A one-piece direct current charger without louvers

Abstract

The present application relates to the technical field of DC charger, in particular to a one-piece DC charger without louvers, which provides a one-piece DC charger without louvers, comprising a cabinet, which is divided into a front compartment and a rear compartment, and is hinged with a front door, the front compartment is provided with a front door assembly, a DC output area, an AC input area and a control area, the rear compartment is provided with an air inlet assembly, an air outlet assembly and a module area, a left 12 / 24V auxiliary source and a right 12 / 24V auxiliary source are fixed at the middle position of the front compartment, and the left 12 / 24V auxiliary source and the right 12 / 24V auxiliary source are electrically connected with the devices of the control area respectively, and a guide rail and a system auxiliary source are fixed below the control area in the cabinet. The present application has the advantages of simple structure, convenient installation, reduced cabinet cost, improved appearance, better heat dissipation of the whole machine, device layout, user convenience, improved assembly efficiency and user experience.

Description

Technical Field

[0001] This invention relates to the field of DC charger technology, and specifically to an integrated DC charger without louvers. Background Technology

[0002] With the development of electric vehicles, charging stations have also experienced explosive growth. Nationwide, the construction and installation of charging stations are being encouraged and supported to meet the charging needs of electric vehicles. When purchasing charging stations, factors such as charging speed, appearance design, component layout, footprint, price, and ease of use directly impact their market share.

[0003] Existing DC chargers use a louvered air intake and exhaust structure, which obstructs airflow and affects the overall heat dissipation. In addition, the structure is complex, difficult to install, and has a high manufacturing cost. Furthermore, the scattered layout of components inside the DC charger results in an uncompacted overall cabinet structure, wasted internal space, a large footprint, and inconvenience for users to assemble and maintain.

[0004] This invention proposes an integrated DC charger without louvers. By using an air inlet funnel and an air outlet funnel, it achieves a simple structure, convenient installation, reduced cabinet costs, improved appearance, and better heat dissipation. Through the layout of components, it can not only meet the user's convenience but also improve assembly efficiency and enhance the user experience. Summary of the Invention

[0005] The purpose of this invention is to overcome the shortcomings of the prior art and provide an integrated DC charger without louvers. This solves the problems mentioned in the background art, where the existing DC chargers with louvered air inlet and outlet structures obstruct airflow, affecting the overall heat dissipation effect. Furthermore, the existing DC chargers have complex structures, are difficult to install, and have high manufacturing costs. Additionally, the dispersed layout of components within the DC charger results in an insufficiently compact overall cabinet structure, wasted internal space, a large footprint, and inconvenience for user assembly and maintenance.

[0006] To achieve the above objectives, the present invention adopts the following technical solution: This invention provides a louver-free integrated DC charger, including a cabinet divided into a front compartment and a rear compartment. A front door is hinged to the cabinet. The front compartment includes a front door assembly, a DC output area, an AC input area, and a control area. The rear compartment includes an air inlet assembly, an air outlet assembly, and a module area. A left-side 12 / 24V auxiliary power source and a right-side 12 / 24V auxiliary power source are fixed in the middle of the front compartment. The left-side and right-side 12 / 24V auxiliary power sources are electrically connected to the devices in the control area. Inside the cabinet, below the control area, a guide rail and a system auxiliary power source are fixed. A circuit breaker, a meter, a socket, a terminal block, and a diode are fixed on the guide rail. The system auxiliary power source is electrically connected to the devices in the front door assembly.

[0007] In one possible implementation, the AC input area includes a copper busbar, a molded case circuit breaker, an air switch, and a surge protector fixed in the front compartment. The molded case circuit breaker has one 800A input and is fixed at the bottom of the front compartment. The incoming line of the molded case circuit breaker is bottom-in and top-out. The back panel of the cabinet is bundled with power lines, which are connected to the output port of the molded case circuit breaker.

[0008] In one possible implementation, the DC output area includes a copper busbar, a DC contactor, a fuse, and a shunt fixed to the front compartment, the DC output area being located above the front compartment, and the DC output area employing top-out wiring.

[0009] In one possible implementation, the air outlet assembly includes an air outlet door panel hinged to the left side of the cabinet, a nut post riveted to the air outlet door panel, an air outlet funnel fixed to the air outlet door panel by the nut and the nut post, and a system fan fixed to the air outlet funnel by self-tapping screws.

[0010] In one possible implementation, the air inlet assembly includes an air inlet door panel hinged to the right side of the cabinet, a mesh fixed on the air inlet door panel, a nut post riveted to the air inlet door panel, an air inlet funnel fixed to the air inlet door panel by the nut and the nut post, a dustproof mesh pressure plate snapped onto the air inlet funnel, and a polyurethane dustproof mesh placed between the air inlet funnel and the dustproof mesh pressure plate.

[0011] In one possible implementation, the control area includes a control panel, a signal acquisition unit, and a battery management system fixed to the front compartment.

[0012] In one possible implementation, a wooden pallet is placed at the bottom of the cabinet, and two lifting rings are fixed at the top of the cabinet.

[0013] In one possible implementation, the front door assembly includes a display screen, a three-color indicator light, a SOC digital display, a card reader, a central control board, and a door lock fixed to the front door.

[0014] In one possible implementation, gun mounts and charging cables are symmetrically fixed on both the left and right sides of the cabinet, with a charging gun fixed on the charging cable, and an antenna and an emergency stop button fixed on the right side of the cabinet.

[0015] The beneficial effects of this invention are as follows: Compared with the prior art, this invention forms an air duct by using an air inlet funnel and an air outlet funnel in conjunction with a system fan. This results in fewer parts, a simpler assembly process, and a polyurethane dustproof mesh and dustproof mesh pressure plate on the air inlet side, ensuring dustproof performance. While simplifying the structure, it also ensures the dustproof and heat dissipation needs of the internal components of the cabinet. The reduction of louvers makes the overall structure simple, easy to install, and lowers the cost of the cabinet. Through the component layout, it can meet the user's convenience, improve assembly efficiency, and enhance the user experience. This invention solves the technical problems of existing DC chargers using louvered air inlet and outlet structures, which hinder airflow, affect the overall heat dissipation effect, and have complex structures, high installation difficulty, and high manufacturing costs. Furthermore, the dispersed layout of components inside the DC charger results in an insufficiently compact overall cabinet structure, wasted internal space, a large footprint, and inconvenience for user assembly and maintenance. Attached Figure Description

[0016] Figure 1 The front view of the internal layout of an integrated DC charger without louvers provided by the present invention.

[0017] Figure 2 Right view of the internal layout of an integrated DC charger without louvers provided by the present invention.

[0018] Figure 3 Left view of the internal layout of an integrated DC charger without louvers provided by the present invention.

[0019] Figure 4 The rear view of an integrated DC charger without louvers provided by the present invention.

[0020] Figure 5 An exploded view of the air inlet assembly in an integrated DC charger without louvers provided by the present invention.

[0021] Figure 6 An exploded view of the air outlet assembly in an integrated DC charger without louvers provided by the present invention.

[0022] Attached diagram labels: 1. Cabinet; 2. DC Output Area; 3. Control Board; 4. Left 12 / 24V Auxiliary Power Supply; 5. Right 12 / 24V Auxiliary Power Supply; 6. Guide Rail; 7. Air Outlet Assembly; 7-1. Air Outlet Door Panel; 7-3. Air Outlet Funnel; 8. Molded Case Circuit Breaker; 9. AC Input Area; 10. Wooden Pallet; 11. Gun Cable; 12. Charging Gun; 13. System Auxiliary Power Supply; 15. Air Inlet Assembly; 15-1. Air Inlet Door Panel; 15-2. Polyurethane Dustproof Net; 15-3. Air Inlet Funnel; 15-4. Dustproof Net Pressure Plate; 17. Lifting Ring; 18. Front Door Assembly; 19. Module Area; 20. Antenna; 21. Emergency Stop Button; 22. System Fan; 23. Gun Mount. Detailed Implementation

[0023] To solve the above-mentioned technical problems, the present invention provides an integrated DC charger without louvers. The technical solution and embodiments of the present invention will now be described in detail with reference to the accompanying drawings.

[0024] In the description of this application, it should be understood that the terms "center", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application.

[0025] In the description of this application, it should be noted that, unless otherwise expressly specified and limited, the terms "installation", "connection" and "joining" should be interpreted broadly, for example, they can refer to fixed connection, detachable connection, or integral connection; for those skilled in the art, the specific meaning of the above terms in this application can be understood according to the specific circumstances.

[0026] The terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this application, unless otherwise stated, "a plurality of" means two or more.

[0027] like Figures 1 to 6 As shown, the present invention provides an integrated DC charger without louvers, including a cabinet 1, which is divided into a front compartment and a rear compartment. A front door is hinged to the cabinet 1. The front compartment is provided with a front door assembly 18, a DC output area 2, an AC input area 9, and a control area. The rear compartment is provided with an air inlet assembly 15, an air outlet assembly 7, and a module area 19. A left 12 / 24V auxiliary power source 4 and a right 12 / 24V auxiliary power source 5 are fixed in the middle of the front compartment. The left 12 / 24V auxiliary power source 4 and the right 12 / 24V auxiliary power source 5 are electrically connected to the devices in the control area. Inside the cabinet 1, below the control area, a guide rail 6 and a system auxiliary power source 13 are fixed. A circuit breaker, a meter, a socket, a terminal block, and a diode are fixed on the guide rail 6. The system auxiliary power source 13 is electrically connected to the devices in the front door assembly 18. The two 12 / 24V auxiliary power sources are located in the middle of the front compartment to supply power to the control area.

[0028] Cabinet 1 is divided into two independent areas: the front compartment and the rear compartment. The power modules are arranged in the rear compartment air duct area, while AC input area 9, DC output area 2, auxiliary power supply, control and other components are concentrated in the front compartment. The strong and weak components are separated into compartments with independent air ducts. The components have high reliability and longer lifespan, which can not only meet the user's convenience, but also improve assembly efficiency and enhance the user experience.

[0029] In one optional embodiment, the AC input area 9 includes a copper busbar, a molded case circuit breaker, an air switch, and a surge protector fixed in the front compartment. A single 800A input molded case circuit breaker 8 is used, fixed at the bottom of the front compartment. The incoming line of the molded case circuit breaker 8 is bottom-in, top-out. Power lines are bundled on the back panel of the cabinet 1 and connected to the outgoing port of the molded case circuit breaker 8. Using a single 800A input molded case circuit breaker 8 reduces device heat generation. The molded case circuit breaker 8 is located at the bottom of the front compartment of the cabinet 1, without an air inlet. This layout allows for wiring and operation from the front compartment, accessible simply by opening the front door, facilitating on-site wiring and maintaining an independent air duct to prevent various impacts and failures caused by its location within the air duct. This layout also results in higher space utilization and a more compact structure for the entire unit.

[0030] This DC charger uses 380V industrial power, a three-phase five-wire system. The molded case circuit breaker 8 has a bottom-in, top-out configuration for its input lines, which reduces the length of the copper busbar and lowers the overall manufacturing cost. The power lines are connected to the output ports of the molded case circuit breaker 8 and are bundled to the back panel of cabinet 1, going sequentially to the AC terminals of each module. Each module's DC terminal has two positive and two negative terminals. The DC output power lines pass through the cable guards on the device mounting plate of cabinet 1 and then run from the rear compartment to the front compartment, where they are sequentially connected to the positive and negative terminals of the copper busbar in the DC output area 2.

[0031] In one optional embodiment, gun mounting brackets 23 and gun wires 11 are symmetrically fixed on both the left and right sides of the cabinet 1. A charging gun 12 is fixed on the gun wire. An antenna 20 and an emergency stop button 21 are fixed on the right side of the cabinet 1. The gun wires 11 are symmetrically distributed. The charging guns 12 are divided into left and right guns, located on the left and right sides of the cabinet 1. Their structural design is completely identical. This compartmentalized layout of the devices not only makes the structure symmetrical and neat, but also effectively reduces the heat exchange during the operation of the cabinet 1 and improves the service life of the devices.

[0032] In one optional embodiment, the DC output area 2 includes a copper busbar, a DC contactor, a fuse, and a shunt fixed in the front compartment. The DC output area 2 is located above the front compartment and adopts an upward cable exit method. Placing the DC output area 2 above the front compartment of the cabinet 1 and adopting an upward cable exit method reduces the risk of the gun cable 11 dragging on the ground, facilitates the user's use of the rear gun insertion and cable coiling operation, and improves the user experience.

[0033] The cabinet 1 can switch between three models with a total power of 240kW, 360kW and 400kW. By reducing the number of power modules and increasing or decreasing the system fan 22, and with other components meeting the cabinet selection design requirements for 240kW, 360kW and 400kW, the cabinet 1 can be modified from 400kW to 240kW, saving R&D costs.

[0034] In one optional embodiment, the air outlet assembly 7 includes an air outlet door plate 7-1 hinged to the left side of the cabinet 1. A nut post is riveted to the air outlet door plate 7-1, and an air outlet funnel 7-3 is fixed to the air outlet door plate 7-1 by the nut and nut post. A system fan 22 is fixed to the air outlet funnel 7-3 by self-tapping screws. The air inlet assembly 15 includes an air inlet door plate 15-1 hinged to the right side of the cabinet 1. A mesh is fixed to the air inlet door plate 15-1, and a nut post is riveted to the air inlet door plate 15-1. An air inlet funnel 15-3 is fixed to the air inlet door plate 15-1 by the nut and nut post. A dustproof mesh pressure plate 15-4 is snapped onto the air inlet funnel 15-3. The air inlet funnel 15-3 and the dustproof mesh pressure plate 15-4 are connected. A polyurethane dustproof net 15-2 is placed between the dust net pressure plate 15-4. The traditional heat dissipation louver structure of this cabinet 1 is eliminated. The air duct is formed by the air inlet funnel 15-3 and the air outlet funnel 7-3 in conjunction with the system fan 22. The funnel structure plays the role of airflow convergence and acceleration. Stable directional airflow can be formed without the need for louver guidance. The number of parts is reduced and the assembly process is simplified. The air inlet side is equipped with a polyurethane dustproof net 15-2 and a dustproof net pressure plate 15-4 to ensure dustproof performance. The polyurethane dustproof net 15-2 can block dust from entering the module area. While simplifying the structure, it ensures the dustproof and heat dissipation requirements of the internal components of the cabinet 1. The reduction of louvers makes the overall structure simple, easy to install, and reduces the cost of the cabinet 1.

[0035] In one optional embodiment, the control area includes a control board 3, a signal acquisition unit, and a battery management system fixed in the front compartment. Two sets of 12 / 24V auxiliary power supplies are symmetrically arranged on the left and right sides of the center of the front compartment to provide power to the control area. The power supply layout is centralized and stable, ensuring the continuous and reliable operation of the control board 3, battery management system, signal acquisition unit, and other low-voltage control components.

[0036] In one optional embodiment, a wooden pallet 10 is placed at the lower end of the cabinet 1, and two lifting rings 17 are fixed at the upper end of the cabinet 1. The top of the cabinet 1 is equipped with lifting rings 17, and the bottom can be fitted with wooden pallets 10 to support hoisting and pallet transfer, which facilitates equipment delivery from the factory and on-site loading, unloading and handling.

[0037] In one optional embodiment, the front door assembly 18 includes a display screen 18-1, a three-color indicator light 18-2, a SOC digital display 18-3, a card reader door panel 18-4, a central control board 18-5, and a door lock 18-6 fixed on the front door. The front door integrates human-computer interaction components such as the display screen 18-1, the three-color indicator light 18-2, the SOC digital display 18-3, the card reader door panel 18-4, the central control board 18-5, and the door lock 18-6, resulting in high integration, a neat overall appearance, and convenient operation for staff.

[0038] Working principle: When the system fan 22 is started, cold air enters through the mesh of the air inlet panel 15-1 on the right side of the cabinet 1. After being filtered by the air inlet funnel 15-3 and the polyurethane dustproof mesh 15-2, it is blown in a direction towards the power module in the rear compartment. After the power module heats up, the hot air flows into the air outlet funnel 7-3 on the left side and is drawn out to the outside of the cabinet 1 by the system fan 22. The front and rear compartments are divided into sections. The power heat source is concentrated in the independent air duct of the rear compartment. The weak and strong electrical components in the front compartment do not participate in the main hot air circulation, reducing the exchange of hot and cold air and reducing the temperature rise of the components. The cabinet 1 sends the 380V three-phase AC power to the power module in the rear compartment after the input protection of the front compartment to complete the AC / DC conversion. The DC power returns to the DC output area of ​​the front compartment and is supplied to the vehicle by the charging guns on both sides. Two 12 / 24V auxiliary power supplies power the control circuit. The main control board 3 communicates with the battery management system to realize constant voltage and constant current charging and safety protection.

[0039] The above description is merely a preferred embodiment of the present invention, and the specific embodiments described above are not intended to limit the present invention. Various modifications and variations can be made within the scope of the technical concept of the present invention. All refinements, modifications, or equivalent substitutions made by those skilled in the art based on the above description are within the scope of protection of the present invention.

Claims

1. A louverless integrated DC charger, characterized in that, The system includes a cabinet (1), which is divided into a front compartment and a rear compartment. The cabinet (1) is hinged with a front door. The front compartment is equipped with a front door assembly (18), a DC output area (2), an AC input area (9), and a control area. The rear compartment is equipped with an air inlet assembly (15), an air outlet assembly (7), and a module area (19). A left 12 / 24V auxiliary power source (4) and a right 12 / 24V auxiliary power source (5) are fixed in the middle of the front compartment. The left 12 / 24V auxiliary power source (4) and the right 12 / 24V auxiliary power source (5) are electrically connected to the devices in the control area. Inside the cabinet (1), below the control area, there is a guide rail (6) and a system auxiliary power source (13). A circuit breaker, a meter, a socket, a terminal block, and a diode are fixed on the guide rail (6). The system auxiliary power source (13) is electrically connected to the devices in the front door assembly (18).

2. The integrated DC charger without louvers according to claim 1, characterized in that, The AC input area (9) includes a copper busbar, a molded case circuit breaker, an air switch, and a surge protector fixed in the front compartment. It uses a molded case circuit breaker (8) with one 800A input. The molded case circuit breaker (8) is fixed at the bottom of the front compartment. The incoming line of the molded case circuit breaker (8) is bottom-in and top-out. The back panel of the cabinet (1) is tied with a power line, which is connected to the outgoing port of the molded case circuit breaker (8).

3. The integrated DC charger without louvers according to claim 1, characterized in that, The DC output area (2) includes a copper busbar, a DC contactor, a fuse and a shunt fixed in the front compartment. The DC output area (2) is located above the front compartment and adopts an upward-outgoing line.

4. The integrated DC charger without louvers according to claim 1, characterized in that, The air outlet assembly (7) includes an air outlet door panel (7-1) hinged to the left side of the cabinet (1). A nut post is pressed and riveted on the air outlet door panel (7-1). An air outlet funnel (7-3) is fixed on the air outlet door panel (7-1) by the nut and the nut post. A system fan (22) is fixed on the air outlet funnel (7-3) by self-tapping screws.

5. The integrated DC charger without louvers according to claim 1, characterized in that, The air inlet assembly (15) includes an air inlet door panel (15-1) hinged to the right side of the cabinet (1). A mesh is fixed on the air inlet door panel (15-1). A nut post is pressed and riveted on the air inlet door panel (15-1). An air inlet funnel (15-3) is fixed on the air inlet door panel (15-1) by the nut and the nut post. A dustproof mesh pressure plate (15-4) is snapped onto the air inlet funnel (15-3). A polyurethane dustproof mesh (15-2) is placed between the air inlet funnel (15-3) and the dustproof mesh pressure plate (15-4).

6. The integrated DC charger without louvers according to claim 1, characterized in that, The control area includes a control panel (3) fixed in the front compartment, a signal acquisition unit, and a battery management system.

7. The integrated DC charger without louvers according to claim 1, characterized in that, The lower end of the cabinet (1) is placed on a wooden pallet (10), and the upper end of the cabinet (1) is fixed with two lifting rings (17).

8. The integrated DC charger without louvers according to claim 1, characterized in that, The front door assembly (18) includes a display screen (18-1), a three-color indicator light (18-2), a SOC digital display (18-3), a card swiping door panel (18-4), a central control board (18-5), and a door lock (18-6) fixed on the front door.

9. A louverless integrated DC charger according to claim 1, characterized in that, The cabinet (1) is symmetrically fixed with gun holders (23) and gun wires (11) on both the left and right sides. A charging gun (12) is fixed on the gun wire. An antenna (20) and an emergency stop button (21) are fixed on the right side of the cabinet (1).

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