the temperature of the output copper busbar sent by the AD converter and send a power adjustment command to the power adjustment module based on the comparison result of the temperature of the output copper busbar and a preset threshold.

Description

Technical Field

[0001] This invention relates to the field of charging pile technology, and more specifically to a device for adjusting the output power of a charging pile terminal and a charging pile. Background Technology

[0002] With the rapid development of the global electric vehicle industry, the market demand for high-power charging stations is increasing. In high-power charging scenarios, the copper busbar of the charging station terminal, as a core conductive component, withstands continuous operation with high current for a long time. The stability of its operating temperature directly affects the operational safety and service life of the charging station.

[0003] However, current installation operations largely rely on manual labor, leading to inconsistent adherence to construction standards and difficulties in precisely quantifying and controlling tightening torque. When the connecting screws at the copper busbar connection points do not reach the specified pre-tightening force, the contact surfaces will not fit tightly, significantly increasing contact resistance. Under high-current charging conditions, according to Joule's law, increased contact resistance will cause abnormal local temperature rises. Prolonged or severe overheating will not only accelerate the aging of the copper busbar material and cause insulation damage, but may even burn out the copper busbar and surrounding components, causing equipment failure or even fire, seriously threatening the safety of charging facility assets and the lives and property of users.

[0004] Existing technical solutions have significant shortcomings in addressing the aforementioned overheating hazards of copper busbars caused by improper construction. Most current charging terminal protection strategies primarily focus on monitoring electrical parameters (such as overcurrent and overvoltage protection), lacking direct and effective sensing of the temperature status of the copper busbar connection points. Once a rapid temperature rise occurs due to poor contact, existing protection mechanisms often fail to respond promptly, unable to provide early warnings or intervene by shutting down the system before the fault worsens, resulting in persistent safety hazards. Summary of the Invention

[0005] The purpose of this invention is to provide a device for adjusting the output power of a charging terminal and a charging pile. This invention can solve or at least partially solve the above-mentioned defects of the prior art.

[0006] To achieve the above objectives, a first aspect of the present invention discloses a device for adjusting the output power of a charging terminal in a charging pile, the device comprising: A temperature sensor is installed on the connection part of the output copper busbar of the charging terminal to collect the temperature of the output copper busbar in real time and send the analog signal corresponding to the temperature of the output copper busbar to the AD converter. An AD converter, connected to the temperature sensor, is used to receive an analog signal corresponding to the temperature of the output copper busbar sent by the temperature sensor, convert the analog signal corresponding to the temperature of the output copper busbar into a digital signal, and send it to the controller. A power adjustment module, connected to the power output unit of the charging terminal, is used to adjust the output power of the power output unit according to instructions from the controller; and The controller, connected to the power regulation module, is used to receive a digital signal corresponding to the temperature of the output copper busbar sent by the AD converter; and when the temperature of the output copper busbar is greater than a preset first threshold: send a power reduction command to the power regulation module; and when the temperature of the output copper busbar is greater than a preset second threshold: send a power cut-off command to the power regulation module, wherein the preset first threshold is less than the preset second threshold.

[0007] Optionally, the temperature sensor is an NTC thermistor, which is fixed to the connection part of the output copper busbar by thermally conductive silicone.

[0008] Optionally, the preset first threshold is 150°C, and the preset second threshold is 200°C; When the temperature of the output copper busbar exceeds the preset first threshold, the controller sends a power reduction command to the power regulation module; when the temperature of the output copper busbar exceeds the preset second threshold, the controller sends a power cut-off command to the power regulation module, including: When the temperature of the output copper busbar exceeds 150°C, the controller sends the following control command to the power regulation module: reduce the output power of the power output unit by 50%; and When the temperature of the output copper busbar exceeds 200°C, the controller sends the following control command to the power regulation module: cut off the power output of the power output unit.

[0009] Optionally, the controller is an STM32 microcontroller, and the controller is connected to the power regulation module through a GPIO interface.

[0010] Optionally, the power regulation module is a thyristor power regulator.

[0011] Optionally, the device may further include a fault reporting module and an operation and maintenance system; When the temperature of the output copper busbar exceeds the preset first threshold, the controller sends a temperature abnormality signal to the fault reporting module, and the fault reporting module reports the temperature abnormality signal and the information of the charging terminal corresponding to the temperature abnormality signal to the operation and maintenance system. The information of the charging terminal includes: the charging terminal's serial number and installation location.

[0012] A second aspect of the present invention discloses a charging pile, including: the device for adjusting the output power of the charging terminal of the charging pile.

[0013] This invention, through real-time and precise monitoring of copper busbar temperature and rapid response to output power adjustment in case of abnormal temperature rise, can prevent copper busbars and connecting devices from burning out due to overheating. It can also help determine the reliability of on-site construction and facilitate maintenance personnel to quickly handle faults. Attached Figure Description

[0014] The accompanying drawings are provided to further illustrate embodiments of the present invention and form part of the specification. They are used together with the following detailed description to explain the embodiments of the present invention, but do not constitute a limitation thereof. In the drawings: Figure 1 A schematic diagram of the device structure for adjusting the output power of a charging terminal in a charging pile, provided by the present invention, is shown.

[0015] Attached Figure Labels 1. Temperature sensor 2. AD converter 3. Power regulation module 4. Controller 5. Output copper busbar 6. Power Output Unit 7. Fault Reporting Module 8. Operation and Maintenance System Detailed Implementation To better understand the above-mentioned objectives, features, and advantages of the present invention, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments. It should be noted that, unless otherwise specified, the embodiments and features described in these embodiments can be combined with each other.

[0016] Many specific details are set forth in the following description in order to provide a full understanding of the invention. However, the invention may also be practiced in other ways different from those described herein, and therefore the scope of protection of the invention is not limited to the specific embodiments disclosed below.

[0017] Figure 1 A schematic diagram of the device structure for adjusting the output power of a charging terminal in a charging pile, provided by the present invention, is shown below. Figure 1 As shown, the present invention discloses a device for adjusting the output power of a charging terminal of a charging pile. The device includes: a temperature sensor 1, an AD converter 2, a power adjustment module 3, and a controller 4.

[0018] Furthermore, temperature sensor 1 will be described in detail.

[0019] Temperature sensor 1 is installed on the connection part of the output copper busbar 5 of the charging terminal, and is used to collect the temperature of the output copper busbar 5 in real time and send the analog signal corresponding to the temperature of the output copper busbar to the AD converter 2.

[0020] The output copper busbar of the charging terminal is the core conductive component that connects the power line from the host input to the terminal charging gun. It is mainly responsible for transmitting high current, transferring electrical energy from the charging station to the vehicle. As a low-resistance conductor, the copper busbar can efficiently transmit high current, reducing heat generation and energy loss.

[0021] The connection portion of the output copper busbar is used to interlock with other conductive components to secure it and enable current transmission. Furthermore, the connection portion is equipped with conductive fasteners to ensure a stable connection between the copper busbar and other conductive components, effectively reducing contact resistance and ensuring safe transmission of high current. The conductive fasteners include bolts or screws, with bolts including bolts and nuts.

[0022] In this embodiment of the invention, the temperature sensor 1 is a surface-mount NTC thermistor, which is firmly fixed to the connection point of the output copper busbar 5 using thermally conductive silicone. The surface-mount NTC thermistor is positioned close to a conductive fastener, which is a screw. It should be noted that the screw of the conductive fastener is a critical heat-generating component. Specifically, during the actual installation and use of the charging terminal, improper on-site construction often results in the output copper busbar connection screws not being tightened properly. This problem increases the contact resistance at the output copper busbar connection point, generating a large amount of Joule heat when a large current passes through, potentially leading to overheating or even burnout of the copper busbar. Therefore, this invention places the temperature sensor on the connection point of the output copper busbar 5, close to the conductive fastener, ensuring accurate real-time temperature measurement of the copper busbar. Furthermore, since the copper busbar is a non-moving component, the surface-mount NTC thermistor can be securely attached.

[0023] Furthermore, the AD converter 2 will be described in detail.

[0024] The AD converter 2 uses a high-precision AD conversion chip and is connected to the temperature sensor 1 via a wire. It is used to receive the analog signal corresponding to the temperature of the output copper busbar sent by the temperature sensor, convert the analog signal corresponding to the temperature of the output copper busbar into a digital signal, and then send it to the controller 4.

[0025] Furthermore, the power regulation module 3 will be described in detail.

[0026] The power adjustment module 3 is electrically connected to the power output unit 6 of the charging terminal and is used to continuously adjust the output power or directly cut off the output according to the instructions of the controller 4.

[0027] In this embodiment of the invention, the power regulation module 3 is implemented using a thyristor power regulator, which mainly achieves continuous power regulation through phase-controlled rectification technology. Its core is to change the conduction angle of the thyristor: by controlling the delay time of the trigger pulse, the starting conduction point of the thyristor is adjusted within each half-cycle of the AC current.

[0028] Furthermore, controller 4 will be described in detail.

[0029] Controller 4, pre-set and stored by a program, includes a first preset threshold and a second preset threshold. It is electrically connected to the power regulation module and is used to receive a digital signal corresponding to the temperature of the output copper busbar sent by the AD converter. When the temperature of the output copper busbar is greater than the first preset threshold, controller 4 sends a power reduction command to the power regulation module. When the temperature of the output copper busbar is greater than the second preset threshold, controller 4 sends a power cut-off command to the power regulation module. The first preset threshold is less than the second preset threshold.

[0030] In this embodiment of the invention, the preset first threshold is 150°C, which is the safe operating temperature threshold for the copper busbar, and the preset second threshold is 200°C. After receiving the digital signal corresponding to the temperature of the copper busbar, the controller 4 compares it with the preset first threshold of 150°C and the preset second threshold of 200°C. When the temperature of the output copper busbar is less than or equal to 150°C, the charging terminal outputs normal power, and the copper busbar temperature is continuously monitored. When the temperature of the output copper busbar exceeds 150°C, the controller 4 sends the following power reduction command to the power regulation module 3: reduce the output power of the power output unit 6 by 50%; If the temperature of the output copper busbar continues to rise to 200°C after the power is reduced, the controller 4 sends the following stop output control command to the power regulation module 3: cut off the power output of the power output unit 6.

[0031] It should also be noted that the preset first threshold and the preset second threshold stored in the controller 4 can be adaptively adjusted according to the model of different charging terminals and the characteristics of copper busbar material, with the corresponding adjustment range being 150℃-200℃.

[0032] In this embodiment of the invention, the controller is an STM32 microcontroller, which is electrically connected to the power regulation module through the GPIO interface of the STM32 microcontroller. The GPIO interface is a general-purpose input / output interface for microcontrollers, referring to the pins on the microcontroller chip that can be controlled independently and dynamically configured as input or output modes through programming.

[0033] In this embodiment of the invention, the device further includes a fault reporting module 7 and an operation and maintenance system 8; the controller 4 is implemented using an STM32 microcontroller and is electrically connected to the fault reporting module 7 via a GPIO interface. When the temperature of the output copper busbar 5 is greater than 150°C, the controller 4 sends a temperature abnormality signal to the fault reporting module 7. The fault reporting module 7 reports the temperature abnormality signal and the charging terminal information corresponding to the temperature abnormality signal to the operation and maintenance system 8, wherein the charging terminal information includes: the charging terminal number and the installation location.

[0034] The fault reporting module 7 establishes a connection with the operation and maintenance system 8 using 4G / 5G or Ethernet communication to ensure the real-time and stable transmission of fault information.

[0035] After receiving an abnormal temperature alarm through the maintenance system 8, the maintenance personnel went to the site to check the tightness of the connecting screws of the output copper busbar 5 of the charging terminal, corrected the construction problems in time, and after troubleshooting, the charging terminal returned to normal operation.

[0036] This invention also provides a charging pile, including the device for adjusting the output power of the charging pile's charging terminal.

[0037] Compared with the prior art, the present invention has the following beneficial effects: First, by monitoring the copper busbar temperature in real time and dynamically adjusting the output current according to the set temperature threshold, the copper busbar can be effectively prevented from being damaged due to overheating, ensuring the stable and safe operation of the charging pile in high-power charging scenarios and extending the service life of the equipment. Secondly, temperature monitoring data can be used to help determine the reliability of on-site construction: if the charging terminal frequently experiences abnormal temperatures after being put into use, it can be inferred that there may be construction problems such as loose copper busbar connection screws. By sending an abnormal temperature alarm to the operation and maintenance system, operation and maintenance personnel can go to the site for inspection and correction as soon as possible, reducing the difficulty of troubleshooting, improving operation and maintenance efficiency, and reducing equipment failures and safety risks caused by construction hazards. Third, the solution has low implementation costs, is easy to promote in the industry, and has low installation and integration difficulty for thermistors and related modules. It is compatible with the transformation of existing European standard charging terminals and the development of new equipment, and has broad application prospects.

[0038] The optional embodiments of the present invention have been described in detail above with reference to the accompanying drawings. However, the embodiments of the present invention are not limited to the specific details in the above embodiments. Within the scope of the technical concept of the embodiments of the present invention, various simple modifications can be made to the technical solutions of the embodiments of the present invention, and these simple modifications all fall within the protection scope of the embodiments of the present invention.

[0039] It should also be noted that the various specific technical features described in the above embodiments can be combined in any suitable manner without contradiction. To avoid unnecessary repetition, the embodiments of the present invention will not describe the various possible combinations separately.

[0040] Those skilled in the art will understand that all or part of the steps in the methods of the above embodiments can be implemented by a program instructing related hardware. This program is stored in a storage medium and includes several instructions to cause a microcontroller, chip, or processor to execute all or part of the steps of the methods described in the various embodiments of this application. The aforementioned storage medium includes: a USB flash drive, a portable hard drive, and a read-only memory (ROM). Various media that can store program code, such as only memory, random access memory (RAM), magnetic disks or optical disks.

[0041] Furthermore, various different implementations of the present invention can be combined arbitrarily, as long as they do not violate the spirit of the present invention, they should also be regarded as the content disclosed in the present invention.

Claims

1. A device for adjusting the output power of a charging terminal in a charging pile, characterized in that, The device includes: A temperature sensor is installed on the connection part of the output copper busbar of the charging terminal to collect the temperature of the output copper busbar in real time and send the analog signal corresponding to the temperature of the output copper busbar to the AD converter. An AD converter, connected to the temperature sensor, is used to receive an analog signal corresponding to the temperature of the output copper busbar sent by the temperature sensor, convert the analog signal corresponding to the temperature of the output copper busbar into a digital signal, and send it to the controller. A power adjustment module, connected to the power output unit of the charging terminal, is used to adjust the output power of the power output unit according to instructions from the controller; and The controller, connected to the power regulation module, is used to receive a digital signal corresponding to the temperature of the output copper busbar sent by the AD converter; and when the temperature of the output copper busbar is greater than a preset first threshold: send a power reduction command to the power regulation module; and when the temperature of the output copper busbar is greater than a preset second threshold: send a power cut-off command to the power regulation module, wherein the preset first threshold is less than the preset second threshold.

2. The apparatus according to claim 1, characterized in that, The temperature sensor is an NTC thermistor, which is fixed to the connection part of the output copper busbar by thermally conductive silicone.

3. The apparatus according to claim 1, characterized in that, The preset first threshold is 150°C, and the preset second threshold is 200°C; When the temperature of the output copper busbar exceeds the preset first threshold, the controller sends a power reduction command to the power regulation module; when the temperature of the output copper busbar exceeds the preset second threshold, the controller sends a power cut-off command to the power regulation module, including: When the temperature of the output copper busbar exceeds 150°C, the controller sends the following control command to the power regulation module: reduce the output power of the power output unit by 50%; and When the temperature of the output copper busbar exceeds 200°C, the controller sends the following control command to the power regulation module: cut off the power output of the power output unit.

4. The apparatus according to claim 1, characterized in that, The controller is an STM32 microcontroller, and it is connected to the power regulation module via a GPIO interface.

5. The apparatus according to claim 1, characterized in that, The power regulation module is a thyristor power regulator.

6. The apparatus according to claim 1, characterized in that, The device also includes a fault reporting module and an operation and maintenance system; When the temperature of the output copper busbar exceeds the preset first threshold, the controller sends a temperature abnormality signal to the fault reporting module, and the fault reporting module reports the temperature abnormality signal and the information of the charging terminal corresponding to the temperature abnormality signal to the operation and maintenance system. The information of the charging terminal includes: the charging terminal's serial number and installation location.

7. A charging pile, characterized in that, include: The apparatus for adjusting the output power of the charging terminal of a charging pile according to any one of claims 1 to 6.

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