Integrated charger

Abstract

The utility model discloses an integrated charger, and belongs to the technical field of charger structure design. Comprising a cabinet body divided into a front bin and a rear bin; the front cabin is provided with a direct current output unit, a control unit, an auxiliary source and an alternating current input unit in sequence from top to bottom; the direct current output unit adopts an upper wire outlet structure; an air outlet assembly is arranged on one side of the rear bin, and an air inlet assembly and a module area are arranged on the other side of the rear bin. The module area is of a detachable structure; a first gun line is arranged on one side outside the cabinet body, and a second gun line is arranged on the other side outside the cabinet body; a front door assembly is arranged on the front bin cabinet door. According to the cabinet provided by the utility model, the electrified devices and the electrical components in the cabinet are distributed in different areas in a compartment arrangement mode, thereby facilitating the wiring of a client, improving the assembly efficiency, enabling the device layout to be more beautiful, and facilitating the heat dissipation of the cabinet and the improvement of the overall performance. Through reasonable layout of devices, simplification of the number and optimization of the structural design, the cost of the charging cabinet is reduced, and meanwhile, the use performance of the cabinet is ensured not to be influenced.

Description

Technical Field

[0001] This utility model belongs to the field of charger structure design technology, and relates to an integrated charger. Background Technology

[0002] With increasing global awareness of environmental protection and the transformation of energy structures, electric vehicles, as a representative of new energy vehicles, are experiencing unprecedented market penetration. This trend has not only driven continuous innovation in electric vehicle technology but has also greatly promoted the rapid development of supporting infrastructure for electric vehicles—charging stations.

[0003] Against the backdrop of the booming development of the charging pile market, customer requirements for charging pile performance are becoming increasingly diversified and sophisticated. Charging speed, as one of the key indicators of charging pile performance, directly affects the charging efficiency of electric vehicles and the user experience. Therefore, improving charging speed while ensuring charging safety has become a constant goal for charging pile manufacturers. Simultaneously, as consumers' demands for product quality and aesthetics increase, factors such as the appearance design, component layout, and footprint of charging piles are gradually becoming key factors influencing consumer purchasing decisions. Furthermore, the ease of use of charging piles is also a significant factor affecting their market share. This includes the ease of installation, simplicity of operation, variety of payment methods, and the speed of fault reporting and after-sales service response. Existing charging piles still have room for improvement in all of these aspects. Utility Model Content

[0004] The purpose of this utility model is to solve the technical problem that the structural layout of charging piles in the prior art is not perfect, and to provide an integrated charger.

[0005] To achieve the above objectives, the present invention adopts the following technical solution:

[0006] In a first aspect, this utility model discloses an integrated charger, comprising a cabinet divided into a front compartment and a rear compartment; the front compartment is provided with a DC output unit, a control unit, an auxiliary power source, and an AC input unit arranged sequentially from top to bottom; the DC output unit adopts an upward cable exit structure; the rear compartment is provided with an air outlet assembly on one side and an air inlet assembly and a module area on the other side; the module area is a detachable structure; a first charging cable is provided on one side of the cabinet body and a second charging cable is provided on the other side; a front door assembly is provided on the front compartment cabinet door.

[0007] Further improvements are made in the following aspects:

[0008] The front door assembly includes a control panel, a card reader, and a display screen; the display screen is equipped with a sunshade.

[0009] The module area consists of two 30 kW modules or two 40 kW modules.

[0010] The top of the front compartment is equipped with a smoke sensor and an audible and visual alarm. The smoke sensor is connected to a controller, which is connected to a cloud platform. An antenna is installed on the top of the cabinet.

[0011] The AC input unit is equipped with an AC contactor and a molded case circuit breaker connected by copper busbars; the output of the AC contactor is connected to a power line, which passes through the cable guard ring on the mounting plate inside the cabinet from the front compartment to the rear compartment, and connects to the AC terminals of each module in the rear compartment.

[0012] The auxiliary power supply voltage is 12V, which powers the control unit and the front door assembly.

[0013] The air outlet assembly is provided with a number of air outlets, and a fan or fan baffle is provided on the air outlet.

[0014] The front compartment is equipped with an air switch, electricity meter and surge protector located adjacent to the auxiliary power source.

[0015] The bottom of the cabinet is equipped with a wooden pallet, and the bottom of the front compartment is equipped with a water immersion sensor, which is connected to an emergency stop protection unit.

[0016] The integrated charger is a three-phase five-wire system and uses 380V industrial power.

[0017] Compared with the prior art, the present invention has the following beneficial effects:

[0018] This utility model discloses an integrated charger. By adopting a front and rear compartment layout and an independent air duct design, modules and components are effectively distributed in different areas, significantly reducing heat exchange during cabinet operation and thus extending the service life of the components. The DC output unit is cleverly placed at the top of the cabinet with an upward cable exit structure, effectively reducing the risk of cable dragging on the ground and greatly facilitating user operations such as plugging in and coiling cables after use. The structural layout of this charging cabinet satisfies both ease of use and significantly improves assembly efficiency. In addition, this design helps reduce the cost of high-power charging cabinets while reducing the heat generated during component operation. The cabinet design is highly flexible, with a detachable modular structure that allows for easy switching between different overall power ratings, thereby reducing R&D costs and meeting the needs of different users. This application proposes an innovative integrated charger structural layout scheme. This scheme aims to reduce the cost of the charging cabinet while ensuring that the performance of the cabinet is not affected by the rational layout and reduction in the number of components, as well as the optimization of the structural design. Furthermore, by distributing the electrical components and electronic parts within the cabinet to different areas through a compartmentalized layout, not only is wiring easier for customers and assembly efficiency improved, but the component layout is also more aesthetically pleasing, which is beneficial for heat dissipation and overall performance enhancement. This innovative component layout not only meets users' needs for the convenience of using charging piles but also improves the user experience, providing strong technical support for the further development and improvement of the charging pile market.

[0019] Furthermore, by installing smoke sensors and audible / visual alarms connected to the top of the front compartment, and integrating them with a controller and cloud platform, the charger can monitor the environmental conditions inside the cabinet in real time. Once smoke is detected, the system immediately triggers an alarm and sends alert information via the cloud platform, thus rapidly responding to potential fire risks and significantly improving the overall safety performance of the unit. The high sensitivity of the smoke sensors allows for early detection of abnormalities within the cabinet, such as overheating or short circuits, which could potentially cause a fire. Timely alarms effectively prevent electrical fires, protecting the safety of personnel and property.

[0020] Furthermore, by installing wooden pallets at the bottom of the cabinet, the charger gains more stable support, effectively improving its overall structural stability and load-bearing capacity. This not only ensures the safety of the charger during placement and use but also helps extend its service life. A water immersion sensor at the bottom of the front compartment can monitor for water accumulation at the bottom of the cabinet in real time. Once water immersion is detected, the sensor immediately triggers the emergency stop protection unit, quickly cutting off the power supply, thus effectively preventing safety hazards such as short circuits, equipment damage, and even fires caused by water. This function significantly improves the charger's waterproof performance and overall safety. Through the cooperation of the water immersion sensor and the emergency stop protection unit, the charger can detect and respond to water immersion in the first instance, avoiding equipment damage and malfunctions caused by water immersion. This reduces maintenance costs and downtime caused by equipment failure, improving the charger's operating efficiency and reliability. Attached Figure Description

[0021] To more clearly illustrate the technical solutions of the embodiments of this utility model, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of this utility model and should not be regarded as a limitation on the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0022] Figure 1 This is a schematic diagram of the internal structure layout of an integrated charger according to the present invention;

[0023] Figure 2 Left view of the internal structure layout of an integrated charger according to this utility model;

[0024] Figure 3 Right view of the internal structure layout of an integrated charger according to this utility model;

[0025] Figure 4 This is a front view of the internal structure layout of an integrated charger according to this utility model.

[0026] The components include: 1. Cabinet; 2. DC output unit; 3. Control unit; 4. Air outlet assembly; 5. Auxiliary power source; 6. AC input unit; 7. AC contactor; 8. First gun line; 9. Wooden pallet; 10. Antenna; 11. Second gun line; 12. Air inlet assembly; 13. Circuit breaker; 14. Electricity meter; 15. Surge protector; 16. Molded case circuit breaker; 17. Front door assembly; 18. Module area; 19. Emergency stop protection unit; 20. Fan; 21. Cable guard ring; 22. Smoke sensor; 23. Water intrusion sensor; 501. Fan baffle; 171. Central control board; 172. Card reader; 173. Display screen; 174. Sunshade. Detailed Implementation

[0027] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this utility model, and not all embodiments. The components of the embodiments of this utility model described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0028] Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention.

[0029] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0030] In the description of the embodiments of this utility model, it should be noted that if terms such as "upper," "lower," "horizontal," or "inner" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship commonly used when the utility model product is in use, they are only for the convenience of describing the utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation on the utility model. Furthermore, terms such as "first" and "second" are only used to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0031] Furthermore, the use of the term "horizontal" does not imply that the component must be absolutely horizontal, but rather that it can be slightly tilted. For example, "horizontal" simply means that its direction is more horizontal than "vertical," and does not mean that the structure must be completely horizontal, but can be slightly tilted.

[0032] In the description of the embodiments of this utility model, it should also be noted that, unless otherwise explicitly specified and limited, the terms "set," "install," "connect," and "link" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.

[0033] The present invention will now be described in further detail with reference to the accompanying drawings:

[0034] See Figure 1 , Figure 2 , Figure 3 and Figure 4 This utility model discloses an integrated charger, characterized in that it includes a cabinet 1 divided into a front compartment and a rear compartment; the front compartment is arranged from top to bottom as a DC output unit 2, a control unit 3, an auxiliary power source 5, and an AC input unit 6; the DC output unit 2 adopts an upward-outgoing cable structure; the front compartment is equipped with a circuit breaker 13, a meter 14, and a surge protector 15 located adjacent to the auxiliary power source 5. The AC input unit 6 is equipped with an AC contactor 7 and a molded case circuit breaker 16 connected by copper busbars; the outlet of the AC contactor 7 is connected to a power line, which passes through a wire guard ring on the mounting plate inside the cabinet 1 from the front compartment to the rear compartment, connecting to the AC terminals of each module in the rear compartment. The auxiliary power source 5 has a voltage of 12V and supplies power to the control unit 3 and the front door assembly 17. The rear compartment is equipped with an air outlet assembly 4 on one side and an air inlet assembly 12 and a module area 18 on the other side. The air outlet assembly 4 is equipped with several air outlets, and a fan 20 or a fan baffle 501 is installed on the air outlet. The module area 18 is a detachable structure, consisting of two 30 kW modules or two 40 kW modules. A first charging cable 8 is located on one side of the cabinet 1, and a second charging cable 11 is located on the other side. A front door assembly 17 is installed on the front cabinet door. The front door assembly 17 includes a control board 171, a card reader 172, and a display screen 173; a sunshade 174 is installed on the display screen 173. A wooden pallet 9 is installed at the bottom of the cabinet 1, and a water immersion sensor 23 is installed at the bottom of the front compartment, connected to an emergency stop protection unit 19. The integrated charger is a three-phase five-wire system, using 380V industrial power. By installing a wooden pallet at the bottom of the cabinet, the charger gains more stable support, effectively improving the overall structural stability and load-bearing capacity. This not only ensures the safety of the charger during placement and use but also helps extend its service life. The water immersion sensor at the bottom of the front compartment can monitor for water accumulation at the bottom of the cabinet in real time. Once water immersion is detected, the sensor immediately triggers the emergency stop protection unit, rapidly cutting off the power supply. This effectively prevents safety hazards such as short circuits, equipment damage, and even fires caused by water. This feature significantly improves the charger's waterproof performance and overall safety. Through the cooperation of the water immersion sensor and the emergency stop protection unit, the charger can detect and respond to water immersion in the first instance, avoiding equipment damage and malfunctions caused by water immersion. This reduces maintenance costs and downtime caused by equipment failures, improving the charger's operating efficiency and reliability.

[0035] A smoke sensor 22 and an audible and visual alarm are connected to the top of the front compartment. The smoke sensor 22 is connected to a controller, which is connected to a cloud platform. An antenna 10 is installed on the top of the cabinet 1. By installing the smoke sensor and audible and visual alarm on the top of the front compartment, and in conjunction with the controller and cloud platform, the charger can monitor the environmental status inside the cabinet in real time. Once smoke is detected, the system will immediately trigger an alarm and send alarm information through the cloud platform, thereby quickly responding to potential fire risks and significantly improving the overall safety performance of the machine. The high sensitivity of the smoke sensor can detect abnormal conditions inside the cabinet early, such as overheating, short circuits, and other factors that may cause a fire. Timely alarms can effectively prevent electrical fires and protect the safety of personnel and property.

[0036] This utility model discloses an integrated charger. By adopting a front and rear compartment layout and an independent air duct design, modules and components are effectively distributed in different areas, significantly reducing heat exchange during cabinet operation and thus extending the service life of the components. The DC output unit is cleverly placed at the top of the cabinet with an upward cable exit structure, effectively reducing the risk of cable dragging on the ground and greatly facilitating user operations such as plugging in and coiling cables after use. The structural layout of this charging cabinet satisfies both ease of use and significantly improves assembly efficiency. In addition, this design helps reduce the cost of high-power charging cabinets while reducing the heat generated during component operation. The cabinet design is highly flexible, with a detachable modular structure that allows for easy switching between different overall power ratings, thereby reducing R&D costs and meeting the needs of different users. This application proposes an innovative integrated charger structural layout scheme. This scheme aims to reduce the cost of the charging cabinet while ensuring that the performance of the cabinet is not affected by the rational layout and reduction in the number of components, as well as the optimization of the structural design. Furthermore, by distributing the electrical components and electronic parts within the cabinet to different areas through a compartmentalized layout, not only is wiring easier for customers and assembly efficiency improved, but the component layout is also more aesthetically pleasing, which is beneficial for heat dissipation and overall performance enhancement. This innovative component layout not only meets users' needs for the convenience of using charging piles but also improves the user experience, providing strong technical support for the further development and improvement of the charging pile market.

[0037] The working principle of this utility model is as follows:

[0038] This utility model proposes a layout scheme for an integrated charger. On the one hand, without affecting the performance of the charging cabinet, the number of components is reduced and the cabinet cost is lowered through reasonable component layout. On the other hand, through compartmentalized arrangement and independent air ducts, the charged components and electrical components inside the cabinet are distributed in different areas. This assembly method not only facilitates customer wiring, but also makes the component layout aesthetically pleasing and conducive to heat dissipation.

[0039] This utility model device adopts a compartmentalized layout, divided into front and rear compartments with independent air ducts. The front compartment mainly consists of a front door assembly 17, a control unit 3, a DC output area 2, and an AC input area 6. The front door assembly 17 houses a display screen 173, a sunshade 174, a card reader panel 172, and a central control board 171. An auxiliary power source 5 is located in the middle of the front compartment, providing power to the display screen 173, the control unit, monitoring unit, signal acquisition unit of the control unit 3, and the BMS system. A meter 14, a circuit breaker 13, and a surge protector 15 are installed on the right side of the auxiliary power source 5. The rear compartment mainly consists of an air intake assembly 12, an air exhaust assembly 4, and a module area 18. The charging gun assemblies are symmetrically distributed, divided into a left gun 8 and a right gun 11, located on the left and right sides of the cabinet, with identical structural designs. This compartmentalized layout not only results in a symmetrical structure and a neat and aesthetically pleasing layout, but also effectively reduces heat exchange during cabinet operation, extending the device's lifespan.

[0040] The molded case circuit breaker 16 is located at the bottom of the front compartment, instead of on the air inlet side. This layout allows for easy wiring and operation from the front compartment, accessible by opening the front door. This facilitates on-site wiring while maintaining an independent air duct, preventing various impacts and malfunctions caused by its location within the duct. The AC contactor 7 is located at the bottom of the front compartment, to the left of the molded case circuit breaker 16, and is connected to the molded case circuit breaker 16 via a copper busbar. This arrangement of the molded case circuit breaker 16 and the AC contactor 7 results in higher space utilization and a more compact structure for the entire unit.

[0041] The cabinet 1 can switch between two models with a total power of 60kW and 80kW. The two 30kW modules in the module area 18 are changed to 40kW modules, the baffle of the air outlet 501 is removed, and a fan 20 is added. All other components meet the requirements of the 80kW cabinet selection design. The cabinet can be modified from 60kW to 80kW, saving R&D costs.

[0042] The DC output 2 is placed above the cabinet 1, and the top cable exit method is adopted to reduce the risk of the gun cable dragging on the ground, making it convenient for users to plug in the gun and coil the cable, thus improving the user experience.

[0043] The integrated charger in this utility model is a DC charger, using 380V industrial power, three-phase five-wire system. The molded case circuit breaker 16 has a top-in, bottom-out input. The molded case circuit breaker 16 and the AC contactor 7 are connected by a copper busbar. The power line is connected to the output of the AC contactor 7. The power line passes through the wire guard ring on the device mounting plate of the cabinet 1. The power line goes from the front compartment to the rear compartment, and then to the AC terminals of each module in sequence. Each module's DC terminal has two positive terminals and two negative terminals. The DC output power line passes through the wire guard teeth on the device mounting plate of the cabinet 1. The power line then goes from the rear compartment to the front compartment, and then connects to the positive and negative terminals of the copper busbar in the DC output area in sequence.

[0044] A smoke sensor 22 is installed on the top of cabinet 1. When smoke is detected, the smoke sensor 22 will upload relevant alarm information to the cloud platform through the controller. The cloud platform will send a message to the site management personnel to remind them to confirm and handle the situation on site. At the same time, the controller will activate the audible and visual alarm on the smoke sensor 22 to remind passers-by and vehicles to stay away from the charging pile. If the site management personnel do not take any action after ten minutes, the controller will send a power-off signal, and the charging pile will stop charging.

[0045] A water ingress sensor 23 is installed at the bottom right side of cabinet 1. When water enters cabinet 1 during heavy rain and the water level reaches the safety warning position, cabinet 1 will activate the power-off self-protection function to improve the safety performance of the whole machine and prevent accidents.

[0046] The above are merely preferred embodiments of this utility model and are not intended to limit the scope of this utility model. Various modifications and variations can be made to this utility model by those skilled in the art. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of this utility model should be included within the protection scope of this utility model.

Claims

1. An integrated charger, characterized in that, The cabinet (1) is divided into a front compartment and a rear compartment. The front compartment is provided with a DC output unit (2), a control unit (3), an auxiliary power source (5) and an AC input unit (6) from top to bottom. The DC output unit (2) adopts an upward cable structure. The rear compartment is provided with an air outlet assembly (4) on one side and an air inlet assembly (12) and a module area (18) on the other side. The module area (18) is a detachable structure. The cabinet (1) is provided with a first gun line (8) on one side and a second gun line (11) on the other side. The front compartment door is provided with a front door assembly (17).

2. The integrated charger according to claim 1, characterized in that, The front door assembly (17) includes a central control board (171), a card reader (172), and a display screen (173); a sunshade (174) is provided on the display screen (173).

3. The integrated charger according to claim 1, characterized in that, The module area (18) consists of two 30 kW modules or two 40 kW modules.

4. The integrated charger according to claim 1, characterized in that, The top of the front compartment is equipped with a smoke sensor (22) and an audible and visual alarm. The smoke sensor (22) is connected to a controller, and the controller is connected to a cloud platform. The top of the cabinet (1) is equipped with an antenna (10).

5. The integrated charger according to claim 1, characterized in that, The AC input unit (6) is equipped with an AC contactor (7) and a molded case circuit breaker (16) connected by copper busbars; the outlet of the AC contactor (7) is connected to a power line, which passes through the wire guard ring on the mounting plate inside the cabinet (1) from the front compartment to the rear compartment and connects to the AC terminals of each module in the rear compartment.

6. The integrated charger according to claim 1, characterized in that, The auxiliary power source (5) has a voltage of 12V and supplies power to the control unit (3) and the front door assembly (17).

7. The integrated charger according to claim 1, characterized in that, The air outlet assembly (4) is provided with a plurality of air outlets, and a fan (20) or a fan baffle (501) is provided on the air outlet.

8. The integrated charger according to claim 1, characterized in that, The front compartment is equipped with an air switch (13), an electricity meter (14) and a surge protector (15) located adjacent to the auxiliary power source (5).

9. The integrated charger according to claim 1, characterized in that, The bottom of the cabinet (1) is provided with a wooden pallet (9), and the bottom of the front compartment is provided with a water immersion sensor (23), which is connected to an emergency stop protection unit (19).

10. The integrated charger according to claim 1, characterized in that, The integrated charger is a three-phase five-wire system and uses 380V industrial power.

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