All-in-one controller with isolation and detection functions and operation machine

Abstract

The utility model discloses an all-in-one controller with isolation and detection functions and an operation machine. The controller comprises an input end, a high-voltage isolation module and a load end, an AC / DC rectifier module is arranged at the input end; after the high-voltage isolation module is connected to the AC / DC rectification module at the input end, a non-isolated power supply of a power grid is converted into an isolated power supply through an isolation device, and the isolated power supply is transmitted to a load end; the load end comprises a DC / AC (Direct Current / Alternating Current) inversion module and a DC / DC step-down module, and is also provided with an insulation monitoring system for monitoring the insulation performance of the controller; the high-voltage isolation module converts a power supply into an isolation power supply and is equipped with an insulation monitoring system, so that the safety performance of the system is improved.

Description

Technical Field

[0001] The utility model relates to an all-in-one controller and an operating machine, in particular to an all-in-one controller and an operating machine with isolation and detection functions, belonging to the technical field of engineering machinery. Background Art

[0002] With the vigorous implementation of the national "dual carbon" policy, green development has been deeply rooted in the hearts of the people, and environmental protection policies have become increasingly comprehensive, which has directly promoted the vigorous development of the new energy industry, and the demand for new energy operating machinery has gradually increased. In addition, the current construction environments such as bridge erection, light rail, and construction sites are equipped with 380V, 50Hz power systems, so plug-in operating machinery has come into being. This article uses plug-in cranes as an example for patent description. By connecting to the power system on the job site, the vehicle body power conversion module and the motor provide power to the entire vehicle, which can achieve zero emissions in crane construction.

[0003] At the same time, plug-in operating machinery also has problems: there is a risk of high-voltage electricity use when the crane is connected to high-voltage electricity for operation. Therefore, a safe and efficient high-voltage power conversion system becomes particularly important.

[0004] In the prior art, such as Figure 1 The independent module controller shown in the figure is connected to an external 380V power system. The whole vehicle is distributed with AC / DC rectifier module 1, DC / AC inverter module 2 and DC / DC buck module 3. Each component is connected by a high-voltage wire harness for energy transfer. The following problems exist: several independent modules are stacked, which are large in size, heavy in weight, and costly. The whole vehicle layout is difficult, and it brings problems such as matching between modules to the OEM. There is no safety protection function (high-voltage isolation and insulation monitoring), and there is a greater risk of electric shock. Figure 2 The integrated controller shown in the figure is connected to an external 380V power system. The vehicle adopts an integrated all-in-one controller, which integrates the AC / DC rectifier module 1, the DC / AC inverter module 2 and the DC / DC buck module 3. The grid power is input to the all-in-one controller, and after conversion by each internal module, it directly drives the load to work. There is no safety protection function (high voltage isolation and insulation monitoring), and there is a greater risk of electric shock. Utility Model Content

[0005] Purpose of the utility model: The purpose of the utility model is to provide an all-in-one controller and operating machinery with isolation and detection functions that can reduce or eliminate the risk of electric shock when personnel operate operating machinery and can monitor insulation performance in real time.

[0006] Technical solution: The all-in-one controller with isolation and detection functions described in the utility model includes an input end, a high-voltage isolation module and a load end;

[0007] The input end is provided with an AC / DC rectifier module;

[0008] After the high-voltage isolation module is connected to the AC / DC rectifier module at the input end, the non-isolated power supply of the power grid is converted into isolated power supply through the isolation device and transmitted to the load end;

[0009] The load end includes a DC / AC inverter module and a DC / DC buck module. The load end is also equipped with an insulation monitoring system for monitoring and recording the insulation performance of the controller.

[0010] Furthermore, the AC / DC rectifier module converts the alternating current of the external power grid into direct current through an uncontrolled rectifier circuit.

[0011] Furthermore, the isolated power supply directly drives the motor through a DC / AC inverter module.

[0012] Furthermore, the DC / DC step-down module steps down the voltage of the isolated power supply to supply power to the low-voltage device.

[0013] Furthermore, the high voltage of the AC / DC rectifier module is provided with reinforced insulation to the ground; the primary side and the secondary side of the DC / DC step-down module are isolated from each other, which is basic insulation; all high voltages inside the controller are additionally insulated from low voltages.

[0014] Furthermore, the load end also includes a PTC heating module.

[0015] Furthermore, the load end also includes a high-voltage electric air-conditioning module.

[0016] Based on the same inventive concept, the utility model also provides an operating machine, including an interactive module and any of the above-mentioned all-in-one controllers with isolation and detection functions.

[0017] Furthermore, the interaction module is used to control all relays inside the controller and interact with the overall operating machinery.

[0018] Furthermore, the interactive control module makes a judgment based on the value recorded by the insulation monitoring system of the controller, and when the value exceeds a preset threshold, the interactive module issues an early warning or cuts off the power supply of the operating machinery.

[0019] Beneficial effects: Compared with the prior art, the utility model has the following significant advantages: 1. The high-voltage isolation converts the power supply into an isolated power supply and is equipped with an insulation monitoring system to improve the safety performance of the system; 2. It meets the needs of plug-in cranes to directly use the three-phase power of the power grid for operation; 3. It reduces costs, reduces occupied space, improves integration, and makes assembly and maintenance more convenient. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 It is a schematic diagram of an independent module controller in the prior art;

[0021] Figure 2 It is a schematic diagram of an integrated controller in the prior art;

[0022] Figure 3 This is a schematic diagram of the topological structure of an embodiment of the utility model;

[0023] Figure 4 It is a schematic diagram of the operation flow of an embodiment of the utility model. DETAILED DESCRIPTION

[0024] The technical solution of the utility model is further described below in conjunction with the accompanying drawings and embodiments.

[0025] As attached Figure 3 As shown, the all-in-one controller with isolation and detection functions described in this embodiment includes an input end, a high-voltage isolation module 5 and a load end;

[0026] The input end is provided with an AC / DC rectifier module 1; after the high-voltage isolation module 5 is connected to the AC / DC rectifier module 1 at the input end, the non-isolated power supply of the power grid is converted into an isolated power supply through an isolation device and transmitted to the load end; the load end includes a DC / AC inverter module 2 and a DC / DC step-down module 3, and the load end is also equipped with an insulation monitoring system 4 for monitoring and recording the insulation performance of the controller.

[0027] The AC / DC rectifier module 1 is integrated and placed at the input end of the all-in-one controller, and converts the AC power of the external power grid into DC power through an uncontrolled rectifier circuit to provide a power source for the entire vehicle; after the high-voltage isolation module 5 is placed on the AC / DC rectifier module 1, the non-isolated power supply of the power grid is converted into an isolated power supply through an isolation device; the isolated power supply directly drives the motor through the DC / AC inverter module 2, and supplies power to the low-voltage equipment through the DC / DC step-down module 3; the load end of the high-voltage isolation module 5 is equipped with an insulation monitoring system 4 to monitor the insulation performance of the high-voltage system in real time and improve the safety performance of the entire system; when the insulation monitoring system 4 detects leakage, it issues an early warning or cuts off the power supply.

[0028] This embodiment designs an all-in-one controller with isolation and detection functions. It is connected to an external 380V power grid, and the 380V non-isolated AC power supply is converted into an isolated 540V DC power supply through the internal integrated rectification and high-voltage isolation module. This DC power outputs a set of three-phase power for driving the motor through the internal inverter module, and can also output a set of 12V, 24V, 36V, 220V and other DC power of any voltage to power the low-voltage system or other power units. At the same time, an insulation monitoring system is equipped at the load end of the isolated power supply to monitor the insulation status of the system in real time.

[0029] The all-in-one controller of this embodiment highly integrates an AC / DC rectifier module 1 , a DC / AC inverter module 2 , a DCDC step-down module 3 , an insulation monitoring system 4 and a high-voltage isolation module 5 .

[0030] As an expanded function of this embodiment, functional modules such as a PTC heating module 6 and a high-voltage electric air conditioning module 7 may also be integrated.

[0031] Like the conventional all-in-one controller, the all-in-one controller of this embodiment contains a DC / AC inverter module 2, a DC / DC buck module 3, a PTC heating module 6 and a high-voltage electric air conditioning module 7, and uses high-voltage direct current to drive the motor and power the low-voltage equipment;

[0032] The all-in-one controller of this embodiment integrates the AC / DC rectifier module 1 at the input end of the all-in-one controller, and converts the AC power of the external power grid into DC power through uncontrolled rectification to provide power source for the whole vehicle;

[0033] After placing the high-voltage isolation module 5 on the AC / DC rectifier module 1, the non-isolated power supply of the grid is converted into an isolated power supply through the isolation device;

[0034] The load end of the high-voltage isolation module 5 is equipped with an insulation monitoring system 4 to monitor the insulation performance of the high-voltage system in real time and improve the safety performance of the entire system.

[0035] Based on the same inventive concept, this embodiment also provides an operating machine, including an interaction module and any of the above-mentioned all-in-one controllers with isolation and detection functions.

[0036] Furthermore, the interaction module is used to control all relays inside the controller and interact with the overall operating machinery; the interaction module includes a motor temperature measurement unit.

[0037] Figure 4 This is the operation flow chart of this embodiment: 380V AC power from the external power grid is used to directly drive the operating machine through an all-in-one controller with isolation and detection functions. The 380V AC power is converted into 540V DC power through the AC / DC rectifier module 1, and then the isolated power is output through the high-voltage isolation module 5. It is transmitted to the motor of the operating machine through the DC / AC inverter module 2 to directly drive the operating machine, and the low-voltage system is powered through the DC / DC step-down module 3. An insulation monitoring system 4 is added to the load end of the isolated power supply to monitor the insulation performance of the high-voltage system in real time.

[0038] The high voltage of the rectifier part is reinforcedly insulated from the ground; the primary and secondary sides of the isolated DC / DC part are isolated, which is basic insulation; the internal high voltage of the electronic control is additionally insulated from the low voltage, and the motor temperature measurement unit of the interactive module is additionally insulated from the three-phase winding of the motor of the operating machinery.

[0039] 1) When there is no ground wire in the three-phase input or the grounding effect is poor, when a single fault occurs on one side (such as a short circuit between the motor power line and the casing), since isolated DC is added inside the whole machine, there is no loop after the short circuit, and there is no risk of electric shock when a person touches the frame on the ground.

[0040] 2) Failure of the internal insulation of the DC-DC, aging of the device, failure of the device, etc., causes a short circuit between the high voltage and the low voltage, and the basic insulation is destroyed. Since an isolated DC is added inside the whole machine, there is no loop after a fault, and there is no risk of electric shock when a person touches the low-voltage part on the vehicle.

[0041] The present embodiment provides an all-in-one controller with a high-voltage isolation function; it also has an insulation monitoring function, and once an insulation problem occurs, an early warning or power supply is cut off immediately.

[0042] The abbreviations in this embodiment are defined as follows:

[0043] All-in-one controller: commonly used in new energy vehicles or operating machinery, it integrates AC / DC conversion, motor drive and other functions, and simultaneously supplies power to high-voltage heating and cooling air conditioners, electric air compressors and other equipment.

[0044] High voltage isolation: A method of converting one or more groups of non-isolated power supplies into one or more groups of isolated power supplies using one or more groups (high voltage frequency conversion / voltage modules, etc.).

[0045] Isolated power supply: There is no direct current loop connection between the input and load ends of the power supply. The driving or conversion efficiency of the power supply is relatively low. The high voltage at the AC input end is blocked before the load end. There is no risk of electric shock if you directly touch any high-voltage line at the load end.

[0046] Non-isolated power supply: There is a direct current loop connection between the input end of the power supply and the output end of the load end. The driving or conversion efficiency of the power supply is high, and the high voltage at the input end of the power supply is introduced into the load end, which poses a risk of electric shock.

[0047] Insulation monitoring system: a device for online real-time monitoring of the insulation status of the bus and branches of the DC power supply system to detect and manage whether it is good.

[0048] Basic Insulation: Insulation that provides basic protection against electric shock.

[0049] Supplementary insulation: Independent insulation applied in addition to basic insulation to prevent electric shock in the event of failure of the basic insulation.

[0050] Reinforced Insulation: A single insulation structure that provides protection equivalent to double insulation.

[0051] The all-in-one controller in this embodiment is actually a five-in-one controller. The controller input is 380V AC. Through rectification and high-voltage isolation, it drives the motor, high-voltage electric air conditioner and PTC heating. At the same time, there is a 24V low-voltage power output. The isolated load end is equipped with insulation monitoring to monitor the system in real time. Different types of high-voltage power inputs, as well as all-in-one controllers that integrate one or more functions such as boost, high-voltage heating and cooling air conditioners, electric air compressors, and electric steering pumps are all within the scope of protection of this patent. The output of the controller, the output of multiple voltage values, and multiple low-voltage outputs are also within the scope of protection of this patent.

[0052] High voltage isolation is not limited to converting non-isolated AC power into isolated AC power. Any integrated all-in-one controller that can convert non-isolated AC / DC power into isolated AC / DC power is within the scope of protection of this patent.

Claims

1. An all-in-one controller with isolation and detection functions, characterized in that: It includes an input end, a high voltage isolation module (5) and a load end; The input end is provided with an AC / DC rectifier module (1); After the high-voltage isolation module (5) is connected to the AC / DC rectifier module (1) at the input end, the non-isolated power supply of the power grid is converted into isolated power supply through the isolation device and transmitted to the load end; The load end comprises a DC / AC inverter module (2) and a DC / DC step-down module (3), and the load end is also equipped with an insulation monitoring system (4) for monitoring and recording the insulation performance of the controller.

2. The all-in-one controller with isolation and detection functions according to claim 1, characterized in that: The AC / DC rectifier module (1) converts alternating current from an external power grid into direct current through an uncontrolled rectifier circuit.

3. The all-in-one controller with isolation and detection functions according to claim 1, characterized in that: The isolated power supply directly drives the motor via a DC / AC inverter module (2).

4. The all-in-one controller with isolation and detection functions according to claim 1, characterized in that: The DC / DC step-down module (3) steps down the voltage of the isolated power supply to supply power to the low-voltage equipment.

5. The all-in-one controller with isolation and detection functions according to claim 1, characterized in that: The high voltage of the AC / DC rectifier module (1) is arranged to be reinforced insulated from the ground; the primary side and the secondary side of the DC / DC step-down module (3) are isolated from each other, which is basic insulation; and all high voltages inside the controller are additionally insulated from low voltages.

6. The all-in-one controller with isolation and detection functions according to claim 1, characterized in that: The load end also includes a PTC heating module (6).

7. The all-in-one controller with isolation and detection functions according to claim 1, characterized in that: The load end also includes a high-voltage electric air conditioning module (7).

8. A working machine, characterized in that: It comprises an interactive module and an all-in-one controller with isolation and detection functions as described in any one of claims 1 to 7.

9. The working machine according to claim 8, characterized in that: The interaction module is used to control all relays inside the controller and interact with the overall operating machinery.

10. The working machine according to claim 8, characterized in that: The interactive module makes a judgment based on the value recorded by the insulation monitoring system (4) of the controller, and when the value exceeds a preset threshold, the interactive module issues an early warning or cuts off the power supply of the operating machine.

Images