Alternating-current quick charging device and extended-range electric vehicle thereof

Abstract

The utility model discloses an alternating current fast charging device and its extended range electric vehicle, including master control drive module, PFC module, bidirectional DC module, the control drive module is equipped with the switch K1 that is used for connecting automobile drive motor and the switch K2 that is used for connecting alternating current charging port, the PFC module is used for converting the alternating current into the direct current, and the bidirectional DC module is used for charging the direct current. The two-way DC module is used for adjusting the voltage of the PFC output circuit, the output end of the PFC module is connected with the two-way DC module, the two-way DC module is provided with an output interface used for being connected with an automobile power battery, and three high-voltage power supply ends of the main control driving module are connected with the two-way DC module through three groups of IGBT assemblies. The problem that in the prior art, an extended-range electric vehicle is rapidly charged through direct current or slowly charged through alternating current, the cost is high or the charging efficiency is low is solved.

Description

Technical Field

[0001] The utility model relates to the technical field of extended-range electric vehicles, in particular to an integrated fast charging device for extended-range electric vehicles. Background Art

[0002] In recent years, the sales of pure electric vehicles have grown rapidly, but at the same time, their insufficient range and imperfect charging facilities have become more prominent. New energy vehicles are showing a diversified development trend. Extended-range electric vehicles, with their own advantages and characteristics, meet the current market demand and become a new force in the current new energy vehicle market.

[0003] Adding a range extender (a combination of an engine and a generator) to a pure electric vehicle, that is, an extended-range electric vehicle, solves the problems of insufficient endurance and mileage anxiety. At the same time, the on-board battery maintains a certain amount of power, so that when the extended-range electric vehicle is running low on fuel, it can be driven to a gas station or other place to refuel. This requires adding an on-board charging system to the electric vehicle. In particular, the motor controller MCU (Motor Control Unit) and the on-board charger OBC (On Board Charge) are the core power conversion components of the entire extended-range electric vehicle, and they need to be miniaturized and integrated.

[0004] At present, the common on-board charging methods for extended-range electric vehicles are AC slow charging or DC fast charging. For example, Chinese patent document CN111688506A (application number 2020106685313) discloses a high-voltage power distribution circuit from a range-extended charger to a power battery and its control method. The charger OBC is a single-body type, with a general power of 3.3Kw / 6.6Kw / 7.2Kw / 12Kw, low charging efficiency, long charging time, and cannot solve the charging efficiency problem well. It cannot fully utilize the working principle and components of the motor controller MCU inverter, resulting in a waste of charging costs.

[0005] The existing products MCU and on-board OBC are basically independent products. For example, the Chinese patent document publication number is CN212171955U (application number 2020201119409), the publication date is 2020-12-18, and the patent name is "A Charging Device". It discloses a new charging device, which includes an OBC on-board charger, a high-voltage DC module, a low-voltage DC module, an internal controller area network CAN bus and a total charging control module; the total charging control module is connected to the high-voltage DC module to form a high-voltage DC charging control circuit; the total charging control module is connected to the low-voltage DC module to form a low-voltage DC charging control circuit; the total charging control module is connected to the internal controller area network CAN bus and the OBC on-board charger in sequence to form an OBC on-board charging control circuit; the high-voltage DC module is connected to the low-voltage DC module. The total charging control module communicates with the OBC on-board charger through the internal controller area network CAN bus to control charging and discharging. Similar to the prior art, the IGBT in the MCU, as a core key component, is generally unavailable in the charging state. At the same time, the charging equipment is converted from the power of the DC fast charging pile, resulting in a waste of charging costs. Summary of the invention

[0006] The technical problem to be solved by the utility model is to realize a device which can save equipment cost and realize fast charging of extended-range electric vehicles.

[0007] In order to achieve the above-mentioned purpose, the technical solution adopted by the utility model is: an AC fast charging device, including a main control drive module, a PFC module, and a bidirectional DC module. The control drive module is provided with a switch K1 for connecting a vehicle drive motor and a switch K2 for connecting an AC charging port. The PFC module converts AC power into DC power. The bidirectional DC module is used to adjust the voltage of the PFC output circuit. The output end of the PFC module is connected to the bidirectional DC module. The bidirectional DC module is provided with an output interface for connecting a vehicle power battery. The three high-voltage power supply ends of the main control drive module are connected to the bidirectional DC module via three groups of IGBT components.

[0008] The bidirectional DC module is provided with a positive main line and a negative main line, and the three high-voltage power supply ends of the main control drive module are each connected to two IGBTs, one of which is connected to the positive main line and the other is connected to the negative main line.

[0009] A capacitor is connected between the positive electrode main line and the negative electrode main line.

[0010] An extended-range electric vehicle is provided with a driving motor, a power battery is connected to a bidirectional DC module of an AC fast charging device via a high-voltage electric box, and a main control driving module is connected to an AC charging port on the vehicle via a switch K2.

[0011] The main control drive module of the AC fast charging device is connected to the drive motor via switch K1.

[0012] The power generation module is connected to the power battery via a high voltage box.

[0013] The power generation module includes a generator, an engine driving the generator, and a generator controller controlling the generator. The output end of the generator is connected to a high-voltage box.

[0014] The utility model has the advantages of extended-range electric vehicles, solves the problems of charging difficulties and range anxiety of pure electric vehicles, and the integrated drive and charging controller has the following advantages:

[0015] (1) The MCU and OBC are combined into one, which saves the entire OBC vehicle charging hardware and uses the working principle of the MCU motor controller inverter to reversely charge the power battery;

[0016] (2) The IGBT used in the MCU has higher current and voltage resistance than the MOS tube used in general on-board chargers. Therefore, the MCU motor controller can charge the power battery at high power.

[0017] (3) The charger and motor controller are deeply integrated (reusing IGBT, voltage and current sensors, etc.) to save product costs;

[0018] (4) Compatible with three-phase AC charging and single-phase AC charging, broadening the application scope of charging products. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] The following is a brief description of the contents of each figure in the utility model specification:

[0020] Figure 1 This is a schematic diagram of the structure of an extended-range electric vehicle;

[0021] Figure 2 This is a schematic diagram of the AC fast charging controller for extended-range electric vehicles. DETAILED DESCRIPTION

[0022] The following is a further detailed description of the specific implementation methods of the present invention, such as the shapes and structures of the components involved, the relative positions and connection relationships between the components, the functions and working principles of the components, the manufacturing process and the operation and use methods, etc., through the description of the embodiments with reference to the accompanying drawings, so as to help those skilled in the art to have a more complete, accurate and in-depth understanding of the inventive concept and technical solution of the present invention.

[0023] Compared with pure electric vehicles, extended-range electric vehicles have added range extenders and fuel tanks, and compared with traditional vehicles, they have added power batteries. Generally speaking, they include range extenders (a combination of an engine and a generator), generator controllers (GCU), drive motors, battery packs, and drive and charging controllers (MCU and OBC integrated into one). According to different usage environments, the working modes of extended-range electric vehicles are divided into pure electric mode and extended-range mode. Regardless of which mode it is in, the wheel driving force is provided independently by the motor, and the engine does not directly participate in the power drive, but only replenishes the power battery. When charging conditions are available, the power of the power battery pack is used first. When the battery power SOC drops to a certain set threshold, the range extender intervenes and starts the extended-range mode to charge the power battery and provide a power source to drive the car.

[0024] When the power battery of the extended-range electric vehicle is low on power, the fuel is insufficient, or the vehicle is not in use, the power battery pack needs to be charged in time through an external power source, and the AC fast charging device of the power battery is realized by integrating the motor controller with the charger. The AC fast charging device includes a main control drive module, a PFC module, and a bidirectional DC module. The main control drive module controls the driving of the PFC module and the bidirectional DC module according to the input signal from the vehicle end. The PFC module converts AC power into DC power. The bidirectional DC module is used to adjust the voltage of the PFC output circuit to adapt to the needs of the electric vehicle power battery.

[0025] Compared with general extended-range electric vehicles, the device of the utility model can use the power grid for fast charging, so the extended-range electric vehicle should give priority to using cheap electric energy to drive. When additional power is needed, the generator set is turned on, and the engine is operated at the optimal working point to drive the generator to work. The output mechanical energy is transmitted to the motor or power battery through the power converter to give full play to its advantages. In order to make full use of electrical energy, reasonably allocate power, and keep the drive motor and engine in the high-efficiency zone, the working modes of the extended-range electric vehicle include pure electric drive mode, range extender and power battery co-drive mode, range extender drive and charging mode, and range extender charging mode.

[0026] The utility model of the extended-range electric vehicle is equipped with an on-board charging device, which can quickly charge the power battery through the AC fast charging controller (MCU and OBC integrated into one) with the help of the power grid when the power battery is insufficient. Figure 2 , mainly achieved through the following control methods:

[0027] When the integrated AC fast charging device is in charging mode, the external AC power supply is connected to the vehicle through the AC charging socket, and the electric energy is converted from three-phase AC to high-voltage DC required by the electric vehicle through the AC fast charging system, and the electric energy is input to the power battery through the power cable. The specific charging process is as follows: When the plug-in gun connects the electric vehicle to the charging gun, the plug-in signal is transmitted to the AC fast charging system, and its main control drive module controls the K1 relay to disconnect. After confirming that the system self-test is fault-free, it drives the K2 relay to close. Then, according to the charging instructions of the BMS and VCU, its main control drive module controls the PFC module and the bidirectional DC module to control the AC boost, DC conversion and DC voltage and current control in real time. The function of charging the power battery.

[0028] When the system is in driving mode, the main control drive module of the AC fast charging system controls the K2 relay to disconnect and the K2 relay to close. After self-testing and vehicle fault-free, the power battery's electrical energy is converted into three-phase AC power through the system's bidirectional DC module and PFC module to drive the motor and the vehicle to move.

[0029] By adopting this technical solution, the MCU integrated AC charging function is realized by reusing electronic components such as IGBT, so as to realize high-power charging of extended-range electric vehicles, increase the charging power input, improve the charging speed, and is very suitable for the application of extended-range electric vehicles. It not only shortens the charging time, but also facilitates the charging process, which is suitable for the use needs of most users, saves time cost and increases efficiency.

[0030] The extended-range electric vehicle has an AC fast charging device for the extended-range electric vehicle. When the power battery is insufficient, the power battery can be quickly charged with the help of the power grid through an AC fast charging controller (MCU and OBC integrated into one).

[0031] When the integrated AC fast charging device is in charging mode, the external AC power source is connected to the vehicle through the AC charging socket, and the electric energy is converted from three-phase AC to high-voltage DC required by the electric vehicle through the AC fast charging system, and then input into the power battery through the power cable. The specific charging process is as follows:

[0032] When the plug-in gun connects the electric vehicle to the charging gun, the plug-in gun signal is transmitted to the AC fast charging system, and its main control drive module controls the K1 relay to disconnect. After confirming that the system self-checks without faults, it drives the K2 relay to close. Then, according to the charging instructions of the BMS and VCU, its main control drive module controls the PFC module and the bidirectional DC module to complete the AC boost, DC conversion and DC voltage and current control in real time to charge the power battery.

[0033] When the system is in driving mode, the main control drive module of the AC fast charging system controls the K2 relay to disconnect and the K2 relay to close. After self-testing and vehicle fault-free, the power battery's electrical energy is converted into three-phase AC power through the system's bidirectional DC module and PFC module to drive the motor and the vehicle to move.

[0034] The present invention is described above by way of example in conjunction with the accompanying drawings. It is obvious that the specific implementation of the present invention is not limited to the above-mentioned method. As long as various non-substantial improvements are made using the method concept and technical solution of the present invention, or the concept and technical solution of the present invention are directly applied to other occasions without improvement, they are all within the protection scope of the present invention.

Claims

1. An AC fast charging device, characterized in that: It includes a main control drive module, a PFC module, and a bidirectional DC module. The control drive module is provided with a switch K1 for connecting to the vehicle drive motor and a switch K2 for connecting to the AC charging port. The PFC module converts AC power into DC power. The bidirectional DC module is used to adjust the voltage of the PFC output circuit. The output end of the PFC module is connected to the bidirectional DC module. The bidirectional DC module is provided with an output interface for connecting to the vehicle power battery. The three high-voltage power supply ends of the main control drive module are connected to the bidirectional DC module via three groups of IGBT components.

2. The AC fast charging device according to claim 1, characterized in that: The bidirectional DC module is provided with a positive main line and a negative main line, and the three high-voltage power supply ends of the main control drive module are connected to two IGBTs, one of which is connected to the positive main line and the other is connected to the negative main line.

3. The AC fast charging device according to claim 2, characterized in that: A capacitor is connected between the positive electrode main line and the negative electrode main line.

4. An extended-range electric vehicle, the electric vehicle is provided with a drive motor, characterized in that: The power battery is connected to the bidirectional DC module of the AC fast charging device as claimed in claim 1, 2 or 3 via a high-voltage electrical box, and the main control drive module is connected to the AC charging port on the car via a switch K2.

5. The extended-range electric vehicle according to claim 4, characterized in that: The main control drive module of the AC fast charging device is connected to the drive motor via switch K1.

6. The extended-range electric vehicle according to claim 5, characterized in that: The power generation module is connected to the power battery via a high-voltage box.

7. The extended-range electric vehicle according to claim 6, characterized in that: The power generation module includes a generator, an engine driving the generator, and a generator controller controlling the generator. The output end of the generator is connected to a high-voltage box.

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