A new energy heavy truck battery swap station fault correction sensor integrated direct current distribution switch device

Abstract

The application discloses a new energy heavy truck battery swap station fault correction sensing integrated direct current distribution switch device, which comprises a total body, a control box and a switch action simulation box; the top of the total body is fixedly connected with a display screen, and the sidewall is inserted with a storage card; the back end of the total body is fixedly connected with three first interfaces, three second interfaces and a power supply interface; the control box is arranged on one side of the total body; the front of the control box is provided with a display panel, a closing button, an opening button, two symmetrically arranged U-shaped handles and a signal jack; and the back end of the control box is inserted and fixedly connected with a power line. The application integrates sensing and correction units, shortens the signal transmission path and shortens the correction response time; the synchronous collection of multiple sensors improves the fault offset detection precision; the automatic closed-loop correction mechanism reduces manual intervention and reduces the misjudgment rate.

Description

Technical Field

[0001] This invention relates to the field of battery swapping station equipment technology for new energy heavy-duty trucks, and in particular to a fault correction sensing integrated DC power distribution switch device for battery swapping stations for new energy heavy-duty trucks. Background Technology

[0002] In battery swapping stations for new energy heavy-duty trucks, DC power distribution switches, as core power distribution components, need to frequently perform closing / opening operations to ensure the continuity of the battery swapping process.

[0003] Existing DC power distribution switchgear has significant drawbacks in operation: the fault correction system is separated from the sensing unit, resulting in the correction process relying on the collaboration of multiple devices, low accuracy of sensing data acquisition, and high correction response delay. For example, in high-load operation scenarios of battery swapping stations (such as continuously swapping batteries for more than 10 heavy trucks during peak hours), wear or mechanical deviation of switch contacts can easily cause malfunctions. Existing devices, due to their lengthy sensing signal transmission links and asynchronous correction commands and execution modules, cannot accurately capture fault offsets in real time, resulting in long correction times (an average of over 30 minutes per correction) and a high false positive rate (approximately 15%), affecting the operating efficiency and equipment lifespan of battery swapping stations. Therefore, we designed a fault correction sensing integrated DC power distribution switchgear for new energy heavy truck battery swapping stations to solve the above problems. Summary of the Invention

[0004] The purpose of this invention is to overcome the shortcomings of low efficiency and insufficient accuracy in fault correction of DC power distribution switches in the prior art, and to provide a DC power distribution switch device with integrated sensing for fault correction of new energy heavy truck swapping stations. Through the integrated design of sensing, control and execution units, it can achieve rapid and accurate fault correction.

[0005] To achieve the above objectives, the present invention adopts the following technical solution:

[0006] A fault correction sensor-integrated DC power distribution switchgear for new energy heavy-duty truck battery swapping stations includes a main unit, a control box, and a switch action simulation box.

[0007] The assembly has a display screen fixedly connected to the top, a memory card inserted into the side wall, and three first interfaces, three second interfaces, and a power interface fixedly connected to the back of the assembly.

[0008] The control box is located on one side of the main body. The front of the control box is equipped with a display panel, a closing button, a closing button, two symmetrically arranged U-shaped handles, and a signal jack. The back of the control box is connected and fixed with a power cord.

[0009] The switch action simulation box is located on one side of the control box. The switch action simulation box includes a box body, a top plate fixedly connected to the top of the box body, three motors fixedly connected to the box body, three fixed circular frames set on the top of the top plate, and sensors inserted into the corresponding fixed circular frames. The output shafts of the three motors are fixedly connected to the corresponding sensors through couplings.

[0010] The control box and the switch action simulation box are connected by a cable. A three-way splitter cable is plugged into the signal jack on the front of the control box. The three output interfaces of the three-way splitter cable are respectively plugged into and fixed to the corresponding first interface of the main body. An optical fiber is plugged into and fixed to the three sensors and the corresponding second interface of the main body.

[0011] Preferably, the two U-shaped handles are symmetrically distributed along the vertical center line of the front of the control box.

[0012] Preferably, the three first interfaces and the second interfaces are arranged at equal intervals along the horizontal direction at the back end of the assembly.

[0013] Preferably, the three second interfaces are located below the three first interfaces, and their positions correspond one-to-one with those of the three first interfaces.

[0014] Preferably, the display screen is embedded and fixed on the top end face of the assembly, with the display surface of the display screen facing upwards.

[0015] Preferably, the memory card is inserted horizontally into the interior of the side wall of the assembly.

[0016] Preferably, the three motors are arranged in a linear array and fixedly placed in the receiving slots opened in the housing.

[0017] Preferably, the top plate is detachably fixed to the top of the box body by bolts, and the three fixed circular frames are integrally injection molded or sheet metal structure with the top plate.

[0018] This invention also discloses a fault correction sensor integrated DC power distribution switch correction method for new energy heavy-duty truck battery swapping stations, which is implemented based on the above-mentioned device and includes the following steps:

[0019] S1. Equipment deployment and access steps: Fix the three DC power distribution switches in the battery swapping station to be calibrated to the three sensors in the switch action simulation box one by one on the same axis. Connect the power and control signals between the control box and the switch action simulation box through cables. Connect the one-to-three splitter cable to the signal jack of the control box and the first interface of the main unit. Connect the two ends of the optical fiber to the second interface of the sensor and the main unit respectively. After completing the full link wiring of the device, connect the power supply of the main unit and the control box respectively.

[0020] S2. Standard Action Reference Calibration Steps: Press the closing button on the control box. The control box sends a synchronous closing drive command to the three motors via cables. The motor drive sensors synchronously collect three types of reference data: closing action stroke, contact pressure, and closing time of the three DC power distribution switches. After the data is transmitted to the main closing unit via optical fiber, the standard closing reference parameters are displayed on the screen. Then, press the opening button, and the standard opening reference parameters are collected in the same way. The above two types of reference data are automatically stored in the memory card to complete the reference calibration.

[0021] S3, Fault Simulation Sensing Acquisition Steps: The control box displays a simulated deviation control command to drive the motor output shaft at the corresponding position to generate a preset action offset, simulating the fault state of the DC power distribution switch. At this time, the three sensors collect the operating data under the fault state in real time, and transmit the sensing signals to the main unit through optical fiber to complete the analysis, classification and storage.

[0022] S4. Fault Deviation Comparison and Correction Steps: The built-in comparison module in the main body compares the fault status data with the pre-stored standard reference parameters, automatically calculates the current action offset value, deviation type and correction compensation parameters of the DC power distribution switch, and transmits the correction command back to the control box through a 1-to-3 cable. The control box outputs a fine-tuning drive signal to drive the motor to drive the power distribution switch components to complete the adjustment until the difference between the real-time data and the standard reference parameters is less than the preset threshold.

[0023] S5. Calibration result archiving and output steps: The system automatically writes the simulated fault type, deviation calculation results, and calibration execution record of the calibration process into the storage card for storage, and displays the calibrated operating status parameters on the display screen.

[0024] This invention also discloses a fault correction sensor-integrated DC power distribution switch correction system for new energy heavy-duty truck battery swapping stations, implemented based on the above-described device, and comprising the following modules:

[0025] Deploy a self-test module: integrated into the main body, used to detect the connection status of the first and second interfaces, verify the signal conductivity of the 1-to-3 cable, the optical loss value of the optical fiber, and the power supply status of the cable. When the wiring is abnormal, the fault location will be indicated on the display screen.

[0026] Control interaction module: Integrated into the closing button, opening button and display panel of the control box, it is used to receive operation commands and convert them into drive signals to be sent to the switch action simulation box, and at the same time send the operation log back to the main unit;

[0027] Action simulation sensor acquisition module: Integrated inside the motor and sensor of the switch action simulation box, it is used to receive drive signals, simulate the action of the power distribution switch through the motor, and collect action stroke, pressure and timing data through the sensor, and transmit them back to the main body through optical fiber.

[0028] Data parsing and comparison module: Integrated into the main body, it is used to store benchmark data, parse real-time acquired data, perform difference comparison and generate correction instructions;

[0029] Data storage and visualization module: Integrated into the overall display screen and memory card, it is used to store calibration data and visualize it on the display screen.

[0030] Compared with the prior art, the beneficial effects of this invention are as follows:

[0031] 1. The integrated sensing and correction unit shortens the signal transmission path and correction response time, reducing it to less than two seconds for timely transmission.

[0032] 2. Multi-sensor synchronous acquisition improves fault offset detection accuracy to ±0.1mm.

[0033] 3. An automated closed-loop correction mechanism reduces manual intervention and lowers the misjudgment rate to below 2%.

[0034] 4. Modular design supports rapid deployment and is suitable for high-load battery swapping station scenarios.

[0035] In summary, this invention optimizes the efficiency and reliability of DC power distribution switch fault correction through hardware integration and software collaboration. Attached Figure Description

[0036] Figure 1 This is a first structural schematic diagram of a fault correction sensor integrated DC power distribution switch device for a new energy heavy truck battery swapping station proposed in this invention.

[0037] Figure 2 This is a schematic diagram of the second structure of a fault correction sensor integrated DC power distribution switch device for a new energy heavy truck battery swapping station proposed in this invention.

[0038] Figure 3 This is a schematic diagram of the third structure of a fault correction sensor integrated DC power distribution switch device for a new energy heavy truck battery swapping station proposed in this invention.

[0039] Figure 4 This is a block diagram of a fault correction sensor integrated DC power distribution switch method for new energy heavy truck battery swapping stations proposed in this invention.

[0040] Figure 5 This is a block diagram of a fault correction sensor integrated DC power distribution switch system for a new energy heavy-duty truck battery swapping station proposed in this invention.

[0041] In the diagram: 1. Main unit, 2. Control box, 3. Switch action simulation box, 4. Cable, 5. One-to-three cable, 6. Fiber optic cable, 11. Display screen, 12. Memory card, 13. First interface, 14. Second interface, 15. Power interface, 21. Display panel, 22. Close button, 23. Open button, 24. U-shaped handle, 25. Signal jack, 26. Power cord, 31. Cabinet, 32. Top plate, 33. Motor, 34. Fixed circular frame, 35. Sensor. Detailed Implementation

[0042] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.

[0043] Reference Figures 1-5 A fault correction sensor integrated DC power distribution switch device for a new energy heavy truck swapping station includes a main body 1, a control box 2, and a switch action simulation box 3. The main body 1 has a display screen 11 fixedly connected to the top and a memory card 12 inserted into the side wall. The back end of the main body 1 is fixed with three first interfaces 13, three second interfaces 14, and a power interface 15.

[0044] The control box 2 is located on one side of the main body 1. The front of the control box 2 is equipped with a display panel 21, a closing button 22, a closing button 23, two symmetrically arranged U-shaped handles 24 and a signal jack 25. The back of the control box 2 is connected and fixed with a power cord 26.

[0045] The switch action simulation box 3 is located on one side of the control box 2. The switch action simulation box 3 includes a box body 31, a top plate 32 fixedly connected to the top of the box body 31, three motors 33 fixedly connected to the box body 31, three fixed circular frames 34 set on the top of the top plate 32, and sensors 35 inserted into the corresponding fixed circular frames 34. The output shafts of the three motors 33 are fixedly connected to the corresponding sensors 35 through couplings.

[0046] Among them, the control box 2 and the switch action simulation box 3 are connected by a cable 4. The signal jack 25 on the front of the control box 2 is connected to a three-way splitter cable 5. The three output interfaces of the three-way splitter cable 5 are respectively connected and fixed to the corresponding first interface 13 of the main body 1. The three sensors 35 and the corresponding second interface 14 of the main body 1 are connected and fixed by an optical fiber 6.

[0047] To optimize performance, two U-shaped handles 24 are symmetrically distributed along the vertical center line of the front of the control box 2, ensuring balanced force application on both sides when the operator moves the control box, preventing damage from bumps and knocks. Three first interfaces 13 and two second interfaces 14 are equidistantly arranged horizontally at the back of the assembly 1, facilitating differentiation of wiring layouts and reducing the probability of incorrect connections. The three second interfaces 14 are located below the three first interfaces 13 and correspond one-to-one with their positions, allowing for separate routing of different types of cables and preventing interference between power and signal cables. The display screen 11 is embedded and fixed to the top surface of the assembly 1, with its display surface facing upwards, allowing for clear reading of operating parameters without bending over. The system is designed to adapt to various on-site operating scenarios. The storage card 12 is inserted horizontally into the side wall of the main body 1, allowing for easy insertion and removal without disassembling the equipment casing, facilitating the quick export of archived calibration data. Three motors 33 are arranged in a linear array within the receiving slots of the housing 31, resulting in a compact structure while ensuring controllable coaxiality deviation of the output shafts of the three motors, thus reducing power transmission losses. The top plate 32 is detachably fixed to the top of the housing 31 via bolts. The three fixed circular frames 34 are integrally injection molded or sheet metal structures with the top plate 32, allowing for quick disassembly of the top plate during internal component maintenance while ensuring the structural strength and installation coaxiality of the fixed circular frames, preventing the sensors from loosening or shifting during long-term operation.

[0048] The complete workflow of this embodiment is as follows:

[0049] The calibration system on this device integrates a deployment self-test module, a control and interaction module, a motion simulation sensing and acquisition module, a data analysis and comparison module, and a data storage and visualization module. The entire calibration method is implemented based on the above-mentioned device.

[0050] First, execute the S1 equipment deployment and access steps: fix the three DC power distribution switches in the swapping station to be calibrated to the three sensors 35 in the switch action simulation box 3 one-to-one on the same axis. Connect the power and control signals between the control box 2 and the switch action simulation box 3 through the cable 4. Connect the one-to-three cable 5 to the signal socket 25 of the control box 2 and the first interface 13 of the main unit 1 respectively. Connect the two ends of the optical fiber 6 to the sensor 35 and the second interface 14 of the main unit 1 respectively. After completing the full link wiring of the device, the deployment self-test module in the main unit 1 automatically detects the connection status of the first interface 13 and the second interface 14, verifies the signal conductivity of the one-to-three cable 5, the optical loss value of the optical fiber 6 and the power supply status of the cable 4. When the wiring is abnormal, the fault location is indicated on the display screen 11. After confirming that there are no abnormalities in all wiring, connect the power supply of the main unit 1 and the control box 2 respectively.

[0051] Then, the S2 standard action benchmark calibration steps are executed: Press the closing button 22 on the control box 2. The control interaction module of the control box 2 receives the operation command and converts it into a drive signal. It sends a synchronous closing drive command to the three motors 33 through the cable 4. The motors 33 drive the sensor 35 to synchronously collect three types of benchmark data: closing action stroke, contact pressure, and closing time of the three DC power distribution switches. After the data is transmitted to the main unit 1 through the optical fiber 6, the standard closing benchmark parameters are displayed on the display screen 11. Then, press the opening button 23. Similarly, the standard opening benchmark parameters are collected. The control interaction module simultaneously sends the operation log back to the main unit 1 and automatically stores the above two types of benchmark data into the storage card 12 to complete the benchmark calibration.

[0052] Next, the S3 fault simulation sensing acquisition step is executed: the operator issues a simulation deviation control command through the display panel 21 of the control box 2, the motion simulation sensing acquisition module receives the drive signal, drives the output shaft of the motor 33 at the corresponding position to generate a preset motion offset, simulates the fault state of the DC power distribution switch, at this time the three sensors 35 collect the running data under the fault state in real time, and transmit the sensing signal to the main body 1 through the optical fiber 6 to complete the analysis, classification and storage.

[0053] Then, the S4 fault deviation comparison and correction step is executed: The data parsing and comparison module integrated in the main body 1 compares the fault status data with the pre-stored standard reference parameters, automatically calculates the current action offset value, deviation type and correction compensation parameters of the DC power distribution switch, and transmits the correction command back to the control box 2 through the 1-to-3 cable 5. The control box 2 outputs a fine-tuning drive signal to drive the motor 33 to drive the power distribution switch components to complete the adjustment until the difference between the real-time data and the standard reference parameters is less than the preset threshold.

[0054] Finally, the S5 step of archiving and outputting calibration results is executed: The data storage and visualization module in the main unit 1 automatically writes the simulated fault type, deviation calculation results, and calibration execution record of the calibration process into the storage card 12 for storage, and displays the calibration status parameters on the display screen 11 to complete the entire calibration process.

[0055] The above are merely preferred embodiments of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A fault correction sensor-integrated DC power distribution switchgear for new energy heavy-duty truck battery swapping stations, characterized in that, Includes the main assembly (1), control box (2), and switch action simulation box (3): The assembly (1) has a display screen (11) fixedly connected to the top and a memory card (12) inserted into the side wall. The back of the assembly (1) has three first interfaces (13), three second interfaces (14) and a power interface (15). The control box (2) is located on one side of the main body (1). The front of the control box (2) is provided with a display panel (21), a closing button (22), a closing button (23), two symmetrically arranged U-shaped handles (24) and a signal jack (25). The back of the control box (2) is connected and fixed with a power cord (26). The switch action simulation box (3) is located on one side of the control box (2). The switch action simulation box (3) includes a box body (31), a top plate (32) fixedly connected to the top of the box body (31), three motors (33) fixedly connected to the box body (31), three fixed circular frames (34) set on the top of the top plate (32), and sensors (35) inserted into the corresponding fixed circular frames (34). The output shafts of the three motors (33) are fixedly connected to the corresponding sensors (35) through couplings. The control box (2) and the switch action simulation box (3) are connected by a cable (4). A three-way splitter cable (5) is plugged into the signal jack (25) on the front of the control box (2). The three output interfaces of the three-way splitter cable (5) are plugged into and fixed to the corresponding first interface (13) of the main body (1). An optical fiber (6) is plugged into and fixed to the three sensors (35) and the corresponding second interface (14) of the main body (1).

2. The fault correction sensor integrated DC power distribution switchgear for new energy heavy-duty truck battery swapping stations according to claim 1, characterized in that, The two U-shaped handles (24) are symmetrically distributed along the vertical center line of the front of the control box (2).

3. The fault correction sensor integrated DC power distribution switchgear for new energy heavy-duty truck battery swapping stations according to claim 1, characterized in that, The three first interfaces (13) and the second interface (14) are arranged at equal intervals along the horizontal direction at the back end of the composite body (1).

4. The fault correction sensor integrated DC power distribution switchgear for new energy heavy-duty truck battery swapping stations according to claim 1, characterized in that, The three second interfaces (14) are located below the three first interfaces (13) and correspond one-to-one with the positions of the three first interfaces (13).

5. The fault correction sensor integrated DC power distribution switchgear for new energy heavy-duty truck battery swapping stations according to claim 1, characterized in that, The display screen (11) is embedded and fixed on the top end face of the assembly (1), with the display surface of the display screen (11) facing upwards.

6. The fault correction sensor integrated DC power distribution switchgear for new energy heavy-duty truck battery swapping stations according to claim 1, characterized in that, The storage card (12) is inserted horizontally into the side wall of the assembly (1).

7. The fault correction sensor integrated DC power distribution switchgear for new energy heavy-duty truck battery swapping stations according to claim 1, characterized in that, The three motors (33) are fixedly arranged in a linear array within the receiving slots of the housing (31).

8. The fault correction sensor integrated DC power distribution switchgear for new energy heavy-duty truck battery swapping stations according to claim 1, characterized in that, The top plate (32) is detachably fixed to the top of the box (31) by bolts, and the three fixed circular frames (34) and the top plate (32) are integrally injection molded or sheet metal structures.

9. A fault correction sensor-integrated DC power distribution switch correction method for new energy heavy-duty truck battery swapping stations, implemented based on the device described in any one of claims 1-8, comprising the following steps: S1. Equipment deployment and access steps: Fix the three DC power distribution switches in the station to be calibrated to the three sensors (35) in the switch action simulation box (3) one by one on the same axis. Connect the power and control signals of the control box (2) and the switch action simulation box (3) through the cable (4). Connect the one-to-three cable (5) to the signal socket (25) of the control box (2) and the first interface (13) of the main body (1) respectively. Connect the two ends of the optical fiber (6) to the second interface (14) of the sensor (35) and the main body (1) respectively. After completing the full link wiring of the device, connect the power supply of the main body (1) and the control box (2) respectively. S2, Standard Action Reference Calibration Steps: Press the closing button (22) on the control box (2). The control box (2) sends a synchronous closing drive command to the three motors (33) through the cable (4). The motors (33) drive the sensor (35) to synchronously collect three types of reference data: closing action stroke, contact pressure, and closing time of the three DC power distribution switches. After the data is transmitted to the main unit (1) through the optical fiber (6), the standard closing reference parameters are displayed on the display screen (11). Then press the opening button (23) and similarly collect the standard opening reference parameters. The above two types of reference data are automatically stored in the storage card (12) to complete the reference calibration. S3, Fault simulation sensing acquisition steps: The simulation deviation control command is issued through the display panel (21) of the control box (2) to drive the output shaft of the motor (33) at the corresponding position to generate a preset action offset, simulating the fault state of the DC power distribution switch. At this time, the three sensors (35) collect the running data under the fault state in real time, and transmit the sensing signal to the main body (1) through the optical fiber (6) to complete the analysis and classification storage. S4. Fault Deviation Comparison and Correction Steps: The built-in comparison module in the main body (1) compares the fault status data with the pre-stored standard reference parameters, automatically calculates the current action offset value, deviation type and correction compensation parameters of the DC power distribution switch, and transmits the correction command back to the control box (2) through the one-to-three cable (5). The control box (2) outputs the fine-tuning drive signal to drive the motor (33) to drive the power distribution switch components to complete the adjustment until the difference between the real-time data and the standard reference parameters is less than the preset threshold. S5. Steps for archiving and outputting calibration results: The system (1) automatically writes the simulated fault type, deviation calculation results, and calibration execution record of the calibration process into the storage card (12) for storage, and displays the calibration operation status parameters on the display screen (11).

10. A fault correction sensor-integrated DC power distribution switch correction system for new energy heavy-duty truck battery swapping stations, implemented based on the device described in any one of claims 1-8, comprising the following modules: Deploy self-test module: integrated in the main body (1), used to detect the connection status of the first interface (13) and the second interface (14), verify the signal conductivity of the one-to-three cable (5), the optical loss value of the optical fiber (6) and the power supply status of the cable (4), and indicate the fault location on the display screen (11) when the wiring is abnormal. Control interaction module: Integrated inside the closing button (22), opening button (23) and display panel (21) of the control box (2), used to receive operation instructions and convert them into drive signals to be sent to the switch action simulation box (3), and at the same time send the operation log back to the main body (1). Action simulation sensor acquisition module: The motor (33) and sensor (35) integrated in the switch action simulation box (3) are used to receive drive signals, simulate the action of the power distribution switch through the motor (33), and collect the action stroke, pressure and timing data through the sensor (35), and transmit them back to the main body (1) through the optical fiber (6). Data parsing and comparison module: integrated in the whole (1), used to store benchmark data, parse real-time acquired data, perform difference comparison and generate correction instructions; Data storage and visualization module: Integrated into the display screen (11) and memory card (12) of the main body (1), used to store correction data and visualize it through the display screen (11).

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