Single-gun direct current charging system

Abstract

The utility model relates to a single-gun direct-current charging system, which comprises a box body, an alternating-current input loop, a power unit, a direct-current output loop, a control loop, a man-machine interaction unit and a thermal management system, a direct current output loop is arranged on the upper portion of the box body, a control loop is arranged below the direct current output loop, an alternating current input loop is arranged below the control loop, a power unit is arranged on the rear side of the control loop, and a man-machine interaction unit is arranged on the box door. According to the utility model, each part is modularized and can be independently installed, so that the standardization and universality of the product are improved, the production of the charging pile is streamlined, and the production efficiency is improved.

Description

Technical Field

[0001] The utility model relates to the technical field of charging piles, in particular to a single-gun direct current charging system. Background Art

[0002] Charging piles refer to charging equipment that provides charging services for electric vehicles. They are mainly divided into floor-standing charging piles and wall-mounted charging piles. They mainly adopt charging methods based on time, electricity metering, and amount metering. At present, there is a lack of DC charging piles in the charging pile market. The DC charging piles on the market are all customized products with poor practicality and compatibility, and low efficiency. Since the DC charging piles on the market are all customized products, the design standards are not unified, resulting in the following problems with similar new energy vehicle charging pile products on the market: low product standardization, low product modularization, low commonality of various components, and serious product homogeneity; which further leads to high production costs and uneven product quality. Summary of the invention

[0003] The purpose of the utility model is to overcome the above-mentioned shortcomings and provide a single-gun DC charging system. In view of the problems of low standardization, low modularization, low commonality of components, uneven quality, etc. of existing products, the product is standardized and modularized in design, the commonality of various components of the product is improved, the production consistency of the product is optimized, the product quality is improved, and the production cost is reduced.

[0004] The purpose of the utility model is achieved in this way:

[0005] A single-gun DC charging system comprises a box body and an AC input circuit, a power unit, a DC output circuit and a control circuit arranged in the box body; a box door that can be opened and closed is arranged on the front side of the box body, an air outlet is arranged on the left side of the box body, and an air inlet is arranged on the right side of the box body;

[0006] The AC input circuit includes an input copper bar, a molded case circuit breaker, a connecting copper bar, a lightning arrester, a first miniature circuit breaker, an AC contactor and a branch terminal; one end of the input copper bar is connected to the three-phase AC incoming line, and the other end is connected to the top of the molded case circuit breaker, reaches the AC contactor through the connecting copper bar, and is connected to the lightning arrester through the first miniature circuit breaker. The AC input then reaches the branch terminal through the AC contactor, and then enters the input end of the power unit;

[0007] The power unit includes a power module and a module box; a plurality of power modules are arranged in the module box of the power unit, the power module is connected to the branch terminal of the AC input circuit, the AC input enters the power module through the branch terminal of the AC input circuit, and performs AC-DC power conversion to the DC output circuit, the power module exchanges data with the control circuit through CAN communication, and the control circuit controls the output and power regulation;

[0008] The DC output circuit includes a first output copper bar, a second output copper bar, a shunt, a fuse, a first DC contactor, a second DC contactor, a third DC contactor, a discharge resistor, an electronic lock drive module, a DC energy meter, an insulation monitoring module, a terminal block and a third output copper bar; the negative pole of the DC power supply output by the power module reaches the inner side of the first DC contactor through the first output copper bar and the shunt, and the positive pole of the DC output power supply output by the power module reaches the inner side of the second DC contactor through the second output copper bar and the fuse; one side of the third output copper bar is connected to the DC gun lines DC+ and DC-, and the other side is connected to the outer sides of the first DC contactor and the second DC contactor, and the first DC contactor and the second DC contactor are connected to the control module of the control circuit, and their disconnection and closing are controlled by the control circuit;

[0009] The control loop includes a control module, a 50W power module, a 150W power module and a second miniature circuit breaker; the control module is provided with a 12V working power supply by the 50W power module and has a 9-way digital input detection function.

[0010] Furthermore, the molded case circuit breaker, AC contactor and lightning arrester in the AC input circuit all have a normally closed switch connected to the control circuit for status detection.

[0011] Furthermore, the shunt is connected to a current interface of a DC energy meter for DC metering to measure current; the third DC contactor and the discharge resistor constitute a discharge circuit to discharge the charge in the load circuit when the power is turned off.

[0012] Furthermore, the input end of the electronic lock driving module is connected to the control module of the control loop, and the output end is connected to the electronic lock control line of the DC charging gun. The control module controls the electronic lock driving module to output a 12V pulse to control the gun line electronic lock to be closed or disconnected.

[0013] Furthermore, the shunt is also connected to the current input interface of the DC power meter, which is used to measure the DC output voltage, current and electric energy. The voltage input interface of the DC power meter is connected to the inner side of the DC contactor. The DC power meter also has an RS485 interface connected to the control module of the control loop for communicating with the control loop.

[0014] Furthermore, the bus detection input port of the insulation detection module is correspondingly connected to the inner side of the first DC contactor and the second DC contactor, and is used to measure the insulation performance on the DC output bus. Each time charging is started, the power module will boost the voltage, and the insulation detection module will detect the insulation resistance of the output bus. The insulation detection module also has an RS485 communication channel, which is connected to the control module of the control loop, and transmits the detection data to the control loop, which determines whether charging is allowed and issues an alarm.

[0015] Furthermore, it also includes a human-computer interaction unit, which includes an LED display module, a touch screen, a radio frequency module and a fourth mounting plate. The LED display module is composed of a three-color LED: an orange power indicator, a green charging indicator and a red alarm prompt; the touch screen is connected to the control module in the control loop through RS485; the radio frequency module is connected to the control module in the control loop through TTL, and the charging pile can be started and stopped by external card swiping.

[0016] Furthermore, it also includes a thermal management system, which includes two temperature measuring probes, a cooling fan and a cooling air duct. The two temperature measuring probes are placed at the air inlet and air outlet of the box and are connected to a control module in a control loop. When the temperature exceeds a reliable threshold, the control module controls the power module to reduce the output power or disconnect the output; the cooling fan is controlled by the control module, and the cooling fan will be started synchronously when charging is started.

[0017] Furthermore, the input copper busbar, molded case circuit breaker, connecting copper busbar, AC contactor, first miniature circuit breaker, lightning arrester and branch terminal of the AC input circuit are all arranged on the first mounting board; the first output copper busbar, second output copper busbar, shunt, fuse, first DC contactor, second DC contactor, third DC contactor, discharge resistor, electronic lock drive module, DC energy meter, insulation monitoring module, wiring terminal and third output copper busbar of the DC output circuit are all arranged on the second mounting board; the control module, 50W power supply module, 150W power supply module and second miniature circuit breaker of the control circuit are all arranged on the third mounting board.

[0018] Furthermore, the first mounting plate, the second mounting plate and the third mounting plate are all arranged in the box, and the first mounting plate, the second mounting plate and the third mounting plate are all detachable plates, so that the AC input circuit, the DC output circuit and the control circuit can be independently installed or disassembled.

[0019] Compared with the prior art, the beneficial effects of the utility model are:

[0020] The utility model provides a single-gun DC charging system, which consists of an AC input circuit, a control circuit, a DC output circuit, a human-computer interaction, a power unit and a thermal management unit. Each part is modularized and can be installed separately, thereby improving the standardization and versatility of the product, streamlining the production of charging piles, and improving production efficiency. At the same time, due to the standardization of the product, the product can be adjusted according to actual needs, greatly reducing the production design cost. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Figure 1 It is a structural schematic diagram of the utility model.

[0022] Figure 2 It is a structural schematic diagram of the AC input circuit of the utility model.

[0023] Figure 3 It is a structural schematic diagram of the DC output circuit of the utility model.

[0024] Figure 4 It is a structural schematic diagram of the control loop of the utility model.

[0025] in:

[0026] Box body 1, air inlet 11, air outlet 12, box door 13, AC input circuit 2, input copper bus 21, molded case circuit breaker 22, connecting copper bus 23, lightning arrester 24, first miniature circuit breaker 25, AC contactor 26, branch terminal 27, first mounting plate 28, power module 31, module box 32, DC output circuit 4, first output copper bus 41, second output copper bus 42, shunt 43, fuse 44, first DC contactor 45, second DC contactor 46, third DC Contactor 47, discharge resistor 48, electronic lock drive module 49, DC energy meter 410, insulation monitoring module 411, terminal block 412, third output copper bus 413, second mounting plate 414, control circuit 5, control module 51, 50W power module 52, 150W power module 53, second miniature circuit breaker 54, third mounting plate 55, human-computer interaction unit 6, LED display module 61, touch screen 62, radio frequency module 63, fourth mounting plate 64, cooling fan 7. DETAILED DESCRIPTION

[0027] In order to better understand the technical solution of the present invention, the following will be described in detail in conjunction with the relevant illustrations. It should be understood that the following specific embodiments are not intended to limit the specific implementation of the technical solution of the present invention, and are only implementations that can be adopted by the technical solution of the present invention. It should be noted that the description of the positional relationship of each component in this article, such as component A being located above component B, is based on the description of the relative positions of the components in the illustration, and is not intended to limit the actual positional relationship of the components. Example 1

[0028] See also Figure 1-Figure 4 , Figure 1 The structural schematic diagram of the utility model is drawn. As shown in the figure, the utility model relates to a single-gun DC charging system, which includes a box body 1 and an AC input circuit 2, a power unit, a DC output circuit 4, a control circuit 5, a human-computer interaction unit 6 and a thermal management system arranged in the box body 1;

[0029] The front side of the box body 1 is provided with an openable and closable box door 13, the left side of the box body 1 is provided with an air outlet 12, and the right side is provided with an air inlet 11; a DC output circuit 4 is provided on the upper part of the box body 1, a control circuit 5 is provided below the DC output circuit 4, an AC input circuit 2 is provided below the control circuit 5, a power unit is provided on the rear side of the control circuit 5, and a human-computer interaction unit 6 is provided on the box door 13.

[0030] The AC input circuit 2 includes an input copper busbar 21, a molded case circuit breaker 22, a connecting copper busbar 23, a lightning arrester 24, a first miniature circuit breaker 25, an AC contactor 26, a branch terminal 27 and a first mounting plate 28; the power unit includes a power module 31 and a module box 32; the DC output circuit 4 includes a first output copper busbar 41, a second output copper busbar 42, a shunt 43, a fuse 44, a first DC contactor 45, a second DC contactor 46, a third DC contactor 47, a discharge resistor 48, an electronic lock driver The control module 49, the DC energy meter 410, the insulation monitoring module 411, the terminal block 412, the third output copper bus 413 and the second mounting plate 414; the control loop 5 includes a control module 51, a 50W power module 52, a 150W power module 53, a second miniature circuit breaker 54, and a third mounting plate 55; the human-computer interaction unit 6 includes an LED display module 61, a touch screen 62, a radio frequency module 63 and a fourth mounting plate 64; the thermal management system includes two temperature measuring probes, a cooling fan 7 and a cooling air duct.

[0031] The input copper busbar 21, the molded case circuit breaker 22, the connecting copper busbar 23, the AC contactor 26, the first miniature circuit breaker 25, the lightning arrester 24 and the branch terminal 27 of the AC input circuit 2 are all arranged on the first mounting plate 28, and the AC input circuit 2 can be installed and removed separately; one end of the input copper busbar 21 is connected to the three-phase AC incoming line, and the other end is connected to the top of the molded case circuit breaker 22, and reaches the AC contactor 26 through the connecting copper busbar 23, and is connected to the lightning arrester 24 through the first miniature circuit breaker 25, ensuring that the AC input circuit has a lightning protection function. When an accident occurs and causes the lightning arrester 24 to fail, the first miniature circuit breaker 25 can be disconnected in time to ensure that the AC input circuit 2 is not affected; the AC input then reaches the branch terminal 27 through the AC contactor 26, thereby entering the input end of the power unit.

[0032] The molded case circuit breaker 22, the AC contactor 26 and the lightning arrester 24 in the AC input circuit 2 all have a normally closed switch connected to the control circuit 5 for status detection.

[0033] A plurality of power modules 31 are arranged in the module box 32 of the power unit, which can support the installation of up to 4 modules, and a specified number of modules can be inserted according to actual needs; the power module 31 is connected to the branch terminal 27 of the AC input circuit 2, and the AC input enters the power module 31 through the branch terminal 27 of the AC input circuit 2, and the AC-DC power is converted to the DC output circuit 4. The power module 31 exchanges data with the control circuit 5 through CAN communication, and the control circuit 5 controls the output and power regulation.

[0034] The first output copper bar 41, the second output copper bar 42, the shunt 43, the fuse 44, the first DC contactor 45, the second DC contactor 46, the third DC contactor 47, the discharge resistor 48, the electronic lock drive module 49, the DC energy meter 410, the insulation monitoring module 411, the wiring terminal 412 and the third output copper bar 413 of the DC output circuit 4 are all arranged on the second mounting plate 414; the modular DC output circuit 4 can be installed and removed separately;

[0035] The negative pole of the DC power output by the power module 31 reaches the inner side of the first DC contactor 45 through the first output copper busbar 41 and the shunt 43, and the positive pole of the DC output power output by the power module 31 reaches the inner side of the second DC contactor 46 through the second output copper busbar 42 and the fuse 44. When the output overcurrent occurs in the circuit, the fuse 44 will be blown to protect the vehicle; one side of the third output copper busbar 413 is connected to the DC gun lines DC+ and DC-, and the other side is connected to the outer sides of the first DC contactor 45 and the second DC contactor 46. The output can be controlled by the DC contactor. The first DC contactor 45 and the second DC contactor 46 are connected to the control module 51 of the control circuit 5, and their disconnection and closing are controlled by the control circuit 5;

[0036] The shunt 43 is connected to the current interface of the DC energy meter 410 for DC metering to measure the current; the third DC contactor 47 and the discharge resistor 48 constitute a discharge circuit, which quickly discharges the charge in the load circuit when the power is turned off, ensuring that the system can respond normally and quickly when it is started next time;

[0037] The input end of the electronic lock driving module 49 is connected to the control module 51 of the control circuit 5, and the output end is connected to the electronic lock control line of the DC charging gun. The control module 51 controls the electronic lock driving module 49 to output a 12V pulse to control the gun line electronic lock to be closed or disconnected;

[0038] The shunt 43 is also connected to the current input interface of the DC energy meter 410, and the DC energy meter 410 is used for measuring the DC output voltage, current and electric energy. The voltage input interface of the DC energy meter 410 is connected to the inner side of the DC contactor 24. The DC energy meter 410 also has an RS485 interface connected to the control module 51 of the control loop 5, which is used to communicate with the control loop 5 and report the detected voltage and current. The electric energy accuracy of the DC energy meter 410 is level 1;

[0039] The bus detection input port of the insulation detection module 411 is connected to the inner side of the first DC contactor 45 and the second DC contactor 46, and is used to measure the insulation performance of the DC output bus. Each time charging is started, the power module 31 will boost the voltage, and the insulation detection module 411 will detect the insulation resistance of the output bus. The insulation detection module 411 also has an RS485 communication, which is connected to the control module 51 of the control circuit 5, and transmits the detection data to the control circuit 5, and the control circuit 5 determines whether charging is allowed and alarms;

[0040] The DC output circuit 4 is also provided with a connection terminal 412 for connecting the signal lines on the DC charging gun with the control circuit 5 .

[0041] The control module 51, 50W power module 52, 150W power module 53 and second miniature circuit breaker 54 of the control loop 5 are all arranged on the third mounting plate 55. The control module 51 is provided with 12V working power by the 50W power module 52 and has a 9-way input detection function, which is used to detect the states of the molded case circuit breaker 22, AC contactor 26, lightning arrester 24 in the AC input loop 2 and the first DC contactor 45, the second DC contactor 46 in the DC output loop 4 and the electronic lock state detection of the gun line;

[0042] The control module 51 has 8 switch control functions, (1) for controlling the start and stop of the AC fan 7 in the thermal management system; (2) for controlling the opening and closing of the first DC contactor 45 / 16 in the DC output circuit 4; (3) for controlling the 150W power module 53 to output a 12V auxiliary power supply to the vehicle BMS; (4) for controlling the opening and closing of the third DC contactor 47 of the discharge module of the DC output circuit 4, thereby controlling the discharge of the charge in the load circuit to ensure that the system can respond normally and quickly when it is started next time; (5) for controlling the power input of the electronic lock drive module 49 in the DC output circuit 4, thereby controlling the electronic lock drive module to output a 12V pulse; (6) The control module 51 also has 3 CAN and 3 RS485 for communicating with the vehicle BMS, the power module 31, the DC energy meter 410 and the human-computer interaction unit 6, etc.

[0043] The LED display module 61, touch screen 62 and radio frequency module 63 of the human-computer interaction unit 6 are all arranged on the fourth mounting plate 64. The LED display module 61 is composed of a three-color LED: an orange power indicator, a green charging indicator and a red warning prompt; the touch screen 62 uses a 7-inch capacitive touch screen, and the touch screen 62 is connected to the control module 51 in the control loop 5 via RS485; the radio frequency module 63 is connected to the control module 51 in the control loop 5 via TTL, and the charging pile can be started and stopped by external card swiping.

[0044] The two temperature measuring probes of the thermal management system are placed at the air inlet 11 and the air outlet 12 of the box 1, and are connected to the control module 51 in the control loop 5. When the temperature exceeds the reliable threshold, the control module 51 controls the power module 31 to reduce the output power or disconnect the output; the cooling fan 7 is controlled by the control module 51, and the cooling fan 7 will be started synchronously when charging is started, and the heat is dissipated through the designed cooling air duct, thereby reducing the internal temperature of the charging pile, ensuring the normal operation of each component, and improving the safety of the charging pile.

[0045] The first mounting plate 28, the second mounting plate 414 and the third mounting plate 55 are all arranged in the box body 1, and the fourth mounting plate 64 is arranged on the box door 13; the first mounting plate 28, the second mounting plate 414, the third mounting plate 55 and the fourth mounting plate 64 are all detachable sheet metal.

[0046] The above are only specific application examples of the utility model, and do not constitute any limitation on the protection scope of the utility model. Any technical solution formed by equivalent transformation or equivalent replacement falls within the protection scope of the utility model.

Claims

1. A single-gun DC charging system, characterized by: It comprises a box body and an AC input circuit, a power unit, a DC output circuit and a control circuit arranged in the box body; the front side of the box body is provided with an openable door, the left side of the box body is provided with an air outlet, and the right side of the box body is provided with an air inlet; The AC input circuit includes an input copper bar, a molded case circuit breaker, a connecting copper bar, a lightning arrester, a first miniature circuit breaker, an AC contactor and a branch terminal; one end of the input copper bar is connected to the three-phase AC incoming line, and the other end is connected to the top of the molded case circuit breaker, reaches the AC contactor through the connecting copper bar, and is connected to the lightning arrester through the first miniature circuit breaker. The AC input then reaches the branch terminal through the AC contactor, and then enters the input end of the power unit; The power unit includes a power module and a module box; a plurality of power modules are arranged in the module box of the power unit, the power module is connected to the branch terminal of the AC input circuit, the AC input enters the power module through the branch terminal of the AC input circuit, and performs AC-DC power conversion to the DC output circuit, the power module exchanges data with the control circuit through CAN communication, and the control circuit controls the output and power regulation; The DC output circuit includes a first output copper bar, a second output copper bar, a shunt, a fuse, a first DC contactor, a second DC contactor, a third DC contactor, a discharge resistor, an electronic lock drive module, a DC energy meter, an insulation monitoring module, a terminal block and a third output copper bar; the negative pole of the DC power supply output by the power module reaches the inner side of the first DC contactor through the first output copper bar and the shunt, and the positive pole of the DC output power supply output by the power module reaches the inner side of the second DC contactor through the second output copper bar and the fuse; one side of the third output copper bar is connected to the DC gun lines DC+ and DC-, and the other side is connected to the outer sides of the first DC contactor and the second DC contactor, and the first DC contactor and the second DC contactor are connected to the control module of the control circuit, and their disconnection and closing are controlled by the control circuit; The control loop includes a control module, a 50W power module, a 150W power module and a second miniature circuit breaker; the control module is provided with a 12V working power supply by the 50W power module and has a 9-way digital input detection function.

2. A single-gun DC charging system according to claim 1, characterized in that: The molded case circuit breaker, AC contactor and lightning arrester in the AC input circuit all have a normally closed switch connected to the control circuit for status detection.

3. A single-gun DC charging system according to claim 1, characterized in that: The shunt is connected to a current interface of a DC electric energy meter for DC metering to measure current; the third DC contactor and the discharge resistor form a discharge circuit to discharge the charge in the load circuit when the power is turned off.

4. A single-gun DC charging system according to claim 1, characterized in that: The input end of the electronic lock driving module is connected to the control module of the control loop, and the output end is connected to the electronic lock control line of the DC charging gun. The control module controls the electronic lock driving module to output a 12V pulse to control the gun line electronic lock to be closed or disconnected.

5. A single-gun DC charging system according to claim 1, characterized in that: The shunt is also connected to the current input interface of the DC power meter, which is used to measure the DC output voltage, current and electric energy. The voltage input interface of the DC power meter is connected to the inner side of the DC contactor. The DC power meter also has an RS485 interface connected to the control module of the control loop for communicating with the control loop.

6. A single-gun DC charging system according to claim 1, characterized in that: The bus detection input port of the insulation monitoring module is connected to the inner side of the first DC contactor and the second DC contactor, and is used to measure the insulation performance of the DC output bus. Each time charging is started, the power module will boost the voltage, and the insulation detection module will detect the insulation resistance of the output bus. The insulation detection module also has an RS485 communication channel, which is connected to the control module of the control loop, and transmits the detection data to the control loop, which determines whether charging is allowed and issues an alarm.

7. A single-gun DC charging system according to claim 1, characterized in that: It also includes a human-computer interaction unit, which includes an LED display module, a touch screen, a radio frequency module and a fourth mounting plate. The LED display module consists of a three-color LED: an orange power indicator, a green charging indicator and a red warning prompt; the touch screen is connected to the control module in the control loop via RS485; the radio frequency module is connected to the control module in the control loop via TTL, and the start and stop of the charging pile can be controlled by external card swiping.

8. A single-gun DC charging system according to claim 1, characterized in that: It also includes a thermal management system, which includes two temperature probes, a cooling fan and a cooling air duct. The two temperature probes are placed at the air inlet and outlet of the box and are connected to a control module in a control loop. When the temperature exceeds a reliable threshold, the control module controls the power module to reduce the output power or disconnect the output. The cooling fan is controlled by the control module, and the cooling fan will be started synchronously when charging is started.

9. A single-gun DC charging system according to claim 1, characterized in that: The input copper busbar, molded case circuit breaker, connecting copper busbar, AC contactor, first miniature circuit breaker, lightning arrester and branch terminal of the AC input circuit are all arranged on the first mounting board; the first output copper busbar, second output copper busbar, shunt, fuse, first DC contactor, second DC contactor, third DC contactor, discharge resistor, electronic lock drive module, DC energy meter, insulation monitoring module, wiring terminal and third output copper busbar of the DC output circuit are all arranged on the second mounting board; the control module, 50W power supply module, 150W power supply module and second miniature circuit breaker of the control circuit are all arranged on the third mounting board.

10. A single-gun DC charging system according to claim 9, characterized in that: The first mounting plate, the second mounting plate and the third mounting plate are all arranged in the box body, and the first mounting plate, the second mounting plate and the third mounting plate are all detachable plates, so that the AC input circuit, the DC output circuit and the control circuit can be independently installed or disassembled.

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