Soft switching control device for power optimizer

Abstract

This invention provides a soft-switching control device for a power optimizer, comprising: a substrate, a circuit structure, an insulating dustproof frame, a power resonant transistor, a control chip, and a main control drive module. The substrate determines the position of the circuit structure, which is covered by the insulating dustproof frame and also determines the positions of the power resonant transistor, the control chip, and the main control drive module. This invention improves upon the substrate by using a clamping frame and soldering layer on a balance plate, along with a central restraint body, to effectively position the bottom PCB board of the circuit structure in parallel soldering. The combination of a calibration fixing body and the balance plate prevents tilting and bending. Furthermore, the use of corner connectors effectively improves the connection balance with the power optimizer. The connectors and magnetic fasteners prevent displacement that occurs during traditional soldering, thus ensuring the connection accuracy between the soft switch and the power optimizer, and preventing component misalignment due to positional deviation.

Description

Technical Field

[0001] This invention relates to the field of switching control technology, and more specifically to a soft-switching control device for a power optimizer. Background Technology

[0002] Power optimizers are core component-level DC / DC conversion devices in energy storage systems. They can achieve independent operating condition regulation and power matching for each energy storage battery cell, accurately adapt and dynamically adjust the voltage and current state of individual cells, and perfectly connect to the back-end energy storage converter equipment. They effectively solve problems such as inconsistency differences and operating condition matching deviations between energy storage battery strings, and significantly improve the charging and discharging efficiency and overall usable capacity of the energy storage system.

[0003] To meet the high-frequency, high-efficiency, and low-loss operation requirements of energy storage batteries, the soft-switching control device on the power optimizer can operate based on the LC resonance principle to realize the ZVS zero-voltage switching and ZCS zero-current switching operation modes of MOSFET devices. Among them, the zero-voltage switching allows the device to complete the conduction and turn-off actions when the voltage across its terminals approaches zero, and the zero-current switching allows the device to complete the switching when the current flowing through it approaches zero, completely avoiding the overlapping range of voltage and current during power conversion, and significantly reducing the switching loss and conduction loss of the device. In summary, the inventors have found that existing soft-switching control devices have the following main defects: When the substrate of the current soft-switching control device is connected and adapted to the power optimizer in parallel, the overall substrate is prone to displacement during welding due to its light weight and small size. This easily reduces the connection accuracy with the power optimizer, thereby affecting the accuracy of the docking between various components, which in turn reduces the production efficiency and yield of the current soft-switching control device and power optimizer. Summary of the Invention

[0004] The technical solution adopted by the present invention to achieve the technical objective is: a soft-switching control device for a power optimizer, the structure of which includes: a substrate, a circuit structure, an insulating dustproof frame, a power resonant transistor, a control chip, and a main control drive module. The substrate determines the position of the circuit structure, and the circuit structure is covered by the insulating dustproof frame and determines the position of the power resonant transistor, the control chip, and the main control drive module.

[0005] As a further improvement of the present invention, the substrate is provided with a calibration fixture, a balance plate, a clamping frame, a welding layer, and a central restraint. The calibration fixture and the balance plate are parallel to each other, and the clamping frame of the balance plate is welded to the edge of the PCB board of the circuit structure through the welding layer and centrally restrained by the central restraint.

[0006] As a further improvement of the present invention, the calibration fixture is further provided with a connector block, a bonding layer, a magnetic block, a central frame, and a limiting groove. The connector block is located at the corner of the bonding layer and the magnetic block is located at the edge. The central frame and the limiting groove are located at the center of the bonding layer and match the position of the clamping frame.

[0007] As a further improvement of the present invention, the alignment fixing body with the parallel balance plates of the substrate allows the plug block of the bonding layer to be embedded inside the power optimizer for position determination. Then, the magnetic block is adsorbed onto the inner wall of the power optimizer, and the position of the clamping frame is determined by the central frame and the limiting groove, so that the clamping frame is precisely fixed to the PCB board of the circuit structure through the soldering layer and the central restraint body.

[0008] As a further improvement of the present invention, the substrate and the circuit structure are parallel to each other, the insulating dustproof frame of the circuit structure is in a raised shape to position the power resonant tube, and there is a safe distance between the control chip and the main control drive module.

[0009] As a further improvement of the present invention, the surface layer of the calibration fixture is parallel to the lower layer of the balance plate, the clamping frame size of the balance plate is adapted to the size of the circuit structure, and the position of the PCB board of the circuit structure is determined by the insertion of the central restraint body.

[0010] As a further improvement of the present invention, the connector block is in the form of a protrusion and four blocks are provided at the corner of the bonding layer. The magnetic block of the bonding layer is parallel to the edge of the bonding layer. The limiting groove of the central frame provides a fixed position for the precise center of the clamping frame.

[0011] As a further improvement of the present invention, the connector block is also provided with a combination block, the lower end of the combination block is fused with the upper end of the block body through a fusion layer, the lower end of the block body is connected to an electric block, and a constant temperature block is also mounted on the side of the block body.

[0012] As a further improvement of the present invention, the combined block is on the same vertical line as the energized block, and the energized block of the block will be inserted into the power optimizer and electrically connected to it. The constant temperature block is cuboid in shape and has a cooling effect to reduce the temperature of the entire substrate.

[0013] As a further improvement of the present invention, the block is also provided with a sliding layer, an insulating block is provided inside the sliding layer, and a connecting groove is opened at one end of the insulating block to communicate with the wiring rail opened inside. A reinforcing sleeve is also provided at the edge of the wiring rail.

[0014] As a further improvement of the present invention, the sliding layer is finely polished and the insulating block combined with the reinforcing sleeve determines the position of the wiring rail. The wiring rail is "L" shaped to conform to the setting direction of the energizing block and the constant temperature block. The connecting groove allows one end of the constant temperature block to be embedded and fixedly connected to the wiring rail.

[0015] As a further improvement of the present invention, the central restraint body is provided with an auxiliary block, which is located at the center of the protrusion. The edge of the protrusion is provided with a penetrating layer to allow the spring to pass through, and one end of the spring is connected to a reinforcing block.

[0016] As a further improvement of the present invention, the auxiliary block is aligned with the center position of the protrusion and four springs pass through the edge penetration layer. The reinforcing block at one end of the spring can press and reinforce the lower center edge of the PCB board of the circuit structure by the spring rebound.

[0017] As a further improvement of the present invention, the auxiliary block is also provided with a contact layer, which is integrated with the irregular block. The irregular block is connected to a locking bolt at its center and a positioning block is provided at its edge.

[0018] As a further improvement of the present invention, the contact layer matches the shape of the irregular block, the locking bolt of the irregular block is located in the center and locks the center of the protrusion through it, and the positioning block has four pieces that match the number of four springs and fixes one end of the spring.

[0019] Compared with the prior art, the present invention has the following beneficial effects: 1. This invention, through the improvement of the substrate, effectively positions the bottom PCB board of the circuit structure by parallel welding through the clamping frame and welding layer on the balance plate and the central restraint body. Then, the combination of the calibration fixing body and the balance plate can avoid tilting and bending. Furthermore, the use of corner plug-in blocks can effectively improve the connection balance with the power optimizer. The plug-in blocks and magnetic fasteners can avoid displacement that occurs during the original welding. Therefore, it can ensure the connection accuracy between the soft switch and the internal part of the power optimizer and prevent component misalignment caused by positional deviation.

[0020] 2. The present invention improves upon the plug-in block by combining the upper block and the fusion layer, thereby enhancing the vertical stability of the connection with the corners of the bonding layer. Then, the lower block, after being electrically connected to the power optimizer, enables the start-up temperature control block to operate. The temperature control block, by being embedded inside the balance plate, reduces the overall temperature, thus effectively lowering the temperature of the entire device and consequently reducing the internal temperature of the power optimizer, preventing the high temperatures caused by the power optimizer from becoming difficult to handle.

[0021] 3. In this invention, after the central restraint body is improved, the auxiliary block and the center of the protrusion are interconnected. The four springs can be positioned by the positioning block on the edge of the irregular block. This allows the springs to rebound and be fixed in place after being embedded in the PCB board of the circuit structure with the reinforcing block, preventing gaps and loosening during assembly. At the same time, the protrusion is fixed together with the central locking bolt, ensuring the firmness of the overall component after splicing and preventing loosening. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of a soft-switching control device, which is a type of power optimizer.

[0023] Figure 2 This is a schematic diagram of a three-dimensional structure of an improved substrate.

[0024] Figure 3 This is a top-view structural diagram of an improved calibration fixture.

[0025] Figure 4 This is a three-dimensional structural diagram of an improved connector block.

[0026] Figure 5 This is a schematic diagram of a cross-sectional view of a modified block structure.

[0027] Figure 6 This is a top-view structural diagram of an improved central restraint block.

[0028] Figure 7 This is a cross-sectional structural diagram of an improved auxiliary block.

[0029] In the diagram: substrate-1, circuit structure-2, insulating dustproof frame-3, power resonant tube-4, control chip-5, main control drive module-6; Calibration fixture-11, balance plate-12, clamping frame-13, welding layer-14, central restraint body-15; Connector block-111, bonding layer-112, magnetic block-113, center frame-114, limiting groove-115; Combined block-1111, fusion layer-1112, block-1113, power-conducting block-1114, constant temperature block-1115; Sliding layer-1131, insulating block-1132, connecting groove-1133, wiring rail-1134, reinforcing sleeve-1135; Auxiliary block-151, protrusion-152, penetrating layer-153, spring-154, reinforcing block-155; Contact layer-1511, irregular block-1512, locking bolt-1513, positioning block-1514. Detailed Implementation

[0030] The present invention will be further described below with reference to the accompanying drawings: Example 1: Figures 1 to 5 As shown: This invention provides a soft-switching control device for a power optimizer. Its structure includes: a substrate 1, a circuit structure 2, an insulating dustproof frame 3, a power resonant tube 4, a control chip 5, and a main control drive module 6. The substrate 1 determines the position of the circuit structure 2, and the circuit structure 2 is covered by the insulating dustproof frame 3 and determines the position of the power resonant tube 4, the control chip 5, and the main control drive module 6.

[0031] The substrate 1 is provided with a calibration fixing body 11, a balance plate 12, a clamping frame 13, a welding layer 14, and a central restraint body 15. The calibration fixing body 11 and the balance plate 12 are parallel to each other, and the clamping frame 13 of the balance plate 12 is welded to the edge of the PCB board of the circuit structure 2 through the welding layer 14 and centrally restrained by the central restraint body 15.

[0032] The calibration fixture 11 is further provided with a connector block 111, an adhesive layer 112, a magnetic block 113, a central frame 114, and a limiting groove 115. The connector block 111 is located at the corner of the adhesive layer 112 and the magnetic block 113 is located at the edge. The central frame 114 and the limiting groove 115 are located at the center of the adhesive layer 112 and match the position of the clamping frame 13.

[0033] In this process, the alignment fixing body 11, which is parallel to each other on the balance plate 12 of the substrate 1, allows the plug block 111 of the bonding layer 112 to be embedded inside the power optimizer for position determination. Then, the magnetic block 113 is attracted to the inner wall of the power optimizer. The center frame 114 and the limiting groove 115 determine the position of the clamping frame 13, so that the clamping frame 13 is precisely fixed and connected to the PCB board of the circuit structure 2 through the soldering layer 14 and the central restraint body 15.

[0034] The substrate 1 and the circuit structure 2 are parallel to each other. The insulating dustproof frame 3 of the circuit structure 2 is in a raised shape to position the power resonant tube 4. The control chip 5 and the main control drive module 6 are spaced apart.

[0035] The surface of the calibration fixture 11 is parallel to the lower layer of the balance plate 12. The size of the clamping frame 13 of the balance plate 12 is adapted to the size of the circuit structure 2, and the position of the PCB board of the circuit structure 2 is determined by the insertion of the central restraint body 15.

[0036] The connector 111 is protruding and four of them are provided at the corners of the bonding layer 112. The magnetic block 113 of the bonding layer 112 is parallel to the edge of the bonding layer 112. The limiting groove 115 of the central frame 114 provides a fixed position for the precise center of the clamping frame 13.

[0037] The connector block 111 is further provided with a combination block 1111. The lower end of the combination block 1111 is integrated with the upper end of the block body 1113 through a fusion layer 1112. The lower end of the block body 1113 is connected to a power-conducting block 1114. A constant temperature block 1115 is also mounted on the side of the block body 1113.

[0038] The combined block 1111 is on the same vertical line as the energized block 1114 via the block body 1113. The energized block 1114 of the block body 1113 will be inserted into the power optimizer and electrically connected to it. The constant temperature block 1115 is cuboid in shape and has a cooling effect to reduce the temperature of the entire substrate 1.

[0039] The block 1113 is also provided with a sliding layer 1131. An insulating block 1132 is provided inside the sliding layer 1131, and a connecting groove 1133 is opened at one end of the insulating block 1132 to communicate with the wiring rail 1134 opened inside. A reinforcing sleeve 1135 is also provided on the edge of the wiring rail 1134.

[0040] The sliding layer 1131 is finely polished, and the insulating block 1132 combined with the reinforcing sleeve 1135 determines the position of the wiring rail 1134. The wiring rail 1134 is "L" shaped to match the setting direction of the energizing block 1114 and the constant temperature block 1115. The connecting groove 1133 allows one end of the constant temperature block 1115 to be embedded and fixedly connected to the wiring rail 1134.

[0041] The specific functions and operation procedures of this embodiment are as follows: In this invention, the soft-switching controller of the power optimizer can be installed inside the power optimizer via a substrate 1, which integrates the overall circuit structure 2, the insulating dustproof frame 3, the power resonant transistor 4, the control chip 5, and the main control drive module 6. Upon power-up, the soft-switching control device automatically operates. The control chip 5, in conjunction with the circuit structure 2 (power main circuit, drive and sampling circuit), samples the component voltage / current and calculates the maximum power point in real time using the MPPT algorithm. It then drives the power MOSFET to perform ZVS / ZCS soft switching, reducing losses and heat generation, and outputting a stable DC voltage (e.g., 85V) to the subsequent stage. The entire process is automatic, requiring no manual intervention. Faults are reported through the backend. The soft-switching control device, when installed inside the power optimizer, can be precisely fixed using the substrate 1. The balance plate 12 of the substrate 1, through the clamping frame 13, the soldering layer 14, and the central restraint body 15, precisely positions and restrains the PCB board at the lower end of the circuit structure 2. Edge welding is then performed through the soldering layer 14 to form a stable integrated structure, thus enabling calibration. The fixing body 11 is directly and parallelly embedded inside the power optimizer. The connectors 111 at the corners of the bonding layer 112 of the fixing body 11 can achieve parallel positioning of the entire bonding layer 112 through the interlocking effect. At the same time, the magnetic block 113 can prevent positional displacement during welding. Furthermore, the central frame 114 and the limiting groove 115 can forcibly position the central restraint body 15 and the circuit structure 2, avoiding tilting or displacement. Therefore, it can effectively improve the connection accuracy between the soft-switching controller and the power optimizer, and ensure precision during production and assembly. This improves accuracy and product yield. The plug block 1113 can then be fixedly connected to the lower corner of the balance plate 12 via the upper fusion layer 1112 and the assembly block 1111. The lower energized block 1114 of the plug block 1113 is then inserted into the power optimizer for electrical connection. During insertion, the insulating block 1132 can be carried into the power optimizer via the sliding layer 1131. Subsequently, the wiring in the wiring rail 1134 can be guided by the reinforcing sleeve 1135 into the connecting groove 1133 and the constant temperature block 1115. Electrical connection is established to power the thermostat block 1115. The thermostat block 1115, embedded inside the edge of the balance plate 12, can cool from the inside. After lowering the temperature of the entire balance plate 12, it continues to lower the temperature inside the entire power optimizer. This prevents damage to components caused by high internal temperatures and improves control accuracy. It also prevents the high internal temperatures caused by factors affecting the soft-switching control device located inside the power optimizer from being difficult to resolve. Therefore, it further improves the safety factor and stability of the soft-switching controller in actual use.

[0042] Example 2: Figures 6 to 7 As shown: This invention provides a soft-switching control device for a power optimizer. Its structure includes an auxiliary block 151 provided in the central restraint body 15, the auxiliary block 151 being located at the center of the protrusion 152, a penetrating layer 153 being provided on the edge of the protrusion 152 for the spring 154 to pass through, and a reinforcing block 155 being connected to one end of the spring 154.

[0043] The auxiliary block 151 is aligned with the center of the protrusion 152 and four springs 154 pass through the edge penetration layer 153. The reinforcing block 155 at one end of the spring 154 can press and reinforce the lower center edge of the PCB board of the circuit structure 2 by the rebound of the spring 154.

[0044] The auxiliary block 151 is also provided with a contact layer 1511, which is integrated with the irregular block 1512. The irregular block 1512 is connected to a locking bolt 1513 at its center and has a positioning block 1514 at its edge.

[0045] The contact layer 1511 and the irregular block 1512 are matched in shape. The locking bolt 1513 of the irregular block 1512 is located in the center and locks the center of the protrusion 152 through it. The positioning block 1514 has four blocks that match the number of four springs 154 and fixes one end of the springs 154.

[0046] The specific functions and operation procedures of this embodiment are as follows: In this invention, the auxiliary block 151 of the central restraint body 15 can stably fix the four positioning blocks 1514 to the center position of the protrusion 152 through the locking bolt 1513 in the center of the irregular block 1512. The penetrating layer 153 on the edge of the protrusion 152 allows the spring 154 positioned by the positioning block 1514 to pass through. The reinforcing block 155 set at one end of the spring 154 can be embedded in the center of the PCB board at the lower end of the circuit structure 2. The spring 154's rebound pushing effect allows the reinforcing block 155 to directly press against the edge of the connection position, thus achieving a reinforcing and fixing effect. This avoids loosening due to gaps during vertical insertion assembly, thereby further improving the positioning accuracy of the circuit structure 2 of the soft switch control device and the accuracy during use.

[0047] Any technical solution that achieves the above-mentioned technical effects by utilizing the technical solutions described in this invention, or by designing similar technical solutions by those skilled in the art under the inspiration of the technical solutions described in this invention, falls within the protection scope of this invention.

Claims

1. A soft-switching control device for a power optimizer, comprising: The circuit includes a substrate (1), a circuit structure (2), an insulating dustproof frame (3), a power resonant tube (4), a control chip (5), and a main control drive module (6). The substrate (1) determines the position of the circuit structure (2), which is covered by the insulating dustproof frame (3) and determines the positions of the power resonant tube (4), the control chip (5), and the main control drive module (6). The circuit structure (2) is characterized by: The substrate (1) is provided with a calibration fixture (11), a balance plate (12), a clamping frame (13), a welding layer (14), and a central restraint (15). The calibration fixture (11) and the balance plate (12) are parallel to each other, and the clamping frame (13) of the balance plate (12) is welded to the edge of the PCB board of the circuit structure (2) through the welding layer (14) and centrally limited by the central restraint (15). The calibration fixture (11) is also provided with a connector (111), a bonding layer (112), a magnetic block (113), a central frame (114), and a limiting groove (115). The connector (111) is located at the corner of the bonding layer (112) and the magnetic block (113) is located at the edge. The central frame (114) and the limiting groove (115) are located at the center of the bonding layer (112) and match the position of the clamping frame (13). By using the parallel calibration fixtures (11) of the balance plate (12) of the substrate (1) to cooperate with each other, the plug block (111) of the bonding layer (112) can be embedded inside the power optimizer for position determination. Then, the magnetic block (113) is attached to the inner wall of the power optimizer, and the center frame (114) and the limiting groove (115) determine the position of the clamping frame (13), so that the clamping frame (13) is precisely fixedly connected to the PCB board of the circuit structure (2) through the soldering layer (14) and the center restraint (15).

2. The soft-switching control device for a power optimizer according to claim 1, characterized in that: The substrate (1) and the circuit structure (2) are parallel to each other. The insulating dustproof frame (3) of the circuit structure (2) is in a raised shape to position the power resonant tube (4). There is a safe distance between the control chip (5) and the main control drive module (6).

3. The soft-switching control device for a power optimizer according to claim 1, characterized in that: The surface of the calibration fixture (11) is parallel to the lower layer of the balance plate (12). The size of the clamping frame (13) of the balance plate (12) is adapted to the size of the circuit structure (2), and the position of the PCB board of the circuit structure (2) is determined by the insertion of the central restraint body (15).

4. The soft-switching control device for a power optimizer according to claim 1, characterized in that: The connector (111) is in a raised shape and four of them are provided at the corner of the bonding layer (112). The magnetic block (113) of the bonding layer (112) is parallel to the edge of the bonding layer (112). The limiting groove (115) of the center frame (114) provides a fixed position for the precise center of the clamping frame (13).

5. The soft-switching control device for a power optimizer according to claim 1, characterized in that: The connector block (111) is also provided with a combination block (1111). The lower end of the combination block (1111) is integrated with the upper end of the block body (1113) through a fusion layer (1112). The lower end of the block body (1113) is connected to a power block (1114). A constant temperature block (1115) is also mounted on the side of the block body (1113). The combined block (1111) is on the same vertical line as the block body (1113) and the energized block (1114). The energized block (1114) of the block body (1113) will be inserted into the power optimizer and electrically connected to it. The constant temperature block (1115) is cuboid in shape and has a cooling effect to reduce the temperature of the entire substrate (1).

6. The soft-switching control device for a power optimizer according to claim 5, characterized in that: The block (1113) is also provided with a sliding layer (1131), an insulating block (1132) is provided inside the sliding layer (1131), and a connecting groove (1133) is opened at one end of the insulating block (1132) to communicate with the wiring rail (1134) opened inside. A reinforcing sleeve (1135) is also provided on the edge of the wiring rail (1134). The sliding layer (1131) is finely polished and the insulating block (1132) combined with the reinforcing sleeve (1135) determines the position of the wiring rail (1134). The wiring rail (1134) is "L" shaped to match the setting direction of the energizing block (1114) and the constant temperature block (1115). The connecting groove (1133) allows one end of the constant temperature block (1115) to be embedded and fixedly connected to the wiring rail (1134) for electrical connection.

7. The soft-switching control device for a power optimizer according to claim 1, characterized in that: The central restraint body (15) is provided with an auxiliary block (151). The auxiliary block (151) is located at the center of the protrusion (152). The edge of the protrusion (152) is provided with a penetrating layer (153) to allow the spring (154) to pass through. One end of the spring (154) is connected to a reinforcing block (155). The auxiliary block (151) is aligned with the center of the protrusion (152) and the four springs (154) pass through the edge penetration layer (153). The reinforcing block (155) at one end of the spring (154) can press and reinforce the lower center edge of the PCB board of the circuit structure (2) by the spring (154) rebounding.

8. The soft-switching control device for a power optimizer according to claim 7, characterized in that: The auxiliary block (151) is also provided with a contact layer (1511), which is integrated with the irregular block (1512). The irregular block (1512) has a locking bolt (1513) connected to its center and a positioning block (1514) provided at its edge. The contact layer (1511) and the irregular block (1512) are matched in shape. The locking bolt (1513) of the irregular block (1512) is located in the center and locks the center of the protrusion (152). The positioning block (1514) has four blocks that match the number of four springs (154) and fixes one end of the spring (154).

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