Pluggable charging pile master control module

Abstract

The utility model relates to the technical field of charging pile master control, in particular to a plug-in type charging pile master control module, which comprises a master control integral outer wrapping case, a master control unit, a communication unit, a direct current meter, an intermediate relay, a switching power supply, a power supply management unit and a quick plug-in wiring terminal, the front end of the master control overall outsourcing case is connected with a master control unit responsible for processing overall operation logic of the charging pile. The master control unit comprises a master control board, an edge computing chip and a data storage module. According to the utility model, the rapid plugging wiring terminals are arranged outside the master control integral outer wrapping case, so that the operation and maintenance are convenient, when the charging pile fails, technicians can check fault points one by one by plugging the corresponding external wiring terminals, rapidly position and replace fault parts, and the working efficiency is improved. According to the utility model, through collaborative innovation of modular plugging design, safety mechanism and intelligent diagnosis, the long-standing problems of low efficiency, high cost and difficult fault positioning in the field of charging pile operation and maintenance are solved.

Description

Technical Field

[0001] This utility model relates to the field of charging pile main control technology, and in particular to a pluggable charging pile main control module. Background Technology

[0002] With the rapid development of the new energy vehicle market, electric vehicles have become an important choice for people's daily travel. Charging piles are the core infrastructure for the development of the new energy vehicle industry, undertaking key functions such as power transmission, battery management, and user interaction. As a "smart hub" connecting the power grid and electric vehicles, their popularization and upgrading are directly related to the promotion efficiency of new energy vehicles, the balance of power grid load, and user experience. The intelligent and modular design of charging piles is of great strategic significance for achieving the "dual carbon" goal and building a green transportation system. The main control module is the "brain" of the charging pile.

[0003] Currently, the power conversion of electric vehicle charging systems is more prone to failure. Traditional charging pile main control modules are welded or screwed together, and replacing parts requires disassembling the entire unit, which takes more than 2 hours. Moreover, most charging station operators need manufacturers to send personnel to the site to handle after-sales service, resulting in a significant waste of manpower, resources, and time. In some cases, untimely after-sales service may even lead to losses for customers. In addition to lacking intelligent diagnostic functions and relying on manual experience for troubleshooting, the system has a high rate of misjudgment and is prone to difficulties in after-sales maintenance, resulting in high operation and maintenance costs and low efficiency.

[0004] Therefore, to address the problems of complex wiring, difficult fault location, and difficult after-sales maintenance of the main control module of traditional charging piles, a pluggable charging pile main control module can be designed. Utility Model Content

[0005] To overcome the problems of complex wiring, difficult fault location, and difficult after-sales maintenance of traditional charging pile main control modules.

[0006] The technical solution of this utility model is as follows: a pluggable charging pile main control module, including a main control integrated chassis, a main control unit, a communication unit, a DC meter, an intermediate relay, a switching power supply, a power management unit, and quick-plug terminals. The front end of the main control integrated chassis is connected to the main control unit responsible for processing the overall operating logic of the charging pile. The main control unit includes a main control board, an edge computing chip, and a data storage module. The front end of the main control integrated chassis is connected to a communication unit for data transmission and remote monitoring. The communication unit includes a PLC control board and a wireless communication module. The front end of the main control integrated chassis is connected to a real-time... A DC meter monitors the energy consumption during charging. An intermediate relay controls the on / off state of the charging circuit at the lower end of the DC meter. A switching power supply providing a stable operating voltage to the main control module is connected to the front end of the main control enclosure. A power management unit, which responds to commands from the main control unit to engage or disengage, is also connected to the front end of the main control enclosure. This power management unit includes a DC relay, a fast-acting fuse, a shunt, a 25*4 galvanized copper busbar, and DC quick-connect terminals. Quick-connect terminals for rapid connection or disconnection between the charging pile and the main control module are connected to both the left and right sides of the main control enclosure's outer wall.

[0007] As a preferred option, the main control unit's overall external chassis has a rectangular structure with a length, width, and height of 120mm, 310mm, and 1000mm, respectively. Several ventilation holes are provided at both the top and bottom of the main control unit's overall external chassis. The main control unit's overall external chassis is made of metal, including but not limited to galvanized steel sheet, stainless steel, or cold-rolled steel sheet.

[0008] Preferably, the front end of the main control unit's external chassis is connected to six DC relays. The front end of the main control unit's external chassis is also connected to a shunt. The front ends of the switching power supply, DC relays, and shunts are all fixed with six 25*4 galvanized copper busbars, which are L-shaped. The front ends of the 25*4 galvanized copper busbars are connected to two fast-acting fuses.

[0009] As a preferred option, the main control unit is equipped with DC quick-connect terminals on both the left and right sides of the outer wall of the main control unit's outer casing, with a total of eight DC quick-connect terminals.

[0010] Preferably, the communication unit supports PLC (charger and vehicle) 4G, WIFI, OCPP1.6 and Ethernet communication protocols, has a built-in encryption chip, uses TLS1.3 protocol to transmit data, and the wireless communication module integrates a signal amplifier with an adjustable transmission power range of 10-30dBm.

[0011] Preferably, the quick-connect terminal block includes a connector and a terminal block holder. The terminal block holder is connected to an external unit. The connector adopts a double-row gold-plated contact design with a contact resistance of ≤0.8mΩ and a plug-in / plug-out life of ≥5000 times. An LED status indicator is provided on the outside of the connector, which indicates the working status through red / green color changes.

[0012] As a preferred option, there are six quick-connect terminals, with the main control board, switching power supply, and power management unit each independently connected to one quick-connect terminal.

[0013] As a preferred option, the quick-connect terminal block also includes an anti-misinsertion structure, which includes a guide groove and a mechanical interlocking buckle, allowing insertion in only one direction to ensure the uniqueness of the insertion direction. A limit switch is provided in the guide groove to prevent the main control unit from being powered on when it is not fully inserted.

[0014] As a preferred option, the edge computing chip adopts a fault diagnosis algorithm, which is based on LSTM neural network to train on historical fault data, analyze parameters such as current harmonics and contactor action timing in real time, realize timely fault warning, and support uploading module health status data to the cloud management platform through encrypted communication protocol (TLS1.3), generate maintenance work orders and automatically dispatch them to the nearest service point.

[0015] The beneficial effects of this utility model are as follows: This pluggable charging pile main control module is equipped with pluggable quick-connect terminals on the main control board, switching power supply, and power management unit, allowing maintenance personnel to complete rapid replacement within minutes. The quick-connect terminals are located outside the main control unit's overall enclosure, facilitating operation and maintenance. When a charging pile malfunctions, technicians can troubleshoot by plugging and unplugging the corresponding external terminals, quickly locating and replacing faulty components. Furthermore, the anti-misplugging structure in the quick-connect terminals utilizes mechanical guidance and interlocking to prevent equipment damage caused by misplugging. Real-time fault analysis and diagnosis are performed using an edge computing chip in the main control unit, promptly alerting maintenance personnel when a fault occurs. Compared to traditional main control mechanisms, this utility model, through its modular pluggable design, safety mechanisms, and intelligent diagnostics, solves the long-standing problems of low efficiency, high cost, and difficulty in fault location in the charging pile maintenance field, demonstrating significant technological advancement and commercial promotion value. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the main control module of the charging pile of this utility model.

[0017] Figure 2 This is a schematic diagram of the frame structure of the main control module for the charging pile of this utility model.

[0018] Explanation of reference numerals in the attached diagram: 1. Main control unit chassis; 2. Main control board; 3. PLC control board; 4. DC meter; 5. Intermediate relay; 6. Switching power supply; 7. DC relay; 8. Shunt; 9. 25*4 galvanized copper busbar; 10. Fast-acting fuse; 11. DC quick-connect terminal block; 12. Quick-connect terminal block. Detailed Implementation

[0019] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0020] Please see Figures 1-2 This utility model provides an embodiment of a pluggable charging pile main control module, including a main control integrated chassis 1, a main control unit, a communication unit, a DC meter 4, an intermediate relay 5, a switching power supply 6, a power management unit, and quick-plug terminals 12. The main control unit responsible for processing the overall operation logic of the charging pile is connected to the front end of the main control integrated chassis 1. The main control unit includes a main control board 2, an edge computing chip, and a data storage module. A communication unit for data transmission and remote monitoring is connected to the front end of the main control integrated chassis 1. The communication unit includes a PLC control board 3 and a wireless communication module. A device for real-time monitoring is also connected to the front end of the main control integrated chassis 1. During the charging process, a DC meter 4 measures the electrical energy. The lower end of the DC meter 4 is connected to an intermediate relay 5 that controls the on / off state of the charging circuit. The front end of the main control enclosure 1 is connected to a switching power supply 6 that provides a stable operating voltage for the main control module. The front end of the main control enclosure 1 is also connected to a power management unit that responds to commands from the main control unit to engage or disengage. The power management unit includes a DC relay 7, a fast-acting fuse 10, a shunt 8, a 25*4 galvanized copper busbar 9, and a DC quick-connect terminal block 11. The left and right sides of the outer wall of the main control enclosure 1 are connected to quick-connect and disconnect terminals 12 for quick connection or disconnection between the charging pile and the main control module of the charging pile.

[0021] Please see Figure 1 In this embodiment, the main control unit chassis 1 is a cuboid structure with a length, width and height of 120mm, 310mm and 1000mm respectively. Several heat dissipation holes are provided at both the top and bottom ends of the main control unit chassis 1. The main control unit chassis 1 is made of metal, including but not limited to galvanized steel plate, stainless steel or cold-rolled steel plate.

[0022] Please see Figure 1In this embodiment, a DC relay 7 is connected to the front end of the main control integrated outer casing 1, and six DC relays 7 are provided. A shunt 8 is connected to the front end of the main control integrated outer casing 1. A 25*4 galvanized copper busbar 9 is fixed to the front end of the switching power supply 6, the DC relays 7, and the shunt 8. Six sets of 25*4 galvanized copper busbars 9 are provided, and the 25*4 galvanized copper busbars 9 have an L-shaped structure. Two fast-acting fuses 10 are connected to the front end of the 25*4 galvanized copper busbars 9. DC fast-acting terminals 11 are connected to the left and right sides of the outer wall of the main control integrated outer casing 1, and eight DC fast-acting terminals 11 are provided.

[0023] Please see Figure 2 In this embodiment, the communication unit supports PLC (charger and vehicle) 4G, WIFI, OCPP1.6 and Ethernet communication protocols, has a built-in encryption chip, uses TLS1.3 protocol to transmit data, and the wireless communication module integrates a signal amplifier with an adjustable transmission power range of 10-30dBm.

[0024] Please see Figure 2 In this embodiment, the quick-connect terminal block 12 includes a connector and a terminal block base. The terminal block base is connected to an external unit. The connector adopts a double-row gold-plated contact design with a contact resistance ≤0.8mΩ and a plug-in / plug-out life ≥5000 cycles. An LED status indicator is provided on the outside of the connector, which indicates the working status through red / green color changes. There are six quick-connect terminal blocks 12. The main control board 2, the switching power supply 6, and the power management unit are each independently connected to one quick-connect terminal block 12. The quick-connect terminal block 12 also includes an anti-misinsertion structure, which includes a guide groove and a mechanical interlocking buckle, allowing insertion in only one direction to ensure the uniqueness of the insertion direction. A limit switch is provided in the guide groove, and the main control unit is prohibited from being powered on when it is not fully inserted.

[0025] Please see Figure 2 In this embodiment, the edge computing chip adopts a fault diagnosis algorithm, which is trained on historical fault data based on LSTM neural network, and analyzes parameters such as current harmonics and contactor action timing in real time. It can provide early warning of potential faults 4-8 hours in advance, and supports uploading module health status data to the cloud management platform through encrypted communication protocol (TLS1.3), generating maintenance work orders and automatically dispatching them to the nearest service point.

[0026] During operation, after receiving a charging request, the main control board 2 closes the charging circuit through the intermediate relay 5. The DC meter 4 monitors the power data in real time and feeds it back to the main control unit. When the shunt 8 detects an abnormal current, the fast-acting fuse 10 will immediately cut off the circuit. At the same time, the edge computing chip analyzes parameters such as current harmonics and contactor action timing based on the LSTM algorithm. Once a fault is detected, it will send an early warning to the cloud through the communication unit so that maintenance personnel can rush to the charging pile to be repaired based on the early warning information. Then, the maintenance personnel will troubleshoot the fault one by one by plugging and unplugging the corresponding external wiring terminals 12 so as to replace the faulty parts in a timely manner.

[0027] The embodiments of the present invention have been described in detail above with reference to the accompanying drawings. However, the present invention is not limited to the above embodiments. Within the scope of knowledge possessed by those skilled in the art, various changes can be made without departing from the spirit of the present invention.

Claims

1. A pluggable charging pile main control module, comprising a main control unit enclosure (1); characterized in that: It also includes a main control unit, a communication unit, a DC meter (4), an intermediate relay (5), a switching power supply (6), a power management unit, and a quick-plug terminal block (12). The front end of the main control unit (1) is connected to the main control unit responsible for processing the overall operation logic of the charging pile. The main control unit includes a main control board (2), an edge computing chip, and a data storage module. The front end of the main control unit (1) is connected to a communication unit for data transmission and remote monitoring.

2. The pluggable charging pile main control module according to claim 1, characterized in that: The communication unit includes a PLC control board (3) and a wireless communication module. The front end of the main control unit's outer casing (1) is connected to a DC meter (4) for real-time monitoring of energy metering during the charging process. The lower end of the DC meter (4) is connected to an intermediate relay (5) for controlling the on / off state of the charging circuit. The front end of the main control unit's outer casing (1) is connected to a switching power supply (6) that provides a stable operating voltage for the main control module. The front end of the main control unit's outer casing (1) is connected to a power management unit for responding to commands from the main control unit to activate or deactivate.

3. The pluggable charging pile main control module according to claim 1, characterized in that: The power management unit includes a DC relay (7), a fast fuse (10), a shunt (8), a 25*4 galvanized copper busbar (9), and a DC fast terminal block (11). The left and right sides of the outer wall of the main control enclosure (1) are connected to quick-connect and disconnect terminals (12) for quick connection or disconnection between the charging pile and the main control module of the charging pile.

4. The pluggable charging pile main control module according to claim 1, characterized in that: The main control unit outer casing (1) is a cuboid structure with a length, width and height of 120mm, 310mm and 1000mm respectively. Several heat dissipation holes are provided at both the top and bottom of the main control unit outer casing (1).

5. The pluggable charging pile main control module according to claim 2, characterized in that: The front end of the main control unit (1) is connected to a DC relay (7), and there are six DC relays (7). The front end of the main control unit (1) is connected to a shunt (8). The front ends of the switching power supply (6), DC relays (7) and shunt (8) are all fixed with 25*4 galvanized copper busbars (9). There are six sets of 25*4 galvanized copper busbars (9), and the 25*4 galvanized copper busbars (9) are L-shaped. The front ends of the 25*4 galvanized copper busbars (9) are connected to fast fuses (10), and there are two fast fuses (10).

6. The pluggable charging pile main control module according to claim 3, characterized in that: The main control unit is equipped with DC quick-connect terminals (11) on both the left and right sides of the outer wall of the main control unit (1). There are eight DC quick-connect terminals (11).

7. The pluggable charging pile main control module according to claim 1, characterized in that: The quick-connect terminal block (12) includes a connector and a terminal block base. The terminal block base is connected to an external unit. The connector adopts a double-row gold-plated contact design with a contact resistance of ≤0.8mΩ and a plug-in / plug-out life of ≥5000 times. An LED status indicator is provided on the outside of the connector, which indicates the working status through red / green color changes.

8. The pluggable charging pile main control module according to claim 6, characterized in that: There are six quick-connect terminal blocks (12), and the main control board (2), the switching power supply (6), and the power management unit are each independently connected to one quick-connect terminal block (12).

9. The pluggable charging pile main control module according to claim 7, characterized in that: The quick-connect terminal block (12) also includes an anti-misinsertion structure, which includes a guide groove and a mechanical interlocking buckle, allowing insertion in only one direction to ensure the uniqueness of the insertion direction. A limit switch is provided in the guide groove, and the main control unit is prohibited from being powered on when it is not fully inserted.

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