Charging controller and vehicle

Abstract

The utility model relates to a charging controller and a vehicle, the charging controller is used for realizing double-gun charging, and the charging controller is characterized by comprising a first charging connector; the first relay assembly comprises a first relay and a second relay, and the first relay and the second relay are respectively connected to the first charging connector; a second charging connector; the second relay assembly comprises a third relay and a fourth relay, and the third relay and the fourth relay are respectively connected to the second charging connector; wherein the first relay assembly is close to one side of the first charging connector, and the second relay assembly is close to one side of the second charging connector. The charging controller and the vehicle have the beneficial effects that the charging controller which can be compatible with two charging piles and is reasonable and reliable in structure and the vehicle are provided.

Description

Technical Field

[0001] The present application relates to the field of charging control technology, and in particular to a charging controller and a vehicle. Background Art

[0002] Today, the development of new energy vehicles is extremely rapid, but the construction of charging facilities still lags behind the development of electric vehicles, and cannot meet the needs of electric vehicle users for charging convenience. There are problems such as long waiting time for users to charge and poor charging experience. Therefore, it is urgent to improve charging efficiency and solve the problem of charging difficulties.

[0003] In order to improve the charging rate of new energy vehicles, the market has begun to invest in 800V charging piles. However, as infrastructure construction, the deployment time of charging piles is delayed. At present, 500V charging piles are still the main ones. In order to meet the compatibility of electric vehicle high-voltage platforms with low-voltage charging piles and realize high-voltage power battery fast charging, new energy vehicles often need to be equipped with an additional voltage boosting device to increase the charging pile voltage to the voltage required for power battery charging.

[0004] Currently, most new energy vehicles do not have charging controllers that are compatible with both types of charging piles. If two specifications of charging controllers are configured, the charging controller will undoubtedly occupy a larger space and have a lower degree of integration. Utility Model Content

[0005] The embodiments of the present application provide a charging controller and a vehicle to at least partially solve the above-mentioned technical problems.

[0006] In order to achieve the above object, according to a first aspect of the present application, a charging controller is provided, comprising:

[0007] A first charging connector;

[0008] A first relay assembly, comprising a first relay and a second relay, wherein the first relay and the second relay are respectively connected to the first charging connector;

[0009] Second charging connector;

[0010] A second relay assembly includes a third relay and a fourth relay, wherein the third relay and the fourth relay are respectively connected to the second charging connector;

[0011] The first relay component is close to one side of the first charging connector, and the second relay component is close to one side of the second charging connector.

[0012] Optionally,

[0013] The charging controller also includes:

[0014] a boost relay connected to the second relay and the fourth relay respectively;

[0015] A boost inductor connected to the boost relay;

[0016] An IGBT module connected to the boost inductor;

[0017] The boost relay, boost inductor and IGBT module are used for boost charging.

[0018] Optionally,

[0019] The boost relay is located between the first relay assembly and the second relay assembly.

[0020] Optionally,

[0021] The first relay is connected to the negative output terminal of the first charging connector, and the second relay is connected to the positive output terminal of the first charging connector;

[0022] The third relay is connected to the negative output terminal of the second charging connector, and the fourth relay is connected to the positive output terminal of the second charging connector;

[0023] Wherein, the first relay is connected to the second relay.

[0024] Optionally,

[0025] The charging controller also includes:

[0026] A positive output conductor connected to an output connector of the charging controller;

[0027] Wherein, the positive output conductor is connected to the boost relay, the second relay and the fourth relay respectively.

[0028] Optionally,

[0029] The charging controller also includes:

[0030] a fully open relay connected to the positive output conductor;

[0031] Wherein, the connection point between the fully open relay and the positive output conductor is located between the boost relay and the second relay and the fourth relay.

[0032] Optionally,

[0033] The charging controller also includes:

[0034] A box body having a mounting space;

[0035] a power relay assembly, comprising a fifth relay and a sixth relay, wherein the fifth relay is connected to the positive output end of the first charging connector, and the sixth relay is connected to the positive output end of the second charging connector;

[0036] a pre-charging resistor, one end of which is connected to the fifth relay and the sixth relay respectively, and the other end of which is connected to the boost relay;

[0037] A pre-filled installation bracket is arranged in the installation space;

[0038] Wherein, the power relay assembly and the pre-charging resistor are respectively installed on the pre-charging mounting bracket.

[0039] Optionally,

[0040] The charging controller also includes:

[0041] A pre-charged control panel is formed with a number of mounting structures;

[0042] Wherein, the pins of the power relay and the pins to the pre-charging resistor are respectively combined with the mounting structure.

[0043] Optionally,

[0044] The charging controller also includes:

[0045] Battery end filter assembly;

[0046] A battery-end negative electrode conductor connected at least between the battery-end filter assembly and the first relay assembly;

[0047] Charging end filter components;

[0048] A negative conductor at the charging end, connected at least between the charging end filter component and the first relay component;

[0049] a plurality of fasteners fixedly connected to the first relay assembly;

[0050] Wherein, the fastener has a pressure portion, the battery terminal negative conductor is fixed between at least one of the pressure portions of the fastener and the first relay assembly, and the charging terminal negative conductor is fixed between another of the pressure portions of the fastener and the first relay assembly.

[0051] Optionally,

[0052] The fastener also has:

[0053] an extension portion extending from the pressure portion in a direction away from the first relay assembly;

[0054] The charging controller also includes:

[0055] The electric control panel is fixedly connected to an end of the extension portion away from the pressure portion.

[0056] According to a second aspect of the present application, a vehicle is provided, comprising the charging controller as described above.

[0057] The beneficial effect of the present application is to provide a charging controller and a vehicle that are compatible with two charging piles and have a reasonable and reliable structure.

[0058] More specifically, some embodiments of the present application may produce the following specific beneficial effects:

[0059] By setting the first charging connector and the second charging connector, the charging controller of the present application can be compatible with two charging piles. At the same time, the first relay component is set close to the first charging connector, and the second relay component is set close to the second charging connector, so as to improve the integration of the charging relay.

[0060] By sharing the same boost relay, boost inductor and IGBT module for boost charging by the first relay assembly and the second relay assembly, the space occupied by the charging controller can be reduced. In addition, the boost relay is located between the first relay assembly and the second relay assembly. Regardless of whether the current is input from the first charging interface or the second charging interface, the same boost relay, boost inductor and IGBT group can be shared for boost charging, so that the connection distance of the entire line is the shortest, reducing the energy loss during the charging process.

[0061] Modularization is achieved by installing the power relay and pre-charging resistor on the pre-charging mounting bracket and fixing the pre-charging control board together through the pins of the power relay and pre-charging resistor. This integrated installation solution not only reduces the connection harness, making the interior of the charging controller neat and beautiful, but also reduces the assembly process due to the high degree of integration, which is conducive to automated production.

[0062] The negative conductor at the battery end and the negative conductor at the charging end are fixed to the first relay assembly by fasteners respectively, and then the electronic control board is installed on the fasteners. The pressure part of the fasteners fastens the negative conductor at the battery end and the negative conductor at the charging end, while the extension part supports the electronic control board. After the electronic control board and the fasteners are fixed, the high-voltage signal can be sampled directly.

[0063] Other features and advantages of the present application will be described in detail in the subsequent detailed description. BRIEF DESCRIPTION OF THE DRAWINGS

[0064] In order to more clearly illustrate the technical solutions in the embodiments of the present application, the following briefly introduces the drawings required for use in the description of the embodiments. Obviously, the drawings described below are only some embodiments of the present application, and those skilled in the art can obtain other drawings based on these drawings without creative work.

[0065] In order to more completely understand the present application and its beneficial effects, the following description will be given in conjunction with the accompanying drawings, wherein the same figure numbers represent the same parts in the following description.

[0066] Figure 1 is a schematic diagram of a charging controller circuit topology provided in an exemplary embodiment of the present disclosure;

[0067] Figure 2 is a schematic diagram of the surrounding structure of a charging controller provided in an exemplary embodiment of the present disclosure;

[0068] Figure 3 is a schematic diagram of a box structure of a charging controller provided in an exemplary embodiment of the present disclosure;

[0069] Figure 4 is another schematic diagram of the box structure of the charging controller provided in an exemplary embodiment of the present disclosure;

[0070] Figure 5 It is a schematic diagram of the structure of the charging terminal connector adapter copper bar fixing seat provided in an exemplary embodiment of the present disclosure;

[0071] Figure 6 It is a schematic diagram of the pre-charging resistor, power relay, mounting cover, and PCB integration provided in an exemplary embodiment of the present disclosure;

[0072] Figure 7 is a schematic diagram of a capacitor structure provided in an exemplary embodiment of the present disclosure;

[0073] Figure 8 is a schematic cross-sectional structural diagram of a charging controller provided in an exemplary embodiment of the present disclosure;

[0074] Fig. 9 yes Figure 8 An enlarged schematic diagram of a portion of

[0075] Fig.10 is a schematic diagram of the assembly of a charging controller provided in an exemplary embodiment of the present disclosure;

[0076] Fig.11 is a schematic diagram of a charging controller provided in an exemplary embodiment of the present disclosure;

[0077] Fig.12is another schematic diagram of a charging controller provided in an exemplary embodiment of the present disclosure;

[0078] Fig.13 is a schematic diagram of the overall structure of a vehicle provided in an exemplary embodiment of the present disclosure;

[0079] Description of reference numerals:

[0080] 1. First charging connector; 2. Ground terminal; 3. Electric control cover; 4. Output connector mounting cover; 5. Output connector; 6. Box; 7. Second charging connector; 8. Water inlet pipe; 9. Water outlet pipe; 10. Low-voltage connector;

[0081] 11. Shielding ribs of the second charging end filter; 12. Cavity of the second charging connector; 13. Shielding ribs of the inductor filter; 14. Cavity of the boost inductor; 15. IGBT pin vias; 16. Cavity of the IGBT capacitor; 17. Shielding ribs of the first charging end filter; 18. Shielding ribs of the first relay filter; 19. Cavity of the first charging connector; 20. Pre-charging cavity; 21. Vias of the output connector; 22. Relay cavity; 23. Shielding ribs of the capacitor; 24. Shielding ribs of the inductor;

[0082] 25. Water channel in zone A; 26. Water outlet; 27. Water inlet; 28. Second charging connector via hole; 29. ​​Second charging connector mounting hole; 30. Output connector mounting hole; 31. First charging connector via hole; 32. First charging connector mounting hole; 33. Water channel in zone B; 34. Water channel outlet in zone B; 35. Water channel in zone A; 36. Water channel cover in zone A; 37. Water channel cover in zone B;

[0083] 38. Connect the copper bar between the output connector and the negative pole of the capacitor; 39. Connect the copper bar between the output connector and the positive pole of the fuse; 40. Connect the copper bar fixing seat to the charging terminal connector; 41. Connect the copper bar between the capacitor and the positive pole of the boost relay;

[0084] 42. Pre-charge control board; 43. Low-voltage connector; 44. High-voltage connector; 45. Pre-charge resistor; 46. Positive pin of pre-charge resistor; 47. Negative pin of pre-charge resistor; 48. Pre-charge mounting bracket; 49. Power relay assembly; K⑤, fifth relay; K⑥, sixth relay; 50. First power relay signal pin; 51. Negative pin of power relay; 52. Second power relay signal pin; 53. Positive pin of power relay;

[0085] 54, capacitor module; 55, first capacitor terminal; 56, transfer copper bar; 57, seventh capacitor terminal; 58, sixth capacitor terminal; 59, fifth capacitor terminal; 60, fourth capacitor terminal; 61, third capacitor terminal; 62, second capacitor terminal;

[0086] 63. Electric control board; 64. Electric control shielding board; 65. First relay assembly; K①, first relay; K②, second relay;

[0087] 66. Charging end filter assembly; 67. Battery end filter assembly magnetic ring; 68. Battery end filter assembly Y capacitor; 69. Battery end filter assembly X capacitor; 70. Charging end negative conductor; 71. Fastener; 711. Pressure portion; 712. Extension portion; 72. First charging end negative conductor; 73. First charging end filter assembly; 74. First charging end filter assembly Y conductor; 75. First charging end filter assembly magnetic ring; 76. First charging end filter assembly X capacitor; 77. Capacitor and inductor connection copper bar; 78. IGBT module driver board; 79. IGBT module; 80. IGBT module sealing ring; 81. Inductor IGBT connection copper bar fixing seat;

[0088] 82. Second charging end filter assembly; 83. Second charging end filter assembly positive copper bar; 84. Second charging end negative conductor; 85. Boost inductor; 86. Inductor IGBT connection copper bar; 87. IGBT side pressure block; 88. Second charging connector mounting cover; 89. First charging connector mounting cover; 90. Second relay assembly; K③, third relay; K④, fourth relay;

[0089] 91. Positive output conductor; 92. Negative output conductor; 93. Buck-boost fuse; 94. Second Hall assembly; 95. Copper bar fixing seat for connecting the capacitor and the positive pole of the boost relay; 96. Copper bar fixing seat for connecting the output connector and the negative pole of the capacitor; 97. First charging end filter assembly; 98. Negative copper bar of the first charging end filter assembly; 99. Positive copper bar of the first charging end filter assembly; k⑧, boost relay;

[0090] K⑦, fully open relay; 102, battery end filter assembly; 103, battery end filter assembly positive conductor; 104, battery end negative conductor; 105, first Hall assembly; 106, waterproof breathable valve; 107, guide rib A; 108, guide rib B; 109, screw;

[0091] 200. Vehicles; DETAILED DESCRIPTION

[0092] The technical solutions in the embodiments of the present application will be described clearly and completely below in conjunction with the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, rather than all of the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative work are within the scope of protection of the present application.

[0093] According to the first aspect of the present disclosure, referring to Figure 1 and Figure 2 As shown, the present application discloses a charging controller, including: a first charging connector 1, a first relay assembly 65, a second charging connector 7 and a second relay assembly 90;

[0094] The first charging connector 1 is used to connect to the power input of the charging pile ①. The first relay assembly 65 includes a first relay K① and a second relay K②, and the first relay K① and the second relay K② are connected to the first charging connector 1 respectively.

[0095] The second charging connector 7 is used to connect to the power input of the charging pile ②. The second relay assembly 90 includes a third relay K③ and a fourth relay K④, and the third relay K③ and the fourth relay K④ are connected to the second charging connector 7 respectively.

[0096] The first relay assembly 65 is close to the first charging connector 1 , and the second relay assembly 90 is close to the second charging connector 7 .

[0097] Through the above technical solution, by setting the first charging connector 1 and the second charging connector 7, the charging controller of the present application can be compatible with two charging piles. At the same time, the first relay component 65 is set close to the first charging connector 1, and the second relay component 90 is set close to the second charging connector 7, so as to improve the integration of the charging controller.

[0098] In some embodiments, reference Figure 1 , Fig.10 and Fig.12 As shown, the charging controller also includes: a boost relay k⑧, a boost inductor 85 and an IGBT module 79.

[0099] The boost relay k⑧ is connected to the second relay K② and the fourth relay K④ respectively; the boost inductor 85 is connected to the boost relay k⑧; the IGBT module 79 is connected to the boost inductor 85; the boost relay k⑧, the boost inductor 85 and the IGBT module 79 are used for boost charging.

[0100] The boost relay k⑧ is located between the first relay assembly 65 and the second relay assembly 90.

[0101] The first relay assembly 65 and the second relay assembly 90 share the same boost relay k⑧, boost inductor 85 and IGBT module 79 for boost charging, which can reduce the space occupied by the charging controller. In addition, the boost relay k⑧ is located between the first relay assembly 65 and the second relay assembly 90. Regardless of whether the current is input from the first charging connector 1 or the second charging connector 7, the same boost relay k⑧, boost inductor 85 and IGBT group can be shared for boost charging, so that the connection distance of the entire line is the shortest, reducing the energy loss during the charging process.

[0102] In some embodiments, reference Figure 1 As shown, the first relay K① is connected to the negative output terminal of the first charging connector 1, and the second relay K② is connected to the positive output terminal of the first charging connector 1; the third relay K③ is connected to the negative output terminal of the second charging connector 7, and the fourth relay K④ is connected to the positive output terminal of the second charging connector 7; wherein the first relay K① and the second relay K② are connected and connected to the negative input terminal of the output connector 5.

[0103] In some embodiments, reference Figure 1 , Fig.10 and Fig.12 As shown, the charging controller further includes: a positive output conductor 91. The positive output conductor 91 is connected to the output connector 5; wherein the positive output conductor 91 is respectively connected to the boost relay k⑧, the second relay K② and the fourth relay K④.

[0104] This solution not only reduces the wiring harness connection time but also allows the wiring harness to be fixed uniformly, saving installation time and space, reducing installation procedures, and facilitating automated production.

[0105] In some embodiments, reference Figure 1 , Fig.10 and Fig.12 As shown, the charging controller further includes: a fully open relay K⑦. The fully open relay K⑦ is connected to the positive output conductor 91. The connection point between the fully open relay K⑦ and the positive output conductor 91 is located between the boost relay k⑧ and the second relay K② and the fourth relay K④.

[0106] In some embodiments, reference Figure 1 , Figure 6 , Fig.10 and Fig.12 As shown, the charging controller also includes: a box 6, a power relay 49, a pre-charging resistor 45 and a pre-charging mounting bracket 48.

[0107] The box 6 has an installation space; the power relay 49 includes a fifth relay K⑤ and a sixth relay K⑥, the fifth relay K⑤ is connected to the positive output end of the first charging connector 1, and the sixth relay K⑥ is connected to the positive output end of the second charging connector 7. One end of the pre-charging resistor 45 is respectively connected to the fifth relay K⑤ and the sixth relay K⑥, and the other end is connected to the boost relay k⑧. The pre-charging mounting bracket 48 is arranged in the installation space; wherein the power relay 49 and the pre-charging resistor 45 are respectively mounted to the pre-charging mounting bracket 48.

[0108] By adopting such a solution, modularization is achieved by installing the power relay 49 and the pre-charging resistor 45 on the pre-charging mounting bracket 48, and fixing the pre-charging control board 42 together through the pins of the power relay 49 and the pre-charging resistor 45. This integrated installation solution not only reduces the connection harness, making the interior of the charging controller neat and beautiful, but also due to the high degree of integration, the assembly process is also reduced, which is conducive to automated production.

[0109] In some embodiments, reference Figure 6 As shown, the charging controller also includes: a pre-charging control board 42.

[0110] The pre-charging control board 42 is formed with a plurality of mounting structures, wherein the pins of the power relay 49 and the pins to the pre-charging resistor 45 are respectively coupled to the mounting structures.

[0111] In some embodiments, reference Figure 8 and Fig. 9 As shown, the charging controller further includes: a battery-end filter assembly 102 , a battery-end negative conductor 104 , a charging-end filter assembly 66 , a charging-end negative conductor 70 and a fastener 71 .

[0112] The negative conductor 104 at the battery end is at least connected between the filter assembly 102 at the battery end and the first relay assembly 65; the negative conductor 70 at the charging end is at least connected between the filter assembly at the charging end and the first relay assembly 65; a plurality of fasteners 71 are provided, fixedly connected to the first relay assembly 65; wherein the fastener 71 has a pressure portion 711 and an extension portion 712, the negative conductor 104 at the battery end is at least fixed between the pressure portion 711 of one fastener 71 and the first relay assembly 65, and the negative conductor 70 at the charging end is fixed between the pressure portion 711 of another fastener 71 and the first relay assembly 65. The extension portion 712 extends from the pressure portion 711 in a direction away from the first relay assembly 65.

[0113] The charging controller further includes an electric control board 63 . The electric control board 63 is fixedly connected to an end of the extension portion 712 away from the pressure portion 711 .

[0114] With such a scheme, the negative conductor 104 at the battery end and the negative conductor 70 at the charging end are fixed to the first relay assembly 65 respectively by fasteners 71, and then the electronic control board 63 is installed on the fasteners 71. The pressure part 711 of the fastener 71 fastens the negative conductor 104 at the battery end and the negative conductor 70 at the charging end, while the extension part 712 supports the electronic control board 63. After the electronic control board 63 is fixed to the fastener 71, the high-voltage signal can be sampled directly.

[0115] refer to Figure 1 As shown, in one case, during the high-voltage power-on process of the charging controller (the high-voltage power-on state means that the vehicle voltage is lower than the output voltage of the charging pile), on the one hand, the capacitive load components in the charging controller are pre-charged through the power battery, thereby protecting the high-voltage components from damage. On the other hand, when the current flows into the boost inductor 85 through the battery-end filter component 102 to store energy, the bus current during the high-voltage power-on process is reduced through the discharge resistor, thereby protecting the high-voltage components of the charging controller from damage.

[0116] When the voltage of the vehicle connected to the charging pile is 800V or the voltage of the whole vehicle is lower than the input voltage of the charging pile, that is, the aforementioned high-voltage power-on process, the capacitive load components are pre-charged through the battery pack current, and the charging controller selects the dual-gun mode to charge the battery pack. When the vehicle is connected to the dual guns, the current flowing out of the charging pile ① passes through the first charging connector 1 through the second relay K②, and the current flowing out of the charging pile ② through the second charging connector 7 and the fourth relay K④ is combined, and the battery pack is charged through the fully-open relay k⑦.

[0117] The above technical solution does not require the charging controller to boost the voltage during the high-voltage power-on process. Compared with the single-gun direct charging technical solution, it effectively reduces the charging loss, can greatly save the charging time, reduce the charging waiting time, and improve the user experience.

[0118] In another case, when the voltage of the vehicle connected to the charging pile is lower than the vehicle's entire vehicle voltage, the input current must be boosted before the battery pack can be charged. In this application, the boost function is achieved by controlling the switching frequency of the upper and lower bridges of the IGBT module 79 through the IGBT module driver board 78.

[0119] Taking the connection to charging pile ① as an example, when the lower bridge of IGBT module 79 is opened, the current flows from the first charging connector 1 through the first charging end filter component 97, passes through the second relay K② and then through the boost relay k⑧ to reach the boost inductor 85, and then the current flows from the boost inductor 85 to the IGBT module 79. At this time, the lower bridge of IGBT module 79 is opened, and the current flows from the negative terminal of IGBT module 79 to the capacitor module 54, and then the current through the capacitor module 54 returns to the first charging connector 1, and the current boost energy storage is completed at this time.

[0120] When the upper bridge of the IGBT module 79 is turned on, the current flowing out of the boost inductor 85 passes through the upper bridge of the IGBT module 79, reaches the buck-boost fuse 93, and then the current enters the battery pack through the battery-end filter component 102. After the current is boosted, high-power boost charging can be achieved, and the charging inlet and the battery pack inlet are both filtered by the secondary filter composed of the battery-end filter component X capacitor 69, the battery-end filter component Y capacitor 68 and the battery-end filter component magnetic ring 67, which is conducive to improving EMC (Electromagnetic Compatibility).

[0121] Reference Figure 1 As shown, the circuit topology diagram only provides one group of IGBT modules 79 , which further reduces the space occupied and saves costs compared to the multiple groups of IGBT modules 79 in the technical solution.

[0122] refer to Figure 2 As shown, the first charging connector 1, the second charging connector 7, the low-voltage connector 10, the water inlet pipe 8, the water outlet pipe 9, the output connector mounting cover plate 4, and the waterproof breathable valve 106 are arranged in the circumferential direction of the charging controller, that is, on the side of the charging controller. The output connector 5 connected to the battery pack, the second charging connector mounting cover plate 88, and the first charging connector mounting cover plate 89 are located below the electric control box. This arrangement makes the layout of the entire charging controller reasonable and reduces space occupation.

[0123] refer to Figure 3 As shown, the charging controller mainly includes: a box body 6, a water channel cover plate 36 in area A, and a water channel cover plate 37 in area B. The box body 6 is further divided into several cavity structures including a second charging connector cavity 12, a boost inductor cavity 14, an IGBT capacitor cavity 16, a first charging connector cavity 19, and a pre-charge cavity 20 by the second charging end filter shielding rib 11, the first charging end filter shielding rib 17, the capacitor shielding rib 23, and the inductor shielding rib 24. By forming an independent cavity structure, the electronic components assembled in each cavity are prevented from being subjected to chaotic electromagnetic interference, which affects the service life of the components, and the utilization rate of the box space is further improved under the premise of ensuring a safe electrical gap.

[0124] refer to Figure 3 and Figure 4As shown, the box body 6 is surrounded by related connector holes and mounting holes: first charging connector hole 31, second charging connector hole 28, output connector hole 21, first charging connector mounting hole 32, second charging connector mounting hole 29, output connector mounting hole 30, etc. In addition, the bottom of the box body 6 is provided with structures such as the A-area water channel 25, the water outlet 26, the water inlet 27, the B-area water channel 33, the B-area water channel cover 37, and the B-area water channel outlet 34 for water channel heat dissipation function, wherein the A-area water channel 25 and the B-area water channel 33 both contain guide rib structures.

[0125] When the charging controller is working, water flows from the water inlet pipe 8 into the water channel 33 of area B. Since the boost inductor 85 will emit a large amount of heat when working, when the water flows through the bottom area of ​​the inductor, the generated heat will be taken away. Under the action of the guide ribs of the water channel 33 of area B, the water flow is guided to the water channel outlet 34 of area B.

[0126] refer to Figure 4 and Figure 8 As shown, the pins of IGBT module 79 are arranged in the middle area of ​​water channel A and water channel B. The heat generated by IGBT module 79 when working will be transferred to water through the pins of IGBT module 79. The water flowing through the outlet 34 of water channel in zone B flows through this area under the action of guide rib A107. The continuous water flow will take away the heat. Then the water flows into water channel 25 in zone A under the guidance of guide rib B108, and finally flows out of water outlet pipe 9 through water outlet groove 26. The water channel cover plate 36 in zone A and the water channel cover plate 37 in zone B are fixedly connected to the box body 6.

[0127] refer to Fig.10 As shown, in some embodiments of the present application, the boost inductor 85 is installed without a shell, so the boost inductor 85 needs to be installed first. First, thermal conductive gel is applied to the boost inductor cavity 14, and then the boost inductor 85 is fixed with screws, and then the boost inductor 85 is packaged with the thermal conductive gel again.

[0128] In some embodiments of the present application, the capacitor module 54 is fixedly installed using screws 109. After the capacitor module 54 is installed, the inductor IGBT fixing seat 81, the IGBT sealing ring 80, and the IGBT module 79 are installed in sequence, and then fixed with the IGBT side pressure block 87 and M5 screws. Then, the IGBT module driving board 78, the capacitor inductor connecting copper bus 77, the inductor IGBT connecting copper bus 86, the boost relay k⑧, the fourth relay K④, the second relay K②, the first charging end filter component 98, the second charging end filter component 82, the battery end filter component 102 and other parts are installed and fixed with corresponding screws 109. Then, the box 6 is turned 90° to install the charging head, and the battery terminal plug-in installation hole on the side of the box is screwed 109 to fix it. Then, the first charging connector 1 and the second charging connector 7 are installed in sequence, and the screws 109 are respectively screwed from the first charging connector installation hole 32 and the second charging connector installation hole 31 at the bottom of the electric control box to fix it.

[0129] Reference Figure 6 As shown, in some embodiments of the present application, a pre-filling mounting bracket 48 is placed in the pre-filling cavity 20, and then the pre-filling resistor 45, the power relay 49, and the pre-filling control board 42 are installed in sequence. After the components in the pre-filling cavity 20 are assembled, the two current first Hall components 105 and the second Hall components 94 are respectively assembled to the battery-end filter component 102 and the negative output conductor 92 in sequence and fixed with screws 109.

[0130] refer to Figure 6 and Fig.10 As shown, in some embodiments of the present application, a pre-filling mounting bracket 48 is placed in the pre-filling cavity 20, and then the pre-filling resistor 45, the power relay 49 and the pre-filling control board 42 are installed in sequence. After the components in the pre-filling cavity 20 are assembled, the two current first Hall components 105 and the second Hall components 94 are respectively assembled to the battery-end filter component 102 and the negative output conductor 92 in sequence and fixed with screws.

[0131] refer to Fig.12 As shown, in some embodiments of the present application, the positive conductor 103 of the battery-end filter assembly is fixed to the fully-open relay k⑦, the positive copper busbar 83 of the second charging-end filter assembly and the negative copper busbar 84 of the second charging-end filter assembly are respectively connected to the positive and negative terminals of the fourth relay K④, and the positive copper busbar 99 of the first charging-end filter assembly and the negative copper busbar 98 of the first charging-end filter assembly are respectively connected to the positive and negative terminals of the second relay K②.

[0132] refer to Figure 5 , Fig.11 and Fig.12As shown, the capacitor inside the charging terminal connector adapter copper bar fixing seat 40 is connected to the boost relay positive pole connecting copper bar 41 and the boost relay k⑧ as well as the capacitor second capacitor terminal 62 with screws, the output connector is connected to the capacitor negative pole connecting copper bar 38 to overlap the battery end filter assembly 102 and the capacitor first capacitor terminal 55 and connect them with screws, the output connector is connected to the insurance positive pole connecting copper bar 39 to connect the battery end filter assembly 102 and the buck-boost insurance 93 with screws, and then the charging terminal connector adapter copper bar fixing seat 40 is fixed inside the box with screws.

[0133] The negative output conductor 92 connects the fourth relay K④ and the battery end filter assembly 102 and fixes them with screws, and then the positive output conductor 91 connects the second relay K②, the fourth relay K④, the boost relay k⑧ and the full-open relay k⑦ and fixes them with screws respectively.

[0134] refer to Fig. 9 As shown, in some embodiments of the present application, the electric control shielding plate 64, the low voltage connector 10, the electric control panel 63, wherein the electric control panel 63 can be supported and fixed by a special fastener 71, and can also be used to measure high voltage signals. After the electric control panel 63 is installed, the plug-in connected to the electric control panel 63 is installed, and then the other three high voltage sampling harnesses and the output connector mounting cover 4 on the side of the box 6 are installed. The box 6 is turned over to install the second charging connector mounting cover 88 and the first charging connector mounting cover 89, and finally the box 6 is turned back to connect the electric control cover 3.

[0135] The present disclosure exemplarily describes the working process of the charging controller:

[0136] When the voltage of the vehicle connected to the charging pile ① is 800V or the voltage of the whole vehicle is lower than the input voltage of the charging pile, that is, during the high-voltage power-on process, when both guns are connected to the charging pile, that is, when the whole vehicle enters the high-voltage power-on process, the current output by the first charging pile passes through the first charging connector 1 and the first charging end filter component 97 to reach the first relay component 65 to divide the current into positive and negative poles to charge the battery, wherein the negative pole passes through the output end of the first relay K①, flows into the battery pack through the battery end negative conductor 104 and the output connector 5, and the positive pole passes through the output end of the second relay K②, flows through the positive output conductor 91 through the fully open relay k⑦, and then passes through The positive conductor 103 of the battery-end filter assembly flows into the battery pack through the output connector 5; the current output by the charging pile ② passes through the second charging connector 7 and the second charging-end filter assembly 82 to reach the second relay assembly 90 to divide the current into positive and negative poles to charge the battery, wherein the negative pole passes through the output end of the third relay K③, and then flows into the battery pack through the negative output conductor 92, the negative conductor 104 at the battery end and the output connector 5; the positive pole passes through the output end of the fourth relay K④, and then flows through the positive output conductor 91 and the fully-open relay k⑦, and then flows into the battery pack through the positive conductor 103 of the battery-end filter assembly and the output connector 5.

[0137] When the voltage of the vehicle connected to the charging pile ① is lower than the voltage of the whole vehicle, taking the connection to the charging pile ① as an example, the current is input by the charging pile ①, and the driving board 78 controls the upper and lower bridge switching frequencies of the IGBT module 79 to complete the boost, and the voltage is adjusted by controlling the duty cycle. The current is input by the first charging connector 1 and passes through the first charging end filter component 97, and then the current is transmitted to the second relay K② by the positive copper bar 99 of the first charging end filter component, and then input to the boost relay through the positive output conductor 91, and then successively through the capacitor and the boost relay positive connection copper bar 41 and the second capacitor terminal 62, wherein the second capacitor terminal 62 is connected to the sixth capacitor terminal 58, and the current flowing out of the sixth capacitor terminal 58 is transmitted to the inductor 85 by the capacitor inductor connection copper bar 77 for boosting, and then the current reaches the IGBT module 79 through the inductor IGBT connection copper bar 86.

[0138] Reference Figure 7 As shown, when the lower bridge of the IGBT module 79 is turned on, the boosted current flows out from the negative terminal of the IGBT module 79 through the fourth capacitor terminal 60, and then flows out from the first capacitor terminal 55 connected to the fourth capacitor terminal 60. The outflowing current passes through the output connector and the capacitor negative electrode connecting copper bus 38 and the battery end negative electrode conductor 104 in turn to reach the first relay K①, and then returns to the charging pile through the first charging end filter component negative electrode copper bus 98. At this time, the current boost energy storage is completed.

[0139] When the upper bridge of the IGBT module 79 is opened, the boosted current flows out from the positive terminal of the IGBT module 79, flows out through the third capacitor terminal 61 and the seventh capacitor terminal 57 connected thereto, and then transmits the current to the boost / step-up fuse 93 through the internal transfer copper bus 56 of the capacitor. The current flowing through the fuse reaches the output connector 5 through the output connector and the fuse positive electrode connecting copper bus 39 and the positive conductor 103 of the battery end filter assembly, and then the current enters the battery pack to charge the battery.

[0140] According to the second aspect of the present disclosure, Fig.13 As shown, a vehicle 200 is provided, which includes the above-mentioned charging controller. The vehicle has all the beneficial effects of the above-mentioned charging controller, and the present disclosure will not be repeated here.

[0141] The vehicle may be a fuel vehicle, a plug-in hybrid vehicle, a new energy vehicle, etc., and the present disclosure does not make any specific limitation on this.

[0142] In the description of this application, the terms "first" and "second" are used for descriptive purposes only and should not be understood as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more features. In the description of this application, the meaning of "plurality" is two or more, unless otherwise clearly and specifically defined.

[0143] In the above embodiments, the description of each embodiment has its own emphasis. For parts that are not described in detail in a certain embodiment, reference can be made to the relevant descriptions of other embodiments.

[0144] The embodiments, implementation methods and related technical features of the present application can be combined and replaced with each other without conflict.

[0145] The above are only preferred embodiments of the present application and do not constitute any form of limitation to the present application. Although the descriptions of each embodiment in the above embodiments of the present application have different focuses, for the parts not described in detail in a certain embodiment, reference can be made to the relevant contents in other embodiments. However, any simple modifications, equivalent changes and modifications made to the above embodiments based on the technical essence of the present application without departing from the content of the technical solution of the present application are still within the scope of the technical solution of the present application.

Claims

1. A charging controller for realizing dual-gun charging, characterized in that: include: A first charging connector; A first relay assembly, comprising a first relay and a second relay, wherein the first relay and the second relay are respectively connected to the first charging connector; Second charging connector; A second relay assembly includes a third relay and a fourth relay, wherein the third relay and the fourth relay are respectively connected to the second charging connector; The first relay component is close to one side of the first charging connector, and the second relay component is close to one side of the second charging connector.

2. The charging controller according to claim 1, characterized in that: The charging controller also includes: a boost relay connected to the second relay and the fourth relay respectively; A boost inductor connected to the boost relay; An IGBT module connected to the boost inductor; The boost relay, boost inductor and IGBT module are used for boost charging.

3. The charging controller according to claim 2, characterized in that: The boost relay is located between the first relay assembly and the second relay assembly.

4. The charging controller according to claim 2, characterized in that: The first relay is connected to the negative output terminal of the first charging connector, and the second relay is connected to the positive output terminal of the first charging connector; The third relay is connected to the negative output terminal of the second charging connector, and the fourth relay is connected to the positive output terminal of the second charging connector; Wherein, the first relay is connected to the second relay.

5. The charging controller according to claim 2, characterized in that: The charging controller also includes: A positive output conductor connected to an output connector of the charging controller; Wherein, the positive output conductor is connected to the boost relay, the second relay and the fourth relay respectively.

6. The charging controller according to claim 5, characterized in that: The charging controller also includes: a fully open relay connected to the positive output conductor; Wherein, the connection point between the fully open relay and the positive output conductor is located between the boost relay and the second relay and the fourth relay.

7. The charging controller according to claim 2, characterized in that: The charging controller also includes: A box body having a mounting space; a power relay assembly, comprising a fifth relay and a sixth relay, wherein the fifth relay is connected to the positive output end of the first charging connector, and the sixth relay is connected to the positive output end of the second charging connector; a pre-charging resistor, one end of which is connected to the fifth relay and the sixth relay respectively, and the other end of which is connected to the boost relay; A pre-filled installation bracket is arranged in the installation space; Wherein, the power relay assembly and the pre-charging resistor are respectively installed on the pre-charging mounting bracket.

8. The charging controller according to claim 7, characterized in that: The charging controller also includes: A pre-charged control panel is formed with a number of mounting structures; Wherein, the pins of the power relay and the pins to the pre-charging resistor are respectively combined with the mounting structure.

9. The charging controller according to claim 1, characterized in that: The charging controller also includes: Battery end filter assembly; A battery-end negative electrode conductor connected at least between the battery-end filter assembly and the first relay assembly; Charging end filter components; A negative conductor at the charging end, connected at least between the charging end filter component and the first relay component; a plurality of fasteners fixedly connected to the first relay assembly; Wherein, the fastener has a pressure portion, the battery terminal negative conductor is fixed between at least one of the pressure portions of the fastener and the first relay assembly, and the charging terminal negative conductor is fixed between another of the pressure portions of the fastener and the first relay assembly.

10. The charging controller according to claim 9, characterized in that: The fastener also has: an extension portion extending from the pressure portion in a direction away from the first relay assembly; The charging controller also includes: The electric control panel is fixedly connected to an end of the extension portion away from the pressure portion.

11. A vehicle, characterized in that: Comprising a charging controller as claimed in any one of claims 1 to 10.

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