Control system of heavy truck battery swap station

Abstract

The utility model discloses a control system of a heavy truck battery swap station, which relates to the technical field of battery swap control systems and comprises a plurality of battery swap controllers which are respectively arranged in battery swap bases of all bins and used for collecting temperature data information in real time when battery modules in a station end battery swap system are charged; the BMS modules are electrically connected with the battery replacement controller and used for monitoring related data information of the battery units and sending the related data information to the battery replacement controller; and the CAN card is electrically connected with the battery replacing controller, the battery replacing controller is also used for uniformly sending the received data information to a CAN bus in a CAN data frame form for data information transmission, and the CAN card summarizes the data information and then uploads the data information to station control end equipment, so that independent communication between each base battery replacing unit of the station end and the station control end is realized. The real-time performance and the accuracy of acquiring the data information of the battery replacing unit by the station control end are improved, and the fault can be accurately reported to the station control end for test adjustment and fault analysis when the battery end has a fault in the battery charging and replacing process.

Description

Technical Field

[0001] The utility model relates to the technical field of battery swapping control systems, and particularly to a control system for a heavy truck battery swapping station. Background Art

[0002] At present, the battery swapping system of an electric heavy truck battery swapping station mainly establishes communication interaction between the battery unit and the station control host through the charger system configured in the station, and realizes the charging control function, battery communication function and station control host communication function by developing on the basis of the charger system platform. Each battery component of the battery swapping unit is connected to the charger through a CAN line, so that each charger has the function of communicating with the BMS in the battery box, thereby judging whether the connection between the charger and the battery box is correct, and obtaining the BMS charging parameters and real-time charging data. Then, the charger is connected to the switch through a hard wire such as a low-voltage communication harness, and the switch uploads the data to the station control host.

[0003] At present, the communication interaction between the battery swapping system and the station control platform in the battery swapping station is less and scattered, resulting in a complex and inflexible interaction logic between the battery swapping system and the whole station. When a fault occurs at the battery end during the charging and swapping process, it is difficult to accurately report it to the station control platform for test adjustment and fault analysis. Content of the Utility Model

[0004] In order to solve the problems of the prior art, the utility model provides a control system for a heavy truck battery swapping station, including: a plurality of battery swapping controllers, which are respectively arranged in the battery swapping bases of each bin, and are used for real-time collecting the temperature data information when the battery modules in the station-side battery swapping system are charging;

[0005] A plurality of BMS modules, which are respectively electrically connected to the battery swapping controllers, and are used for monitoring the relevant data information of the battery unit and sending it to the battery swapping controllers;

[0006] A CAN card, which is electrically connected to the battery swapping controller. The battery swapping controller is also used for uniformly sending the received data information to the CAN bus in the form of a CAN data frame for data information transmission, and the CAN card uploads the aggregated data information to the station control terminal device.

[0007] Further, it further includes: a power supply module, which is electrically connected to the battery swapping controller, the CAN card and the BMS module.

[0008] Further, it further includes: proximity sensors, which are installed on both sides of the battery swapping base in the buffer bin, and are electrically connected to the battery swapping controller and the power supply module in the battery swapping base in the buffer bin. The proximity sensors are used for real-time collecting the data signal when a battery pack falls in the battery swapping base in the buffer bin, and transmitting it to the station control terminal device through the battery swapping controller in the battery swapping base in the buffer bin.

[0009] Further, it further includes an off-line data recorder, electrically connected to the battery swapping controller and the power supply module, for recording data throughout the process.

[0010] Further, the power supply module is a 480w power supply module, which is used to distribute the power supply to each electrical component module after passing the 24V stable DC voltage source converted by the slave-end AC-DC inverter through an insurance.

[0011] The beneficial effects of the technical solution provided by the present utility model are as follows: First, in the present utility model, a corresponding battery swapping controller is configured for the battery swapping base of each bin, and then the battery swapping controller is connected to the CAN card, realizing the independent communication between the battery swapping unit of each battery swapping base at the station end and the station control end, uploading information such as the battery swapping process positioning information, the current and temperature during the charging process, etc. to the station control end, improving the timeliness and accuracy of the station control end to obtain the data information of the battery swapping unit, and accurately reporting to the station control end for test adjustment and fault analysis when a fault occurs at the battery end during the charging and battery swapping process.

[0012] Second, proximity sensors are installed on both sides of the battery swapping base in the buffer bin, replacing the quick-change connector for the vacancy in the buffer bin, completing the acquisition of the signals for lifting and positioning the battery pack, better improving the trajectory logic of the transfer bin path and the working efficiency of the battery swapping process, and shortening the battery swapping time.

[0013] Furthermore, the solution jointly controlled by the battery swapping controller and the CAN card in the present utility model can adapt to different specifications of battery swapping stations according to actual needs, and meet various architecture solutions of the basic module or the basic module plus the expansion module through the adjustable and configured modular battery swapping control system unit, improving the flexibility of the overall station layout plan.

[0014] In addition, the control system of the heavy truck battery swapping station is separately powered by the power supply module, realizing the electrical power distribution isolation of each module of the battery swapping control system. Description of the Drawings

[0015] Figure 1 is the power distribution topology diagram of a control system of a heavy truck battery swapping station provided by the present utility model;

[0016] Figure 2 is the CAN network topology diagram of the communication interaction of a control system of a heavy truck battery swapping station provided by the present utility model. Detailed Embodiment

[0017] Next, the technical solutions in the embodiments of the present application will be clearly and completely described in conjunction with the drawings in the embodiments of the present application. Obviously, the described embodiments are only a part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present application.

[0018] To make the objectives, technical solutions, and advantages of the present utility model clearer, the following will further describe the embodiments of the present utility model in detail with reference to the accompanying drawings.

[0019] It should be noted that in this embodiment, the orientation or positional relationship indicated by "bottom", "top", etc. is based on the orientation or positional relationship shown in the accompanying drawings. It is only for the convenience of describing the present application and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation. Therefore, it should not be construed as a limitation to the present application.

[0020] It also should be noted that in this embodiment, unless otherwise clearly specified and defined, the terms "arranged" and "connected" should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or an integral connection; it can be directly connected, or indirectly connected through an intermediate medium, and it can be the communication inside two elements. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0021] See Figure 1 and Figure 2 , a control system for a heavy-duty truck battery swapping station, including a number of battery swapping controllers, a number of BMS modules, a CAN card, a power module, proximity sensors, and an offline data recorder.

[0022] The battery swapping controllers are respectively arranged in the battery swapping bases of each bin. The battery swapping controllers are built-in with data acquisition units, which can complete multi-channel high-quality real-time acquisition of temperature information during the charging of battery modules in the station-side battery swapping system.

[0023] Each BMS module corresponds to a battery swapping controller and is electrically connected to the corresponding battery swapping controller through a low-voltage wire harness. The BMS module sends the relevant data of each monitored battery unit to the corresponding battery swapping controller. For example, voltage and current monitoring data, etc. The BMS module also controls the charging and discharging process of the battery, prevents abnormal states such as overcharging and over-discharging of the battery module, and performs real-time monitoring of the battery health and performance.

[0024] The proximity sensors are installed on both sides of the battery swapping base of the buffer bin and are electrically connected to the battery swapping controller of the buffer bin battery swapping base through a low-voltage wire harness. The detection sensing range of the proximity sensor should be less than 3 mm within the horizontal plane of the top of the rubber gasket of the battery swapping base. It can replace the quick-change connector to perform proximity detection on the battery pack falling into the buffer bin. When the proximity sensor detects that a battery pack has fallen, it sends a low-level signal to the battery swapping controller, thereby completing the signal transmission; the input / output ports of the battery swapping controller can accurately receive and send the battery landing signal on the battery swapping base and the proximity sensor signal of the buffer bin.

[0025] The CAN card is electrically connected to all battery swapping controllers via the CAN bus. The battery swapping controllers send relevant data of battery cells sent by the BMS module, data signals when a battery pack drops in the buffer bin of the battery swapping base sent by the proximity sensor, temperature information during battery module charging collected, etc. to the CAN bus in the form of CAN data frames for data information transmission. The CAN card converts the message information of the CAN data frames into data packets that can be recognized and transmitted by the TCP / IP network protocol. The CAN card acts as a gateway to upload the data packets to the station control terminal device via the Ethernet, completing the communication interaction with the entire station. In addition, the CAN card supports 2KV electromagnetic isolation, ensuring stable communication of the system while enabling high-speed data transmission.

[0026] The off-line data recorder is electrically connected to the battery swapping controller via a low-voltage wire harness. The off-line data recorder receives and stores the status signals sent by the battery swapping controller into the local memory card, enabling full-process data recording for easy data analysis and subsequent statistical playback.

[0027] The power module is a 480w power module, which is electrically connected to electrical component modules such as the battery swapping controller, BMS module, CAN card, proximity sensor, and off-line data recorder via low-voltage wire harnesses. The power module distributes the 24V stable DC voltage source converted from the AC / DC inverter at the station end to each electrical component module of the station-end battery swapping system after passing through the fuse. The power module provides a high-level or low-level signal source for the battery swapping control system of the heavy truck battery swapping station, and determines the selection of high and low levels according to the input / output port level detection characteristics of the battery swapping controllers on each battery swapping base.

[0028] When the battery swapping station executes a battery swapping instruction, the battery swapping robot first lifts the battery pack from the vehicle end and places it into the buffer bin. At this time, the proximity sensor on the battery swapping base of the buffer bin obtains the proximity signal and reports it to the station control terminal device through the battery swapping controller. Then the battery swapping robot selects the fully charged battery pack with the nearest distance as the priority and lifts it into the vehicle end. At this time, the fast-changing connector of this bin reports the disconnected state between the battery pack and the battery swapping base to the station control terminal device for display. Finally, the battery swapping robot moves the battery pack removed from the vehicle end in the buffer bin to the vacant bin for placement and charging. At this time, the low signal of the proximity sensor in the buffer bin is disconnected, and the fast-changing connector in the battery bin where the battery drops obtains the battery's landing information and the change information of the NTC resistance value during charging, and reports it to the station control terminal device for display, completing the control system work process under a battery swapping instruction.

[0029] It should be noted that in the present utility model, a modular battery swapping control system unit is adopted, and battery swapping controllers with corresponding IDs are configured for the battery swapping bases of each bin. Then, the battery swapping controllers are connected to the CAN card, realizing independent communication between each battery swapping unit at the station end and the station control end. Information such as the positioning information during the battery swapping process and the current and temperature during the charging process are uploaded to the station control end, improving the real-time performance and accuracy of the station control end in obtaining data information of the battery swapping unit.

[0030] Secondly, proximity sensors are installed on both sides of the battery swapping base in the buffer bin, replacing the quick-change connectors for the vacancies in the buffer bin, and completing the acquisition of signals for lifting and positioning the battery pack, enabling the buffer bin to better improve the trajectory logic of the transfer path and the working efficiency of the battery swapping process, and shortening the battery swapping time.

[0031] Furthermore, the solution jointly controlled by the battery swapping controller and the CAN card in the present utility model can be adapted to different specifications of battery swapping stations according to actual needs. Through the modular battery swapping control system unit with adjustable configuration, various architecture solutions of basic modules or basic modules plus expansion modules can be satisfied, enhancing the flexibility of the overall station layout plan.

[0032] For example, referring to Figure 1 and Figure 2 , the control system of this heavy truck battery swapping station can include a basic module and an expansion module. The basic module can include four battery swapping controllers, one power module 1, and four BMS modules. The four battery swapping controllers are respectively arranged in the battery swapping bases of four bins. The four BMS modules are respectively electrically connected to the four battery swapping controllers. The four battery swapping controllers and the four BMS modules are both electrically connected to the power module 1. The expansion module includes one power module 2, three battery swapping controllers, three BMS modules, and two proximity sensors. One battery swapping controller is arranged in the battery swapping base of the buffer bin, and the other two battery swapping controllers are arranged in the battery swapping bases of the other two charging bins. The two proximity sensors are respectively connected to both sides of the battery swapping base in the buffer bin. The three BMS modules are respectively electrically connected to the three battery swapping controllers. The two proximity sensors, the three BMS modules, and the three battery swapping controllers are all electrically connected to the power module 2. The four battery swapping controllers in the basic module and the three battery swapping controllers in the expansion module are jointly electrically connected to the CAN card.

[0033] The adoption of modular battery swapping units can be adapted to different specifications of battery swapping stations such as basic modules or basic plus expansion modules. And through modular design, multiple independent battery swapping units are integrated into a battery swapping control system, and a dedicated control unit centrally manages these modules, realizing the distribution of low-voltage power, the acquisition and processing of signal data, and the task control of electrical equipment. While enhancing the versatility of the battery swapping control electrical architecture at the station end, it reduces the complexity of maintenance work and labor costs.

[0034] In addition, a separate power distribution is carried out for the control system of the heavy truck battery swapping station. Two power modules in the power distribution cabinet supply power to each battery swapping unit of the basic module and the expansion module respectively, so as to achieve electrical power distribution isolation for each module of the battery swapping control system.

[0035] The above are only the preferred embodiments of the present invention, and are not intended to limit the present invention. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principles of the present invention shall be included within the protection scope of the present invention.

Claims

1. A control system for a heavy truck swap station, characterized in that: include: Several battery swap controllers are arranged in the battery swap base of each bay, and are used to collect temperature data information of the battery module when charging in the station-side battery swap system in real time; A plurality of BMS modules are electrically connected to the battery swap controller respectively, and are used to monitor relevant data information of the battery cells and send the information to the battery swap controller; The CAN card is electrically connected to the battery swap controller. The battery swap controller is also used to send the received data information in the form of CAN data frames to the CAN bus for data information transmission. The CAN card aggregates the data information and uploads it to the station control terminal device.

2. The control system of the heavy truck swap station according to claim 1 is characterized in that: Also includes: The power module is electrically connected to the battery replacement controller, the CAN card and the BMS module.

3. The control system of the heavy truck swap station according to claim 2 is characterized in that: Also includes: The proximity sensor is installed on both sides of the cache compartment battery exchange base and is electrically connected to the battery exchange controller and the power module of the cache compartment battery exchange base. The proximity sensor is used to collect data signals when a battery pack falls on the cache compartment battery exchange base in real time, and transmit them to the station control end device through the battery exchange controller of the cache compartment battery exchange base.

4. The control system of the heavy truck swap station according to claim 3 is characterized in that: Also includes: An offline data recorder is electrically connected to the battery replacement controller and the power module and is used for recording data of the entire process.

5. The control system of the heavy truck swap station according to claim 4, characterized in that: The power module is a 480w power module, which is used to distribute power to each electrical component module after the 24V stable DC voltage source converted from the AC / DC inverter at the station end passes through the insurance.

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