A charging gun electronic lock control device, control system and control method

Abstract

This application discloses a charging gun electronic lock control device, control system, and control method. The device includes: an auxiliary source for converting input electrical energy into multiple output voltages; a DSP control unit connected to a first output terminal of the auxiliary source for receiving control commands and outputting control signals; a detection unit connected to a second output terminal of the auxiliary source and the DSP control unit for detecting the microswitch status of the charging gun electronic lock and the internal temperature of the charging gun, and transmitting the detection signals to the DSP control unit; and an electronic lock control circuit connected to the second output terminal of the auxiliary source and the DSP control unit for receiving control signals from the DSP control unit to control the electronic lock to perform unlocking or locking actions. This invention, by connecting the auxiliary source, DSP control unit, detection unit, and electronic lock control circuit, can receive control commands and output control signals.

Description

Technical Field

[0001] This application relates to the field of charging gun control technology, and more specifically, to a charging gun electronic lock control device, control system and control method. Background Technology

[0002] With the transformation of the energy structure and the increasing awareness of environmental protection, the electric vehicle industry has developed rapidly. As a key component of the electric vehicle energy supply infrastructure, the safety and intelligence level of charging equipment are directly related to user experience and public safety. The charging gun, as the physical interface connecting the charger and the electric vehicle, is crucial for ensuring the safe operation of high-power charging. In actual charging processes, if the charging gun plug and socket fail to lock reliably, it may lead to safety accidents such as pulling the gun while it is energized, poor contact causing overheating, or even electric arcing, posing a serious threat to personal and property safety. Therefore, effective monitoring and reliable control of the charging gun connection status has become an important research direction in the field of charging technology.

[0003] Currently, most common electronic lock control solutions for charging guns on the market use control circuits built with discrete components. Their basic operating mode involves controlling the power supply to the electromagnetic lock or micro-motor lock via a simple switching circuit to achieve locking or unlocking. For connection status detection, they typically rely on a single switching signal provided by the micro-switch inside the electronic lock to determine whether the locking mechanism is in place. Some solutions also include simple overcurrent or short-circuit protection, usually relatively independent of the charger's main control system, interacting only through a few hard-wired signals, such as receiving a locking command or providing a locking status signal.

[0004] However, existing technical solutions have significant functional deficiencies. First, their functionality is relatively limited, mainly focusing on the on / off control of the electronic lock, lacking a comprehensive understanding of the charging gun's operating environment. For example, they cannot monitor the internal temperature of the charging gun, making it difficult to prevent the risk of thermal runaway due to excessive contact resistance or high ambient temperature. Second, their level of intelligence is insufficient; their information interaction with the charger or battery management system (BMS) is extremely limited, only able to transmit simple status signals and unable to form a collaborative control strategy. When the electronic lock experiences abnormalities such as microswitch failure or locking mechanism jamming, existing control modules often cannot promptly and accurately identify and report the specific fault type, let alone proactively coordinate with the charger to quickly cut off the high-voltage output, posing serious safety hazards. Summary of the Invention

[0005] To address at least one defect or improvement need in the prior art, the present invention provides a charging gun electronic lock control device, control system, and control method, which solves the problem that the existing charging gun electronic lock control scheme is limited by its single function and lack of environmental perception and intelligent coordination mechanism, resulting in the inability to monitor abnormal temperatures in real time, accurately identify electronic lock faults, and coordinate with the charger to quickly cut off the output, thus posing serious safety hazards.

[0006] To achieve the above objectives, according to a first aspect of the present invention, a charging gun electronic lock control device is provided, comprising: Auxiliary power source, used to convert input electrical energy into multiple output voltages; The DSP control unit is connected to the first output terminal of the auxiliary source and is used to receive control commands and output control signals. The detection unit is connected to the second output terminal of the auxiliary source and the DSP control unit. It is used to detect the micro-switch status of the charging gun electronic lock and the internal temperature of the charging gun, and transmit the detection signal to the DSP control unit. The electronic lock control circuit is connected to the second output terminal of the auxiliary source and the DSP control unit. It receives control signals from the DSP control unit to control the electronic lock to perform unlocking or locking actions.

[0007] In one possible implementation, the electronic lock control circuit includes: The first relay has a first coil and at least two sets of contacts; The second relay has a second coil and contacts; The first transistor has its base connected in series with a first resistor and is connected to the DSP control unit to receive the first control signal. Its collector is connected to the first coil and its emitter is grounded. The second transistor has its base connected in series with a third resistor and is connected to the DSP control unit to receive the second control signal. Its collector is connected to the second coil and its emitter is grounded. The first output terminal is used to connect to the first end of the electronic lock; The second output terminal is used to connect to the second end of the electronic lock; The contact group of the first relay is connected between the third output terminal of the auxiliary source, the contact of the second relay, the first output terminal and the second output terminal, and is used to switch the voltage polarity of the first output terminal and the second output terminal according to the first control signal. The contacts of the second relay are connected in series in the power supply circuit and are used to control the on / off state of the power supply circuit according to the second control signal.

[0008] In one possible implementation, the first relay is a double-pole double-throw relay, having a first common terminal, a first normally open terminal, a first normally closed terminal, a second common terminal, a second normally open terminal, and a second normally closed terminal; The first common terminal is connected to the third output terminal of the auxiliary source; the first normally open terminal is connected to the first end of the contact of the second relay; the first normally closed terminal is connected to the second output terminal; the second common terminal is grounded; the second normally open terminal is connected to the second output terminal; the second normally closed terminal is connected to the first end of the contact of the second relay; and the second end of the contact of the second relay is connected to the first output terminal.

[0009] In one possible implementation, the electronic lock control circuit also includes: The second resistor is connected between the base of the first transistor and ground; The fourth resistor is connected between the base of the second transistor and ground; The first capacitor is connected between the base of the first transistor and ground. The second capacitor is connected between the base of the second transistor and ground.

[0010] In one possible implementation, the electronic lock control circuit also includes: The anode of the first diode is connected to the third output terminal of the auxiliary source, and the cathode of the first diode is connected to the first relay. The second diode is connected in parallel with the first coil, and the anode of the second diode is connected to the collector of the first transistor, and the cathode of the second diode is connected to the third output terminal of the auxiliary source. The third diode is connected in parallel with the second coil, and the anode of the third diode is connected to the collector of the second transistor, while the cathode of the third diode is connected to the fifth resistor and the second coil. The fifth resistor has one end connected to the third voltage and the other end connected to the second coil.

[0011] In one possible implementation, the auxiliary sources include: A rectifier bridge, whose input terminal is connected to the input terminal of an auxiliary source, is used to rectify the input AC power into DC power; A flyback converter, whose input terminal is connected to the output terminal of a rectifier bridge, or directly connected to the DC power input from an auxiliary source; The flyback converter includes a transformer, a first switch and a second switch. The first switch and the second switch are connected in series and then connected to the primary winding of the transformer to form a two-tube flyback topology. The output terminals of the flyback converter include a first output voltage terminal, a second output voltage terminal, and a third output voltage terminal, which are used to output the first voltage, the second voltage, and the third voltage, respectively.

[0012] In one possible implementation, the DSP control unit includes: The microcontroller chip has multiple general-purpose input / output ports and multiple analog-to-digital conversion ports; A CAN transceiver connects to the CAN communication port of a DSP microcontroller chip and is used for differential signal communication with an external charger or battery management system. The microcontroller chip's first general-purpose input / output port is connected to the electronic lock control circuit and is used to output a first control signal; the microcontroller chip's second general-purpose input / output port is connected to the electronic lock control circuit and is used to output a second control signal; the microcontroller chip's first analog-to-digital converter port is connected to the detection unit and is used to receive a microswitch status signal; the microcontroller chip's second analog-to-digital converter port is connected to the detection unit and is used to receive a temperature detection signal.

[0013] In one possible implementation, the detection unit includes: The micro switch detection interface is used to connect the micro switch of the electronic lock and convert the on / off state of the micro switch into an electrical signal that is transmitted to the DSP control unit. The temperature detection interface is used to connect to the temperature sensor inside the charging gun and transmit the temperature detection signal to the DSP control unit.

[0014] According to a second aspect of the present invention, a charging control system is also provided, including a charger, a battery management system and a charging gun, and further including an electronic lock control device for the charging gun in any of the above possible implementations.

[0015] According to a third aspect of the present invention, a charging gun electronic lock control method is also provided, applied to the charging gun electronic lock control device of any of the above possible implementations, comprising: The on / off state of the micro switch of the charging gun electronic lock is detected in real time and converted into an electrical signal; The DSP control unit determines whether the electronic lock is unlocked or locked based on electrical signals. The DSP control unit reports the electronic lock's operating status to the charger or battery management system via CAN communication; The DSP control unit receives CAN communication commands from the charger or battery management system to unlock or lock the electronic lock.

[0016] In summary, compared with the prior art, the above-described technical solutions conceived by this invention can achieve the following beneficial effects: This invention provides a charging gun electronic lock control device. By setting an auxiliary source, the input electrical energy is converted into multiple outputs of different voltage levels, providing independent power to the DSP control unit, detection unit, and electronic lock control circuit, ensuring stable operation of each functional module. The DSP control unit is connected to the auxiliary source, detection unit, and electronic lock control circuit, capable of receiving external control commands and outputting control signals. Simultaneously, it receives detection signals transmitted from the detection unit, achieving centralized control of the electronic lock control circuit and real-time processing of detection data. The detection unit, connected to the auxiliary source and DSP control unit, can simultaneously detect the on / off state of the microswitch of the charging gun electronic lock and the internal temperature of the charging gun, converting mechanical switch signals and temperature analog signals into electrical signals and transmitting them to the DSP control unit, achieving real-time perception of the electronic lock's locking state and the charging gun's operating environment. The electronic lock control circuit, connected to the auxiliary source and DSP control unit, receives control signals from the DSP control unit and controls the electronic lock to perform unlocking or locking actions based on the control signals, achieving precise drive control of the electronic lock. The DSP control unit, based on the received control commands and the microswitch status and temperature signals fed back from the detection unit, precisely controls the electronic lock to perform unlocking or locking actions, achieving closed-loop control of the electronic lock. Meanwhile, the DSP control unit interacts with external devices to control the electronic lock's actions according to external commands, enabling remote control and collaborative operation. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0018] Figure 1 A schematic diagram of a structure of an embodiment of the electronic lock control device for a charging gun provided by the present invention; Figure 2 This is a circuit diagram of an embodiment of the electronic lock control circuit provided by the present invention. Detailed Implementation

[0019] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention. Furthermore, the technical features involved in the various embodiments of this invention described below can be combined with each other as long as they do not conflict with each other.

[0020] The terms "first," "second," "third," etc., in the specification, claims, and accompanying drawings of this application are used to distinguish different objects, not to describe a specific order. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover non-exclusive inclusion. For example, a process, method, system, product, or apparatus that includes a series of steps or units is not limited to the listed steps or units, but may optionally include steps or units not listed, or may optionally include other steps or units inherent to these processes, methods, products, or apparatuses.

[0021] This invention provides a charging gun electronic lock control device, control system, and control method, which are described below.

[0022] Please see Figure 1 , Figure 1 This is a schematic diagram of a structure of an embodiment of the electronic lock control device for a charging gun provided by the present invention. In a specific embodiment of the present invention, an electronic lock control device 100 for a charging gun is disclosed, comprising: Auxiliary source 110 is used to convert input electrical energy into multiple output voltages; The DSP control unit 120 is connected to the first output terminal of the auxiliary source 110 and is used to receive control commands and output control signals. The detection unit 130 is connected to the second output terminal of the auxiliary source 110 and the DSP control unit 120. It is used to detect the micro switch status of the charging gun electronic lock and the internal temperature of the charging gun, and transmit the detection signal to the DSP control unit 120. The electronic lock control circuit 140 is connected to the second output terminal of the auxiliary source 110 and the DSP control unit 120, and receives the control signal sent by the DSP control unit 120 to control the electronic lock to perform unlocking or locking actions.

[0023] In the above embodiments, the input of the auxiliary source 110 is alternating current or direct current, and the output of the auxiliary source 110 includes a first output voltage, a second output voltage, and a third output voltage. In a preferred embodiment, the first output voltage of the auxiliary source 110 is 3.3V, connected to the DSP control unit 120, and supplies power to the DSP control unit 120; the second output voltage of the auxiliary source 110 is 5V, connected to the detection unit 130, and supplies power to the detection unit 130; the third output voltage of the auxiliary source 110 is 12V, connected to the electronic lock control circuit 140, and supplies power to the electronic lock control circuit 140. It should be noted that the specific voltage values ​​in this application can also be adjusted according to actual usage needs, and this application does not further limit them.

[0024] The DSP control unit 120 is connected to the auxiliary power source 110 and receives the 3.3V voltage provided by the auxiliary power source 110; the DSP control unit 120 is connected to the detection unit 130 and receives the detection signal transmitted by the detection unit 130; the DSP control unit 120 is connected to the electronic lock control circuit 140 and sends control signals to the electronic lock control circuit 140; the DSP control unit 120 is also connected to the BMS or charger via CAN communication, receives the unlocking command or locking command issued by the BMS or charger, and reports the working status of the electronic lock to the BMS or charger.

[0025] The detection unit 130 is connected to the auxiliary source 110 and receives the 5V voltage provided by the auxiliary source 110; the detection unit 130 is connected to the DSP control unit 120 and transmits the detection signal to the DSP control unit 120; the detection unit 130 is used to detect the on / off state of the micro switch of the charging gun electronic lock and to detect the internal temperature of the charging gun.

[0026] The electronic lock control circuit 140 is connected to the auxiliary power source 110 and receives the 12V voltage provided by the auxiliary power source 110; the electronic lock control circuit 140 is connected to the DSP control unit 120 and receives the control signals sent by the DSP control unit 120; the electronic lock control circuit 140 is used to control the electronic lock to perform unlocking or locking actions.

[0027] Compared with the prior art, the charging gun electronic lock control device 100 provided in this embodiment converts the input electrical energy into multiple outputs of different voltage levels to independently power the DSP control unit 120, the detection unit 130, and the electronic lock control circuit 140, ensuring the stable operation of each functional module. By setting an auxiliary source 110 and connecting the output terminal of the auxiliary source 110 to the DSP control unit 120, the detection unit 130, and the electronic lock control circuit 140 respectively, it can receive control commands and output control signals. At the same time, it can receive the detection signals transmitted by the detection unit 130, realize centralized control of the electronic lock control circuit 140 and real-time processing of detection data, and detect the micro-switch status of the charging gun electronic lock and the internal temperature of the charging gun, and transmit the detection signals to the DSP control unit 120 to realize real-time perception of the electronic lock locking status and the charging gun working environment. The system receives control signals from the DSP control unit 120 and controls the electronic lock to perform unlocking or locking actions based on these signals, achieving precise drive control of the electronic lock. It converts mechanical switch signals and temperature analog signals into electrical signals for the DSP control unit 120 to process, enabling the DSP control unit 120 to make corresponding control decisions based on the actual state and temperature of the electronic lock. Based on the received control commands and the micro-switch status and temperature signals fed back by the detection unit 130, it precisely controls the electronic lock to perform unlocking or locking actions, achieving closed-loop control of the electronic lock. It can also interact with external devices, control the electronic lock's actions according to external commands, and has the ability to remotely control and collaborate.

[0028] Please see Figure 2 , Figure 2 This is a circuit diagram of one embodiment of the electronic lock control circuit provided by the present invention. In some embodiments of the present invention, the electronic lock control circuit 140 includes: The first relay has a first coil and at least two sets of contacts; The second relay has a second coil and contacts; The first transistor has its base connected in series with a first resistor and is connected to the DSP control unit 120 to receive the first control signal. Its collector is connected to the first coil and its emitter is grounded. The second transistor has its base connected in series with a third resistor and is connected to the DSP control unit 120 to receive the second control signal. Its collector is connected to the second coil and its emitter is grounded. The first output terminal is used to connect to the first end of the electronic lock; The second output terminal is used to connect to the second end of the electronic lock; The contact group of the first relay is connected between the third output terminal of the auxiliary source 110, the contact of the second relay, the first output terminal and the second output terminal, and is used to switch the voltage polarity of the first output terminal and the second output terminal according to the first control signal. The contacts of the second relay are connected in series in the power supply circuit and are used to control the on / off state of the power supply circuit according to the second control signal.

[0029] In some embodiments of the present invention, the first relay is a double-pole double-throw relay, having a first common terminal, a first normally open terminal, a first normally closed terminal, a second common terminal, a second normally open terminal, and a second normally closed terminal; The first common terminal is connected to the third output terminal of the auxiliary source 110; the first normally open terminal is connected to the first end of the contact of the second relay; the first normally closed terminal is connected to the second output terminal; the second common terminal is grounded; the second normally open terminal is connected to the second output terminal; the second normally closed terminal is connected to the first end of the contact of the second relay; and the second end of the contact of the second relay is connected to the first output terminal.

[0030] In some embodiments of the present invention, the electronic lock control circuit 140 further includes: The second resistor is connected between the base of the first transistor and ground; The fourth resistor is connected between the base of the second transistor and ground; The first capacitor is connected between the base of the first transistor and ground. The second capacitor is connected between the base of the second transistor and ground.

[0031] In some embodiments of the present invention, the electronic lock control circuit 140 further includes: The anode of the first diode is connected to the third output terminal of the auxiliary source, and the cathode of the first diode is connected to the first relay. The second diode is connected in parallel with the first coil, and the anode of the second diode is connected to the collector of the first transistor, and the cathode of the second diode is connected to the third output terminal of the auxiliary source. The third diode is connected in parallel with the second coil, and the anode of the third diode is connected to the collector of the second transistor, while the cathode of the third diode is connected to the fifth resistor and the second coil. The fifth resistor has one end connected to the third voltage and the other end connected to the second coil.

[0032] In the above embodiment, the first resistor and the second resistor constitute the base bias network of the first transistor. The first resistor is connected in series between the DSP control unit 120 and the base of the first transistor, acting as a current limiter to restrict the current flowing from the DSP control unit 120 to the base, preventing excessive base current from damaging the transistor or the output port of the DSP control unit 120. The second resistor is connected between the base of the first transistor and ground, acting as a pull-down resistor. When the DSP control unit 120 is not outputting a signal or is in a high-impedance state, the second resistor pulls the base potential down to ground, ensuring that the first transistor is in a reliable off state and preventing the transistor from being falsely turned on due to a floating base. The resistance values ​​of the first and second resistors determine the switching speed and saturation depth of the transistor. Typically, the first resistor has a smaller value to ensure sufficient base drive current, while the second resistor has a larger value to balance the pull-down effect and signal transmission efficiency.

[0033] The third and fourth resistors form the base bias network of the second transistor. Their working principle is the same as that of the first and second resistors. They are used to limit the base current and provide pull-down bias, respectively, to ensure that the second transistor can be reliably turned on when the DSP control unit 120 outputs a signal and reliably turned off when there is no signal.

[0034] First capacitor ( Figure 2 C2) is connected between the base of the first transistor and ground, serving as a filter and anti-interference agent. This capacitor, connected in parallel with the second resistor, forms a low-pass filter, which can filter out high-frequency noise coupled into the transmission path from the DSP control unit 120, preventing noise signals from falsely triggering the transistor to conduct. Simultaneously, the first capacitor provides a certain charge storage effect during switching, which can appropriately slow down the rise rate of the base voltage, avoiding electromagnetic interference caused by excessively steep drive signals.

[0035] Second capacitor ( Figure 2 C3 in the circuit is connected between the base of the second transistor and ground. Its function is the same as that of the first capacitor: to filter out high-frequency noise, improve the anti-interference capability of the second transistor drive circuit, and ensure the accuracy and stability of the switching action.

[0036] The first diode is connected between the third output terminal of the auxiliary power source and the first relay. Its anode is connected to the third output terminal of the auxiliary power source, and its cathode is connected to the first relay. This diode serves as polarity protection, preventing reverse voltage from being applied to the relay coil due to circuit wiring errors or abnormal conditions, thus protecting the relay from being damaged by reverse voltage.

[0037] The second diode is connected in parallel with the first coil. Its anode is connected to the collector of the first transistor, and its cathode is connected to the third output terminal of the auxiliary source. This diode is a freewheeling diode. When the first transistor switches from the on state to the off state, the current in the first coil cannot change abruptly, which would generate a reverse induced electromotive force. The second diode provides a freewheeling path for this induced current, allowing it to be circulated and consumed by the diode, thus preventing the induced electromotive force from being superimposed between the collector and emitter of the transistor, which could lead to transistor breakdown and damage.

[0038] The third diode is connected in parallel with the second coil. Its anode is connected to the collector of the second transistor, and its cathode is connected to the third output terminal of the auxiliary source through the fifth resistor. The working principle of this diode is the same as that of the second diode, providing a freewheeling path for the second coil and protecting the second transistor from damage by reverse induced electromotive force at the moment of turn-off.

[0039] The fifth resistor is connected between the third voltage and the coil of the second relay, serving as a current limiter. The coil of the second relay has a fixed DC resistance, and the coil current is determined by this resistance when the third voltage is applied directly. The series connection of the fifth resistor further limits the coil current, adjusting the relay's pull-in force and power consumption, preventing the coil from overheating and being damaged due to excessive current. Simultaneously, the fifth resistor and the coil of the second relay form a first-order RL circuit, which can appropriately slow down the rise rate of the coil current, reducing the inrush current at the moment the relay pulls in.

[0040] Reference Figure 2 The working principle of the electronic lock control circuit shown is as follows: When the DSP control unit receives the locking command from the BMS or charger, the DSP sends a high level of 3.3V to RY1. The relay K1 switches from being on at pins 4 and 6 to being on at pins 4 and 8, and from being on at pins 11 and 13 to being on at pins 9 and 13. After a preset interval, the DSP sends a high level of 3.3V to RY2, the relay K2 is turned on, the voltage between EL+ and EL- of the electronic lock is +12V, and the electronic lock is locked. After the detection circuit detects that the electronic lock is locked, the DSP sends a low level of 0V to RY2, disconnects the relay K2, and prevents the electronic lock from continuously being powered on and overheating. After receiving the unlock command from the BMS or charger, the DSP control unit sends a low level (0V) to RY1. Relay K1 switches from being on at pins 4 and 8 to being on at pins 4 and 6, and from being on at pins 9 and 13 to being on at pins 11 and 13. After a preset interval, the DSP sends a high level (3.3V) to RY2, and relay K2 is activated. The voltage between EL+ and EL- of the electronic lock is -12V, and the electronic lock is unlocked. After the detection circuit detects that the electronic lock is locked, the DSP sends a low level (0V) to RY2, disconnecting relay K2 to prevent the electronic lock from continuously being powered on and overheating, thus providing stronger security and reliability.

[0041] In some embodiments of the present invention, the auxiliary source 110 includes: The rectifier bridge, whose input terminal is connected to the input terminal of the auxiliary source 110, is used to rectify the input AC power into DC power; The flyback converter has its input terminal connected to the output terminal of the rectifier bridge, or directly connected to the DC power input from the auxiliary source 110. The flyback converter includes a transformer, a first switch and a second switch. The first switch and the second switch are connected in series and then connected to the primary winding of the transformer to form a two-tube flyback topology. The output terminals of the flyback converter include a first output voltage terminal, a second output voltage terminal, and a third output voltage terminal, which are used to output the first voltage, the second voltage, and the third voltage, respectively.

[0042] In the above embodiment, the auxiliary source 110 adopts a dual-transistor flyback topology to achieve wide voltage input and multiple outputs. A rectifier bridge is connected to the input terminal of the auxiliary source 110. When the input is AC, the rectifier bridge rectifies the AC into pulsating DC; when the input is DC, the rectifier bridge only serves as a conduction path, and the DC passes directly through. The rectified DC is then fed into the flyback converter.

[0043] The flyback converter is the core of the auxiliary source 110, and its working principle is based on the energy storage and release of a transformer. The first and second switching transistors are connected in series to the primary winding of the transformer, forming a two-transistor flyback structure. When both transistors are turned on simultaneously, the input voltage is applied across the primary winding, storing energy. At this time, the secondary winding is not conducting due to the reverse bias of the diodes. When both transistors are turned off simultaneously, the current in the primary winding cannot change abruptly, generating a reverse induced electromotive force. The diodes in the secondary winding are forward biased, and the stored energy is released to the secondary side. The voltage across the two series-connected transistors when turned off is clamped to the input voltage, rather than the input voltage plus the reflected voltage in a traditional single-transistor flyback converter. Therefore, transistors with lower voltage ratings can be used.

[0044] The transformer secondary side has multiple windings, corresponding to the first, second, and third output voltage terminals, respectively. By adjusting the turns ratio of each winding, different voltage levels can be obtained, namely the first, second, and third voltages. Electrical isolation between the output voltages is achieved through the transformer, improving system safety and anti-interference capabilities.

[0045] The auxiliary power source 110 achieves compatibility with both AC and DC inputs through a circuit topology of a rectifier bridge and a flyback converter. The rectifier bridge allows the device to be connected to either the AC grid or the DC bus, without distinguishing between input types; it's plug-and-play and adaptable to various power supply scenarios in charging stations. It can directly connect to single-phase 220V AC, three-phase 380V AC, or 250V-800V DC.

[0046] The dual-transistor flyback topology offers significant advantages over the traditional single-transistor flyback. The two switches are connected in series to share the voltage stress, and the voltage across each switch is clamped to the input voltage level, rather than the sum of the input and reflected voltages as in a single-transistor flyback. Therefore, lower-voltage switches can be used, reducing device cost and selection complexity. Furthermore, in the dual-transistor flyback structure, when the switches are off, the energy stored in the transformer leakage inductance is fed back to the input side through diodes, rather than being dissipated in the snubber circuit, thus improving power conversion efficiency.

[0047] The multiple windings on the secondary side of the transformer enable the auxiliary power source 110 to simultaneously output three isolated DC voltages, powering the DSP control unit 120, the detection unit 130, and the electronic lock control circuit 140 respectively. Each output voltage is independent and does not interfere with the others, avoiding power coupling issues between different functional modules. The first voltage (e.g., 3.3V) provides a suitable operating voltage for the DSP control unit 120, meeting its low power consumption and high speed requirements; the second voltage (e.g., 5V) powers the detection unit 130, compatible with various sensors and signal conditioning circuits; and the third voltage (e.g., 12V) provides sufficient drive capability for the electronic lock control circuit 140, ensuring reliable relay engagement and powerful electronic lock operation.

[0048] In some embodiments of the present invention, the DSP control unit 120 includes: The microcontroller chip has multiple general-purpose input / output ports and multiple analog-to-digital conversion ports; A CAN transceiver connects to the CAN communication port of a microcontroller chip and is used for differential signal communication with an external charger or battery management system. The microcontroller chip's first general-purpose input / output port is connected to the electronic lock control circuit 140 and is used to output a first control signal; the microcontroller chip's second general-purpose input / output port is connected to the electronic lock control circuit 140 and is used to output a second control signal; the microcontroller chip's first analog-to-digital converter port is connected to the detection unit 130 and is used to receive a microswitch status signal; the microcontroller chip's second analog-to-digital converter port is connected to the detection unit 130 and is used to receive a temperature detection signal.

[0049] In the above embodiment, the DSP control unit 120, with a microcontroller chip at its core, forms a complete control and communication hub in conjunction with a CAN transceiver. The microcontroller chip integrates a central processing unit, memory, and various peripheral interfaces. Its general-purpose input / output ports can be configured to digital output mode to output high-level or low-level control signals; its analog-to-digital converter port can convert externally input analog voltage signals into digital quantities for internal processing.

[0050] The first general-purpose input / output port is configured in digital output mode and is connected to the electronic lock control circuit 140. When the microcontroller chip receives a locking command, this port outputs a first control signal (e.g., high level); when it receives an unlocking command, this port outputs the opposite level (e.g., low level). The second general-purpose input / output port is also configured in digital output mode and is used to output a second control signal to control the on / off state of the electronic lock power supply circuit. The digital signal levels output by these two ports are low (e.g., 3.3V) and cannot directly drive the relay; therefore, they need to be connected to the base of the transistor in the electronic lock control circuit 140 for amplification.

[0051] The first analog-to-digital converter (ADC) port is connected to the detection unit 130 and receives an analog signal representing the state of the microswitch. The microswitch typically forms a voltage divider circuit with pull-up or pull-down resistors; changes in its on / off state cause a voltage jump at this port. The microcontroller chip determines whether the microswitch is closed or open by detecting the voltage value. The second ADC port is also connected to the detection unit 130 and receives an analog signal representing the internal temperature of the charging gun. The resistance of the temperature sensor (such as a thermistor) changes with temperature, which is converted into a changing voltage by a matching circuit. The microcontroller chip acquires this voltage and performs calculations to obtain the actual temperature value.

[0052] The CAN transceiver connects the microcontroller chip's CAN communication port to the external CAN bus. The digital logic level (e.g., 3.3V) output by the microcontroller chip is converted by the CAN transceiver into the differential signals (CAN_H and CAN_L) required by the CAN bus, enabling long-distance, interference-resistant communication with the charger or battery management system. At the same time, the CAN transceiver also converts the differential signals received on the bus into digital logic levels and sends them to the microcontroller chip.

[0053] This DSP control unit 120, through the cooperation of a microcontroller chip and a CAN transceiver, achieves bidirectional communication with the charger or battery management system. The microcontroller chip can receive unlocking and locking commands from the charger or BMS in real time, and report information such as the electronic lock's operating status and temperature faults. This makes the electronic lock control device an integral part of the entire charging system, rather than an isolated end effector, laying the foundation for the implementation of a collaborative control strategy.

[0054] The microcontroller chip's general-purpose input / output port directly outputs the first and second control signals to control the coordinated operation of the two relays in the electronic lock control circuit 140. Since the control signals are generated by software, the control timing can be flexibly adjusted according to actual needs, such as switching polarity before powering on, or cutting off power before resetting polarity, thus achieving precise timing control of the electronic lock and preventing damage or failure due to improper control timing.

[0055] The microcontroller chip's analog-to-digital converter port acquires microswitch status signals and temperature detection signals in real time, converting analog physical quantities into digital quantities for processing. Compared to traditional solutions that can only detect the on / off state of switches, this solution can identify analog anomalies such as poor microswitch contact and temperature sensor drift, providing richer information for fault diagnosis. Simultaneously, the digital processing facilitates software filtering, calibration, and threshold determination, improving the accuracy and reliability of the detection.

[0056] The introduction of the CAN transceiver enables the DSP control unit 120 to access the CAN network of the charging system. The CAN bus has strong anti-interference capabilities and error handling mechanisms, making it suitable for industrial sites with complex electromagnetic environments, such as charging piles. Differential signal transmission effectively suppresses common-mode interference, ensuring the reliability of long-distance communication. When the detection unit 130 detects an abnormality in the electronic lock or temperature, the microcontroller chip can immediately report the fault information via the CAN transceiver, enabling the charger or BMS to respond quickly and cut off the output, eliminating potential safety hazards at their source.

[0057] In some embodiments of the present invention, the detection unit 130 includes: The micro switch detection interface is used to connect the micro switch of the electronic lock and convert the on / off state of the micro switch into an electrical signal to be transmitted to the DSP control unit 120. The temperature detection interface is used to connect to the temperature sensor inside the charging gun and transmit the temperature detection signal to the DSP control unit 120.

[0058] In the above embodiment, the detection unit 130 includes two parts: a microswitch detection interface and a temperature detection interface, which are responsible for collecting the mechanical position status of the electronic lock and the thermal status information of the charging gun, respectively. The microswitch detection interface is used to connect to the microswitch inside the electronic lock. The microswitch is a mechanical limit switch installed at the end of the bolt's movement trajectory. When the electronic lock is locked, the bolt pushes the contact of the microswitch, causing its internal contacts to close; when the electronic lock is unlocked, the bolt leaves the microswitch, and the contacts reset and open. The microswitch detection interface is usually used in conjunction with a pull-up resistor or a pull-down resistor to form a simple circuit. For example, when using a pull-up method, the interface is internally connected to a reference voltage (such as 5V or 3.3V) through a resistor. When the microswitch is open, the interface voltage is pulled up to the reference voltage; when the microswitch is closed, the interface is shorted to ground, and the voltage is pulled down to zero. The voltage change constitutes an electrical signal representing the on / off state of the microswitch, which is directly transmitted to the analog-to-digital conversion port or general-purpose input / output port of the DSP control unit 120.

[0059] The temperature detection interface is used to connect to the temperature sensor installed inside the charging gun. Commonly used temperature sensors include negative temperature coefficient (NTC) thermistors, positive temperature coefficient (PTC) thermistors, or semiconductor temperature sensors. Taking a NTC thermistor as an example, its resistance decreases as the temperature increases. The temperature detection interface is typically connected in series with a fixed resistor to form a voltage divider circuit. A reference voltage is applied across the two ends of the series circuit, and the intermediate node serves as the voltage output point connected to the analog-to-digital converter (ADC) port of the DSP control unit 120. When the temperature changes, the thermistor resistance changes, and the voltage at the voltage divider node changes linearly. The DSP control unit 120 acquires this voltage value and converts it into the corresponding temperature value using a built-in algorithm.

[0060] The detection unit 130 achieves real-time and accurate sensing of the electronic lock's mechanical position through a microswitch detection interface. The microswitch is directly installed on the bolt's movement path, and its on / off state corresponds one-to-one with the actual position of the bolt, eliminating errors and delays from intermediate switching processes. The DSP control unit 120, by reading the level signal from this interface, can accurately determine whether the electronic lock is truly locked or unlocked, avoiding the uncertainty caused by relying solely on control commands to infer the state. When a locking command is issued, if the microswitch is not detected to be closed within a specified time, the DSP control unit 120 can determine it as a locking fault; when an unlocking command is issued, if the microswitch is not detected to be open within a specified time, it can determine it as an unlocking fault.

[0061] Through a temperature detection interface, this device incorporates the internal temperature of the charging gun into its real-time monitoring range. During high-current charging, the charging gun generates heat due to factors such as the contact resistance between the plug and socket, and the cable resistance. If heat dissipation is poor or the contacts age, the temperature may rise sharply, posing a risk of thermal runaway. The temperature detection interface, in conjunction with the built-in temperature sensor, continuously monitors changes in the internal temperature of the charging gun and transmits the temperature data to the DSP control unit 120 in real time. The DSP control unit 120 can be set with multiple temperature thresholds: when the temperature exceeds the warning threshold, a warning message is reported; when the temperature exceeds the danger threshold, a fault is immediately reported and the charger is coordinated to cut off the output, preventing accidents caused by overheating from the outset.

[0062] Both the microswitch detection interface and the temperature detection interface use analog or digital signal transmission methods, directly matching the analog-to-digital conversion port or general-purpose input / output port of the DSP control unit 120. This eliminates the need for complex signal conditioning circuits, simplifying hardware design. The two detection functions are integrated into the same detection unit 130, sharing the same power supply (5V) and the same communication interface (connected to the DSP control unit 120), achieving efficient utilization of detection resources and reducing device size and cost.

[0063] The introduction of two detection interfaces enables this device to sense the external world. The microswitch status reflects the mechanical health of the electronic lock, and the temperature reflects the thermal state of the charging gun. Together, they constitute comprehensive monitoring of the charging gun's operating status. The DSP control unit 120 reports these two types of detection data to the charger or BMS via CAN communication, allowing the upper-level control system to fully grasp the real-time status of the charging gun and providing data support for intelligent functions such as dynamic scheduling, fault warning, and maintenance reminders during the charging process. When abnormal detection data is detected, a multi-level protection mechanism can be triggered, achieving comprehensive safety protection from early warning to shutdown, and from local to remote operation.

[0064] According to a second aspect of the present invention, a charging control system is also provided, including a charger, a battery management system and a charging gun, and further including a charging gun electronic lock control device 100 of any of the above possible implementations.

[0065] According to a third aspect of the present invention, a charging gun electronic lock control method is also provided, applied to the charging gun electronic lock control device 100 in any of the above possible implementations, comprising: The on / off state of the micro switch of the charging gun electronic lock is detected in real time and converted into an electrical signal; The DSP control unit 120 determines whether the electronic lock is in an unlocked or locked state based on the electrical signal. The DSP control unit 120 reports the electronic lock's operating status to the charger or battery management system via CAN communication; The DSP control unit 120 receives CAN communication commands from the charger or battery management system to control the unlocking or locking of the electronic lock.

[0066] In the above embodiments, closed-loop sensing of the electronic lock's mechanical position is achieved by real-time detection of the microswitch's state. Traditional open-loop control methods only send commands without checking the execution results. When the electronic lock fails to actually reach its position due to mechanical jamming, power supply abnormalities, or other reasons, the control system is unaware of this and may mistakenly allow charging as normal, creating a safety hazard. This application uses the real-time state of the microswitch as the feedback loop for control, ensuring that every control action is based on evidence and its results are verifiable.

[0067] The DSP control unit 120's function of determining the electronic lock's status endows the control system with autonomous sensing capabilities. The software's de-jitter processing of the acquired signals eliminates interference from mechanical vibration and contact bounce, making status judgments more accurate and reliable. When microswitches experience poor contact due to aging, contamination, or other reasons, the DSP control unit 120 can detect potential faults early through abnormal fluctuations in the level signal, rather than waiting until complete failure to reveal the problem. Continuous status monitoring also creates a timeline of the electronic lock's actions, providing a data foundation for fault analysis and lifespan prediction.

[0068] The mechanism of reporting operating status via CAN communication transforms the electronic lock control device from an isolated end-user device into an intelligent node within the charging system network. The charger or battery management system can obtain the accurate status of the electronic lock in real time and incorporate it into the comprehensive judgment of charging enable conditions. For example, the charger can be set to only allow output after receiving a locked-in status, fundamentally preventing hot-plugging. If the electronic lock fails to lock properly due to an abnormality, the charger can refuse to start charging and prompt the user to check, intercepting potential safety hazards before charging begins.

[0069] The process of receiving CAN commands for unlocking or locking enables remote and precise control of the electronic lock. The charger or battery management system can automatically issue commands based on the charging progress: a locking command during the charging preparation phase and an unlocking command upon completion of charging. In public charging scenarios, the operating platform can also use the charger as a relay to remotely lock the lock to prevent customers from skipping out on their payments, or remotely force unlock it in emergencies to ensure safety. The preset timing logic during control (switching polarity before powering on, and promptly cutting off power upon completion) ensures reliable operation of the electronic lock while preventing coil overheating and damage from prolonged power supply, thus extending the lock's lifespan.

[0070] In other words, this method connects the four stages of detection, judgment, reporting, and execution in a closed loop, forming a complete control cycle. Each control action is initiated based on the state judgment of the previous moment, each state change is reported via the communication network, and each command execution is verified by feedback. This closed-loop control mechanism makes the electronic lock's working state fully controllable, fully visible, and fully traceable, significantly improving the safety and reliability of the charging process.

[0071] It should be noted that, for the sake of simplicity, the foregoing method embodiments are all described as a series of actions. However, those skilled in the art should understand that this application is not limited to the described order of actions, as some steps may be performed in other orders or simultaneously according to this application. Furthermore, those skilled in the art should also understand that the embodiments described in the specification are preferred embodiments, and the actions and modules involved are not necessarily essential to this application.

[0072] In the above embodiments, the descriptions of each embodiment have different focuses. For parts not described in detail in a certain embodiment, please refer to the relevant descriptions in other embodiments.

[0073] In the several embodiments provided in this application, it should be understood that the disclosed apparatus can be implemented in other ways. For example, the apparatus embodiments described above are merely illustrative; for instance, the division of units is only a logical functional division, and in actual implementation, there may be other division methods. For example, multiple units or components may be combined or integrated into another system, or some features may be ignored or not executed. Furthermore, the coupling or direct coupling or communication connection shown or discussed may be through some service interface; the indirect coupling or communication connection between devices or units may be electrical or other forms.

[0074] The units described as separate components may or may not be physically separate. The components shown as units may or may not be physical units; that is, they may be located in one place or distributed across multiple network units. Some or all of the units can be selected to achieve the purpose of this embodiment according to actual needs.

[0075] Furthermore, the functional units in the various embodiments of this application can be integrated into one processing unit, or each unit can exist physically separately, or two or more units can be integrated into one unit. The integrated unit can be implemented in hardware or as a software functional unit.

[0076] The foregoing description is merely an exemplary embodiment of this disclosure and should not be construed as limiting the scope of this disclosure. Any equivalent changes and modifications made in accordance with the teachings of this disclosure shall still fall within the scope of this disclosure. Those skilled in the art will readily conceive of embodiments of this disclosure upon considering the specification and practicing the disclosure herein. This application is intended to cover any variations, uses, or adaptations of this disclosure that follow the general principles of this disclosure and include common knowledge or customary techniques in the art not described herein. The specification and embodiments are to be considered exemplary only, and the scope and spirit of this disclosure are defined by the claims.

[0077] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0078] Those skilled in the art will readily understand that the above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A charging gun electronic lock control device, characterized in that, include: Auxiliary power source, used to convert input electrical energy into multiple output voltages; The DSP control unit is connected to the first output terminal of the auxiliary source and is used to receive control commands and output control signals. The detection unit is connected to the second output terminal of the auxiliary source and the DSP control unit, and is used to detect the micro-switch status of the charging gun electronic lock and the internal temperature of the charging gun, and transmit the detection signal to the DSP control unit. The electronic lock control circuit is connected to the second output terminal of the auxiliary source and the DSP control unit, and receives the control signal sent by the DSP control unit to control the electronic lock to perform unlocking or locking actions.

2. The charging gun electronic lock control device according to claim 1, characterized in that, The electronic lock control circuit includes: The first relay has a first coil and at least two sets of contacts; The second relay has a second coil and contacts; The first transistor has its base connected in series with a first resistor and is connected to the DSP control unit to receive a first control signal. Its collector is connected to the first coil and its emitter is grounded. The second transistor has its base connected in series with a third resistor and is connected to the DSP control unit to receive the second control signal. Its collector is connected to the second coil and its emitter is grounded. The first output terminal is used to connect to the first end of the electronic lock; The second output terminal is used to connect to the second end of the electronic lock; The contact group of the first relay is connected between the third output terminal of the auxiliary source, the contact of the second relay, the first output terminal and the second output terminal, and is used to switch the voltage polarity of the first output terminal and the second output terminal according to the first control signal. The contacts of the second relay are connected in series in the power supply circuit and are used to control the on / off state of the power supply circuit according to the second control signal.

3. The charging gun electronic lock control device according to claim 2, characterized in that, The first relay is a double-pole double-throw relay, having a first common terminal, a first normally open terminal, a first normally closed terminal, a second common terminal, a second normally open terminal, and a second normally closed terminal; The first common terminal is connected to the third output terminal of the auxiliary source; the first normally open terminal is connected to the first end of the contact of the second relay; the first normally closed terminal is connected to the second output terminal; the second common terminal is grounded; the second normally open terminal is connected to the second output terminal; the second normally closed terminal is connected to the first end of the contact of the second relay; and the second end of the contact of the second relay is connected to the first output terminal.

4. The charging gun electronic lock control device according to claim 2, characterized in that, The electronic lock control circuit also includes: The second resistor is connected between the base of the first transistor and ground; The fourth resistor is connected between the base of the second transistor and ground; The first capacitor is connected between the base of the first transistor and ground; The second capacitor is connected between the base of the second transistor and ground.

5. The charging gun electronic lock control device according to claim 2, characterized in that, The electronic lock control circuit also includes: A first diode, the anode of which is connected to the third output terminal of the auxiliary source, and the cathode of which is connected to the first relay; The second diode is connected in parallel with the first coil, and the anode of the second diode is connected to the collector of the first transistor, and the cathode of the second diode is connected to the third output terminal of the auxiliary source. The third diode is connected in parallel with the second coil, and the anode of the third diode is connected to the collector of the second transistor, while the cathode of the third diode is connected to the fifth resistor and the second coil. The fifth resistor has one end connected to the third voltage and the other end connected to the second coil.

6. The charging gun electronic lock control device according to claim 1, characterized in that, The auxiliary source includes: A rectifier bridge, whose input terminal is connected to the input terminal of the auxiliary source, is used to rectify the input AC power into DC power; The flyback converter has its input terminal connected to the output terminal of the rectifier bridge, or directly connected to the DC power input from the auxiliary source. The flyback converter includes a transformer, a first switch and a second switch. The first switch and the second switch are connected in series and then connected to the primary winding of the transformer to form a two-tube flyback topology. The flyback converter has a first output voltage terminal, a second output voltage terminal, and a third output voltage terminal, which are used to output the first voltage, the second voltage, and the third voltage, respectively.

7. The charging gun electronic lock control device according to claim 1, characterized in that, The DSP control unit includes: The microcontroller chip has multiple general-purpose input / output ports and multiple analog-to-digital conversion ports; A CAN transceiver, connected to the CAN communication port of the microcontroller chip, is used for differential signal communication with an external charger or battery management system. The microcontroller chip has a first general-purpose input / output port connected to the electronic lock control circuit for outputting a first control signal; a second general-purpose input / output port connected to the electronic lock control circuit for outputting a second control signal; a first analog-to-digital converter port connected to the detection unit for receiving a microswitch status signal; and a second analog-to-digital converter port connected to the detection unit for receiving a temperature detection signal.

8. The charging gun electronic lock control device according to claim 1, characterized in that, The detection unit includes: The micro switch detection interface is used to connect the micro switch of the electronic lock and convert the on / off state of the micro switch into an electrical signal and transmit it to the DSP control unit. The temperature detection interface is used to connect to the temperature sensor inside the charging gun and transmit the temperature detection signal to the DSP control unit.

9. A charging control system, comprising a charger, a battery management system, and a charging gun, characterized in that, It also includes the electronic lock control device for the charging gun according to any one of claims 1 to 8.

10. A method for controlling an electronic lock on a charging gun, applied to the electronic lock control device for a charging gun according to any one of claims 1 to 8, characterized in that, include: The on / off state of the micro switch of the charging gun electronic lock is detected in real time and converted into an electrical signal; The DSP control unit determines whether the electronic lock is in an unlocked or locked state based on the electrical signal. The DSP control unit reports the electronic lock's working status to the charger or battery management system via CAN communication. The DSP control unit receives CAN communication commands from the charger or battery management system to unlock or lock the electronic lock.

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