Gear-modularized battery-replaceable high-power program-controlled load device

Abstract

The utility model discloses a gear modularization replaceable power large power program control load device, comprising a box body and a heat radiation fan, the top of the box body is provided with a first integrated mainboard and a second integrated mainboard, the first integrated mainboard is provided with a main control module, a first power supply conversion module and a power supply switching module, and the second integrated mainboard is provided with a second power supply switching module. The second integrated mainboard is provided with a gear switching module and a temperature control module, the top of the side wall of the box body is provided with a modular load, and one side of the second power supply conversion module is provided with a detachable battery replacement module; the modularized load adopts an iron-chromium-aluminum alloy resistance wire. According to the utility model, the gear modularized high-power resistance wire is adopted, so that the high-power and high-current charging requirement is met, the gear modularized high-power resistance wire is divided into a plurality of gear modules, the maintenance difficulty is reduced, and the material loss and cost of maintenance are reduced. And an easy-to-disassemble battery replacement module is matched, so that the problem that no electricity can be taken on site is solved, the endurance anxiety of the device is also solved through battery replacement, and the workload of one day is easily completed.

Description

Technical Field

[0001] The utility model relates to the field of high-power program-controlled load devices, and in particular to a high-power program-controlled load device with modularized gear positions and interchangeable batteries. Background Art

[0002] Currently, existing charging pile on-site calibration equipment generally adopts the real-load calibration method, which requires a matching programmable load device to simulate the charging current. On-site calibration environments vary greatly. If there is electricity nearby, it is good to use an external mains power supply, but there is often a situation where there is no electricity. Most existing methods use the voltage output by the charging pile to power the device. The control module flow chart is shown in Figure 1 .

[0003] Furthermore, long-term high-power testing exposes the load device to prolonged high temperatures and high loads. Currently, for portability, most load devices use alloy resistance wire or spring resistors for their high-power components. These resistors must be manually wound, placing high demands on workers' winding skills. Furthermore, these consumable materials can lead to the need for repairs due to damage to a resistor. For highly integrated load devices, all resistance wires or spring resistors must be removed and rewound, a time-consuming and labor-intensive process. Furthermore, the removed resistance wire cannot often be reused, increasing losses and costs. Summary of the Invention

[0004] In response to the above-mentioned problems, the present utility model proposes a gear-modularized, replaceable, high-power programmable load device, which solves the defects of the existing method of removing the resistance wire or spring resistor of all gears and rewinding them, which is very time-consuming and labor-intensive, and in most cases the removed resistance wire cannot be reused, which increases loss and cost.

[0005] The technical solutions adopted by this utility model are as follows:

[0006] A gear-modularized, battery-swappable, high-power programmable load device comprises: a box and a cooling fan; a first integrated mainboard and a second integrated mainboard are mounted on the top of the box; a main control module, a first power conversion module and a power supply switching module are mounted on the first integrated mainboard; a gear switching module and a temperature control module are mounted on the second integrated mainboard; a modular load is mounted on the top of the side wall of the box; a detachable battery-swappable module is mounted on one side of the second power conversion module; the modular load uses an iron-chromium-aluminum alloy resistance wire.

[0007] Optionally, the cooling fan is installed on the back of the box.

[0008] Optionally, a second power conversion module and a third power conversion module are mounted on the side wall of the box body, and the second power conversion module is located above the third power conversion module.

[0009] Optionally, the main control module is used to collect the output voltage and output current of the charging pile, and automatically correct the resistance gear. At the same time, it controls the load gear switching according to demand, monitors the load box temperature inside the load device, as well as the fan speed and operating status, and takes corresponding protective measures in time when the fan stops, overheats, or overcurrent faults occur.

[0010] Optionally, the temperature control module uses a bimetallic strip as a temperature sensing element.

[0011] Optionally, the gear switching module is used to close the corresponding relay and simulate the charging current according to the required voltage and current in the charging pile on-site calibration equipment message.

[0012] Optionally, the detachable battery exchange module includes a battery pack and a press-to-lock spring module. The press-to-lock spring module is installed at the bottom of the battery pack, and the press-to-lock spring module consists of a compression spring and a locking mechanism.

[0013] Optionally, the power supply switching module is used to automatically select an external AC power supply, a charging pile output voltage or a lithium battery power supply according to the current operating status.

[0014] Optionally, the cooling fan is used to cooperate with the main control module so that the speed is adapted according to the temperature when the load device is cooling, and when the fan stops, it is detected and the load is cut off in time. Beneficial effects

[0015] 1. This utility model uses a modular high-power resistor wire to meet the charging needs of high power and high current, and is divided into multiple modules, which reduces the difficulty of maintenance, material loss and cost. It is also equipped with an easily removable battery replacement module, which solves the problem of no power on site. Battery replacement also solves the battery life anxiety of the device, making it easy to complete a day's work. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 This is a control module flow chart of the existing program-controlled load device of the present utility model;

[0017] Figure 2 This is a control module flow chart of the gear-modularized, battery-swappable, high-power programmable load device of Example 1 of the present utility model;

[0018] Figure 3 It is a three-dimensional structural diagram of the gear-modularized, battery-swappable, high-power programmable load device of Example 1 of the present utility model.

[0019] The reference numerals in the figures are:

[0020] 1. Box, 2. Cooling fan, 3. First integrated motherboard, 4. Second integrated motherboard, 5. Main control module, 6. First power conversion module, 7. Power supply switching module, 13. Gear switching module, 8. Temperature control module, 9. Modular load, 10. Second power conversion module, 11. Third power conversion module, 12. Removable battery replacement module. DETAILED DESCRIPTION

[0021] The following is a further detailed description of the specific implementation of the present invention in conjunction with the accompanying drawings and examples. The following examples are used to illustrate the present invention, but are not intended to limit the scope of the present invention.

[0022] In the description of the present invention, unless otherwise specified, "plurality" means two or more; the terms "upper," "lower," "left," "right," "inner," "outer," "front end," "rear end," "head," "tail," etc., indicating positions or location relationships, are based on the positions or location relationships shown in the accompanying drawings and are intended solely for the purpose of facilitating the description of the present invention and simplifying the description. They do not indicate or imply that the devices or components referred to must have a specific orientation, be constructed, or operate in a specific orientation, and therefore should not be construed as limiting the present invention. In addition, the terms "first," "second," "third," etc., etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance. In the description of the present invention, it should be noted that, unless otherwise expressly specified or limited, the terms "connected" and "connected" should be understood broadly, for example, to mean a fixed connection, a detachable connection, or an integral connection; a mechanical connection, a direct connection, or an indirect connection through an intermediate medium. A person of ordinary skill in the art will understand the specific meanings of the above terms in the present invention based on the specific circumstances.

[0023] Example 1

[0024] The technical solutions adopted by this utility model are as follows:

[0025] like Figure 2 and Figure 3 As shown, the utility model discloses a gear-modularized, replaceable, high-power programmable load device, comprising: a box body 1 and a cooling fan 2, the top of the box body is equipped with a first integrated mainboard 3 and a second integrated mainboard 4, the first integrated mainboard is equipped with a main control module 5, a first power conversion module 6 and a power supply switching module 7, the second integrated mainboard is equipped with a gear switching module 13 and a temperature control module 8, the top of the side wall of the box body is equipped with a modular load 9, the main control module is used to collect the output voltage and output current of the charging pile, and automatically correct the resistance gear, while controlling the load gear switching according to demand, monitoring the load box temperature inside the load device, as well as the fan speed regulation and operating status, and taking corresponding protective measures in time when the fan stops, overheats, and overcurrent faults occur.

[0026] The cooling fan is installed on the back of the box. The second power conversion module 10 and the third power conversion module 11 are installed on the side wall of the box, and the second power conversion module is located above the third power conversion module.

[0027] One side of the second power conversion module is equipped with a detachable power exchange module 12. The temperature control module uses a bimetallic strip as a temperature sensing element.

[0028] The gear switching module is used to close the corresponding relay and simulate the charging current according to the relevant required voltage and current in the charging pile on-site calibration equipment message.

[0029] The detachable battery-swap module includes a battery pack and a push-on, self-locking spring module. The module, comprised of a compression spring and a locking mechanism, is mounted at the bottom of the battery pack. The power switching module automatically selects between an external AC power source, the charging station output voltage, or a lithium battery based on the current operating status.

[0030] The modular load uses an iron-chromium-aluminum alloy resistance wire. The cooling fan is used to cooperate with the main control module to adapt the speed of the load device to the temperature when dissipating heat, and to detect and cut off the load in time when the fan stops.

[0031] In this embodiment, the main control module uses GigaDevice GD32F470ZIT6 as its CPU, which is a 32-bit microcontroller based on the Arm Cortex-M4 core. Compared with the M3 core, the M4 core uses a more advanced process, has lower power consumption, and is a faster processor with a main frequency of up to 240MHz. It can support embedded applications with higher algorithm complexity and also ensures high-speed data processing capabilities.

[0032] In this embodiment, the shift switch module utilizes Hongfa's HFE82V series high-voltage relays, which offer low and stable contact resistance, IP67-rated contacts, and a mechanical durability of up to 2 x 105 cycles. Misensor's HVR24 series high-power reed relays boast a dielectric strength of up to 6 kVDC, high load current capability, low contact resistance, and long-life sealed contacts.

[0033] In this embodiment, the temperature control module utilizes a KSD9700 thermal protector, using a bimetallic strip as the temperature sensing element. This device features rapid operation, precise temperature control, high control current, and a long service life. The MF58B-10K NTC thermistor offers excellent stability, high reliability, a wide temperature measurement range of -30°C to 300°C, high accuracy, fast thermal sensing, and high sensitivity. Dual hardware and software over-temperature protection significantly enhances device safety.

[0034] In this embodiment, the cooling fan uses the Jihengda YY17251H24B series high-air-volume DC cooling fan with an air volume of up to 440CFM, a fire protection level of 94V-0, and intelligent control functions such as PWM speed regulation and RD stop alarm output.

[0035] In this embodiment, the modular load utilizes iron-chromium-aluminum alloy resistance wire, which exhibits excellent resistance, oxidation resistance, high-temperature stability, and corrosion resistance. Its high resistivity allows the load device to achieve higher load power within a limited space. This embodiment features a modularized load structure, dividing multiple load modules, such as 10A, 30A, and 60A, into multiple load modules. This facilitates manufacturing, improves production efficiency and product flexibility, and facilitates subsequent maintenance, reducing overall costs and enhancing product quality.

[0036] In this embodiment, the battery adopts a 25.2V voltage, a set of 4A charging current interfaces, and a set of 15A power supply current interfaces.

[0037] In this embodiment, the first power conversion module is an ACDC module, which inputs AC220V and outputs DC24V.

[0038] In this embodiment, the second power conversion module is a wide-range DCDC module with an input of DC200-1000V and an output of DC24V.

[0039] In this embodiment, the third power conversion module uses an input of DC8-36V and an output of DC24V.

[0040] During implementation, a modular, swappable, high-power, programmable load device with a gear position is connected to the on-site calibration equipment for the charging pile. After startup, the load device automatically switches to the external mains power channel mode based on whether an external mains power source is available. If an external power source is available, the device is powered by the detachable battery swap module. Once the charging pile outputs the charging voltage as required and enters the formal charging phase, the load device automatically switches to the charging pile power channel, with the charging pile providing the entire device power.

[0041] The load device receives instructions from the on-site charging pile calibration equipment, applies the appropriate load to simulate the charging current, and activates the fan to dissipate heat. This modular, swappable, high-power programmable load device continuously measures charging voltage, current, load box temperature, and fan operation in real time. After the test is complete, the charging pile stops output, and the load device adaptively switches back to external mains power (priority) or the removable battery swap module to continue dissipating heat.

[0042] The above description is only a preferred embodiment of the present invention and does not limit the scope of patent protection of the present invention. Any equivalent structural transformation made by using the contents of the description and drawings of the present invention, directly or indirectly applied in other related technical fields, is also included in the scope of protection of the present invention.

Claims

1. A modular, switchable, high-power programmable load device, characterized in that: include: The box body and the cooling fan are installed, the top of the box body is equipped with a first integrated mainboard and a second integrated mainboard, the first integrated mainboard is equipped with a main control module, a first power conversion module and a power supply switching module, the second integrated mainboard is equipped with a gear switching module and a temperature control module, the top of the side wall of the box body is equipped with a modular load, the side wall of the box body is equipped with a second power conversion module and a third power conversion module, and a detachable battery replacement module is installed on one side of the second power conversion module; the modular load adopts iron-chromium-aluminum alloy resistance wire.

2. A modular, switchable, high-power programmable load device with gear positions as claimed in claim 1, characterized in that: The heat dissipation fan is installed on the back side of the box.

3. A modular, battery-swappable, high-power programmable load device with gear positions as claimed in claim 1, characterized in that: The second power conversion module is located above the third power conversion module.

4. A gear-modularized, battery-swappable, high-power programmable load device as described in claim 1, 2 or 3, characterized in that: The main control module is used to collect the output voltage and output current of the charging pile, and automatically correct the resistance gear. At the same time, it controls the load gear switching according to demand, monitors the load box temperature inside the load device, as well as the fan speed regulation and operating status, and takes corresponding protective measures in time when the fan stops, overheats, or overcurrent faults occur.

5. A gear-modularized, battery-swappable, high-power programmable load device as described in claim 1, 2 or 3, characterized in that: The temperature control module uses a bimetallic strip as a temperature sensing element.

6. A gear-modularized, battery-swappable, high-power programmable load device as described in claim 1, 2 or 3, characterized in that: The gear switching module is used to close the corresponding relay and simulate the charging current according to the relevant required voltage and current in the charging pile on-site calibration equipment message.

7. A gear-modularized, battery-swappable, high-power programmable load device as described in claim 1, 2 or 3, characterized in that: The detachable battery exchange module includes a battery pack and a press-to-lock spring module. The press-to-lock spring module is installed at the bottom of the battery pack. The press-to-lock spring module consists of a compression spring and a locking mechanism.

8. A gear-modularized, battery-swappable, high-power programmable load device as claimed in claim 1, 2 or 3, characterized in that: The power supply switching module is used to automatically select an external AC power supply, a charging pile output voltage or a lithium battery for power supply according to the current operating status.

9. A gear-modularized, battery-swappable, high-power programmable load device as described in claim 1, 2 or 3, characterized in that: The cooling fan is used to cooperate with the main control module so that the speed of the load device is adapted according to the temperature when dissipating heat, and when the fan stops, it is discovered in time and the load is cut off.

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