A charging pile power distribution device, a configuration method thereof, and a parallel machine scheduling method
By using a modularly designed charging pile power distribution device and parallel scheduling method, the problems of numerous contactors, severe line occupation, and difficulty in capacity expansion in existing technologies have been solved. This has enabled flexible charging gun output and efficient power scheduling, supporting MW-level maximum output power and convenient fault handling.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- HANGZHOU LIVOLTEK POWER CO LTD
- Filing Date
- 2026-03-18
- Publication Date
- 2026-07-14
AI Technical Summary
Existing charging pile power distribution technology suffers from problems such as a large number of contactors, severe line occupation, inability to adapt to different charging gun methods, and difficulty in capacity expansion.
The system employs a flexible charging pile power distribution device, including components such as housing, busbar, DC contactor, and control board. Through modular design and the opening and closing of the DC contactor, it enables multiple charging gun output modes to support diverse charging needs. Furthermore, it enhances power scheduling flexibility through parallel scheduling methods.
It enables flexible switching between multiple charging modes, supports maximum output power in the MW range, meets the requirements of fast charging and supercharging, and its modular design facilitates fault replacement, improving system fault tolerance and power scheduling flexibility.
Smart Images
Figure CN122393736A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of vehicle charging technology, and in particular to a charging pile power distribution device, its configuration method, and its parallel scheduling method. Background Technology
[0002] The power distribution technology of charging piles directly affects the power utilization rate of the equipment. Currently, the market offers full-matrix, half-matrix, and ring power distribution technologies. Full-matrix power distribution requires a large number of contactors. While improved half-matrix distribution can reduce the number of power distribution devices, it results in significant line occupation. Ring power distribution can reduce costs, but each terminal has very few power access paths, and line damage can drastically reduce distribution capacity. Furthermore, each power distribution matrix can only adapt to one charging gun mode, unable to simultaneously support different charging gun modes, and cannot be expanded through parallel bridging. Summary of the Invention
[0003] The purpose of this invention is to solve the problems existing in the prior art and to provide a charging pile power distribution device and its configuration method and parallel scheduling method, which is flexible and convenient to use and can meet diverse charging needs.
[0004] The objective of this invention is achieved through the following technical solution:
[0005] A charging pile power distribution device includes a housing, multiple busbars, multiple DC contactors, a control board, a communication debugging interface, an auxiliary power supply port, an address device, and a cooling fan. The busbars, DC contactors, and control board are all located inside the housing, while the communication debugging interface, auxiliary power supply port, address device, and cooling fan are all located on the side of the housing. Each busbar is connected to three other busbars via DC contactors, and the DC contactors, communication debugging interface, auxiliary power supply port, address device, and cooling fan are all connected to the control board.
[0006] Preferably, the plurality of DC contactors are all located in the middle of the housing, and the plurality of busbars are distributed on the sides of the plurality of DC contactors. Each busbar is provided with a copper busbar or a laminated busbar between it and the three DC contactors.
[0007] Preferably, the plurality of busbars extend from the same end of the housing.
[0008] Preferably, the multiple busbars have different heights, and each busbar is provided with an insulating support column between itself and the bottom of the housing or the busbar below it.
[0009] Preferably, a status indicator light is provided on the outer surface of the housing, and the status indicator light is connected to the control board.
[0010] Preferably, the control board is equipped with a temperature sensor.
[0011] Preferably, there are two cooling fans, both located on the outer side of the housing, and the two cooling fans respectively draw air from and blow air into the housing.
[0012] Preferably, the housing is provided with a control adapter plate, which is connected to the control plate.
[0013] This specification also provides a configuration method for a charging pile power distribution device, the charging pile power distribution device including multiple busbars and multiple DC contactors, each busbar having three other busbars connected to it via DC contactors respectively;
[0014] The configuration method includes:
[0015] Based on the number of output terminals required by the charging pile power distribution device, N groups of buses are formed by one bus, two adjacent buses, or multiple adjacent buses. The DC contactors between buses in the same group are set to normally closed.
[0016] If N≤3, each bus group is connected to each other bus group through a DC contactor, and the remaining DC contactors are set to normally open.
[0017] If N > 4, each bus group is connected to the other three bus groups through a DC contactor, and the remaining DC contactors are set to normally open.
[0018] This specification also provides a parallel scheduling method for a charging pile power distribution device, including:
[0019] Based on the configuration method described above, the power distribution device of each charging pile is configured;
[0020] Based on the total number of output terminals required by all charging pile power distribution devices to be connected in parallel, at least one pair of busbars between two adjacent charging pile power distribution devices are connected by cables.
[0021] Power dispatch is achieved by closing all DC contactors between any two busbars.
[0022] The advantages of this invention are:
[0023] 1. Flexible in use, it can achieve various gun output methods and meet diverse charging needs by opening and closing the DC contactor and paralleling multiple devices according to different needs;
[0024] 2. Parallel operation between multiple devices is convenient, requiring no additional hardware or structure. At the same time, the maximum output power after parallel operation can reach the MW level, meeting the needs of fast charging and supercharging.
[0025] 3. It adopts a modular design, which makes it more versatile. Depending on the usage scenario, it can meet the usage requirements through configuration. At the same time, each module is lightweight, highly integrated, and can be quickly replaced in case of failure. Attached Figure Description
[0026] Figure 1 This is a schematic diagram of the structure of a charging pile power distribution device provided in the embodiments of this specification;
[0027] Figure 2 This is a schematic diagram of the structural principle of a charging pile power distribution device provided in the embodiments of this specification;
[0028] Figure 3 This is a schematic diagram of the structural layout of the bus and DC contactor provided in the embodiments of this specification;
[0029] Figure 4 This is a schematic diagram of the structural layout of the bus and DC contactor provided in the embodiments of this specification;
[0030] Figure 5 A flowchart illustrating a configuration method for a charging pile power distribution device provided in the embodiments of this specification;
[0031] Figure 6 A schematic diagram of a configuration structure for a four-output bus provided in the embodiments of this specification;
[0032] Figure 7 A simplified schematic diagram illustrating the configuration structure of a four-output busbar provided in this embodiment of the specification;
[0033] Figure 8 A schematic diagram of a configuration structure for a three-output bus provided in the embodiments of this specification;
[0034] Figure 9 A flowchart illustrating a parallel scheduling method for a charging pile power distribution device provided in the embodiments of this specification;
[0035] Figure 10 A schematic diagram of a parallel operation method provided in the embodiments of this specification;
[0036] Figure 11 A schematic diagram of another parallel operation method provided in the embodiments of this specification;
[0037] In the diagram: 1-Housing; 2-Busbar; 201-Horizontal bend; 202-Left and right bends; 3-DC contactor; 4-Control board; 5-Communication debugging interface; 6-Auxiliary power supply port; 7-Address device; 8-Cooling fan; 9-Copper busbar; 10-Insulating support column; 11-Control adapter board; 12-Hidden handle. Detailed Implementation
[0038] The present invention will now be described in further detail with reference to the accompanying drawings and specific embodiments.
[0039] like Figure 1 As shown, this embodiment provides a charging pile power distribution device, including a housing 1, multiple busbars 2, multiple DC contactors 3, a control board 4, a communication debugging interface 5, an auxiliary power supply port 6, an address device 7, and a cooling fan 8. The housing 1 is rectangular to facilitate installation inside the charging pile. The busbars 2, DC contactors 3, and control board 4 are all housed within the housing 1. The communication debugging interface 5, auxiliary power supply port 6, address device 7, and cooling fan 8 are all located on the side of the housing 1. All of these components are connected to the control board 4. The communication debugging interface 5 is used to connect to external debugging equipment for debugging the device or communicating with the control board, such as setting the on / off states of the DC contactors. The auxiliary power supply port 6 supplies power to the control board 4 and other electrical components. Addressing device 7 typically uses a DIP switch. This serves two purposes: firstly, to identify different power distribution devices, i.e., different charging stations; and secondly, to set the positive or negative of the busbar. In the charging station industry, for electrical safety and heat dissipation considerations, the control circuits for the positive and negative terminals are usually placed in different cabinets or modules. Similarly, a single power distribution device can only provide either a positive or negative terminal, while a complete charging circuit must include both. Therefore, two power distribution devices are needed to form a complete charging circuit. This makes the power distribution device more versatile; two identical devices can be used together, and the positive or negative of the busbar can be set via a DIP switch. Replacement in case of failure is also more convenient and efficient.
[0040] like Figure 2 As shown in the diagram, taking eight buses as an example, AH represents buses, and K1-K12 represent DC contactors. Each bus is connected to three other buses via DC contactors. Using the matrix structure of this embodiment, power switching between buses is more efficient and flexible. For example, power from point C can be switched to point A by closing K4, power from point E can be switched to point A by closing K9, and power from point B can be switched to point A by closing K1. Power from all three points can be accessed simultaneously by closing only the DC contactors. If one DC contactor fails, power can be dispatched through other DC contactors without affecting the overall power dispatch. If K1 fails, power from point A can be dispatched to point B by closing K5, K9, and K10, resulting in high system fault tolerance. Similarly, point B can call the three adjacent power units through K1, K2, and K10 respectively. Using this matrix structure, only twelve DC contactors are needed to realize the busbar calling the three adjacent power units, which greatly reduces the number of DC contactors, saves costs, and improves the flexibility of power scheduling.
[0041] Figure 2 Each busbar in the system can be connected to a separate busbar for output, meaning it can output up to eight independent busbars, thus supporting simultaneous charging of eight charging guns. Another advantage of this embodiment is its versatility; it can be used in various applications... Figure 2 Taking an eight-bus structure as an example, it can support 2-8 charging guns, and a power distribution device is not needed for single-gun charging. Depending on the required number of charging guns, simply setting the corresponding DC contactor to normally closed will short-circuit two adjacent buses, meaning these two buses will share an independent busbar. For example, setting K9 in the diagram to normally closed will short-circuit A and E, allowing them to share an independent busbar. Adding the six independent busbars from the other six buses, a total of seven independent busbars are output, supporting seven-gun charging. This pattern continues, and changing the charging gun configuration does not require altering the overall structure of the device. If the two buses are still connected to separate power units, the power of the shared independent busbar is the total power of both power units; if the two buses are connected to a single power unit, the power of the shared independent busbar is the power of one power unit. The choice is flexible and can be made as needed.
[0042] like Figure 3 and 4 As shown, since each busbar needs to be connected to three DC contactors, in order to make the structure more orderly and compact, all twelve DC contactors 3 are located in the middle of the housing 1 and are divided into three columns of four. The middle column is staggered with the other two columns of DC contactors laterally, so that the positions of any three adjacent DC contactors are relatively compact, which facilitates connection to the same busbar. Eight busbars 2 are distributed on the sides of the twelve DC contactors 3. Each busbar 2 is provided with a copper busbar 9 or a laminated busbar between it and three DC contactors 3. In this embodiment, a copper busbar is specifically used, which is smaller and lighter, which helps to reduce the size and weight of the entire device. Specifically, eight buses are evenly distributed on the left and right sides of the twelve direct contactors, that is, four buses on each side. At the same time, the four buses on the same side are arranged sequentially along the height direction. In order to make full use of the space at the end of the housing and make the position distribution of the input and output terminals of the eight buses more reasonable, two of the four buses on the same side are provided with horizontal bends 201 so that the input and output terminals are close to the middle. Meanwhile, the highest bus is provided with vertical bends 202 to avoid its input and output terminals being too high.
[0043] As described above, the four busbars on the same side are arranged sequentially along the height direction. Therefore, to ensure structural stability, each busbar 2 is provided with an insulating support column 10 between itself and the bottom of the housing or the busbar below it to provide stable support. Meanwhile, all eight busbars 2 extend from the same end of the housing for easy wiring operations. Additionally, a concealed handle 12 is provided on the outer side of the housing 1 facing away from the extended ends of the busbars to prevent interference between the extended ends of the busbars and the internal structure of the charging pile when the device is pulled out.
[0044] A status indicator light is provided on the outer side of the housing 1. The status indicator light is connected to the control board and is used to indicate the status of the device. For example, yellow indicates operation with fault, green indicates normal operation, and red indicates shutdown due to fault.
[0045] In order to monitor the temperature inside the device, a temperature sensor is installed on the control board 4 to detect abnormal temperatures in a timely manner, and to disconnect the control circuit or issue an alarm.
[0046] There are two cooling fans 8, both located on the outer side of the housing 1 for easy disassembly and replacement; and the two cooling fans 8 respectively draw air from and blow air into the housing to create convection inside the device and improve heat dissipation efficiency.
[0047] In addition, a control adapter board 11 is provided inside the housing 1. The control adapter board 11 is connected to the control board 4 to provide more interfaces and facilitate wiring.
[0048] like Figure 5 As shown, this specification also provides a configuration method for a charging pile power distribution device. As mentioned above, the charging pile power distribution device mainly includes multiple busbars and multiple DC contactors. Each busbar has three other busbars connected to it through DC contactors.
[0049] Configuration methods include:
[0050] S200, based on the number of output terminals required by the charging pile power distribution device, forms N groups of buses, with one bus, two adjacent buses, or multiple adjacent buses as a group, and the DC contactors between the buses in the same group are set to normally closed;
[0051] s204a, if N>4, then each bus group is connected to the other three bus groups through a DC contactor, and the remaining DC contactors are set to normally open;
[0052] s204b, if N≤3, then each bus group is connected to each other bus group through a DC contactor, and the remaining DC contactors are set to normally open.
[0053] Similarly, as Figure 2Taking the eight bus structures shown as an example, if only four independent busbars need to be output, the following configuration can be used: Set K2, K6, K9, and K12 to normally closed, so that B and D form one group, F and H form another, A and E form another, and C and G form another, for a total of four busbar groups. Each group can output one independent busbar, thus supporting four-gun charging. Simultaneously, set K8 and K11 to normally open to simplify the actual working structure and ensure that each busbar group is connected to the other three busbar groups via a DC contactor, thus satisfying the flexibility of power switching. The final configuration is as follows: Figure 6 The matrix structure shown, Figure 7 This more intuitively demonstrates the matrix structure of four independent bus outputs.
[0054] The above only demonstrates one method of configuring four independent bus outputs, that is, a configuration in which each group contains two buses. Of course, the number of buses in each group can be different. For example, E, H and F can be grouped together, and A can be grouped separately. In this case, K5 needs to be set to normally closed, and K9 needs to be restored to the open and controllable state, which can also output four independent buses.
[0055] If N≤3, there are at most three busbars. Even if they are connected in pairs, only three DC contactors are needed. Therefore, it is sufficient to fully connect multiple busbars, and set the remaining DC contactors to normally open to ensure the flexibility of power switching. Figure 8 The diagram shows a matrix structure with three independent output buses. One configuration method is used as an example for illustration: [The diagram shows a matrix structure with three independent output buses.] Figure 2 Setting K3 and K12 to normally closed groups creates a group for C, D, and G. Setting K1 and K9 to normally closed groups creates a group for A, B, and E. Setting K6 to normally closed groups creates a group for F and H. Only DC contactors K2, K5, and K7 between these three groups are retained, while the remaining contactors K4, K8, K10, and K11 are set to normally open, thus forming the following... Figure 8 The matrix structure shown.
[0056] like Figure 9 As shown in the figure, this specification also provides a parallel scheduling method for a charging pile power distribution device, including:
[0057] Based on the configuration method described above, the power distribution device of each charging pile is configured;
[0058] Based on the total number of output terminals required by all charging pile power distribution devices to be connected in parallel, at least one pair of busbars between two adjacent charging pile power distribution devices are connected by cables.
[0059] Power dispatch is achieved by closing all DC contactors between any two busbars.
[0060] Depending on actual needs, two or more power distribution devices can be connected in parallel. The number of output buses of each power distribution device can also be configured according to actual requirements. The following describes two specific parallel connection methods.
[0061] like Figure 10 The diagram shows a parallel configuration using two eight-channel output matrices and one four-channel output matrix. Point A of charging station 1 is directly connected to point H of charging station 2 via a cable; point E of charging station 1 is directly connected to point E of charging station 2 via a cable; point D of charging station 2 is directly connected to point C of charging station 3 via a cable; and point C of charging station 2 is directly connected to point D of charging station 3 via a cable. This allows for six output channels from points B, C, D, F, H, and G of charging station 1 to an independent busbar; four output channels from points AE, BD, CG, and HF of charging station 2 to an independent busbar; and six output channels from the junction points A, B, E, F, G, and H of charging station 3 to an independent busbar, for a total of sixteen independent busbar outputs. That is, each output point connected by a cable can only output one independent busbar. If one independent busbar is output from point A of charging station 1, then point HF of charging station 2 cannot output an independent busbar. This six-, four-, six-channel allocation is designed to ensure a relatively even distribution of charging gun outputs across the three charging stations.
[0062] Combination Figure 10 One specific scheduling method is as follows: if point C of pile 1 needs to schedule the power of point C of pile 3, scheduling can be performed by closing K4 of pile 1, K7 of pile 2, and K3 of pile 3. Similarly, if point E of pile 3 calls point A of pile 1, the furthest path can be scheduled by closing K4 and K9 of pile 3, K1 of pile 2, and K9 of pile 1.
[0063] like Figure 11 The diagram shows a configuration using three eight-channel output matrices in parallel. Pile 1's output A is directly connected to Pile 2's output A via a cable, and Pile 2's output E is directly connected to Pile 3's output E via a cable. This allows for eight outputs from Pile 1's A, B, C, D, E, F, H, and G to an independent busbar; six outputs from Pile 2's B, C, D, F, H, and G to an independent busbar; and eight outputs from Pile 3's A, B, C, D, E, F, H, and G to an independent busbar, for a total of twenty-two independent busbar outputs.
[0064] Combination Figure 11 One specific dispatching method is as follows: if point A of pile 1 needs to dispatch the power at point E of pile 3, dispatching can be achieved by closing K9 of pile 2, which only requires closing one DC contactor. If point E of pile 1 needs to dispatch the power at point E of pile 3, dispatching can be achieved by closing both DC contactors K9 of pile 1 and K9 of pile 2.
[0065] It should also be noted that two charging piles can be connected by one, two, or more cables. The more cables there are, the more flexible the power scheduling will be. However, the number of charging guns will be reduced by one for each cable. Therefore, parallel operation is required based on the actual number of charging guns needed.
[0066] The above are merely preferred embodiments of the present invention, and are implementations based on the overall concept of the present invention. Furthermore, the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.
Claims
1. A power distribution device for a charging pile, characterized in that, It includes a housing, multiple busbars, multiple DC contactors, a control board, a communication debugging interface, an auxiliary power supply port, an address device, and a cooling fan. The busbars, DC contactors, and control board are all located inside the housing, while the communication debugging interface, auxiliary power supply port, address device, and cooling fan are all located on the side of the housing. Each busbar is connected to three other busbars via DC contactors. The DC contactors, communication debugging interface, auxiliary power supply port, address device, and cooling fan are all connected to the control board.
2. The charging pile power distribution device according to claim 1, characterized in that, The multiple DC contactors are all located in the middle of the housing, and the multiple busbars are distributed on the sides of the multiple DC contactors. Each busbar is provided with a copper busbar or a laminated busbar between it and the three DC contactors.
3. The charging pile power distribution device according to claim 1, characterized in that, The multiple busbars all extend from the same end of the housing.
4. The charging pile power distribution device according to claim 1, characterized in that, The multiple busbars have different heights, and each busbar is provided with an insulating support column between itself and the bottom of the housing or the busbar below it.
5. A charging pile power distribution device according to claim 1, characterized in that, A status indicator light is provided on the outer surface of the housing, and the status indicator light is connected to the control board.
6. A charging pile power distribution device according to claim 1, characterized in that, The control board is equipped with a temperature sensor.
7. A charging pile power distribution device according to claim 1, characterized in that, The cooling fan has two parts, both located on the outer side of the housing. The two cooling fans respectively draw air from and blow air into the housing.
8. A charging pile power distribution device according to claim 1, characterized in that, The housing contains a control adapter board, which is connected to the control board.
9. A method for configuring a power distribution device for a charging pile, characterized in that, The charging pile power distribution device includes multiple busbars and multiple DC contactors, and each busbar is connected to three other busbars through DC contactors respectively; The configuration method includes: Based on the number of output terminals required by the charging pile power distribution device, N groups of buses are formed by one bus, two adjacent buses, or multiple adjacent buses. The DC contactors between buses in the same group are set to normally closed. If N≤3, each bus group is connected to each other bus group through a DC contactor, and the remaining DC contactors are set to normally open. If N > 4, each bus group is connected to the other three bus groups through a DC contactor, and the remaining DC contactors are set to normally open.
10. A parallel scheduling method for a charging pile power distribution device, characterized in that, include: Based on the configuration method described in claim 9, each charging pile power distribution device is configured; Based on the total number of output terminals required by all charging pile power distribution devices to be connected in parallel, at least one pair of busbars between two adjacent charging pile power distribution devices are connected by cables. Power dispatch is achieved by closing all DC contactors between any two busbars.