Integrated high-power charger

Abstract

The utility model discloses an integrated high-power charger, which belongs to the technical field of structural design and comprises a cabinet, the cabinet is divided into a front bin and a rear bin, the front bin is sequentially provided with a direct-current output unit, an auxiliary source unit and an alternating-current input unit from top to bottom, and the front bin is fixedly connected with a front door assembly; the rear bin is provided with a module unit, an air inlet assembly and an air outlet assembly are arranged on the two sides of the rear bin respectively, and an alternating current contactor is arranged at the bottom of the air outlet assembly. A gun line and a gun hanging seat are symmetrically arranged on the left side and the right side of the machine cabinet, the gun line is connected with a charging gun, and the charging gun is placed on the gun hanging seat. The charging cabinet structure provided by the utility model not only can meet the use convenience, but also can improve the assembly efficiency, effectively reduce the cost of a high-power charging cabinet, and reduce the heat generated in the operation process of devices.

Description

TECHNICAL FIELD

[0001] The patent belongs to the technical field of structural design, and particularly relates to an integrated high-power charger. BACKGROUND

[0002] With the rapid development of new energy electric vehicles, the market demand for chargers is also increasing. On the basis of meeting the use performance, there are higher and higher demands for the appearance, overall structure layout, operation convenience and later use cost of the charger. The reasonable internal layout design of the charger directly affects the appearance design, use convenience and maintenance convenience, therefore, the reasonable internal layout design of the charger is paid more and more attention.

[0003] In the field of new energy electric vehicle chargers, although the existing technology has made certain progress, there are still many deficiencies. The internal components of the traditional charger are often scattered, resulting in a large number of components. The structure design of the cabinet of some chargers is unreasonable, the space utilization rate is low, and the cabinet volume is too large. The internal layout of the traditional charger pays more attention to functionality and ignores the overall aesthetics. Random placement of components and cable chaos affect the visual image of the product. The heat dissipation design of some chargers is unreasonable, the heat dissipation channel is not smooth, and heat accumulates inside, affecting the performance and life of electronic components. Especially in high-temperature environments or long-time continuous charging processes, overheating problems may cause charger failure, reducing charging efficiency and reliability.

[0004] Therefore, an integrated high-power charger is proposed. CONTENT OF THE UTILITY MODEL

[0005] The utility model aims at providing an integrated high-power charger to overcome the shortcomings of the prior art.

[0006] An integrated high-power charger includes a cabinet, the cabinet is divided into a front compartment and a rear compartment, the front compartment is sequentially provided with a DC output unit, an auxiliary source unit and an AC input unit from top to bottom, and the front compartment is fixedly connected with a front door assembly; the rear compartment is provided with a module unit, and an air inlet assembly and an air outlet assembly are arranged on the two sides of the rear compartment respectively, and the air outlet assembly is provided with an AC contactor at the bottom; gun wires and gun hanging seats are symmetrically arranged on the left and right sides of the cabinet, and the gun wires are connected with charging guns, and the charging guns are placed in the gun hanging seats.

[0007] Further, the AC input unit includes two plastic casing circuit breakers, the two plastic casing circuit breakers are located at the bottom of the front compartment of the cabinet, and the two plastic casing circuit breakers are connected with the AC contactor through copper bars.

[0008] Further, the auxiliary source unit comprises a first auxiliary source, second left auxiliary sources and second right auxiliary sources are arranged on the left and right sides of the first auxiliary source, a guide rail is arranged below the first auxiliary source, and third left auxiliary sources and third right auxiliary sources are arranged on the left and right sides of the guide rail.

[0009] Further, the front door assembly is provided with an indicator light, a display screen, an SOC digital display, a card swiping plate and a centralized control panel.

[0010] Further, the air outlet assembly comprises a fan baffle and a system fan, and the fan baffle is located below the system fan.

[0011] Further, the cabinet top is provided with an adjustable speed cooling fan.

[0012] Further, the DC output unit is also provided with a parallel contactor.

[0013] Further, the guide rail is provided with an electric meter, an air switch, a socket, a terminal strip and a diode.

[0014] Further, the left side of the cabinet is provided with an antenna and an emergency stop button.

[0015] Further, the bottom of the cabinet is provided with a wooden pallet, and the top of the cabinet is provided with a lifting ring.

[0016] Compared with the prior art, the utility model has the following beneficial technical effects:

[0017] The utility model discloses an integrated high-power charger which adopts front and rear warehouse layout, and the DC output unit, auxiliary source unit and AC input unit are arranged in the front warehouse.

[0018] The DC output unit is located at the top of the front warehouse and adopts the upper wire outlet mode, so that the gun wire naturally falls, the risk of floor abrasion caused by traditional lower wire outlet is avoided, the cable is not crushed and soaked by rainwater, the wire winding operation path is simplified, and the user's gun insertion time is shortened.

[0019] By increasing or decreasing the number of module units and adjusting the heat dissipation configuration, this cabinet can switch between four models with total power of 320kW, 360kW, 400kW, and 480kW, reducing R&D costs and increasing applicability.

[0020] The cabinet is compatible with parallel contactors, which can enable single-gun output of all the power of the whole machine, or dual-gun output to evenly distribute all the power of the whole machine, thereby improving the charging power and charging voltage of single-gun charging.

[0021] This charger solves the problems of high cost, poor heat dissipation, low flexibility, and unsightly appearance of traditional high-power charging equipment through compartmentalized thermal isolation, dynamic power adaptation, parallel output optimization, and heat dissipation design. Attached Figure Description

[0022] Fig. 1 This is a front view of the interior of an integrated high-power charger according to an embodiment of the present invention.

[0023] Fig. 2 This is a schematic diagram of the interior left side of an integrated high-power charger according to an embodiment of this utility model.

[0024] Fig. 3 This is a right-side view of the interior of an integrated high-power charger according to an embodiment of this utility model.

[0025] In the diagram: 1. Cabinet; 2. DC output unit; 2-1. Parallel contactor; 3. Controller; 4. Second auxiliary power source on the left; 5. First auxiliary power source; 6. Third auxiliary power source; 7. Air outlet assembly; 7-1. Fan damper; 7-2. System fan; 8. Molded case circuit breaker; 9. AC input unit; 10. Wooden pallet; 11. Charging cable; 12. Charging gun; 13. Third auxiliary power source on the right; 14. Second auxiliary power source on the right; 15. Air inlet assembly; 16. Hanging ring; 17. Cooling fan; 18. Front door assembly; 18-1. Indicator light; 18-2. Display screen; 18-3. SOC digital display; 18-4. Card reader; 18-5. Central control board; 19. Module unit; 20. Antenna; 21. Emergency stop button; 22. AC contactor; 23. Gun holder. Detailed Implementation

[0026] To enable those skilled in the art to better understand the present invention, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort should fall within the protection scope of the present invention.

[0027] It should be noted that the terms "first," "second," etc., in the specification, claims, and accompanying drawings of this utility model are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate so that the embodiments of the utility model described herein can be implemented in orders other than those illustrated or described herein. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover non-exclusive inclusion; for example, a process, method, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or apparatus.

[0028] This utility model proposes an integrated high-power 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 a reasonable layout of components. 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 wiring for customers, but also results in an aesthetically pleasing component layout and promotes heat dissipation. Specific implementation details are as follows:

[0029] See Figs. 1 to 3 An integrated high-power charger includes a cabinet 1, which is divided into a front compartment and a rear compartment. The front compartment, from top to bottom, houses a DC output unit 2, an auxiliary power unit, and an AC input unit 9. A front door assembly 18 is fixedly connected to the front compartment. The rear compartment houses a module unit 19, with an air inlet assembly 15 and an air outlet assembly 7 on each side. An AC contactor 22 is located at the bottom of the air outlet assembly 7. Charging cables 11 and charging gun mounts 23 are symmetrically arranged on the left and right sides of the cabinet 1, with the charging cables 11 connected to charging guns 12, which are placed on the charging gun mounts 23. An antenna 20 and an emergency stop button 21 are located on the left side of the cabinet 1. The physical isolation design between the front and rear compartments reduces heat exchange across areas during high-power operation, minimizing thermal damage to components and extending equipment lifespan. The symmetrical layout of the charging cables and mounting guns, along with the hierarchical arrangement of the equipment in the front compartment, results in a neat and aesthetically pleasing layout. The cabinet 1 places the DC output unit 2 above the front compartment of the cabinet 1, adopting an upward cable exit method to reduce the risk of the gun cable dragging on the ground, making it convenient for users to insert guns and coil cables, thus improving the user experience.

[0030] In some preferred embodiments of this utility model, the AC input unit 9 adopts a dual-input configuration, which can reduce device heat generation and cost. Specifically, the AC input unit 9 includes two molded case circuit breakers 8, which are located at the bottom of the front compartment of the cabinet 1, without being placed on the air inlet side. This layout allows customers to perform wiring and operation from the front compartment, which can be accessed by opening the front door, facilitating on-site wiring and maintaining an independent air duct, preventing various influences and failures caused by being located in the air duct. The AC contactor 22 is located at the bottom of the air outlet in the rear compartment of the cabinet, and the two molded case circuit breakers 8 are connected to the AC contactor 22 via copper busbars. The layout of the molded case circuit breakers 8 and the AC contactor 22 makes the overall space utilization more efficient and the structure more compact.

[0031] In some preferred embodiments of this utility model, the front door assembly 18 is provided with an indicator light 18-1, a display screen 18-2, a SOC digital display 18-3, a card reader 18-4, and a central control board 18-5.

[0032] In some preferred embodiments of this utility model, the auxiliary power unit includes a first auxiliary power source 5, with a second auxiliary power source 4 on the left and a second auxiliary power source 14 on the right on both sides of the first auxiliary power source 5. A guide rail is provided below the first auxiliary power source 5, with a third auxiliary power source 6 on the left and a third auxiliary power source 13 on the right on both sides of the guide rail. A controller 3 is provided to the left of the second auxiliary power source 4. The first auxiliary power source 5 is a 12V auxiliary power source for the system, located in the center of the front compartment, and supplies power to the display screen 18-2 and the SOC digital display 18-3. The second auxiliary power sources 4 on the left and 14 on the right are 24V auxiliary power sources, which supply power to the controller 3. The third auxiliary power sources 6 on the left and 13 on the right are 12V auxiliary power sources, which supply power to the controller 3. A meter, circuit breaker, socket, terminal block, and diode are installed on the guide rail.

[0033] In some preferred embodiments of this utility model, the air outlet component 7 includes a fan baffle 7-1 and a system fan 7-2, with the fan baffle 7-1 located below the system fan 7-2. The cabinet can switch between four models with total power of 320kW, 360kW, 400kW, and 480kW. By reducing the number of module units, increasing or decreasing the number of fan baffles 7-1 at the air outlet, and increasing or decreasing the number of system fans 7-2, and with other components of the charger meeting the cabinet selection design requirements for 480kW, 320kW, 360kW, and 400kW, the cabinet can be modified from 480kW to 320kW, saving R&D costs.

[0034] It should be noted that this integrated high-power charger uses 380V industrial power, three-phase five-wire system, and the molded case circuit breaker 8 uses bottom inlet and top outlet. Using bottom inlet and top outlet can reduce the length of copper busbar and reduce the manufacturing cost of the whole machine. The molded case circuit breaker 8 and AC contactor 22 are connected by copper busbar. The power line is connected to the outlet of AC contactor 22. The power line is tied to the back panel of cabinet 1 and goes to the AC terminal of each module in sequence. Two positive terminals and two negative terminals come out of the DC terminal of each module. The DC output power line passes through the wire guard teeth on the device mounting plate of the cabinet. The power line then goes from the rear compartment to the front compartment and is connected to the positive and negative terminals of the copper busbar of the DC output area (2) in sequence.

[0035] In some preferred embodiments of this utility model, an adjustable-speed cooling fan 17 is installed on the top of the cabinet 1 to cool the DC output unit 2.

[0036] In some preferred embodiments of this utility model, the DC output unit 2 is further provided with a parallel contactor 2-1; the cabinet is compatible with the parallel contactor 2-1, so that when only one charging gun is charging, the entire power of the whole machine can be output by a single gun, thereby improving the charging power and charging voltage of the single gun. When both charging guns are charging, the entire power of the whole machine can also be evenly distributed between the two guns.

[0037] In some preferred embodiments of this utility model, a wooden pallet 10 is provided at the bottom of the cabinet 1, and a lifting ring 16 is provided at the top of the cabinet 1; it supports hoisting and forklift installation, and can realize rapid relocation.

[0038] The embodiments described above only illustrate some implementations of this utility model, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the utility model patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this utility model, and these all fall within the protection scope of this utility model. Therefore, the protection scope of this utility model patent should be determined by the appended claims.

Claims

1. An integrated high-power charger, characterized by, Including cabinet (1), the cabinet (1) is divided into front warehouse and rear warehouse, the front warehouse is sequentially provided with DC output unit (2), auxiliary source unit, AC input unit (9) from top to bottom, the front warehouse is fixedly connected with front door assembly (18);The rear warehouse is provided with module unit (19), and the rear warehouse is provided with air inlet assembly (15) and air outlet assembly (7) on both sides respectively, and the bottom of the air outlet assembly (7) is provided with AC contactor (22);The cabinet (1) is symmetrically provided with gun wire (11) and gun seat (23) on the left and right sides, and the gun wire (11) is connected with the charging gun (12), and the charging gun (12) is placed in the gun seat (23).

2. The integrated high-power charger of claim 1, wherein, The AC input unit (9) includes two plastic shell circuit breakers (8), and the two plastic shell circuit breakers (8) are located at the bottom of the front warehouse of the cabinet (1), and the two plastic shell circuit breakers (8) are connected with the AC contactor (22) through copper bars.

3. The integrated high-power charger of claim 1, wherein, The auxiliary source unit includes first auxiliary source (5), and the left and right sides of the first auxiliary source (5) are provided with left second auxiliary source (4) and right second auxiliary source (14), and the bottom of the first auxiliary source (5) is provided with guide rail, and the left and right sides of the guide rail are provided with left third auxiliary source (6) and right third auxiliary source (13);The left side of the left second auxiliary source (4) is provided with controller (3).

4. The integrated high-power charger of claim 1, wherein, The front door assembly (18) is provided with indicator light (18-1), display screen (18-2), SOC digital display (18-3), card swiping plate (18-4) and centralized control panel (18-5).

5. The integrated high-power charger of claim 1, wherein, The air outlet assembly (7) includes fan baffle (7-1) and system fan (7-2), and the fan baffle (7-1) is located below the system fan (7-2).

6. The integrated high-power charger of claim 1, wherein, The top of the cabinet (1) is provided with adjustable speed cooling fan (17).

7. The integrated high-power charger of claim 1, wherein, The DC output unit (2) is further provided with parallel contactor (2-1).

8. The integrated high-power charger of claim 3, wherein, The guide rail is installed with electric meter, air switch, socket, terminal strip and diode.

9. The integrated high-power charger of claim 1, wherein, The left side of the cabinet (1) is provided with antenna (20) and emergency stop button (21).

10. The integrated high-power charger of claim 1, wherein, The bottom of the cabinet (1) is provided with wooden pallet (10), and the top of the cabinet (1) is provided with lifting ring (16).

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