Air cooling and noise reduction system for high-power charging pile

Abstract

An air cooling and noise reduction system for a high-power charging pile comprises a shell, and a cross beam is arranged in the middle of the shell; the inner cavity of the shell is divided into an upper mounting cavity and a lower mounting cavity by the cross beam; a charging module is mounted in the upper mounting cavity, and a PDU control module is mounted in the lower mounting cavity; a first temperature sensor is mounted in the charging module; a first door body is mounted on one side of the upper mounting cavity, and a flow guide air duct extending downwards into the lower mounting cavity is arranged on the other side of the upper mounting cavity; a second temperature sensor is further mounted on the first door body; side cavities are further formed in the side edges of the upper mounting cavity and the lower mounting cavity of the shell; an intelligent electric energy meter and a PCU mainboard are installed in the side cavity. A noise sensor is installed at the position, close to an air duct air outlet, of the flow guide air duct. And a multi-stage rotating speed adjusting fan is arranged in the flow guide air duct. The high-power charging pile air cooling and noise reduction system provided by the utility model is efficient in heat dissipation, low in noise and energy-saving.

Description

Technical Field

[0001] This utility model relates to the field of electric vehicle charging technology, specifically to a high-power charging pile air-cooled cooling and noise reduction system. Background Technology

[0002] With the increasing popularity of electric vehicles, the demand for high-power charging piles has increased dramatically. High-power charging piles of 480kW can significantly shorten charging time and improve charging efficiency. However, high-power charging piles generate a lot of heat during operation, requiring an efficient heat dissipation system to ensure the normal operation and safety of the equipment.

[0003] Existing high-power charging stations generally use forced air cooling, but this has the following drawbacks:

[0004] 1. Conflict between heat dissipation and noise: High power requires a large air volume for heat dissipation, resulting in excessive noise (>75dB), which is difficult to meet the noise limit requirements (≤65dB) in residential areas, parking lots and other scenarios.

[0005] 2. Risk of heat buildup: Due to the uneven airflow distribution in traditional duct designs, localized high temperatures (operating temperature exceeding 55℃) may occur inside the power module. This overheating condition can cause three negative effects:

[0006] 1) Triggers the derating protection mechanism of the power module, significantly extending the charging cycle;

[0007] 2) It accelerates the aging process of electronic components and shortens the service life of equipment;

[0008] 3) In extreme cases, it may trigger a chain reaction of uncontrolled fever, posing a serious safety hazard;

[0009] 3. High energy consumption: The fan runs continuously regardless of the load, resulting in high energy consumption. Utility Model Content

[0010] The purpose of this invention is to solve the technical problem of providing a high-power charging pile air-cooled cooling and noise reduction system that is efficient in heat dissipation, low in noise, and energy-saving.

[0011] To solve the above-mentioned technical problems, the technical solution of this utility model is as follows:

[0012] A high-power charging pile air-cooled cooling and noise reduction system includes a housing, with a crossbeam in the middle of the housing; the crossbeam divides the inner cavity of the housing into an upper mounting cavity and a lower mounting cavity communicating with the upper mounting cavity; a charging module is installed in the upper mounting cavity, and a PDU control module is installed in the lower mounting cavity; a first temperature sensor is installed in the charging module; a first door is installed on one side of the upper mounting cavity, and a guide air duct extending downward into the lower mounting cavity is provided on the other side of the upper mounting cavity; a second door corresponding to the guide air duct is installed on one side of the lower mounting cavity, and a third door is installed on the other side; the first... An air inlet is provided on one door, and a second temperature sensor for monitoring the outdoor temperature is also installed on the first door; an air outlet communicating with the air duct is provided on the second door; both the third door and the second door are provided with auxiliary air outlets for assisting heat dissipation; the housing has side cavities on the sides of its upper and lower mounting cavities; a smart energy meter and a PCU motherboard are installed in the side cavities; a noise sensor is installed near the air outlet of the air duct; and a multi-stage speed-adjustable fan is provided in the air duct, tilting downwards towards the air outlet.

[0013] The air inlet is provided with a dustproof cotton layer and a sound insulation cotton layer; the air outlet of the air duct is provided with a sound insulation cotton layer.

[0014] The inner wall of the air duct is a sound-absorbing panel, the outer wall is a sound-insulating panel, and sound-insulating cotton is filled between the inner and outer walls.

[0015] The air inlet and the two auxiliary air outlets are each connected to a baffle assembly that covers the air outlet; the baffle assembly is composed of multiple vertically arranged baffles that are inclined downwards from inside the housing to outside the housing; adjacent baffles are spaced apart, and among adjacent baffles, the lower end of the upper baffle is lower than the upper end of the lower baffle.

[0016] The charging module is equipped with a cooling fan near the air inlet; the cooling fan exhausts air to the charging module near the air duct.

[0017] The PCU motherboard is electrically connected to the second temperature sensor, the noise sensor, the multi-stage speed-adjustable fan, and the PDU control module; the PDU control module is connected to the smart energy meter and the charging module; the charging module is electrically connected to the first temperature sensor.

[0018] The cooling fan is electrically connected to the charging module.

[0019] The technical effects achievable by this invention are as follows: Compared with existing technologies, the beneficial effects of this technical solution are as follows:

[0020] 1. High-efficiency heat dissipation: Under full load of 480kW, the ambient temperature of the charging module can be controlled at around 55℃, ensuring the normal operation of key components inside the charging module;

[0021] 2. Low noise: By combining sound insulation materials (e.g., sound insulation cotton layer, sound absorption board, sound insulation board, sound insulation cotton) with the usage method of this utility model (i.e., noise data collection in step S4), the noise level of the charging pile can be significantly reduced, the user experience can be improved, and the impact on the surrounding environment can be reduced.

[0022] 3. Energy saving: The method of using this utility model can adjust the fan speed according to actual needs by adjusting the multi-level speed, reducing unnecessary energy consumption and lowering operating costs;

[0023] 4. Water ingress prevention: The design of the downward-extending airflow duct and the baffle assembly of this utility model can effectively prevent external liquids (such as water) from entering the housing, ensuring the normal operation of the components inside the housing;

[0024] In summary, this technical solution demonstrates significant advantages in terms of heat dissipation efficiency, energy consumption, space utilization, and temperature control accuracy. It can more effectively address the heat dissipation challenges of charging piles in high-temperature environments and improve the stability and safety of the equipment. Attached Figure Description

[0025] The present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments:

[0026] Figure 1 This is a schematic diagram of the structure of a high-power charging pile air-cooled cooling and noise reduction system according to the present invention;

[0027] Figure 2 This is a schematic diagram of the structure of a high-power charging pile with all doors unfolded.

[0028] Figure 3 This is a schematic diagram of the electrical component connections for a high-power charging pile's air-cooled cooling and noise reduction system.

[0029] Figure 4 This is a cross-sectional view of a high-power charging pile air-cooled cooling and noise reduction system according to this utility model.

[0030] Figure 5 yes Figure 4 Enlarged view of part A;

[0031] Figure 6 This is a three-dimensional view of a high-power charging pile air-cooled cooling and noise reduction system according to the present invention;

[0032] Figure 7This is an internal diagram of a high-power charging pile air-cooled cooling and noise reduction system according to this utility model.

[0033] Figure 8 It is a three-dimensional charging module Figure 1 ;

[0034] Figure 9 It is a three-dimensional charging module Figure 2 ;

[0035] Figure 10 This is a flowchart illustrating the usage method of a high-power charging pile air-cooled cooling and noise reduction system according to this utility model. Detailed Implementation

[0036] The present invention will now be described in further detail with reference to the accompanying drawings.

[0037] See Figures 1 to 10 .

[0038] A high-power charging pile air-cooled cooling and noise reduction system includes a housing 1, with a crossbeam 2 in the middle of the housing 1; the crossbeam 2 divides the inner cavity of the housing 1 into an upper mounting cavity 3 and a lower mounting cavity 4 communicating with the upper mounting cavity 3; a charging module 5 is installed in the upper mounting cavity 3, and a PDU control module 6 is installed in the lower mounting cavity 4; a first temperature sensor 15 is installed in the charging module 5; a first door 7 is installed on one side of the upper mounting cavity 3, and a guide air duct 8 extending downward into the lower mounting cavity 4 is provided on the other side of the upper mounting cavity 3; a second door 9 corresponding to the guide air duct 8 is installed on one side of the lower mounting cavity 4, and a third door 10 is installed on the other side; the first door 7 has an opening at the top. The system includes an air inlet 11 and a second temperature sensor 12 for monitoring the outdoor temperature on the first door 7. An air outlet 13 communicating with the air duct 8 is provided on the second door 9. An auxiliary air outlet 14 for assisting heat dissipation is provided on both the third door 10 and the second door 9. A side cavity 16 is provided on the sides of the upper mounting cavity 3 and lower mounting cavity 4 of the housing 1, and a smart energy meter 17 and a PCU motherboard 18 are installed inside the side cavity 16. A noise sensor 19 is installed near the air outlet 13 in the air duct 8. A multi-stage speed-adjustable fan 20 is installed inside the air duct 8, tilting downwards towards the air outlet 13.

[0039] This invention introduces air intake through air inlet 11, which passes through the charging module 5 to cool it down. Then, driven by the multi-speed adjustable fan 20, the air enters the air duct 8 and finally exits through the air outlet 13, thus cooling the charging module 5. For the heat dissipation of the PDU control module 6, this invention provides auxiliary air outlets 14 on both the third door 10 and the second door 9 to assist in heat dissipation.

[0040] To reduce noise, this utility model has a dustproof cotton layer and a sound insulation cotton layer on the air inlet 11, and a sound insulation cotton layer on the air outlet 13 of the air duct; the inner wall of the air guide duct 8 is a sound-absorbing board, the outer wall is a sound insulation board, and the space between the inner and outer walls is filled with sound insulation cotton. The sound insulation cotton layer, the sound-absorbing board, the sound insulation board, and the sound insulation cotton help to reduce noise; while the dustproof cotton layer is used to prevent dust from entering the housing 1 through the air inlet 11.

[0041] Regarding water ingress prevention, the air inlet 11 and the two auxiliary air outlets 14 of this utility model are all connected to baffle assemblies that cover the air outlets; the baffle assembly consists of multiple vertically arranged baffles 31 that are inclined downwards from inside the housing 1 to outside the housing 1. Preferably, the baffle assembly on the air inlet 11 consists of 14 baffles 31, the baffle assembly on the third door 10 consists of 14 baffles 31, and the baffle assembly on the second door 9 consists of 10 baffles 31; adjacent baffles 31 are spaced apart, and among adjacent baffles 31, the lower end of the upper baffle 31 is lower than the upper end of the lower baffle 31 (for reference). Figure 4 , 5 By setting the baffle plate 31 as described above, external liquids (such as water) can be effectively blocked from entering the housing 1. Furthermore, the air duct 8 of this utility model adopts a downward extending design, which can effectively block external liquids (such as water) from entering the housing 1 from the air duct outlet 13, thereby achieving a water-proof effect.

[0042] Preferably, the charging module 5 of this utility model is equipped with a cooling fan 41 near the air inlet 11, and the cooling fan 41 exhausts air to the end of the charging module 5 near the air duct 8; the cooling fan 41 helps to dissipate heat inside the charging module 5, and its effect is better.

[0043] In terms of the connection of electrical components, the PCU motherboard 18 of this utility model is electrically connected to the second temperature sensor 12, the noise sensor 19, the multi-level speed regulating fan 20 and the PDU control module 6 respectively. The PDU control module 6 is connected to the smart energy meter 17 and the charging module 5 respectively. The charging module 5 is electrically connected to the first temperature sensor 15 and the cooling fan 41 respectively. This utility model starts working by supplying power to the PCU motherboard 18 and the charging module 5.

[0044] The specific steps for using the above-mentioned high-power charging pile air-cooled cooling and noise reduction system are as follows:

[0045] S1 Ambient Temperature Threshold Judgment: The ambient temperature of the charging pile is monitored by the second temperature sensor 12. When the outdoor temperature (T_outdoor) is ≥35℃, the ambient temperature is high. To ensure heat dissipation, the multi-speed fan 20 is prioritized to start the high-speed mode, and then noise data collection is initiated. When the outdoor temperature (T_outdoor) is <35℃, the power load classification judgment is initiated.

[0046] S2 Power Load Classification Judgment: When the smart meter 17 detects a high load, i.e., I≥80%, it decides to enter the emergency layer, and the multi-level speed regulating fan 20 immediately starts high-speed mode, and then enters noise data collection; when the smart meter detects a low load, i.e., I<80%, it enters the module temperature threshold judgment.

[0047] S3 module temperature threshold judgment: When the first temperature sensor 15 detects that the temperature T of the charging module 5 is ≥ 55℃, the multi-level speed regulating fan 20 immediately starts the high-speed mode (to ensure the safety of the core component charging module 5), and then enters noise data collection; when the first temperature sensor 15 detects that the temperature T of the charging module 5 is < 55℃, the multi-level speed regulating fan 20 switches to the medium-speed mode (to balance heat dissipation and energy consumption), and then enters noise data collection.

[0048] S4 Noise Data Collection: When the noise sensor 19 detects noise N≥65dB, the multi-stage speed regulating fan 20 switches to low-speed mode for noise reduction, and then enters module temperature collection for threshold judgment; when the first temperature sensor 15 detects that the charging module 5 temperature T≥55℃, the multi-stage speed regulating fan 20 immediately starts high-speed mode (to ensure the safety of the core component charging module 5), and then ends; when the first temperature sensor 15 detects that the charging module 5 temperature T<55℃, it maintains the original mode, and then ends; when the noise sensor 19 detects N<65dB, it maintains the current mode, and then ends.

[0049] Through the above adjustment strategies, charging piles can effectively control noise propagation and reduce energy consumption while maintaining efficient heat dissipation. The application of intelligent algorithms enables charging piles to make dynamic adjustments based on real-time data, thereby improving system operating efficiency and user experience.

[0050] The air-cooled cooling and noise reduction system with isolated air duct of this utility model includes the following key components:

[0051] I. Air-cooled cooling system:

[0052] Airflow duct 8 design: An independent airflow duct is set up inside the charging pile for the charging module 5. A multi-speed adjustable fan 20 is installed at a 30° angle at 100mm from the outlet of the charging module 5 to force airflow and remove heat. The airflow duct 8 outlet adopts a "forward and downward" method to exhaust the air. The connection between the airflow duct 8 and the charging module 5 adopts a sealed structure to prevent backflow.

[0053] Multi-speed adjustable fan 20: The multi-speed adjustable fan 20 supports three speed settings: low speed (1200rpm), medium speed (1800rpm), and high speed (2400rpm) to meet different load requirements.

[0054] Thermal field equalization strategy: Optimize the air duct cross-section through CFD simulation to ensure that the airflow uniformly covers the heat-generating area and eliminate local hot spots.

[0055] Airflow duct 8 noise reduction system:

[0056] A 10mm thick layer of sound-absorbing cotton with a density of 32kg / m³ is installed at the inlet and outlet of the air duct 8 to effectively absorb the noise generated by the multi-speed adjustable fan 20 and reduce the noise level.

[0057] The air duct 8 adopts a multi-layer structure, with sound-absorbing panels on the inner wall and sound-insulating panels on the outer wall. Sound-insulating cotton is filled between the two walls, which can form multiple sound barriers to further isolate noise.

[0058] Closed-loop control system based on temperature-noise feedback:

[0059] Using intelligent algorithms, the operating mode of the fan is dynamically adjusted according to the load of the charging pile and the ambient temperature, achieving the dual goals of energy saving and noise reduction.

[0060] II. Sensors:

[0061] (1) Temperature sensing layer: A first temperature sensor 15 and a second temperature sensor 12 are respectively arranged inside the charging module 5 and on the first door 7, with an accuracy of ±0.1℃ and a response time of 1 second, to monitor the temperature of the charging module 5 and the ambient temperature respectively.

[0062] (2) Noise monitoring layer: Noise sensor 19 (A weighted, range 30~100dB) is installed at the air outlet 13 of the air duct of the lower installation cavity 4.

[0063] (3) Load monitoring layer: A smart energy meter 17 is installed under the PCU motherboard 18. Data is uploaded to the cloud platform in real time, and the background displays the charging pile's voltage, current, power, and energy consumption curves in real time.

[0064] III. Controller:

[0065] The host uses a self-developed high-performance PCU motherboard 18 as the controller. Based on the data collected by the sensor, it automatically adjusts the speed of the multi-level speed control fan 20 to optimize heat dissipation and noise reduction.

[0066] IV. Intelligent Algorithms:

[0067] Employing intelligent algorithms, the fan's operating mode is dynamically adjusted based on the charging pile's load, ambient temperature, module temperature, and noise level to achieve the dual goals of energy saving and noise reduction. The control logic is shown in the table below (three-level decision-making mechanism):

[0068] Decision-making level Triggering conditions Control Action Response delay Emergency Level Outdoor ambient temperature (T) ≥ 35℃; electrical load (I) ≥ 80%; internal ambient temperature of charging module (T) ≥ 55℃ Switch to high-speed mode immediately <500ms Optimization layer Noise N≥65dB(A) & T<55℃ Gradient descent to compliance threshold 3s / gear

[0069] Dynamic trade-off strategy:

[0070] Load Priority Mode: Under high load (>80%), priority is given to heat dissipation (temperature ≤55℃), and noise ≥65dB(A) is allowed.

[0071] Silent priority mode: When the load is low (<80%), the speed is dynamically adjusted with noise ≤65dB(A) as the constraint.

Claims

1. A high-power charging pile air cooling and noise reduction system, comprising a shell (1), characterized in that: The shell (1) is provided with a beam (2) in the middle; the beam (2) divides the inner cavity of the shell (1) into an upper installation cavity (3) and a lower installation cavity (4) communicated with the upper installation cavity (3); the upper installation cavity (3) is provided with a charging module (5), and the lower installation cavity (4) is provided with a PDU control module (6); the charging module (5) is provided with a first temperature sensor (15); one side of the upper installation cavity (3) is provided with a first door body (7), and the other side of the upper installation cavity (3) is provided with a flow guide air duct (8) extending downward into the lower installation cavity (4); one side of the lower installation cavity (4) is provided with a second door body (9) corresponding to the flow guide air duct (8), and the other side is provided with a third door body (10); the first door body (7) is provided with an air inlet (11), and the first door body (7) is further provided with a second temperature sensor (12) for monitoring the outdoor temperature; the second door body (9) is provided with an air duct air outlet (13) communicated with the flow guide air duct (8); the third door body (10) and the second door body (9) are both provided with an auxiliary air outlet (14) for auxiliary heat dissipation; the shell (1) is further provided with a side cavity (16) on the side of the upper installation cavity (3) and the lower installation cavity (4); the side cavity (16) is provided with an intelligent electric energy meter (17) and a PCU mainboard (18); the flow guide air duct (8) is provided with a noise sensor (19) near the air duct air outlet (13); the flow guide air duct (8) is provided with a multi-stage rotating speed adjusting fan (20) inclined downward to the air duct air outlet (13).

2. The wind-cooling and noise-reducing system of a high-power charging pile according to claim 1, characterized in that: The air inlet (11) is provided with a dustproof cotton layer and a soundproof cotton layer; the air duct air outlet (13) is provided with a soundproof cotton layer.

3. The wind-cooling and noise-reducing system of a high-power charging pile according to claim 1, characterized in that: The inner wall of the flow guide air duct (8) is an acoustic panel, the outer wall is a soundproof panel, and the inner wall and the outer wall are filled with soundproof cotton.

4. The wind-cooling and noise-reducing system of a high-power charging pile according to claim 1, characterized in that: The air inlet (11) and the two auxiliary air outlets (14) are both connected with a flow baffle assembly covering the air inlets; the flow baffle assembly is composed of a plurality of vertically arranged flow baffles (31) inclined downward from the inside of the shell (1) to the outside of the shell (1); adjacent flow baffles (31) are arranged at intervals, and among adjacent flow baffles (31), the lower end height of the upper flow baffle (31) is lower than the upper end height of the lower flow baffle (31).

5. The wind-cooling and noise-reducing system of a high-power charging pile according to claim 1, characterized in that: The charging module (5) is provided with a heat dissipation fan (41) near the air inlet (11); the heat dissipation fan (41) blows air to the charging module (5) near the flow guide air duct (8).

6. The wind-cooling and noise-reducing system of a high-power charging pile according to claim 1, characterized in that: The PCU mainboard (18) is electrically connected with the second temperature sensor (12), the noise sensor (19), the multi-stage rotating speed adjusting fan (20) and the PDU control module (6) respectively; the PDU control module (6) is connected with the intelligent electric energy meter (17) and the charging module (5) respectively; the charging module (5) is electrically connected with the first temperature sensor (15).

7. The wind-cooling and noise-reducing system of a high-power charging pile according to claim 5, characterized in that: The heat dissipation fan (41) is electrically connected with the charging module (5).

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