Switching power supply module and control method for industrial battery charging

Abstract

The application relates to a switching power module and a control method for industrial battery charging, which comprises an integrated power module, an output fuse connected to the output end of the integrated power module, an output relay connected to the output end of the output fuse, an auxiliary power supply connected to the integrated power module, an external BMS power supply auxiliary source connected to the auxiliary power supply, and a BMS communication board connected to the external BMS power supply auxiliary source, the integrated power module and the output relay respectively; the application can reduce external wiring, improve system reliability, reduce cost, and enhance the safety protection function through integrated design.

Description

Technical Field

[0001] The present invention relates to the technical field of switching power supplies, and particularly relates to a switching power supply module and a control method for industrial battery charging. Background Art

[0002] Currently, industrial battery charging systems generally adopt a decentralized design, where components such as power modules, output relays, output fuses, auxiliary power supplies, external BMS power supply auxiliary sources, and BMS communication boards are each independently arranged. The power module is separated from the BMS communication board and needs to be connected through external interfaces and cables, resulting in communication delays and signal interference; the output fuse and output relay, as external additional circuits, increase wiring nodes and fault points; the auxiliary power supply and the external BMS power supply auxiliary source are separated, occupying additional space and having complex wiring. This decentralized architecture leads to a large system volume, high manufacturing costs, reduced reliability, and cumbersome installation and maintenance operations. The industrial battery charging environment has strict requirements for safety, efficiency, and intelligent levels. Existing solutions are difficult to integrate comprehensive protection and control functions in a compact space and cannot achieve rapid linkage response between power output and battery management. Summary of the Invention

[0003] The main objective of the present invention is to provide a switching power supply module and a control method for industrial battery charging, which can reduce external wiring through integrated design, improve system reliability, reduce costs, and enhance safety protection functions at the same time.

[0004] To achieve the above objective, the present invention provides a switching power supply module for industrial battery charging, including: An integrated power module, an output fuse connected to the output end of the integrated power module, an output relay connected to the output end of the output fuse, an auxiliary power supply connected to the integrated power module, an external BMS power supply auxiliary source connected to the auxiliary power supply, and a BMS communication board respectively connected to the external BMS power supply auxiliary source, the integrated power module, and the output relay; The integrated power module is used to convert an AC power supply into a DC charging output; The output fuse is used to blow and cut off the charging circuit when the output current exceeds a threshold; The output relay is used to receive the on-off control signal sent by the BMS communication board and respond to the on-off control signal to control the on-off of the charging circuit; The auxiliary power supply is used to provide working voltages for each control chip inside the integrated power module and the external BMS power supply auxiliary source; The external BMS power supply auxiliary source is used to provide a working power supply for an external BMS; The BMS communication board is used to communicate with an external BMS, and to send output adjustment commands to the integrated power module and on / off control signals to the output relay based on the communication results.

[0005] Furthermore, the integrated power module includes: The input terminal of the EMI filter circuit (S1) is used to connect to the AC power supply to filter out high-frequency noise and electromagnetic interference in the input AC power supply; The input terminal of the rectifier filter circuit (S2) is connected to the output terminal of the EMI filter circuit (S1) to rectify the filtered AC power into DC power and output DC bus voltage. The input terminals of the interleaved PFC circuits (S3, S4, S10 and S11) are connected to the output terminal of the rectifier filter circuit (S2) to boost the DC bus voltage to a preset 400V DC voltage and achieve power factor correction. The input terminals of the phase-shifted full-bridge circuit (S14, S15 and S16) are connected to the output terminals of the interleaved PFC circuit (S3, S4, S10 and S11) to convert 400V DC voltage into high-frequency AC voltage. The input terminal of the full-wave rectifier circuit (S12) is connected to the output terminal of the phase-shifted full-bridge circuit (S14, S15 and S16) to rectify the high-frequency AC voltage into a DC charging voltage. The input terminal of the output filter circuit (S13) is connected to the output terminal of the full-wave rectifier circuit (S12) to perform inductor-capacitor filtering on the DC charging voltage and output a stable charging voltage to the output fuse. The main control chip (S22) is connected to the control terminals of the interleaved PFC circuits (S3, S4, S10 and S11) and the phase-shifted full-bridge circuits (S14, S15 and S16) respectively, and is used to receive the output adjustment signal sent by the BMS communication board, and control the working state of the interleaved PFC circuits (S3, S4, S10 and S11) and the phase-shifted full-bridge circuits (S14, S15 and S16) according to the signal.

[0006] Furthermore, the output insurance includes: Flyback power supply control chip (S26): includes main control IC_U4, used to output PWM signal; The input terminal of the drive and rectification filter circuit (S24) is connected to the output terminal of the flyback power supply control chip (S26) and is used to drive the power transistor and transformer according to the PWM signal to output multiple DC voltages. The input terminal of the voltage negative feedback control circuit (S27) is connected to the output terminal of the drive and rectification filter circuit (S24), and the output terminal of the voltage negative feedback control circuit (S27) is connected to the feedback input terminal of the flyback power supply control chip (S26) to sample the output voltage and feed it back to the flyback power supply control chip (S26) to stabilize the output voltage.

[0007] Furthermore, the external BMS power supply auxiliary power source includes: The input terminals of the flyback power supply circuit (S24, S25, S26 and S27) are connected to the DC bus inside the integrated power module to output 12V or 5V auxiliary power. Relay control circuit (S30): Its input terminal is connected to the output terminal of the flyback power supply circuit (S24, S25, S26 and S27), and its control terminal is connected to the first control signal output terminal of the BMS communication board, used to control the on and off of the relay according to the instructions of the BMS communication board. External connector (S32): Its input end is connected to the output end of the relay control circuit (S30), and its output end is used to connect to the power input end of the external BMS to provide working power to the external BMS.

[0008] Furthermore, the BMS communication board includes: Main control circuit (S43): includes main control IC_U32, used to process communication data with external BMS and generate output adjustment signals and on / off control signals; Communication circuit (S28): Its input terminal is connected to the communication terminal of the main control circuit (S43), and its output terminal is used to connect to the CAN interface of the external BMS to realize bidirectional communication with the external BMS.

[0009] The present invention also provides a switching power supply control method for industrial battery charging, applied to the switching power supply module for industrial battery charging described in any one of the above claims, comprising: When connected to an AC power source, the integrated power module converts the AC power into a DC charging output. At the same time, the auxiliary power source draws power from the integrated power module to provide operating voltage for the various control chips inside the integrated power module and the external BMS power supply auxiliary source. After the external BMS power supply is powered on, it provides working power to the external BMS. The BMS communication board communicates with the external BMS to obtain battery status information fed back by the external BMS. The BMS communication board sends an output adjustment command to the integrated power module based on the acquired battery status information. The integrated power module adjusts the voltage and / or current of its DC charging output in response to the output adjustment command. The BMS communication board sends an on / off control signal to the output relay based on the acquired battery status information, and the output relay responds to the on / off control signal to control the on / off of the charging circuit.

[0010] Furthermore, when the battery status information obtained by the BMS communication board indicates that at least one of the battery voltage, current, or temperature exceeds a preset threshold, the BMS communication board sends an on / off control signal to the output relay to disconnect the charging circuit, and the output relay responds to the on / off control signal to disconnect the charging circuit.

[0011] Furthermore, the integrated power module adjusts the voltage and / or current of its DC charging output in response to the output regulation command, including: The integrated power module samples its own output DC charging voltage and current in real time, compares the sampled values ​​with the set values ​​carried in the output adjustment command, and adjusts the PWM duty cycle of its internal switching transistors according to the comparison results, so that the output DC charging voltage and / or current approaches the set values.

[0012] Furthermore, when the BMS communication board sends an on / off control signal to the output relay, it also sends a power supply control signal to the external BMS power supply auxiliary source to control the external BMS power supply auxiliary source to supply power to the external BMS or stop supplying power.

[0013] Furthermore, before the BMS communication board communicates with an external BMS, it also includes: The connection status signal between the charging gun and the battery is obtained through the physical connection detection interface of the charging gun, and the voltage and temperature of the battery are obtained through the local battery detection circuit. The BMS communication board initiates communication with the external BMS only when the connection status signal indicates that the charging gun and the battery are physically connected, and the voltage and temperature of the battery are within the preset normal operating range.

[0014] The present invention provides a switching power supply module and control method for industrial battery charging, which has the following beneficial effects: By highly integrating the integrated power module, output fuse, output relay, auxiliary power supply, external BMS power supply auxiliary power source, and BMS communication board into a single module, and limiting the BMS communication board to directly connect to the integrated power module and output relay respectively, the communication delay and electromagnetic interference problems caused by external interfaces and cables are solved, and the communication path is shortened. By integrating the output fuse and output relay at the output end and directly controlling them through the BMS communication board, the defects of external additional circuits that increase wiring nodes and fault points are overcome, reducing the failure rate and improving reliability. By unifying the auxiliary power supply and the external BMS power supply auxiliary power source, the space occupation and wiring complexity problems caused by separate settings are eliminated, reducing the size, simplifying wiring, and lowering costs. By integrating all functional components, the cumbersome installation and maintenance caused by distributed design are avoided, achieving a compact structure that facilitates deployment and maintenance. By sending output adjustment commands to the integrated power module and on / off control signals to the output relay simultaneously through the BMS communication board, coordinated control of power output and circuit on / off is achieved. It can quickly respond according to battery status, meeting the safety and intelligence requirements of industrial charging. Attached Figure Description

[0015] To more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the description of the embodiments of the present invention will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0016] Figure 1 This is a general structural diagram of a switching power supply module for industrial battery charging according to an embodiment of the present invention; Figure 2 This is one of the circuit diagrams of an integrated power module in one embodiment of the present invention; Figure 3 This is one of the circuit diagrams of an integrated power module in one embodiment of the present invention; Figure 4 This is one of the circuit diagrams of an integrated power module in one embodiment of the present invention; Figure 5 This is one of the circuit diagrams of the auxiliary power supply in one embodiment of the present invention; Figure 6 This is one of the circuit diagrams of the auxiliary power supply in one embodiment of the present invention; Figure 7 This is one of the circuit diagrams of the auxiliary power supply in one embodiment of the present invention; Figure 8 This is one of the circuit diagrams of an auxiliary power source for external BMS in one embodiment of the present invention; Figure 9 This is one of the circuit diagrams of the BMS communication board in one embodiment of the present invention; Figure 10 This is one of the circuit diagrams of the BMS communication board in one embodiment of the present invention; Figure 11 This is a flowchart of a switching power supply control method for industrial battery charging according to an embodiment of the present invention.

[0017] The realization of the objective, functional features and advantages of the present invention will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0018] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0019] It should be understood that, when used in this specification and the appended claims, the term "comprising" indicates the presence of the described features, integrals, steps, operations, elements, and / or components, but does not exclude the presence or addition of one or more other features, integrals, steps, operations, elements, components, and / or collections thereof. It should also be understood that, as used in this specification and the appended claims, the term "and / or" refers to any combination of one or more of the associated listed items and all possible combinations, and includes such combinations.

[0020] Furthermore, in the description of this invention and the appended claims, the terms "first," "second," "third," etc., are used only to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0021] References to "one embodiment" or "some embodiments" as described in this specification mean that one or more embodiments of the invention include a specific feature, structure, or characteristic described in connection with that embodiment. Therefore, the phrases "in one embodiment," "in some embodiments," "in other embodiments," "in still other embodiments," etc., appearing in different parts of this specification do not necessarily refer to the same embodiment, but rather mean "one or more, but not all, embodiments," unless otherwise specifically emphasized. The terms "comprising," "including," "having," and variations thereof mean "including but not limited to," unless otherwise specifically emphasized.

[0022] Reference Figure 1-7 As shown, the present invention provides a switching power supply module for industrial battery charging, comprising: An integrated power module, an output fuse connected to the output terminal of the integrated power module, an output relay connected to the output terminal of the output fuse, an auxiliary power supply connected to the integrated power module, an external BMS power supply auxiliary power source connected to the auxiliary power supply, and a BMS communication board connected to the external BMS power supply auxiliary power source, the integrated power module, and the output relay respectively. The integrated power module is used to convert AC power into DC charging output; The output fuse is used to blow when the output current exceeds the threshold, thus cutting off the charging circuit. The output relay is used to receive the on / off control signal sent by the BMS communication board, and respond to the on / off control signal to control the on / off of the charging circuit. The auxiliary power supply is used to provide operating voltage for the control chips inside the integrated power module and the external BMS power supply auxiliary power source; The external BMS power supply auxiliary power source is used to provide working power to the external BMS; The BMS communication board is used to communicate with an external BMS, and to send output adjustment commands to the integrated power module and on / off control signals to the output relay based on the communication results.

[0023] Based on the above circuit structure, the complete circuit structure is as follows: An AC power input is connected to the input terminal of the integrated power module. The integrated power module internally includes: an EMI filter circuit S1, a rectifier filter circuit S2, interleaved PFC circuits S3, S4, S10 and S11, phase-shifted full-bridge circuits S14, S15 and S16, a full-wave rectifier circuit S12, an output filter circuit S13, and a main control chip S22.

[0024] The input terminal of the EMI filter circuit S1 is connected to an AC power supply, and the output terminal is connected to the rectifier filter circuit S2. The output terminal of the rectifier filter circuit S2 is connected to the interleaved PFC circuits S3, S4, S10, and S11. The output terminal of the interleaved PFC circuit is connected to the phase-shifted full-bridge circuits S14, S15, and S16. The output terminal of the phase-shifted full-bridge circuit is connected to the full-wave rectifier circuit S12. The output terminal of the full-wave rectifier circuit is connected to the output filter circuit S13. The output terminal of the output filter circuit S13 is the output terminal of the integrated power module, and is connected to one end of the output fuse F3. The other end of the output fuse F3 is connected to the input terminals of the output relays K2, K3, and K4. The output terminals of the output relays are used to connect to an external battery.

[0025] The auxiliary power supply includes a flyback power supply control chip S26, a drive and rectification filter circuit S24, and a voltage negative feedback control circuit S27. The flyback power supply control chip S26 outputs a PWM signal to the drive and rectification filter circuit S24, and the drive and rectification filter circuit S24 outputs multiple DC voltages, one of which is fed back to the feedback input terminal of the flyback power supply control chip S26 via the voltage negative feedback control circuit S27 to stabilize the output voltage. The output terminal of the auxiliary power supply is connected to the power supply terminals of each control chip inside the integrated power module and the input terminal of the external BMS auxiliary power supply.

[0026] The external BMS power supply auxiliary source includes flyback power supply circuits S24, S25, S26, and S27, a relay control circuit S30, and an external connector CN5. The input terminals of the flyback power supply circuits S24, S25, S26, and S27 are connected to the DC bus inside the integrated power module, and their output terminals are connected to the input terminal of the relay control circuit S30. The control terminal of the relay control circuit S30 is connected to the first control signal output terminal of the BMS communication board, and its output terminal is connected to the external connector CN5. The external connector CN5 is used to connect to the power input terminal of the external BMS to provide operating power to the external BMS.

[0027] The BMS communication board includes a main control circuit S43 and a CAN communication circuit S28. The communication terminal of the main control circuit S43 is connected to the CAN communication circuit S28, which is used to connect to the CAN interface of an external BMS to achieve bidirectional communication. The main control circuit S43 is also provided with a second control signal output terminal and a third control signal output terminal. The second control signal output terminal is connected to the control command receiving terminal of the main control chip S22 in the integrated power module and is used to send output adjustment commands. The third control signal output terminal is connected to the control coil terminal of the output relay and is used to send on / off control signals.

[0028] When the switching power supply module is working, AC power is converted into DC charging output by the integrated power module, and the external battery is charged through the output fuse and output relay. The auxiliary power supply draws power from the integrated power module to provide operating voltage for itself and the external BMS power supply auxiliary power source. After the external BMS power supply auxiliary power source supplies power to the external BMS, the BMS communication board establishes CAN communication with the external BMS to obtain status information such as battery voltage, current, and temperature. According to the obtained status information, the BMS communication board sends an output adjustment command to the integrated power module. The main control chip S22 responds to the command to adjust the working state of the interleaved PFC circuit and the phase-shifted full-bridge circuit, thereby adjusting the voltage and / or current of the DC charging output. At the same time, the BMS communication board sends an on / off control signal to the output relay according to the status information. The output relay responds to the signal to engage or disengage to control the on / off of the charging circuit, realizing safe and intelligent charging of the battery.

[0029] like Figure 1-7 As shown, in one embodiment, the integrated power module includes: The input terminal of the EMI filter circuit S1 is used to connect to an AC power source to filter out high-frequency noise and electromagnetic interference in the input AC power source. Specifically, the EMI filter circuit S1 includes an AC input terminal, a fuse, a varistor, a surge protector, and a two-stage EMI filter inductor-capacitor network. The input terminal of the EMI filter circuit S1 is connected to an AC power supply, and its output terminal is connected to the input terminal of the rectifier filter circuit S2; it is used to filter out high-frequency noise and electromagnetic interference in the input AC power supply.

[0030] The input terminal of the rectifier filter circuit S2 is connected to the output terminal of the EMI filter circuit S1, and is used to rectify the filtered AC power into DC power and output DC bus voltage. Specifically, the rectifier-filter circuit S2 includes rectifier bridges BD2 and BD3, and a large-capacity electrolytic capacitor. The input terminal of the rectifier-filter circuit S2 is connected to the output terminal of the EMI filter circuit S1, and its output terminal is connected to the input terminal of the interleaved PFC circuit; it is used to rectify the filtered AC power into DC power and output a smooth DC bus voltage.

[0031] The input terminals of the interleaved PFC circuits S3, S4, S10 and S11 are connected to the output terminal of the rectifier filter circuit S2, which is used to boost the DC bus voltage to a preset 400V DC voltage and achieve power factor correction. Specifically, the interleaved PFC circuit consists of a drive and switching circuit S3, a power supply chip and peripheral circuit S4, a power supply chip U7 control and protection circuit S10, and an RC filter circuit S11. Among these: Drive and switching circuit S3: includes switching transistors Q3 and Q4 and their driving resistors.

[0032] S4: power chip and peripheral circuitry: includes power chip U7 and peripheral resistors and capacitors.

[0033] Power chip U7 control and protection circuit S10: includes overvoltage and overcurrent protection circuits for U7.

[0034] The RC filter circuit S11 includes an RC filter network used to filter the PD signal, PFC_OFF signal, and interleaved PFC current sampling signals PFC-CS1 and PFC-CS2 of U7. The input terminal of the interleaved PFC circuit is connected to the output terminal of the rectifier filter circuit S2, and its output terminal is connected to the input terminal of the phase-shifted full-bridge circuit; it is used to boost the DC bus voltage to a preset 400V DC voltage and achieve power factor correction.

[0035] The input terminals of the phase-shifted full-bridge circuits S14, S15 and S16 are connected to the output terminals of the interleaved PFC circuits S3, S4, S10 and S11, and are used to convert 400V DC voltage into high-frequency AC voltage. Specifically, the phase-shifted full-bridge circuit consists of an isolation drive circuit S14, a phase-shifted full-bridge power transistor drive and resonant circuit S15, a phase-shifted full-bridge control chip, and peripheral circuits S16. Among these: Isolation drive circuit S14: includes isolation transformers T3 and T4 and drive chips U16 and U17.

[0036] Phase-shifted full-bridge power transistor drive and resonant circuit S15: includes power switching transistors Q15, Q16, Q19, Q20 and resonant inductor and capacitor.

[0037] Phase-shifted full-bridge control chip and peripheral circuit S16: includes control chip U18 and its peripheral resistors and capacitors.

[0038] The input terminal of the phase-shifted full-bridge circuit is connected to the output terminal of the interleaved PFC circuit, and its output terminal is connected to the input terminal of the full-wave rectifier circuit S12; it is used to convert 400V DC voltage into high-frequency AC voltage.

[0039] The input terminal of the full-wave rectifier circuit S12 is connected to the output terminals of the phase-shifted full-bridge circuits S14, S15 and S16, and is used to rectify the high-frequency AC voltage into a DC charging voltage. Specifically, the full-wave rectifier circuit S12 includes a full-wave rectifier bridge composed of transformers T2 and T5 and rectifier diodes. The input terminal of the full-wave rectifier circuit S12 is connected to the output terminal of the phase-shifted full-bridge circuit, and its output terminal is connected to the input terminal of the output filter circuit S13; it is used to rectify high-frequency AC voltage into DC charging voltage.

[0040] The input terminal of the output filter circuit S13 is connected to the output terminal of the full-wave rectifier circuit S12, and is used to perform inductor-capacitor filtering on the DC charging voltage to output a stable charging voltage to the output fuse. Specifically, the output filter circuit S13 includes an output inductor L, an output capacitor EC, and a relay control circuit including relays K2, K3, and K4, and a drive circuit. The input terminal of the output filter circuit S13 is connected to the output terminal of the full-wave rectifier circuit S12, and its output terminal is connected to one end of the output fuse F3; it is used to filter the DC charging voltage using an inductor and capacitor to output a stable charging voltage to the output fuse.

[0041] The main control chip S22 is connected to the control terminals of the interleaved PFC circuits S3, S4, S10 and S11 and the control terminals of the phase-shifted full-bridge circuits S14, S15 and S16, respectively. It is used to receive the output adjustment signal sent by the BMS communication board and control the working state of the interleaved PFC circuits S3, S4, S10 and S11 and the phase-shifted full-bridge circuits S14, S15 and S16 according to the signal.

[0042] Specifically, the main control chip S22 includes a main control chip U22 and its peripheral circuits, including a crystal oscillator, a reset circuit, and an ADC sampling interface. The main control chip S22 is connected to the control terminal of the power supply chip U7 in the interleaved PFC circuit via S10 and the control terminal of the control chip U18 in the phase-shifted full-bridge circuit. Simultaneously, its communication terminal is connected to the BMS communication board via an isolation communication circuit S44. It receives output adjustment signals sent by the BMS communication board and controls the operating state of the interleaved PFC circuit and the phase-shifted full-bridge circuit according to these signals, thereby adjusting the output voltage and current.

[0043] Specifically, it also includes an AC input signal and an optocoupler S5. The input terminal of the AC input signal and optocoupler S5 is connected to the input detection signal and the output of the hysteresis comparator S8 (input voltage abnormality signal), and the output terminal is connected to the main control chip S22. When the input voltage is too high or too low, the detection signal and the hysteresis comparator S8 output a high level through the comparator. After Q13 is turned on, the signal and the optocoupler S5 isolate and transmit the abnormal signal to the main control chip S22.

[0044] The control signal and the input terminal of optocoupler S6 are connected to the power-on signal output terminal of the main control chip S22, and the output terminal is connected to the control and protection circuit S10 of the power supply chip U7. The main control chip S22 controls the power supply chip U7 to start or stop through the optocoupler isolation of the control signal and optocoupler S6.

[0045] The input of the input detection signal and the input of the hysteresis comparator S8 are connected to the AC input voltage divider signal, and the output is connected to the AC input signal and the optocoupler S5. Internally, it contains an operational amplifier U10 and a hysteresis comparator circuit, which compares the input voltage with a reference to generate overvoltage / undervoltage logic signals.

[0046] The AC input signal and high voltage signal sampling S9 includes a resistor voltage divider network (R42-R47, R48-R53 sample the input voltage; R53-R63, R69-R74 sample the 400V bus voltage). The output terminal is connected to the power supply chip U7 to provide feedback on the input voltage and PFC output voltage, enabling the power supply chip U7 to achieve closed-loop control.

[0047] The input of the analog-to-digital converter circuit S19, which samples output voltage, current, battery voltage, and temperature, is connected to the filter circuit S13 (output voltage V_OUT, battery voltage BATT+), S20 (current sampling VIO), and thermistors RT1 / RT2 (temperature). The output is connected to the ADC pins (VOLT_AD, CUR_AD, TEM_AD, etc.) of the main control chip S22. This converts the analog sampled signals into digital signals for processing by the main control chip S22.

[0048] This embodiment highly integrates the integrated power module, output fuse, output relay, auxiliary power supply, external BMS power supply, and BMS communication board into a single module. By limiting the BMS communication board to direct connection to the integrated power module and output relay, it avoids distributed external wiring, reduces system size, lowers manufacturing costs, and simplifies installation and maintenance. By connecting the output fuse and output relay in series at the output terminal of the integrated power module and directly controlling them via the BMS communication board, it overcomes the wiring nodes and fault points of external circuits, reducing the failure rate and improving the safety and reliability of the charging circuit. Simultaneously communicating with the external BMS and sending output adjustment commands to the integrated power module and on / off control signals to the output relay via the BMS communication board, it can coordinately adjust charging parameters and circuit on / off in real time based on battery status, shortening the communication path, reducing signal delay, and meeting the requirements for intelligent and rapid linkage.

[0049] like Figure 1-7 As shown, in one embodiment, the output insurance includes: Flyback power supply control chip S26: includes main control IC_U4, used to output PWM signal; Specifically, the flyback power supply control chip S26 includes the main control IC_U4 and its peripheral circuits such as start-up resistors R27 and R31, and filter capacitor C16. Its PWM output terminal is connected to the control electrode of power transistor Q1 in the drive and rectifier filter circuit S24, and is used to output PWM signals to control the switching action of the power transistor.

[0050] The input terminal of the drive and rectification filter circuit S24 is connected to the output terminal of the flyback power supply control chip S26, and is used to drive the power transistor and transformer according to the PWM signal to output multiple DC voltages. Specifically, the drive and rectification filter circuit S24 includes a power MOSFET Q1, a flyback transformer T1, a secondary rectifier diode, and an output filter capacitor. Its input terminal is connected to the PWM output terminal of the flyback power supply control chip S26, and its output terminal outputs multiple DC voltages such as 12V and 5V, and is also connected to the input terminal of the voltage negative feedback control circuit S27. It is used to drive Q1 and T1 to perform energy conversion according to the PWM signal, and output a stable DC voltage after rectification and filtering.

[0051] The input terminal of the voltage negative feedback control circuit S27 is connected to the output terminal of the drive and rectification filter circuit S24, and the output terminal of the voltage negative feedback control circuit S27 is connected to the feedback input terminal of the flyback power supply control chip S26, which is used to sample the output voltage and feed it back to the flyback power supply control chip S26 to stabilize the output voltage.

[0052] Specifically, the voltage negative feedback control circuit S27 includes sampling resistors R34 and R39, and feedback elements U5 and U6. The DC voltage output from the drive and rectification filter circuit S24 is divided by the sampling resistors R34 and R39 and connected to the input of U5. The output of U5 is connected to the input of U6. The output of U6 is connected to the COMP pin, the feedback input of the flyback power supply control chip S26. When the output voltage changes, U5 detects the change in the divided voltage and drives U6. U6 transmits the feedback signal to the COMP pin of the flyback power supply control chip S26, which then adjusts the PWM duty cycle accordingly to stabilize the output voltage.

[0053] This embodiment integrates a flyback power supply control chip, drive and rectification filter circuit, and voltage negative feedback control circuit into the auxiliary power supply. It can directly draw power from the integrated power module to output multiple DC voltages, supplying power to each control chip and the external BMS auxiliary power source. This avoids the need for a separate auxiliary power supply, simplifying the power supply architecture and reducing size and cost. Through the closed-loop feedback of operational amplifier U5A and optocoupler U6 in the voltage negative feedback control circuit, the sampled voltage is compared with the reference voltage, and the PWM duty cycle is adjusted to keep the output voltage stable under different conditions, overcoming the shortcomings of low accuracy and easy fluctuation in open-loop control. The error signal, after voltage division by the sampling resistor, is transmitted to the COMP pin of the control chip via optocoupler isolation, achieving electrical isolation between the output and input sides. It also adjusts the PWM duty cycle in real time when the output fluctuates, improving the anti-interference capability and long-term operational reliability of the auxiliary power supply.

[0054] like Figure 1-7 As shown, in one embodiment, the external BMS power supply auxiliary source includes: The input terminals of the flyback power supply circuits S24, S25, S26 and S27 are connected to the DC bus inside the integrated power module to output 12V or 5V auxiliary power. Specifically, the flyback power supply circuits S24, S25, S26, and S27 share a flyback topology with the auxiliary power supply. Specifically, they include a flyback power supply control chip S26, a main control IC_U4, a drive and rectification / filtering circuit S24, a voltage negative feedback control circuit S27, and a buck circuit S25. The input terminals of the flyback power supply circuits S24, S25, S26, and S27 are connected to the DC bus inside the integrated power module, such as a rectified and filtered 400V bus. Their output terminals output 12V or 5V auxiliary power, which are respectively connected to the input terminals of the relay control circuit S30 and the buck circuit S25. The buck circuit S25 further converts the 12V to 3.3V for use by the control chip.

[0055] The relay and control signal S7 are connected in series in the input circuit or starting circuit of the auxiliary power supply. When AC power is applied, the 12V output of the auxiliary power supply immediately drives the relay to engage, which is used to connect the main power or the auxiliary power supply itself. The relay coil is connected to the 12V output of the auxiliary power supply, and the contacts control the AC input or DC bus.

[0056] Relay control circuit S30: Its input terminal is connected to the output terminals of the flyback power supply circuits S24, S25, S26 and S27, and its control terminal is connected to the first control signal output terminal of the BMS communication board, used to control the on and off of the relay according to the instructions of the BMS communication board. Specifically, the relay control circuit S30 includes a relay K6, a control signal input terminal 1A+_DR, a current-limiting resistor, and a driving transistor. The input terminal of the relay control circuit S30 is connected to the 12V or 5V output terminals of the flyback power supply circuits S24, S25, S26, and S27. Its control terminal is connected to the first control signal output terminal of the BMS communication board, i.e., the 1A+_DR signal, and its output terminal is connected to the power input terminal of the external connector S32. When the BMS communication board sends a high-level 1A+_DR signal, the driving transistor conducts, the coil of relay K6 is energized, and the output voltage of the flyback power supply circuit is transmitted to the external connector through the relay contacts. When 1A+_DR is low, relay K6 disconnects, cutting off the external power supply.

[0057] External connector S32: Its input terminal is connected to the output terminal of the relay control circuit S30, and its output terminal is used to connect to the power input terminal of the external BMS to provide working power to the external BMS.

[0058] Specifically, the external connector S32, also known as the CN5 connector, includes power and signal pins. Its input terminal is connected to the contact of the relay K6 output terminal of the relay control circuit S30, and its output terminal is used to connect to the power input terminal of the external BMS, providing operating power to the external BMS. Additionally, the external connector S32 may also include a CAN communication pin for data exchange between the BMS communication board and the external BMS.

[0059] This embodiment integrates a flyback power supply circuit into the external BMS auxiliary power supply and connects it to the internal DC bus of the integrated power module. This allows for direct 12V or 5V auxiliary power output from the main power link, eliminating the need for an external independent power supply device, simplifying the power supply architecture, and reducing cost and size. By setting up a relay control circuit and connecting it to the first control signal output terminal of the BMS communication board, the relay can be controlled on and off as needed according to commands, achieving intelligent switching management of the external BMS power supply, avoiding continuous power supply, reducing standby power consumption, and improving energy efficiency. By sending the flyback power supply output to the external BMS via the relay control circuit and external connector, combined with data interaction between the BMS communication board and the external BMS, an integrated power supply and communication interface can be provided for the BMS, simplifying external wiring and improving integration and reliability.

[0060] like Figure 1-7 As shown, in one embodiment, the BMS communication board includes: Main control circuit S43: includes main control IC_U32, used to process communication data with external BMS and generate output adjustment signals and on / off control signals; Specifically, the main control circuit S43 includes the main control IC_U32 and its peripheral circuits, including a crystal oscillator circuit S42, a reset circuit, and power supply decoupling capacitors. The communication terminal of the main control circuit S43 is connected to the input terminal of the communication circuit S28; its control signal output terminal is connected to the control command receiving terminal of the integrated power module via the isolation communication circuit S44 and the control coil terminal of the output relay; it is used to process communication data with the external BMS and generate output adjustment signals and on / off control signals based on the processing results.

[0061] Communication circuit S28: Its input terminal is connected to the communication terminal of the main control circuit S43, and its output terminal is used to connect to the CAN interface of the external BMS to realize bidirectional communication with the external BMS.

[0062] Specifically, the communication circuit S28 includes a CAN transceiver chip such as TJA1050 or ISO1050, along with its peripheral matching resistors, common-mode chokes, and ESD protection devices. The input of the communication circuit S28 is connected to the communication terminal of the main control circuit S43, and its output is connected to the CAN interface of an external BMS via an external connector such as a CN5 connector. This enables bidirectional CAN communication between the main control circuit S43 and the external BMS, transmitting real-time battery status information (voltage, current, temperature) and charging control commands.

[0063] Specifically, it also includes: a charging gun electromagnetic lock control sub-circuit S31. When charging starts, the main control circuit S43 outputs EL1_DR to make K10 engage, and the electromagnetic lock is energized to lock the charging gun, preventing it from being accidentally pulled out during charging. When charging ends or there is an abnormality, the main control circuit S43 cancels the signal, the electromagnetic lock is released, and the charging gun can be pulled out.

[0064] The input terminal of the isolation communication circuit S34 is connected to the UART pins (RX1_RS232, TX1_RS232) of the main control circuit S43. After passing through the isolation chip U30 and the 232 transceiver chip U12, it is output to the external connector CON20 for RS232 communication with the host computer or other devices.

[0065] The dry contact circuit S36 controls relays K7 / 8 / 9 to output high and low levels. The input of dry contact circuit S36 is connected to the GPIO control signal of U32 in the main control circuit S43, and the output is connected to the coils of relays K7, K8, and K9. The relay contacts output dry contact signals. This is used for external status indication or linkage control.

[0066] The buck step-down circuit and the linear regulator circuit S38 step down 12VS to 3.3V (VDD_LCD). The input terminal is connected to 12VS (from the auxiliary power supply or other 12V power supply), and the output terminal VDD_LCD is 3.3V, which is used for LCD display or other low-voltage circuits.

[0067] The reserved test point and software upgrade location S39 is directly connected to the relevant pins of U32 of the main control circuit S43 (such as SWD, JTAG or UART) for program burning and debugging.

[0068] A switch input detection interface S40 on the BMS communication board connects to the CN6 connector S33 and is used to detect whether the charging gun has been correctly inserted into the battery interface (such as the CC1 signal of the national standard charging gun confirming the physical connection, or the closed / open state of the micro switch), so that the BMS communication board can identify the connection / disconnection status of the charging gun, thereby controlling the safe start and termination of the charging process.

[0069] The external testing, communication, and software programming port S41 is a multi-pin connector that connects to the communication port (such as CAN, RS232, SPI) and programming port of U32 in the main control circuit S43 for external device testing, communication, and firmware upgrades.

[0070] This embodiment integrates the main control circuit and CAN communication circuit into the BMS communication board, and limits the main control circuit to connect to the integrated power module and the output relay respectively. This enables real-time bidirectional communication with an external BMS, avoiding cable connections and communication delays caused by separate designs, and improving response speed and integration. The main control circuit generates output adjustment signals and on / off control signals based on battery status information, and sends them to the integrated power module and the output relay respectively. This dynamically adjusts the charging voltage, current, and loop on / off, achieving closed-loop intelligent management and overcoming the linkage lag caused by the separation of power regulation and loop control. The CAN communication circuit uses a standard CAN bus interface, which is compatible with various industrial BMSs. Utilizing its high anti-interference and multi-node characteristics, it ensures reliable data transmission in complex environments, improving system stability and applicability.

[0071] 6. A switching power supply control method for industrial battery charging, applied to the switching power supply module for industrial battery charging as described in any one of the preceding claims, comprising: Step S1: Connect to AC power. The integrated power module converts the AC power into DC charging output. At the same time, the auxiliary power supply draws power from the integrated power module to provide working voltage for the control chips inside the integrated power module and the external BMS power supply auxiliary power source. Specifically, the AC power supply is first connected to the EMI filter circuit S1, which includes a fuse, a varistor, a surge protector, and a two-stage common-mode and differential-mode filter network to filter out high-frequency noise and electromagnetic interference in the input power supply and output clean AC power to the rectifier filter circuit S2.

[0072] In the rectifier-filter circuit S2, rectifier bridges BD2 and BD3 perform full-wave rectification of the AC power, which is then smoothed and filtered by a large-capacity electrolytic capacitor to generate a stable DC bus voltage. This DC bus voltage is simultaneously fed into the input terminals of the interleaved PFC circuit and the auxiliary power supply. In the interleaved PFC circuit, the power chip U7, located at S4, controls the switching transistors Q3 and Q4 to conduct interleaved through the drive and switching circuit S3, boosting the DC bus voltage to 400V. At the same time, the power chip U7 controls and protects the circuit S10 and the RC filter circuit S11 to achieve power factor correction of the input current, outputting a stable 400V DC voltage to the phase-shifted full-bridge circuits S14, S15, and S16.

[0073] The phase-shifted full-bridge control chip U18, located in S16, generates a phase-shifted PWM signal. After being amplified by the isolation drive circuit S14, it drives the phase-shifted full-bridge power transistors Q15, Q16, Q19, Q20 and the resonant circuit S15, converting 400V DC into a high-frequency AC square wave. This wave is then coupled to the full-wave rectifier circuit S12 via transformers T2 and T5. The rectifier diodes in the full-wave rectifier circuit S12 rectify the high-frequency AC into pulsating DC. Finally, the output filter circuit S13 smooths and filters the DC through inductors and capacitors, resulting in a stable DC charging output voltage.

[0074] The flyback power supply control chip S26 in the auxiliary power supply draws power from the DC bus through starting resistors R27 and R31, generating a PWM signal to drive the power transistor Q1 and transformer T1 in the drive, rectification, and filtering circuit S24. The secondary winding of the transformer is rectified and filtered to output multiple DC voltages, such as 12V and 5V. One of the 12V voltages is divided by sampling resistors R34 and R39 in the voltage negative feedback control circuit S27, and then fed back to the COMP pin of the flyback power supply control chip S26 through U5 and U6, forming a closed-loop voltage regulation to ensure stable output voltage. This 12V voltage provides the operating voltage for the main control chip S22, power chip U7, phase-shifted full-bridge control chip U18, and other control chips inside the integrated power module, and also provides input power for the external BMS auxiliary power supply.

[0075] Step S2: After the external BMS power supply auxiliary power source is powered on, it provides working power to the external BMS. The BMS communication board communicates with the external BMS to obtain the battery status information fed back by the external BMS. Specifically, when the 12V voltage output from the auxiliary power supply is applied to the flyback power supply circuits S24, S25, S26, and S27 in the external BMS power supply auxiliary power source, the flyback power supply control chip S26 inside the circuit starts to work. Through the drive and rectification filter circuit S24, the 12V voltage is further converted into a stable 5V or 12V auxiliary power supply, which is then output to the input terminal of the relay control circuit S30.

[0076] At this time, the main control circuit S43 in the BMS communication board has not yet sent a conduction command to the relay control circuit S30, the relay K6 remains in the open state, and the external connector S32 has no power output. The main control circuit S43 establishes a communication connection with the external BMS through the CAN communication circuit S28: the CAN controller inside the main control circuit S43 converts the query frame requesting battery voltage, current, temperature, and other status information into digital signals, which are then converted into differential signals by the transceiver in the CAN communication circuit S28 and sent to the external BMS through the corresponding pin of the external connector S32.

[0077] After receiving a response from the external BMS, a CAN data frame containing the real-time battery status values ​​(voltage, current, and temperature) is transmitted back. The CAN communication circuit S28 receives the differential signal and converts it back to a digital signal, which is then sent to the CAN controller of the main control circuit S43. After parsing the battery status information, the main control circuit S43 first determines whether the battery is within a normal rechargeable range, such as the voltage not being lower than the undervoltage threshold, not being higher than the overcharge threshold, and the temperature being within the allowable range.

[0078] If the battery condition is determined to be normal, the main control circuit S43 outputs a high-level first control signal to the relay control circuit S30, driving the transistor to conduct and energizing the relay K6 coil. The auxiliary power output from the flyback power supply circuit is sent to the output terminal of the external connector S32 through the relay K6 contact, thereby providing working power to the external BMS. If the battery condition is abnormal, the main control circuit S43 does not send a conduction command and reports a fault.

[0079] After the external BMS is powered on, the main control circuit S43 continuously communicates periodically with the external BMS through the CAN communication circuit S28 to obtain dynamic status information such as battery voltage, current, and temperature in real time, providing data for subsequent charging parameter adjustment and loop on / off control.

[0080] Step S3: The BMS communication board sends an output adjustment command to the integrated power module based on the acquired battery status information. The integrated power module adjusts the voltage and / or current of its DC charging output in response to the output adjustment command. Specifically, the main control circuit S43 continuously receives battery status information from the external BMS via the CAN communication circuit S28, including the current battery voltage, charging current requirement, battery temperature, and maximum allowable charging parameters. Based on this information, the main control IC_U32 inside the main control circuit S43 calculates the target output voltage and / or target output current values ​​required for the current stage according to a preset charging curve, such as a constant current-constant voltage mode, and generates an output adjustment command containing voltage and / or current setpoints. This command is sent as a digital signal from the control signal output terminal of the main control circuit S43, electrically isolated via the isolation communication circuit S44 to eliminate ground loop interference and protect the low-voltage control side, and finally sent to the control command receiving terminal of the main control chip S22 in the integrated power module.

[0081] The main control chip S22 receives and parses the output adjustment command to obtain the voltage setpoint and / or current setpoint. The digital signal processor inside the main control chip S22 converts the setpoint into the corresponding digital reference signal and outputs it to the voltage and current reference follower circuit S17.

[0082] The RC filter network in the voltage-current reference follower circuit S17 smooths the digital reference signal into continuous analog reference voltages VS (voltage reference) and VS1 (current reference). After the follower enhances the driving capability, the signals are transmitted to the voltage loop control circuit S18 and the current loop control circuit S21, respectively. The voltage loop control circuit S18 receives the output voltage sample value from the output of the output filter circuit S13 in real time. After the sample value is divided by resistors R268, R269, R272, and R278, the sample value is compared with VS. The error signal is amplified by the operational amplifier U20 and then sent to pin EA of the phase-shifted full-bridge control chip U18.

[0083] The current loop control circuit S21 receives the current sample value output by the current sampling amplifier circuit S20 in real time. This value is obtained by amplifying the voltage across the sampling resistor RS5 in the output loop via U20B. The sample value is compared with VS1, and the error signal is also sent to pin EA of U18. U18 adjusts the PWM duty cycle of its output according to the error signal from pin EA. After passing through the isolation drive circuit S14 and the phase-shifted full-bridge power transistors Q15, Q16, Q19, and Q20, the output voltage and current of the full-wave rectifier circuit S12 and the output filter circuit S13 are changed, so that the actual output DC charging voltage and / or current approaches the set value in the output adjustment command, thereby realizing the dynamic adjustment of charging parameters.

[0084] Step S4: The BMS communication board sends an on / off control signal to the output relay based on the acquired battery status information. The output relay responds to the on / off control signal to control the on / off of the charging circuit.

[0085] Specifically, during operation, the main control circuit S43 continuously monitors battery status information acquired from the external BMS and local detection signals acquired through the charging gun detection interfaces S33, S29, S30, and S37. The main control IC_U32 inside the main control circuit S43 determines whether the charging circuit is allowed to conduct based on preset safety logic. When all conditions are met—for example, the battery voltage is within the normal range, the battery temperature is below the protection threshold, the CC1 signal is valid indicating a normal physical connection between the charging gun and the battery, and no charging prohibition command is received from the BMS—the main control circuit S43 sends a high-level on / off control signal to the control coil of the output relay through its third control signal output terminal. This signal, amplified by the relay control / drive circuit in the output filter circuit S13, energizes the coils of output relays K2, K3, and K4, causing the relay contacts to close. This allows the DC charging current output by the integrated power module to flow into the external battery through the output fuse F3 and the relay contacts, thus completing the charging circuit. When the main control circuit S43 detects an abnormal state, the main control IC_U32 immediately switches the on / off control signal to a low level. The relay control / drive circuit cuts off the relay coil current, the relay contacts open, the charging circuit is disconnected, and charging of the battery stops. If the output current exceeds the fuse threshold of the output fuse F3, F3 will blow itself as a hardware backup protection to further ensure safety.

[0086] While issuing the disconnect command, the main control circuit S43 also reports the fault or full charge status to the external BMS via the CAN communication circuit S28, and can illuminate the fault indicator light or sound the alarm via the indicator light control circuit S35. The entire on / off control process is completed by the main control circuit S43 based on real-time battery status information.

[0087] The method provided in this embodiment highly integrates power conversion, auxiliary power supply, BMS power supply, and communication into a single module, avoiding external cables and communication delays caused by distributed designs, and improving system integration and charging response speed. The BMS communication board sends output adjustment commands to the integrated power module based on battery status, dynamically adjusting the charging voltage and current to overcome the defects of fixed or lagging power output, optimizing the charging curve, and extending battery life. The BMS communication board sends on / off control signals to the output relay based on the same battery status, combined with hardware protection from the output fuse, achieving dual software and hardware safety protection, improving the safety and reliability of the charging process.

[0088] In one embodiment, when the battery status information obtained by the BMS communication board indicates that at least one of the battery voltage, current, or temperature exceeds a preset threshold, the BMS communication board sends an on / off control signal to the output relay to disconnect the charging circuit, and the output relay disconnects the charging circuit in response to the on / off control signal.

[0089] Specifically, the main control circuit S43 acquires battery status information from the external BMS via the CAN communication circuit S28, and simultaneously acquires the charging gun temperature through the gun temperature detection interface of the relay control circuit S30, and the battery voltage connected to the national standard charging gun through the battery voltage detection interface. The main control circuit S43 compares the acquired battery voltage, current, and temperature values ​​with preset normal range thresholds. When it determines that at least one of the battery voltage, current, or temperature exceeds the preset normal range, the main control circuit S43 identifies it as an abnormal state and immediately sends a low-level on / off control signal to the control coil of the output relay through its third control signal output terminal. After being processed by the relay control / drive circuit in the output filter circuit, this signal de-energizes the output relay coil, opens the relay contacts, and disconnects the charging circuit. At the same time, the main control circuit S43 reports the corresponding fault to the external BMS via the CAN communication circuit S28 and provides fault indication through the indicator light and buzzer control circuit.

[0090] The method provided in this embodiment, by real-time monitoring of battery voltage, current, and temperature and comparing them with preset thresholds, can immediately send a disconnect signal to the output relay via the BMS communication board when any parameter exceeds the safe range. This avoids the risks of overcharging, over-discharging, or overheating caused by communication delays or lack of linkage protection in existing technologies, thereby significantly improving the safety of the industrial battery charging process. By directly controlling the output relay to cut off the charging circuit through the BMS communication board, and combining local temperature gun detection and battery voltage detection, seamless integration of software commands and hardware execution is achieved. This overcomes the shortcomings of traditional solutions, such as delayed protection actions or reliance on single protection components, thus improving the real-time performance and reliability of protection response. By simultaneously reporting fault information to the external BMS and driving indicator lights and buzzers for local alarms, dual feedback of remote fault status notification and on-site warning is achieved, facilitating maintenance personnel to quickly locate the cause of abnormalities, thereby reducing troubleshooting time and improving system maintainability.

[0091] In one embodiment, the integrated power module adjusts the voltage and / or current of its DC charging output in response to the output regulation command, including: The integrated power module samples its own output DC charging voltage and current in real time, compares the sampled values ​​with the set values ​​carried in the output adjustment command, and adjusts the PWM duty cycle of its internal switching transistors according to the comparison results, so that the output DC charging voltage and / or current approaches the set values.

[0092] Specifically, the main control chip S22 receives the output adjustment command sent by the BMS communication board via the isolation communication circuit S44, and parses out the voltage setpoint and / or current setpoint. The main control chip S22 converts the setpoint into a digital reference signal and outputs it to the voltage and current reference follower circuit S17. The RC filter network in the voltage and current reference follower circuit S17 smooths the digital reference signal into continuous analog reference voltage VS and current reference VS1, which are then transmitted to the voltage loop control circuit S18 and the current loop control circuit S21, respectively, via the follower. The output voltage sample value is taken from the output terminal of the output filter circuit S13, and after being divided by resistors R268, R269, R272, and R278, it is sent to the voltage loop control circuit S18; the output current sample value is taken from both ends of the sampling resistor RS5 in the output loop, and after being amplified by the current sampling amplifier circuit S20, it is sent to the current loop control circuit S21. The voltage loop control circuit S18 compares the output voltage sample value with VS, and the error signal is processed by the operational amplifier U20 and sent to the EA pin of the phase-shifted full-bridge control chip U18. The current loop control circuit S21 compares the output current sample value with VS1, and the error signal is also sent to the EA pin of U18. U18 adjusts the PWM duty cycle of its output based on the error signal input from the EA pin. This PWM signal passes through the isolation drive circuit S14 and the phase-shifted full-bridge power transistors Q15, Q16, Q19, and Q20, changing the output voltage and current of the full-wave rectifier circuit S12 and the output filter circuit S13, so that the actual output DC charging voltage and / or current gradually approaches the set value in the output adjustment command, realizing closed-loop voltage and current regulation. The main control chip S22 continuously monitors the sampled value and dynamically adjusts the reference signal to ensure that the output parameters always follow the changes in the set value.

[0093] The method provided in this embodiment samples the DC charging voltage and current in real time and compares them with the set values ​​in the output adjustment command. Based on the comparison results, it dynamically adjusts the PWM duty cycle to achieve closed-loop control of the output voltage and / or current. This overcomes the shortcomings of open-loop control, where output parameters are easily affected by input fluctuations and load changes, thus significantly improving the stability and accuracy of the charging output. The voltage loop control circuit and current loop control circuit respectively compare the sampled values ​​with the reference values ​​and send them directly to the EA pin of the phase-shifted full-bridge control chip. This shortens the PWM duty cycle adjustment path and improves response speed, avoiding the delay introduced by digital processing in traditional solutions, thereby achieving rapid tracking of battery demand changes. By continuously monitoring the sampled values ​​and dynamically adjusting the reference signal through the main control chip, the output parameters always approach the set values. It can automatically switch adjustment modes at different charging stages, such as constant current and constant voltage, without external intervention, thus optimizing the charging curve and extending battery life.

[0094] In one embodiment, when the BMS communication board sends an on / off control signal to the output relay, it also sends a power supply control signal to the external BMS power supply auxiliary source to control the external BMS power supply auxiliary source to supply power to the external BMS or stop supplying power.

[0095] Specifically, while sending on / off control signals to output relays K2, K3, and K4, the main control circuit S43 simultaneously sends a power supply control signal, namely the 1A+_DR signal, to the relay control circuit S30 in the external BMS auxiliary power supply via its first control signal output terminal. When the main control circuit S43 sends an on / off control signal to the output relays to connect the charging circuit, it synchronously outputs the 1A+_DR signal. This signal drives relay K6 via the relay control circuit S30, causing the K6 contacts to close. The 12V or 5V auxiliary power output from the flyback power circuits S24, S25, S26, and S27 is then supplied to the A1+ terminal of the external connector S32 via the K6 contacts, providing operating power to the external BMS. When the main control circuit S43 sends an on / off control signal to the output relays to disconnect the charging circuit, it stops outputting the 1A+_DR signal, relay K6 returns to the open state, and the external BMS auxiliary power supply stops supplying power to the external BMS. Through the above-mentioned linkage control, the on / off state of the charging circuit is consistent with the power supply status of the external BMS, ensuring that the BMS is powered only during the charging process, and avoiding the BMS from being continuously powered in standby or fault states.

[0096] The method provided in this embodiment links the power supply control of the external BMS auxiliary power source with the on / off control of the output relay. This allows the BMS communication board to send power supply control signals simultaneously with the on / off control signals. This ensures that power is supplied to the external BMS synchronously when the charging circuit is on and disconnected synchronously when the charging circuit is off. This avoids the standby power consumption or abnormal charging issues caused by independent BMS power supply control in existing technologies, thereby reducing system standby power consumption and improving energy efficiency. Through this linked control, the external BMS auxiliary power source only provides operating power to the BMS during charging and automatically disconnects power when not charging. This prevents the BMS from aging or malfunctioning due to prolonged charging, extending the lifespan of the external BMS and improving overall system reliability. By issuing both the power supply control signal and the on / off control signal from the same BMS communication board, no additional controller or external wiring is required. This achieves logical unification of the charging circuit state and the BMS power supply state, simplifying the control logic, avoiding malfunctions caused by signal asynchrony, and improving the coordination and safety of system control.

[0097] In one embodiment, before the BMS communication board communicates with an external BMS, it further includes: The connection status signal between the charging gun and the battery is obtained through the physical connection detection interface of the charging gun, and the voltage and temperature of the battery are obtained through the local battery detection circuit. When the connection status signal indicates that the charging gun and the battery are physically connected, and the voltage and temperature of the battery are both within the specified range... Preset The BMS communication board only initiates communication with the external BMS when the system is within its normal operating range.

[0098] In the above embodiments, the descriptions of each embodiment have different focuses. For parts that are not described in detail or recorded in a certain embodiment, please refer to the relevant descriptions of other embodiments.

[0099] Those skilled in the art will recognize that the units and algorithm steps of the various examples described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, or a combination of computer software and electronic hardware. Whether these functions are implemented in hardware or software depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementation should not be considered beyond the scope of this application.

[0100] In the embodiments provided in this application, it should be understood that the disclosed apparatus / devices and methods can be implemented in other ways. For example, the apparatus / device embodiments described above are merely illustrative. For instance, the division of modules or 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 interfaces; the indirect coupling or communication connection between devices or units may be electrical, mechanical, or other forms.

[0101] 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.

[0102] The above-described embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this application, and should all be included within the protection scope of this application.

Claims

1. A switching power supply module for charging industrial batteries, characterized in that, include: An integrated power module, an output fuse connected to the output terminal of the integrated power module, an output relay connected to the output terminal of the output fuse, an auxiliary power supply connected to the integrated power module, an external BMS power supply auxiliary power source connected to the auxiliary power supply, and a BMS communication board connected to the external BMS power supply auxiliary power source, the integrated power module, and the output relay respectively. The integrated power module is used to convert AC power into DC charging output; The output fuse is used to blow when the output current exceeds the threshold, thus cutting off the charging circuit. The output relay is used to receive the on / off control signal sent by the BMS communication board, and respond to the on / off control signal to control the on / off of the charging circuit. The auxiliary power supply is used to provide operating voltage for the control chips inside the integrated power module and the external BMS power supply auxiliary power source; The external BMS power supply auxiliary power source is used to provide working power to the external BMS; The BMS communication board is used to communicate with an external BMS, and to send output adjustment commands to the integrated power module and on / off control signals to the output relay based on the communication results.

2. The switching power supply module for industrial battery charging according to claim 1, characterized in that, The integrated power module includes: The input terminal of the EMI filter circuit (S1) is used to connect to an AC power supply to filter out high-frequency noise and electromagnetic interference in the input AC power supply. The input terminal of the rectifier filter circuit (S2) is connected to the output terminal of the EMI filter circuit (S1) to rectify the filtered AC power into DC power and output DC bus voltage. The input terminals of the interleaved PFC circuits (S3, S4, S10 and S11) are connected to the output terminal of the rectifier filter circuit (S2) to boost the DC bus voltage to a preset 400V DC voltage and achieve power factor correction. The input terminals of the phase-shifted full-bridge circuit (S14, S15 and S16) are connected to the output terminals of the interleaved PFC circuit (S3, S4, S10 and S11) to convert 400V DC voltage into high-frequency AC voltage. The input terminal of the full-wave rectifier circuit (S12) is connected to the output terminal of the phase-shifted full-bridge circuit (S14, S15 and S16) to rectify the high-frequency AC voltage into a DC charging voltage. The input terminal of the output filter circuit (S13) is connected to the output terminal of the full-wave rectifier circuit (S12) to perform inductor-capacitor filtering on the DC charging voltage and output a stable charging voltage to the output fuse. The main control chip (S22) is connected to the control terminals of the interleaved PFC circuits (S3, S4, S10 and S11) and the phase-shifted full-bridge circuits (S14, S15 and S16) respectively, and is used to receive the output adjustment signal sent by the BMS communication board, and control the working state of the interleaved PFC circuits (S3, S4, S10 and S11) and the phase-shifted full-bridge circuits (S14, S15 and S16) according to the signal.

3. The switching power supply module for industrial battery charging according to claim 1, characterized in that, The auxiliary power supply includes: Flyback power supply control chip (S26): includes main control IC_U4, used to output PWM signal; The input terminal of the drive and rectification filter circuit (S24) is connected to the output terminal of the flyback power supply control chip (S26) and is used to drive the power transistor and transformer according to the PWM signal to output multiple DC voltages. The input terminal of the voltage negative feedback control circuit (S27) is connected to the output terminal of the drive and rectification filter circuit (S24), and the output terminal of the voltage negative feedback control circuit (S27) is connected to the feedback input terminal of the flyback power supply control chip (S26) to sample the output voltage and feed it back to the flyback power supply control chip (S26) to stabilize the output voltage.

4. The switching power supply module for industrial battery charging according to claim 1, characterized in that, The external BMS power supply auxiliary power source includes: The input terminals of the flyback power supply circuit (S24, S25, S26 and S27) are connected to the DC bus inside the integrated power module to output 12V or 5V auxiliary power. Relay control circuit (S30): Its input terminal is connected to the output terminal of the flyback power supply circuit (S24, S25, S26 and S27), and its control terminal is connected to the first control signal output terminal of the BMS communication board, used to control the on and off of the relay according to the instructions of the BMS communication board. External connector (S32): Its input end is connected to the output end of the relay control circuit (S30), and its output end is used to connect to the power input end of the external BMS to provide working power to the external BMS.

5. The switching power supply module for industrial battery charging according to claim 1, characterized in that, The BMS communication board includes: Main control circuit (S43): includes main control IC_U32, used to process communication data with external BMS and generate output adjustment signals and on / off control signals; Communication circuit (S28): Its input terminal is connected to the communication terminal of the main control circuit (S43), and its output terminal is used to connect to the CAN interface of the external BMS to realize bidirectional communication with the external BMS.

6. A switching power supply control method for industrial battery charging, characterized in that, The switching power supply module for industrial battery charging according to any one of claims 1-5 includes: When connected to an AC power source, the integrated power module converts the AC power into a DC charging output. At the same time, the auxiliary power source draws power from the integrated power module to provide operating voltage for the various control chips inside the integrated power module and the external BMS power supply auxiliary source. After the external BMS power supply is powered on, it provides working power to the external BMS. The BMS communication board communicates with the external BMS to obtain battery status information fed back by the external BMS. The BMS communication board sends an output adjustment command to the integrated power module based on the acquired battery status information. The integrated power module adjusts the voltage and / or current of its DC charging output in response to the output adjustment command. The BMS communication board sends an on / off control signal to the output relay based on the acquired battery status information, and the output relay responds to the on / off control signal to control the on / off of the charging circuit.

7. The switching power supply control method for industrial battery charging according to claim 6, characterized in that, When the battery status information obtained by the BMS communication board indicates that at least one of the battery voltage, current or temperature exceeds a preset threshold, the BMS communication board sends an on / off control signal to the output relay to disconnect the charging circuit, and the output relay responds to the on / off control signal to disconnect the charging circuit.

8. A switching power supply control method for industrial battery charging according to claim 6, characterized in that, The integrated power module adjusts the voltage and / or current of its DC charging output in response to the output regulation command, including: The integrated power module samples its own output DC charging voltage and current in real time, compares the sampled values ​​with the set values ​​carried in the output adjustment command, and adjusts the PWM duty cycle of its internal switching transistors according to the comparison results, so that the output DC charging voltage and / or current approaches the set values.

9. A switching power supply control method for industrial battery charging according to claim 6, characterized in that, When the BMS communication board sends an on / off control signal to the output relay, it also sends a power supply control signal to the external BMS power supply auxiliary source to control the external BMS power supply auxiliary source to supply power to the external BMS or stop supplying power.

10. The switching power supply control method for industrial battery charging according to claim 6, characterized in that, Before the BMS communication board communicates with an external BMS, it also includes: The connection status signal between the charging gun and the battery is obtained through the physical connection detection interface of the charging gun, and the voltage and temperature of the battery are obtained through the local battery detection circuit. The BMS communication board initiates communication with the external BMS only when the connection status signal indicates that the charging gun and the battery are physically connected, and the voltage and temperature of the battery are within the preset normal operating range.

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