Multi-purpose power conversion control system

Abstract

The application provides a multipurpose power conversion control system, which adopts a two-stage power conversion architecture of a front-stage PFC and a rear-stage DAB bidirectional full-bridge DC / DC, and cooperates with MCU full-closed loop control, so that not only bidirectional energy flow between a power grid and a battery is realized, but also defects of single function, discrete equipment, poor adaptability and low intelligent degree in the prior art are overcome. The system can automatically identify AC, DC and charging pile input signals, and adaptively switch to a work mode of voltage reduction charging, DC power supply or voltage increase inversion, and the system integrates multiple functions of vehicle-mounted charging, V2G power feeding, V2L discharging, charging pile power taking and outdoor inversion output, and has high power factor, wide voltage adaptation range and high integration degree, and in combination with a multi-standard communication module supporting OTA remote upgrading, the intelligent operation and maintenance level and the operation safety and reliability of the equipment are significantly improved.

Description

Technical Field

[0001] This invention relates to the field of power conversion control technology, and in particular to a multi-purpose power conversion control system. Background Technology

[0002] With the rapid development of new energy vehicles, energy storage power supplies, and outdoor mobile power supply technologies, the market has placed higher demands on the integration and multifunctionality of power conversion equipment.

[0003] Currently, in typical application scenarios, core power conversion functions such as charging, boosting, bucking, and inversion often require dedicated equipment. For example, charging electric vehicles requires dedicated charging stations or chargers, powering outdoor appliances requires independent inverters, and battery charge / discharge management requires matching DC / DC converters. This decentralized equipment system has many drawbacks in practical applications. On the one hand, users must purchase and carry multiple devices to achieve complete power management functions, which not only significantly increases equipment procurement costs but also makes the overall system bulky, becoming a huge burden, especially for space-constrained vehicle-mounted or outdoor emergency scenarios. On the other hand, the wiring structure between multiple devices is cumbersome and complex, and the installation and debugging process requires strong professional expertise. Ordinary users without professional electrical knowledge not only face a high barrier to entry but also risk equipment damage or safety hazards due to wiring errors. In addition, most existing equipment is designed for a single power type and cannot simultaneously support multiple input power sources such as AC mains power, DC energy storage systems, and DC charging stations, resulting in poor scenario adaptability. At the same time, the existing equipment generally has a low level of intelligence and lacks advanced operation and maintenance functions such as remote status monitoring, fault diagnosis and online program upgrades. As a result, once the equipment is deployed, its functions are fixed and cannot be iterated or repaired remotely, resulting in high maintenance costs and untimely response.

[0004] Therefore, how to provide an integrated and highly reliable power conversion control system that can integrate multiple power conversion functions, adaptively match different input sources, and has intelligent operation and maintenance capabilities is a technical problem that urgently needs to be solved by those skilled in the art. Summary of the Invention

[0005] The purpose of this invention is to provide a multi-purpose power conversion control system to solve the problems existing in the prior art.

[0006] To achieve the above objectives, the present invention provides the following solution: This invention provides a multi-purpose power conversion control system, comprising: Electromagnetic interference (EMI) filtering unit, pre-stage power factor correction (PFC) unit, post-stage DAB bidirectional full-bridge DC / DC / DC unit, microcontroller unit (MCU), auxiliary power supply unit, and communication module; The front-stage PFC unit and the rear-stage DAB bidirectional full-bridge DC / DC unit constitute a two-stage power conversion architecture. The front-stage PFC unit is used to realize bidirectional AC / DC conversion, and the rear-stage DAB bidirectional full-bridge DC / DC unit is used to realize electrical isolation and bidirectional buck-boost, so as to realize bidirectional energy flow between the grid side and the battery side. The MCU control unit is used to achieve precise closed-loop control of system voltage, current, and power.

[0007] Preferably, the system is configured with a buck charging mode; In the buck charging mode, the AC or DC input voltage is filtered and noise-reduced by the EMI filter unit, then rectified or boosted by the pre-stage PFC unit, and then bucked by the post-stage DAB bidirectional full-bridge DC / DC unit to achieve stable power supply or charging for batteries or low-voltage electrical equipment.

[0008] Preferably, in the buck charging mode, when the external input is AC power, the front-end PFC unit performs boost rectification and power factor correction to output a stable DC bus voltage. When the external input is DC and its voltage is lower than the system preset bus voltage, the MCU control unit controls the front-end PFC unit to boost the voltage to the target bus voltage; when the external input DC voltage meets the bus operating requirements, the MCU control unit controls the front-end PFC unit to maintain a pass-through state. The MCU control unit samples the output voltage and current signals in real time and adjusts the operating parameters of the front-end PFC unit and the rear-end DAB bidirectional full-bridge DC / DC unit in a closed loop.

[0009] Preferably, the system is configured with a DC charging pile power supply mode; In the DC charging pile power supply mode, the MCU control unit sends a target voltage request signal to the DC charging pile through the communication module. After confirming that the input voltage output by the charging pile is stable and the parameters are compliant, it controls the subsequent DAB bidirectional full-bridge DC / DC unit to work in buck mode to achieve buck-regulated output.

[0010] Preferably, the system is configured with a boost inverter operating mode; In the boost inverter operating mode, the DC voltage input from the battery side is boosted to the system preset bus voltage by the subsequent DAB bidirectional full-bridge DC / DC unit, and then the DC bus voltage is inverted into power frequency AC by the preceding PFC unit, and finally output after being filtered by the EMI filter unit.

[0011] Preferably, the MCU control unit is configured to automatically identify the type of input power supply, which includes AC power supply, DC power supply and DC charging pile; The MCU control unit is also used to adaptively control the system to switch to the corresponding buck charging mode or DC charging pile power mode based on the identification result, without the need for manual switching throughout the process.

[0012] Preferably, the communication module includes at least one communication standard selected from Bluetooth, Wi-Fi, 2.4G wireless, 5G, and GSM (Global System for Mobile Communications). The communication module is used to upload the device's operating status parameters in real time and supports remote upgrades of the MCU control unit's program via OTA.

[0013] Preferably, the subsequent DAB bidirectional full-bridge DC / DC unit regulates voltage and current under the control of the MCU control unit.

[0014] Preferably, the auxiliary power supply unit is used to start after an effective voltage is applied to any input terminal of the system, and to provide working power to the MCU control unit.

[0015] Preferably, the system is applied to at least one of the following scenarios: on-board charging, vehicle-to-grid (V2G) power supply, vehicle-to-load (V2L) external discharge, charging pile power supply, outdoor AC inverter power supply, and battery charging and discharging.

[0016] The present invention achieves the following beneficial technical effects compared to the prior art: This invention provides a multi-purpose power conversion control system. By employing a two-stage power conversion architecture—a front-end PFC and a rear-end DAB bidirectional full-bridge DC / DC converter—and combined with MCU full closed-loop control, it not only achieves bidirectional energy flow between the power grid and the battery but also overcomes the shortcomings of existing technologies, such as single functionality, discrete equipment, poor adaptability, and low intelligence. The system can automatically identify AC, DC, and charging pile input signals and adaptively switch to buck charging, DC power supply, or boost inverter modes. It integrates multiple functions, including on-board charging, V2G power supply, V2L discharge, charging pile power intake, and outdoor inverter output. It features a high power factor, wide voltage adaptation range, and high integration. Combined with a multi-standard communication module supporting OTA remote upgrades, it significantly improves the intelligent operation and maintenance level and operational safety and reliability of the equipment. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0018] Figure 1 This is a block diagram of the overall system structure of the present invention; Figure 2 This is a flowchart illustrating the buck charging mode workflow of the present invention. Figure 3 This is a flowchart illustrating the power extraction mode of the DC charging pile of the present invention. Figure 4 This is a flowchart illustrating the AC output mode of the boost inverter of the present invention. Detailed Implementation

[0019] Unless otherwise specified, the terms "connection" and "linkage" used in this application include both direct and indirect connections (linkages). In the description of this invention, it should be understood that the terms "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," and "counterclockwise," etc., indicating orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, are used only for the convenience of describing the invention and for 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 the invention.

[0020] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "over," and "on top" of the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0021] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0022] The purpose of this invention is to provide a multi-purpose power conversion control system to solve the problems existing in the prior art.

[0023] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0024] Example 1: Please refer to Figure 1 , Figure 1 This is a block diagram of the overall system structure of the present invention. The present invention provides a multi-purpose power conversion control system, which aims to solve the problems of existing power conversion equipment having limited functionality, inability to adaptively match multiple input sources, and low intelligence. The system mainly includes an electromagnetic interference (EMI) filtering unit, a pre-stage power factor correction (PFC) unit, a post-stage DAB bidirectional full-bridge DC / DC / DC unit, a microcontroller unit (MCU), an auxiliary power supply unit, and a communication module. From an overall architectural perspective, the present invention adopts a two-stage power conversion architecture. The pre-stage PFC unit is responsible for bidirectional AC / DC conversion, while the post-stage DAB bidirectional full-bridge DC / DC unit is used for electrical isolation and bidirectional buck-boost. The two work together to achieve bidirectional energy flow between the grid side and the battery side. The MCU control unit, as the control core of the system, is responsible for achieving precise closed-loop control of the system voltage, current, and power. The auxiliary power supply unit is used to start after an effective voltage is applied to any input terminal of the system and provides operating power to the MCU control unit, ensuring that the control system can be powered on first and enter standby mode after power is applied.

[0025] In actual operation, once a valid voltage is applied to any input terminal of the system, the auxiliary power supply unit immediately starts and supplies power to the MCU control unit. The MCU control unit then automatically identifies the type of input power, including AC power, DC power, and DC charging pile. Based on the identification result, the MCU control unit can adaptively control the system to switch to the corresponding buck charging mode or DC charging pile power mode, without requiring manual switching (boost charging requires manual setting by the user). The communication module integrates at least one of the following communication standards: Bluetooth, Wi-Fi, 2.4G wireless, 5G, and GSM global mobile communication system. It is used to upload the device's operating status parameters such as voltage, current, power, temperature, and fault codes in real time, and supports remote upgrades of the MCU control unit's program via OTA, thus enabling functional iteration and fault repair without disassembling the device.

[0026] The following describes in detail several core working modes of the present invention in specific implementation scenarios.

[0027] Please refer to Figure 2 , Figure 2This is a flowchart illustrating the buck charging mode operation of the present invention. The present invention features a buck charging mode suitable for AC mains power or external high-voltage DC input, primarily used to power low-voltage electrical equipment or charge various batteries. In this mode, the AC or DC input voltage is filtered and noise-reduced by an EMI filter unit, then rectified or boosted by a pre-stage PFC unit, and finally bucked by a post-stage DAB bidirectional full-bridge DC / DC unit to achieve stable power supply or charging of batteries or low-voltage electrical equipment. Specifically, when the external input is AC, the pre-stage PFC unit can use a bridgeless PFC topology for boost rectification and power factor correction, outputting a stable DC bus voltage. This bus voltage is then fed to the post-stage DAB bidirectional full-bridge DC / DC unit, where it is bucked and outputs voltage and current adapted to the load. When the external input is DC, the MCU control unit monitors the input voltage parameters in real time. If the DC input voltage is lower than the system's preset bus voltage, the MCU control unit controls the preceding PFC unit to boost the voltage to the target bus voltage. If the input DC voltage already meets the bus operating requirements, the MCU control unit controls the preceding PFC unit to remain in a pass-through state, i.e., without additional boosting. After processing by the preceding stage, the voltage is then stepped down by the subsequent DAB unit and output. Throughout the process, the MCU control unit dynamically adjusts the operating parameters of the preceding PFC unit and the subsequent DAB bidirectional full-bridge DC / DC unit by sampling the voltage and current signals at the output in real time, thereby achieving high-precision regulated voltage and current output.

[0028] Please refer to Figure 3 , Figure 3 This is a flowchart illustrating the power extraction mode of the DC charging pile according to the present invention. The present invention also includes a DC charging pile power extraction mode to meet the need for obtaining power from public or private DC charging piles. In this mode, the MCU control unit first sends a target voltage request signal to the DC charging pile via the communication module. Upon receiving this instruction, the DC charging pile responds and outputs the corresponding operating voltage. After this input voltage is transmitted through the front-end PFC unit, the MCU control unit continuously monitors the voltage parameters at the input terminal. After confirming that the input voltage output by the charging pile is stable and the parameters are compliant, the MCU control unit controls the subsequent DAB bidirectional full-bridge DC / DC unit to operate in buck mode. During operation, the MCU control unit continuously samples the voltage and current data at the output terminal, dynamically adjusts the control parameters of the device, and achieves closed-loop voltage and current stabilization output, thereby providing stable low-voltage DC power to the subsequent equipment or battery.

[0029] Please refer to Figure 4 , Figure 4This is a flowchart illustrating the boost inverter AC output mode of this invention. The invention features a boost inverter mode, primarily used to convert the DC power from the battery into standard industrial frequency AC power for AC loads. In this mode, the power battery or other DC power source is connected to the system's DC input. When the user issues an inverter command, the MCU control unit first monitors the voltage and current parameters at the battery input in real time. Once the operating conditions are confirmed to be normal, the inverter operation begins. The DC voltage input from the battery side is first boosted to the system's preset DC bus voltage by the subsequent DAB bidirectional full-bridge DC / DC unit. Subsequently, this stable DC bus voltage is fed to the pre-stage PFC unit, which operates in inverter mode, converting the DC bus voltage into 220V or 110V industrial frequency AC power. Finally, this industrial frequency AC power is output for use by various household appliances or outdoor electrical equipment. Throughout the entire operation, the MCU control unit continuously collects voltage and current signals from each stage of the circuit, dynamically optimizing control strategies such as phase shift angle and switching frequency to achieve stable closed-loop control of the system.

[0030] Furthermore, the subsequent DAB bidirectional full-bridge DC / DC unit in this invention can adopt a bidirectional full-bridge topology, and the voltage and current can be precisely regulated through the control technology of the MCU control unit. This control method can effectively regulate the magnitude and direction of energy transfer, which is the key to achieving efficient bidirectional conversion.

[0031] In summary, the multi-purpose power conversion control system provided by this invention, through the structure and control method described in the above specific embodiments, achieves automatic identification of AC, DC, and charging pile input signals, and can adaptively switch to working modes such as buck charging, DC power supply, or boost inverter. This system integrates multiple functions including on-board charging, vehicle-to-grid (V2G) power supply, vehicle-to-load (V2L) external discharge, charging pile power supply, outdoor AC inverter power supply, and battery charging and discharging. It features high power factor, wide voltage adaptation range, high integration, and safe and reliable operation, and can be widely applied in new energy vehicles, energy storage power supplies, outdoor emergency power supply, battery charging and discharging, and other technical scenarios.

[0032] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0033] It should be noted that the components mentioned in the above embodiments are all general standard parts or components known to those skilled in the art. Their structures and principles can be learned by those skilled in the art through technical manuals or conventional experimental methods.

[0034] This invention has illustrated its principles and implementation methods using specific examples. The descriptions of these embodiments are merely illustrative of the method and its core ideas; furthermore, those skilled in the art will recognize that modifications may be made to the specific implementation methods and application scope based on the principles of this invention. Therefore, the content of this specification should not be construed as limiting the invention.

Claims

1. A multi-purpose power conversion control system, characterized in that, include: Electromagnetic interference (EMI) filtering unit, pre-stage power factor correction (PFC) unit, post-stage DAB bidirectional full-bridge DC / DC / DC unit, microcontroller unit (MCU), auxiliary power supply unit, and communication module; The front-stage PFC unit and the rear-stage DAB bidirectional full-bridge DC / DC unit constitute a two-stage power conversion architecture. The front-stage PFC unit is used to realize bidirectional AC / DC conversion, and the rear-stage DAB bidirectional full-bridge DC / DC unit is used to realize electrical isolation and bidirectional buck-boost, so as to realize bidirectional energy flow between the grid side and the battery side. The MCU control unit is used to achieve precise closed-loop control of system voltage, current, and power.

2. The multi-purpose power conversion control system according to claim 1, characterized in that, The system is equipped with a buck charging mode; In the buck charging mode, the AC or DC input voltage is filtered and noise-reduced by the EMI filter unit, then rectified or boosted by the pre-stage PFC unit, and then bucked by the post-stage DAB bidirectional full-bridge DC / DC unit to achieve stable power supply or charging for batteries or low-voltage electrical equipment.

3. The multi-purpose power conversion control system according to claim 2, characterized in that, In the buck charging mode, when the external input is AC, the front-end PFC unit performs boost rectification and power factor correction to output a stable DC bus voltage. When the external input is DC and its voltage is lower than the system preset bus voltage, the MCU control unit controls the front-end PFC unit to boost the voltage to the target bus voltage; when the external input DC voltage meets the bus operating requirements, the MCU control unit controls the front-end PFC unit to remain in a pass-through state. The MCU control unit samples the output voltage and current signals in real time and adjusts the operating parameters of the front-end PFC unit and the rear-end DAB bidirectional full-bridge DC / DC unit in a closed loop.

4. The multi-purpose power conversion control system according to claim 1, characterized in that, The system is equipped with a DC charging pile power supply mode. In the DC charging pile power supply mode, the MCU control unit sends a target voltage request signal to the DC charging pile through the communication module. After confirming that the input voltage output by the charging pile is stable and the parameters are compliant, it controls the subsequent DAB bidirectional full-bridge DC / DC unit to work in buck mode to achieve buck-regulated output.

5. The multi-purpose power conversion control system according to claim 1, characterized in that, The system is configured with a boost inverter operating mode; In the boost inverter operating mode, the DC voltage input from the battery side is boosted to the system preset bus voltage by the subsequent DAB bidirectional full-bridge DC / DC unit, and then the DC bus voltage is inverted into power frequency AC by the preceding PFC unit, and finally output after being filtered by the EMI filter unit.

6. The multi-purpose power conversion control system according to claim 1, characterized in that, The MCU control unit is configured to automatically identify the type of input power, including AC power, DC power, and DC charging pile. The MCU control unit is also used to adaptively control the system to switch to the corresponding buck charging mode or DC charging pile power mode based on the identification result, without the need for manual switching throughout the process.

7. The multi-purpose power conversion control system according to claim 1, characterized in that, The communication module includes at least one of the following communication standards: Bluetooth, Wi-Fi, 2.4G wireless, 5G, and GSM (Global System for Mobile Communications). The communication module is used to upload the device's operating status parameters in real time and supports remote upgrades of the MCU control unit's program via OTA.

8. The multi-purpose power conversion control system according to claim 1, characterized in that, The subsequent DAB bidirectional full-bridge DC / DC unit regulates voltage and current through the control of the MCU control unit.

9. The multi-purpose power conversion control system according to claim 1, characterized in that, The auxiliary power supply unit is used to start after an effective voltage is applied to any input terminal of the system, and to provide working power to the MCU control unit.

10. The multi-purpose power conversion control system according to any one of claims 1 to 9, characterized in that, The system is applied to at least one of the following scenarios: on-board charging, vehicle-to-grid (V2G) power supply, vehicle-to-load (V2L) external discharge, charging pile power supply, outdoor AC inverter power supply, and battery charging and discharging.

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