Mining intelligent charger

Abstract

The utility model discloses a mining intelligent charger comprising a voltage reduction and rectification module, a DC / DC module, a control system, and a switch power supply and a button and display module which are electrically connected with the control system. The voltage reduction and rectification module is used for converting input alternating current into direct current suitable for battery charging; the DC / DC module is used for converting the direct current into stable current or voltage; the switching power supply is used for converting an input alternating current into a low-voltage direct current power supply required by an internal control system of the charger; and the keyboard and display module is used for setting a charging mode and charging time parameters and displaying the running state and the charging process of the equipment. A constant-current, constant-voltage and small-constant-current intelligent three-stage charging mode is adopted, so that the intelligent charging device has the advantages of high charging efficiency, simplicity in operation, light weight, small size and the like, and has multiple protection functions of reverse connection, overload, short circuit, overheating and the like and time-delay starting and power-off memory self-starting functions.

Description

Technical Field

[0001] This utility model relates to the technical field of mining charging equipment, specifically to a mining intelligent charger. Background Technology

[0002] In recent years, with the rapid development of intelligent and automated coal mine equipment, large-capacity battery locomotives, such as trackless rubber-tired vehicles and monorail locomotives, have been widely used in coal mine production as traction and transportation tools. However, most of the chargers currently used in coal mines adopt traditional charging technology with silicon rectification. These chargers suffer from low charging power, long charging time, low efficiency, low power factor, high harmonics, and poor dynamic response. Furthermore, they cannot guarantee the charging process requirements of the batteries during charging, which seriously affects the battery life and cannot meet the needs of intelligent and automated equipment in coal mines. Summary of the Invention

[0003] To solve the above-mentioned technical problems, this utility model proposes the following technical solution:

[0004] In a first aspect, this utility model provides a mining intelligent charger, including: a step-down and rectification module, a DC / DC module, a control system, and a switching power supply, buttons, and a display module electrically connected to the control system;

[0005] The step-down and rectification module is used to convert the input AC power into DC power suitable for battery charging.

[0006] The DC / DC module is used to convert the direct current into a stable current or voltage;

[0007] The switching power supply is used to convert the input AC power into low-voltage DC power required by the internal control system of the charger.

[0008] The keyboard and display module are used to set the charging mode and charging time parameters, and to display the device's operating status and charging process.

[0009] In one possible implementation, the step-down and rectification module includes: a three-phase isolation transformer and a three-phase bridge fully controlled rectifier circuit, wherein the first terminal of the three-phase isolation transformer is electrically connected to the AC input power supply, the second terminal of the three-phase isolation transformer is electrically connected to the first terminal of the three-phase bridge fully controlled rectifier circuit, and the second terminal of the three-phase bridge fully controlled rectifier circuit is electrically connected to the DC / DC module.

[0010] In one possible implementation, the three-phase bridge fully controlled rectifier circuit includes a power frequency AC transformer. The U-phase output terminal of the power frequency AC transformer is electrically connected to the first terminal of a first thyristor and the first terminal of a second thyristor. The second terminal of the first thyristor is electrically connected to the first terminal of a third thyristor, the first terminal of a fifth thyristor, and the first terminal of a first DC reactor. The W-phase output terminal of the power frequency AC transformer is electrically connected to the second terminal of the third thyristor and the first terminal of a fourth thyristor. The V-phase output terminal of the power frequency AC transformer is electrically connected to the second terminal of the fifth thyristor and the first terminal of a sixth thyristor. The second terminal of the second thyristor is electrically connected to the second terminal of the fourth thyristor, the second terminal of the sixth thyristor, and the first terminal of a first resistor. The second terminal of the first resistor is electrically connected to the second terminal of the first DC reactor.

[0011] In one possible implementation, the first input terminal of the DC / DC module is electrically connected to the first terminal of a first capacitor, the drain of a first damped field-effect transistor, the drain of a second damped field-effect transistor, and the drain of a third damped field-effect transistor. The second input terminal of the DC / DC module is electrically connected to the second terminal of the first capacitor, the anode of a first diode, the anode of a second diode, the anode of a third diode, the first terminal of a second capacitor, and the first output terminal of the DC / DC module. The source of the first damped field-effect transistor is electrically connected to the cathode of the first diode and the first terminal of a first inductor. The source of the second damped field-effect transistor is electrically connected to the cathode of the second diode and the first terminal of a second inductor. The source of the third damped field-effect transistor is electrically connected to the cathode of the third diode and the first terminal of the third inductor. The second terminal of the second capacitor is electrically connected to the second terminals of the first inductor, the second terminals of the second inductor, the second terminals of the third inductor, and the first terminal of a second DC reactor. The second terminal of the second DC reactor is electrically connected to the second output terminal of the DC / DC module.

[0012] In one possible implementation, the control system includes a charging control system and a power control system. The charging control system uses a combination of a DSP chip and a 32-bit microprocessor chip to control the entire charging process and monitor the status of the equipment. The power control system controls the output of the power supply according to the set voltage and current parameters.

[0013] In one possible implementation, the button and display module includes function keys and a display screen, wherein the function keys include a menu key, an up key, a down key, an OK key, a power key, and a write parameter key;

[0014] The menu button is used to select various sub-functional modules;

[0015] The up arrow key is used to select the additional function;

[0016] The down arrow key is used to select the subtract function;

[0017] The confirmation button is used to confirm the function;

[0018] The power button is used to control the charger to start and stop.

[0019] The write parameter key is used to set battery parameters and charging parameters.

[0020] In one possible implementation, the display screen includes charger operating status, battery parameters, charging mode, remaining battery capacity and internal resistance parameters after battery connection, charging process parameters, current charging voltage and current values, historical interface display, temperature value display of important components, various alarm parameters, alarm records, and alarm cancellation methods.

[0021] In one possible implementation, a sampling module and an alarm module are also included. The sampling module is used to collect data on the output current, battery terminal voltage, DC bus voltage, and device temperature. The alarm module is used to issue an alarm for abnormal conditions during the charging process.

[0022] Compared with the prior art, the beneficial effects of the present invention are:

[0023] This utility model adopts a three-stage intelligent charging method of constant current, constant voltage, and small constant current, which has the advantages of high charging efficiency, simple operation, light weight, and small size. It also has multiple protection functions such as reverse connection, overload, short circuit, and overheating, as well as delayed start, soft start, and power-off memory self-start functions.

[0024] This utility model of a mining intelligent charger features scientific charging power control technology, which can automatically shut down when the battery is fully charged, ensuring that the battery is fully charged without overcharging or undercharging, thus extending the battery's lifespan. It is applicable to various battery types such as nickel-chromium, nickel-metal hydride, lead-acid, and lithium-ion batteries. Attached Figure Description

[0025] Figure 1 A schematic diagram of a control system for a mining intelligent charger provided in an embodiment of this utility model;

[0026] Figure 2 A schematic diagram of the intelligent charger for mining provided in this embodiment of the utility model;

[0027] Figure 3 A schematic diagram of the rectifier circuit provided for an embodiment of this utility model;

[0028] Figure 4 A schematic diagram of a DC / DC module circuit provided for an embodiment of this utility model;

[0029] Figure 5 This utility model provides an interface for setting charging parameters for a mining smart charger. Detailed Implementation

[0030] The present solution will now be described in conjunction with the accompanying drawings and specific embodiments.

[0031] Figure 1 A schematic diagram of a control system for a mining intelligent charger provided in an embodiment of this utility model is shown below. Figure 1 The intelligent charger for mining in this embodiment includes: a step-down and rectification module, a DC / DC module, a control system, and a switching power supply, a button and display module, a sampling module and an alarm module electrically connected to the control system.

[0032] The control system includes a charging control system and a power control system. In this embodiment, the charging control system uses a combination of a DSP chip and a 32-bit microprocessor chip to control the entire charging process and monitor the status of the equipment. The power control system is used to control the output of the power supply according to the set voltage and current parameters.

[0033] Switching power supplies are used to convert input AC power into low-voltage DC power required by the charger's internal control system. See also Figure 2 In this embodiment, the step-down and rectification module includes a three-phase isolation transformer and a three-phase bridge fully controlled rectifier circuit. The first terminal of the three-phase isolation transformer is electrically connected to the AC input power supply, the second terminal of the three-phase isolation transformer is electrically connected to the first terminal of the three-phase bridge fully controlled rectifier circuit, and the second terminal of the three-phase bridge fully controlled rectifier circuit is electrically connected to the DC / DC module. The K1 output contactor is used for reverse connection protection of the battery load. When the battery is connected, the control system detects the battery polarity. If the battery polarity is correct, the control system sends a command to close K1 and simultaneously sends a battery connection completion signal to the host computer, waiting for the host computer's charger command for charging control. If the battery polarity is incorrect, the control system sends a battery reverse connection signal to the host computer, indicating a charging fault that requires manual troubleshooting.

[0034] The step-down and rectification module converts the input AC power into DC power suitable for battery charging. In this embodiment, the three-phase bridge fully controlled rectifier circuit consists of one power frequency AC transformer TR, six thyristor modules (VT1-VT6), and one DC reactor L1. Figure 3The U-phase output terminal of the power frequency AC transformer is electrically connected to the first terminal of the first thyristor VT1 and the first terminal of the second thyristor VT2, respectively. The second terminal of the first thyristor VT1 is electrically connected to the first terminal of the third thyristor VT3, the first terminal of the fifth thyristor VT5, and the first terminal of the first DC reactor L5. The W-phase output terminal of the power frequency AC transformer is electrically connected to the second terminal of the third thyristor VT3 and the first terminal of the fourth thyristor VT4, respectively. The V-phase output terminal of the power frequency AC transformer is electrically connected to the second terminal of the fifth thyristor VT5 and the first terminal of the sixth thyristor VT6, respectively. The second terminal of the second thyristor VT2 is electrically connected to the second terminal of the fourth thyristor VT4, the second terminal of the sixth thyristor VT6, and the first terminal of the first resistor R1, respectively. The second terminal of the first resistor R1 is electrically connected to the second terminal of the first DC reactor L5. Three-phase AC power is introduced into the U, W, and V points of the power frequency AC transformer. The controller sends dual narrow pulses to drive two thyristors to conduct simultaneously. The pulses of the six thyristors are in the order VT1, VT2, VT3, VT4, and VT5, with a phase difference of 60° between each thyristor. The pulses of the common cathode group VT1, VT3, and VT5 and the pulses of the common anode group VT2, VT4, and VT6 are respectively 120° out of phase. Thus, based on the conduction of the two thyristors, the voltage difference between the connected two phases is filtered by reactor L1 and converted into DC voltage.

[0035] In this embodiment, the DC / DC module is used to convert direct current into a stable current or voltage. Figure 4 The first input terminal of the DC / DC module is electrically connected to the first terminal of the first capacitor C1, the drain of the first damped field-effect transistor Q1, the drain of the second damped field-effect transistor Q2, and the drain of the third damped field-effect transistor Q3, respectively. The second input terminal of the DC / DC module is electrically connected to the second terminal of the first capacitor C1, the anode of the first diode D1, the anode of the second diode D2, the anode of the third diode D3, the first terminal of the second capacitor C2, and the first output terminal of the DC / DC module, respectively. The source of the first damped field-effect transistor Q1 is connected to the cathode of the first diode D1 and the first inductor L1, respectively. The first terminal of the second capacitor C2 is electrically connected to the first terminal of the second inductor L1, the second terminal of the second inductor L2, the source of the second damped field-effect transistor Q2 is electrically connected to the cathode of the second diode D2 and the first terminal of the second inductor L2, the source of the third damped field-effect transistor Q3 is electrically connected to the cathode of the third diode D3 and the first terminal of the third inductor L3, the second terminal of the second capacitor C2 is electrically connected to the second terminal of the first inductor L1, the second terminal of the second inductor L2, the second terminal of the third inductor L3 and the first terminal of the second DC reactor L4, and the second terminal of the second DC reactor L4 is electrically connected to the second output terminal of the DC / DC module.

[0036] The Buck triple circuit design significantly reduces the current stress on the switching transistors, allowing the use of common components and snubber circuits to meet design requirements. The adoption of PWM carrier phase-shift triple technology triples the equivalent power output, greatly reducing the size and cost of the output filter.

[0037] The sampling module is used to collect data on output current, battery terminal voltage, DC bus voltage, and equipment temperature. In this embodiment, the charging current and battery terminal voltage are displayed in real time on the screen, allowing users to easily and promptly know the charging parameter values ​​and the current stage of the charging process. Simultaneously, by detecting various temperature values, the system determines whether it should be in operating mode (i.e., charging the battery). If any temperature value exceeds the allowable limit, the system immediately shuts down.

[0038] See Figure 5 The keyboard and display module is used to set charging mode and charging time parameters, and to display the device's operating status and charging process. In this embodiment, the keyboard and display module includes function keys and a display screen. The function keys include a menu key, an up key, a down key, an OK key, a power key, and a write parameter key. The menu key is used to select various sub-function modules, the up key is used to select the add function, the down key is used to select the subtract function, the OK key is used to confirm the function, the power key is used to control the charger's start and stop, and the write parameter key is used to set battery parameters and charging parameters. The display screen includes the charger's operating status, battery parameters, charging mode, remaining battery capacity and internal resistance parameters after battery connection, charging process parameters (including remaining charging time and the current charging stage), current charging voltage and current values, historical interface display (including historical voltage and current values), temperature values ​​of important components, various alarm parameters, alarm records, and alarm cancellation methods.

[0039] The alarm module is used to alert for abnormal situations during the charging process.

[0040] To use, connect the battery pack to the output terminal of the mining smart charger, then turn on the power. The mining smart charger control system will then begin operation. Battery parameters can then be set via buttons and the display module. If the default battery parameters match the current battery parameters, no further setting is required; otherwise, manual setting is necessary. After each setting, pressing the write parameter button will automatically save the battery and charging parameters to the EEPROM. Subsequent uses will not require resetting; the user simply needs to recall the corresponding parameter set. The smart charger can store 100 sets of battery parameters by default (this can be adjusted according to user requirements), facilitating settings for different battery packs.

[0041] The intelligent charging machine for mining will automatically select the appropriate charging parameters based on the battery parameters, such as charging voltage, charging current, charging time, etc.

[0042] The control system then performs self-checks on parameters such as whether the battery pack is connected, whether the battery polarity is correct, whether the battery pack is functioning properly, and whether the charging parameters are set correctly. If the self-check is successful, manually pressing the power button initiates the charging process using the set charging mode, method, and parameters. After charging is complete, the intelligent charger automatically disconnects the contactor and displays "Charging Completed" on the screen. If the self-check fails, the screen displays corresponding fault information, prompting the user to check. If the fault persists, pressing the power button will not start the charging process. Once the fault is cleared, the intelligent charger restarts the self-check, and the charging process begins only after everything is normal. If the battery pack is not disconnected after charging is complete, the intelligent charger determines whether the float charging conditions are met. If so, float charging is initiated, connecting the contactor until fully charged. After float charging is complete, the contactor automatically disconnects and displays "Charging Completed" on the screen.

[0043] It should be noted that, in this document, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0044] The above description is merely a specific embodiment of this utility model. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in this utility model should be included within the protection scope of this utility model. The protection scope of this utility model should be determined by the scope of the claims.

Claims

1. A smart charger for mining, characterized in that, include: A step-down and rectification module, a DC / DC module, a control system, and a switching power supply, buttons, and a display module electrically connected to the control system; The step-down and rectification module is used to convert the input AC power into DC power suitable for battery charging. The DC / DC module is used to convert the direct current into a stable current or voltage; The switching power supply is used to convert the input AC power into low-voltage DC power required by the internal control system of the charger. The keyboard and display module are used to set the charging mode and charging time parameters, and to display the device's operating status and charging process.

2. The intelligent charger for mining according to claim 1, characterized in that, The step-down and rectification module includes: a three-phase isolation transformer and a three-phase bridge fully controlled rectifier circuit. The first end of the three-phase isolation transformer is electrically connected to the AC input power supply, the second end of the three-phase isolation transformer is electrically connected to the first end of the three-phase bridge fully controlled rectifier circuit, and the second end of the three-phase bridge fully controlled rectifier circuit is electrically connected to the DC / DC module.

3. The intelligent charger for mining according to claim 2, characterized in that, The three-phase bridge fully controlled rectifier circuit includes a power frequency AC transformer. The U-phase output terminal of the power frequency AC transformer is electrically connected to the first terminal of the first thyristor and the first terminal of the second thyristor. The second terminal of the first thyristor is electrically connected to the first terminal of the third thyristor, the first terminal of the fifth thyristor, and the first terminal of the first DC reactor. The W-phase output terminal of the power frequency AC transformer is electrically connected to the second terminal of the third thyristor and the first terminal of the fourth thyristor. The V-phase output terminal of the power frequency AC transformer is electrically connected to the second terminal of the fifth thyristor and the first terminal of the sixth thyristor. The second terminal of the second thyristor is electrically connected to the second terminal of the fourth thyristor, the second terminal of the sixth thyristor, and the first terminal of the first resistor. The second terminal of the first resistor is electrically connected to the second terminal of the first DC reactor.

4. The intelligent charger for mining according to claim 1 or 2, characterized in that, The first input terminal of the DC / DC module is electrically connected to the first terminal of the first capacitor, the drain of the first damped field-effect transistor, the drain of the second damped field-effect transistor, and the drain of the third damped field-effect transistor. The second input terminal of the DC / DC module is electrically connected to the second terminal of the first capacitor, the anode of the first diode, the anode of the second diode, the anode of the third diode, the first terminal of the second capacitor, and the first output terminal of the DC / DC module. The source of the first damped field-effect transistor is electrically connected to the cathode of the first diode and the first terminal of the first inductor. The source of the second damped field-effect transistor is electrically connected to the cathode of the second diode and the first terminal of the second inductor. The source of the third damped field-effect transistor is electrically connected to the cathode of the third diode and the first terminal of the third inductor. The second terminal of the second capacitor is electrically connected to the second terminal of the first inductor, the second terminal of the second inductor, the second terminal of the third inductor, and the first terminal of the second DC reactor. The second terminal of the second DC reactor is electrically connected to the second output terminal of the DC / DC module.

5. The intelligent charger for mining according to claim 1, characterized in that, The control system includes a charging control system and a power control system. The charging control system uses a combination of a DSP chip and a 32-bit microprocessor chip to control the entire charging process and monitor the status of the equipment. The power control system controls the output of the power supply according to the set voltage and current parameters.

6. The intelligent charger for mining according to claim 1, characterized in that, The button and display module includes function keys and a display screen. The function keys include a menu key, an up key, a down key, an OK key, a power key, and a write parameter key. The menu button is used to select various sub-functional modules; The up arrow key is used to select the additional function; The down arrow key is used to select the subtract function; The confirmation button is used to confirm the function; The power button is used to control the charger to start and stop. The write parameter key is used to set battery parameters and charging parameters.

7. The intelligent charger for mining according to claim 6, characterized in that, The display screen includes charger operating status, battery parameters, charging mode, remaining battery capacity and internal resistance parameters after battery connection, charging process parameters, current charging voltage and current values, historical interface display, temperature value display of important components, various alarm parameters, alarm records, and alarm cancellation methods.

8. The intelligent charger for mining according to claim 1, characterized in that, It also includes a sampling module and an alarm module. The sampling module is used to collect data on the output current, battery terminal voltage, DC bus voltage, and equipment temperature. The alarm module is used to alert for abnormal conditions during the charging process.

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