480kW split charging pile wiring structure

Abstract

The utility model relates to the technical field of charging piles, in particular to a 480kW split charging pile wiring structure which comprises a cabinet body provided with a top layer, a first layer of rear cross beams and a second layer of rear cross beams at intervals in sequence from top to bottom in the height direction, a first mounting position is arranged between the top layer and the first layer of rear cross beams, and a second mounting position is arranged between the first layer of rear cross beams and the second layer of rear cross beams. A third mounting position is arranged below the second-layer rear cross beam; the top-layer rear cross beam is provided with a first wire arrangement part corresponding to the positive wire outlet end of the first power conversion module in the first installation position, and the first-layer rear cross beam is provided with a second wire arrangement part corresponding to the negative wire outlet end of the first power conversion module and the positive wire outlet end of the second power conversion module in the second installation position. And the second-layer rear cross beam is provided with a third wire arrangement part corresponding to the cathode wire outlet end of the second power conversion module. According to the utility model, vertical modular layout of the power conversion module and the power distribution assembly can be realized, cable cross winding can be avoided by layered isolation of positive and negative buses, and electromagnetic coupling interference is reduced.

Description

Technical Field

[0001] This utility model relates to the field of charging pile technology, and more specifically, to a wiring structure for a 480kW split charging stack. Background Technology

[0002] With the widespread application of high-power split-type charging stacks, the rationality of their internal high-voltage line layout places stringent requirements on system reliability, electromagnetic compatibility, and engineering implementation efficiency. Existing high-power charging stacks typically employ a modular stacking design, integrating multiple power conversion modules and power distribution components within a cabinet. However, this approach has significant shortcomings in the hierarchical management and cable arrangement of high-voltage outgoing lines.

[0003] On the one hand, in traditional wiring structures, high-voltage power supply lines and low-voltage control lines are often arranged in parallel on the same layer. The strong electromagnetic radiation generated by high-power DC current can easily cause coupling interference to communication signals, leading to increased bit error rate in charging control signals, increased data transmission delay, and even safety hazards such as malfunction of protection devices. On the other hand, for high-voltage wiring with multiple modules connected in parallel, existing solutions lack a systematic layered guidance design. The positive and negative terminals of each power conversion module are often concentrated in the same area or adjacent layers, without forming an independent physical isolation channel. When multiple power conversion modules work simultaneously, the alternating magnetic field generated by the high-current cables not only exacerbates the electromagnetic induction noise of adjacent lines but also causes unbalanced power output due to inconsistent line impedance, affecting system-level electromagnetic compatibility performance and energy conversion efficiency.

[0004] Furthermore, in existing fuel cell stack structures, the wiring area between the power distribution components and the module output terminals lacks a standardized cable management structure, resulting in widespread cable tangling and cross-wiring. This leads to difficulties in wiring during installation, a high error rate, and difficulty in quickly locating faulty lines during later maintenance, severely reducing the efficiency of engineering construction and operation and maintenance. Especially in high-power scenarios, the high current-carrying requirements and dense arrangement of the DC output copper busbars further amplify the aforementioned electromagnetic interference and messy wiring problems. Current technology has not yet developed a layered cable management solution for the positive and negative output terminals of multiple modules, failing to meet the requirements of high-voltage, high-power charging systems for the safety, stability, and maintainability of the wiring layout.

[0005] Therefore, there is an urgent need to design a separate charging stack wiring scheme that can realize hierarchical isolation of high-voltage lines, zoned management of positive and negative busbars, and integrate a standardized wiring structure, so as to solve the technical problems of severe electromagnetic interference, messy wiring and inconvenient operation and maintenance in the existing technology. Utility Model Content

[0006] The purpose of this utility model is to provide a wiring structure for a 480kW split charging stack. By layering a top-level rear crossbeam, a first-level rear crossbeam, and a second-level rear crossbeam along the height of the cabinet, independent first, second, and third mounting positions are formed, realizing a vertical modular layout of the power conversion module and the power distribution component. The first, second, and third cable management sections corresponding to each layer of crossbeams respectively guide the positive and negative terminals of the first and second power conversion modules, forming a layered and isolated wiring channel for the positive and negative busbars. This effectively avoids the cross-entanglement of high-voltage cables, reduces electromagnetic coupling interference generated by high-power current, and improves the electromagnetic compatibility of the system. This solves the problem of how to achieve layered isolation of high-voltage lines, zoned management of positive and negative busbars, and integrate a standardized cable management structure, thus solving the technical problems of severe electromagnetic interference, chaotic wiring, and inconvenient operation and maintenance in the prior art.

[0007] This utility model is achieved through the following technical solution: a 480kW split charging stack wiring structure, including a cabinet, wherein the cabinet is provided with a top rear crossbeam, a first rear crossbeam and a second rear crossbeam at intervals from top to bottom along the height direction, a first mounting position is provided between the top rear crossbeam and the first rear crossbeam, and a first power conversion module is provided in the first mounting position, a second mounting position is provided between the first rear crossbeam and the second rear crossbeam, and a second power conversion module is provided in the second mounting position, and a third mounting position is provided below the second rear crossbeam, and a power distribution component is provided in the third mounting position;

[0008] The power distribution component has several DC output copper busbars at the front end of the cabinet. The first end of each DC output copper busbar is connected to the positive and negative output terminals of the first power conversion module and the second power conversion module respectively. The second end of each DC output copper busbar extends to the rear end of the cabinet to form a copper busbar wiring area for wiring the charging terminal.

[0009] The top layer rear crossbeam has a first cable management section corresponding to the positive terminal of the first power conversion module, the first layer rear crossbeam has a second cable management section corresponding to the negative terminal of the first power conversion module and the positive terminal of the second power conversion module, and the second layer rear crossbeam has a third cable management section corresponding to the negative terminal of the second power conversion module.

[0010] According to a preferred embodiment, the top rear crossbeam is a C-shaped steel, and the rear end of the top rear crossbeam is provided with a tail cap plate. The tail cap plate is arranged parallel to the rear end face of the top rear crossbeam. The first cable management part is a first cable management groove opened on the tail cap plate. The front end of the tail cap plate has a first contact surface for contacting the positive terminal output of the first power conversion module. The first cable management groove is connected to the first contact surface.

[0011] According to a preferred embodiment, the first layer rear crossbeam is a C-shaped steel, the second cable management section is a second cable management groove opened in the middle of the first layer rear crossbeam, the front end of the first layer rear crossbeam has a second contact surface for contacting the negative terminal output of the first power conversion module and the positive terminal output of the second power conversion module, and the second cable management groove is connected to the second contact surface.

[0012] According to a preferred embodiment, the second rear crossbeam is a C-shaped steel, and an L-shaped line support plate is provided at the rear end of the second rear crossbeam. The first end of the L-shaped line support plate is connected to the second rear crossbeam, and the second end face of the L-shaped line support plate is parallel to the rear end face of the second rear crossbeam. The upper end of the L-shaped line support plate has a third contact surface for contacting the negative terminal output of the second power conversion module.

[0013] According to a preferred embodiment, cable tie fixing holes are provided on the first, second, and third bonding surfaces.

[0014] According to a preferred embodiment, the cabinet has side panels on both sides, and the inner side of the side panels is provided with a first side beam, a second side beam and a third side beam in sequence from top to bottom along the height direction of the cabinet. The first side beam is connected to the end of the top layer rear beam, the second side beam is connected to the end of the first layer rear beam, and the third side beam is connected to the end of the second layer rear beam.

[0015] According to a preferred embodiment, a wire guide plate is provided below the third side beam. The wire guide plate is arranged parallel to the lower end face of the third side beam. A third wire management groove is formed between the outer side of the wire guide plate and the inner side of the side plate. The third mating surface is connected to the third wire management groove.

[0016] According to a preferred embodiment, the lower end face of the third side beam is connected to a limiting plate, the limiting plate extends along the height direction of the cabinet and is spaced apart from the inner side of the side plate, the cable guide plate is connected to the limiting plate, and an accommodating space for accommodating the negative terminal output of the second power conversion module is formed between the upper end of the cable guide plate and the rear end of the limiting plate.

[0017] The technical solution of the 480kW split charging stack wiring structure provided by this utility model has at least the following advantages and beneficial effects: This utility model achieves a vertical modular layout of the power conversion module and the power distribution component by setting a top-level rear crossbeam, a first-level rear crossbeam, and a second-level rear crossbeam in the height direction of the cabinet, forming an independent first mounting position, a second mounting position, and a third mounting position; the first, second, and third wiring sections set on each layer of crossbeams respectively guide the positive terminal wire of the first power conversion module, the negative terminal wire of the first module, the positive terminal wire of the second module, and the negative terminal wire of the second module, forming a wiring channel with layered isolation of positive and negative busbars, which can effectively avoid the cross-entanglement of high-voltage cables, reduce the electromagnetic coupling interference generated by high-power current, and improve the electromagnetic compatibility of the system. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the rear side of the cabinet provided in Embodiment 1 of this utility model;

[0019] Figure 2 This is a schematic diagram of the internal frame of the cabinet provided in Embodiment 1 of this utility model;

[0020] Attached reference numerals: 100-cabinet, 110-top rear crossbeam, 120-first rear crossbeam, 121-second cable management channel, 130-second rear crossbeam, 140-first mounting position, 150-second mounting position, 160-third mounting position, 170-top tail cover plate, 180-side panel, 181-first side crossbeam, 182-second side crossbeam, 183-third side crossbeam, 200-L-shaped cable tray, 300-cable tie fixing hole, 400-cable guide plate, 410-third cable management channel, 500-limiting plate, 510-accommodating space. Detailed Implementation

[0021] 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.

[0022] Example 1

[0023] To reduce electromagnetic coupling interference caused by high-power current and improve the electromagnetic compatibility of the system, this invention proposes a wiring structure for a 480kW split-type charging stack.

[0024] The wiring structure of the 480kW split-type charging stack in this embodiment includes a cabinet 100, see [link / reference]. Figure 1 and Figure 2As shown, the cabinet 100 is provided with a top-level rear crossbeam 110, a first-level rear crossbeam 120 and a second-level rear crossbeam 130 at intervals from top to bottom along the height direction.

[0025] The top rear crossbeam 110 and the first rear crossbeam 120 are provided with a first mounting position 140, and a first power conversion module is provided in the first mounting position 140. The first rear crossbeam 120 and the second rear crossbeam 130 are provided with a second mounting position 150, and a second power conversion module is provided in the second mounting position 150. The second rear crossbeam 130 is provided with a third mounting position 160 below it, and a power distribution component is provided in the third mounting position 160.

[0026] The power distribution component has several DC output copper busbars at the front end of the cabinet 100. The first end of each DC output copper busbar is connected to the positive and negative output terminals of the first power conversion module and the second power conversion module, and the second end of each DC output copper busbar extends to the rear end of the cabinet 100 to form a copper busbar wiring area for wiring the charging terminal.

[0027] The top-layer rear crossbeam 110 has a first cable management section corresponding to the positive terminal of the first power conversion module; the first-layer rear crossbeam 120 has a second cable management section corresponding to the negative terminal of the first power conversion module and the positive terminal of the second power conversion module; and the second-layer rear crossbeam 130 has a third cable management section corresponding to the negative terminal of the second power conversion module. In this embodiment, the positive terminal of the first power conversion module passes through the first cable management section, runs along the top of the first power conversion module to the front end of the cabinet 100, and then runs vertically downwards or downwards along the side of the cabinet 100, finally connecting to the corresponding contactor, and then connecting to the DC output copper busbar through the contactor. Similarly, the negative terminal of the first power conversion module and the positive terminal of the second power conversion module... The negative terminal wire exits through the second cable management section. It should be noted that a partition is provided between the first power conversion module and the second power conversion module. The negative terminal wire of the first power conversion module passes through the upper end of the partition to the front end of the cabinet 100, and then goes vertically downward or down along the side of the cabinet 100, finally connecting to the corresponding contactor, and then connecting to the DC output copper busbar through the contactor. The positive terminal wire of the second power conversion module passes through the lower end of the partition to the front end of the cabinet 100, and then goes vertically downward or down along the side of the cabinet 100, finally connecting to the corresponding contactor, and then connecting to the DC output copper busbar through the contactor. The negative terminal wire of the second power conversion module exits through the third cable management section and finally connects to the DC output copper busbar through the corresponding contactor. Detailed descriptions are omitted here.

[0028] Specifically, this utility model achieves a vertical modular layout of the power conversion module and power distribution component by layering a top-level rear crossbeam 110, a first-level rear crossbeam 120, and a second-level rear crossbeam 130 along the 100-meter height of the cabinet, forming independent first mounting positions 140, second mounting positions 150, and third mounting positions 160. The first, second, and third cable management sections corresponding to each layer of crossbeams guide the positive and negative terminals of the first and second power conversion modules, respectively, forming a layered and isolated cable routing channel for the positive and negative busbars. This effectively avoids the cross-entanglement of high-voltage cables, reduces electromagnetic coupling interference caused by high-power current, and improves the electromagnetic compatibility of the system.

[0029] Example 2

[0030] This embodiment, based on the technical solution provided in Embodiment 1, further explains the specific structure of the first to third thread-arranging sections:

[0031] In this embodiment, the top rear crossbeam 110 is a C-shaped steel, and the rear end of the top rear crossbeam 110 is provided with a tail cap plate. The tail cap plate is arranged parallel to the rear end face of the top rear crossbeam 110. The first cable management part is a first cable management groove opened on the tail cap plate. The front end of the tail cap plate has a first contact surface for contacting the positive terminal output of the first power conversion module. The first cable management groove is connected to the first contact surface, providing a directional cable management channel and a contact fixing surface for the positive terminal output of the first power conversion module.

[0032] Furthermore, the first layer rear crossbeam 120 is also a C-shaped steel, and the second cable management part is a second cable management groove 121 opened in the middle of the first layer rear crossbeam 120. The front end of the first layer rear crossbeam 120 has a second contact surface for contacting the negative terminal output of the first power conversion module and the positive terminal output of the second power conversion module. The second cable management groove 121 is connected to the second contact surface, providing a directional cable management channel and a contact fixing surface for the negative terminal output of the first power conversion module and the positive terminal output of the second power conversion module.

[0033] Specifically, the connection design between the bonding surface and the cable management channel allows the positive and negative cables to be neatly arranged along a preset path, avoiding the layout chaos caused by the free bending of the cables. At the same time, the structural strength of the C-shaped steel is used to enhance the support rigidity of the cable management section, reducing the impact of high-current cable vibration on the connection reliability.

[0034] In some embodiments, the second-layer rear crossbeam 130 is also a C-shaped steel, but unlike the upper cable outlet structure, the cable outlet structure here does not extend from directly below the second power conversion module to the front end of the cabinet 100. Specifically, in this embodiment, the rear end of the second-layer rear crossbeam 130 is provided with an L-shaped cable tray 200. The first end of the L-shaped cable tray 200 is connected to the second-layer rear crossbeam 130, and the second end face of the L-shaped cable tray 200 is parallel to the rear end face of the second-layer rear crossbeam 130. The upper end of the L-shaped cable tray 200 has a third contact surface for contacting the negative cable outlet of the second power conversion module, providing end support and directional guidance structure for the negative cable outlet of the second power conversion module. Specifically, the mechanical support of the L-shaped structure can prevent the connection terminal from being overloaded due to the large cross-section negative cable sags under its own weight. At the same time, the planar guiding design of the contact surface can avoid the copper busbar wiring area below, improving wiring accuracy and overall layout neatness.

[0035] In this embodiment, to achieve rigid fixing of the cable, cable tie fixing holes 300 are provided on the first, second, and third mating surfaces. The cable tie fixing holes 300 provided on the first, second, and third mating surfaces provide standardized fixing points for cable bundling, realizing rigid fixing of flexible cables. This design can effectively suppress the risk of cable wear caused by electromagnetic vibration during fuel cell operation, and at the same time facilitate maintenance personnel to quickly organize the cable bundle with cable ties, avoiding the cable loosening problem caused by traditional free binding, and significantly improving the long-term reliability of the wiring structure.

[0036] Example 3

[0037] This embodiment, based on the technical solution provided in Embodiment 2, further explains the third cable management section and its corresponding cable exit structure:

[0038] In this embodiment, the cabinet 100 has side panels 180 on both sides. Along the height direction of the cabinet 100, the inner side of each side panel 180 is provided with a first side beam 181, a second side beam 182, and a third side beam 183 spaced apart from top to bottom. The first side beam 181 is connected to the end of the top-layer rear beam 110, the second side beam 182 is connected to the end of the first-layer rear beam 120, and the third side beam 183 is connected to the end of the second-layer rear beam 130. This embodiment utilizes the cabinet... The first side beam 181, the second side beam 182, and the third side beam 183 on both sides of the cabinet 100 are connected to the ends of the top rear beam 110, the first layer rear beam 120, and the second layer rear beam 130, respectively, forming a three-dimensional support frame. This structure can greatly enhance the overall rigidity of the cabinet 100, ensure the structural stability of the cable management section and installation position of each layer during long-term high-current operation, and avoid cable connection loosening or cable management channel misalignment caused by deformation of the cabinet 100, thus providing a reliable mechanical support foundation for high-voltage cable routing.

[0039] Furthermore, a wire guide plate 400 is provided below the third side beam 183. The wire guide plate 400 is arranged parallel to the lower end face of the third side beam 183. A third wire management groove 410 is formed between the outer side of the wire guide plate 400 and the inner side of the side plate 180. The third mating surface is connected to the third wire management groove 410. The lower end face of the third side beam 183 is connected to a limiting plate 500. The limiting plate 500 extends along the height direction of the cabinet 100 and is spaced apart from the inner side of the side plate 180. The cable guide plate 400 is connected to the limiting plate 500. The upper end of the cable guide plate 400 and the rear end of the limiting plate 500 form a receiving space 510 for accommodating the negative terminal output of the second power conversion module, providing a precise path constraint and anti-offset structure for the negative terminal output of the second power conversion module. The vertical extension design of the limiting plate 500 can prevent the cable from shifting to the middle of the cabinet 100, avoid cross contact with the power distribution component, eliminate the risk of short circuit caused by cable displacement from a structural level, and improve the inherent safety of the system.

[0040] 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. A wiring structure for a 480kW split-type charging stack, characterized in that, The system includes a cabinet (100), which has a top-level rear crossbeam (110), a first-level rear crossbeam (120), and a second-level rear crossbeam (130) spaced apart from top to bottom along the height direction. A first mounting position (140) is provided between the top-level rear crossbeam (110) and the first-level rear crossbeam (120), and a first power conversion module is provided in the first mounting position (140). A second mounting position (150) is provided between the first-level rear crossbeam (120) and the second-level rear crossbeam (130), and a second power conversion module is provided in the second mounting position (150). A third mounting position (160) is provided below the second-level rear crossbeam (130), and a power distribution component is provided in the third mounting position (160). The power distribution component has several DC output copper busbars at the front end of the cabinet (100). The first end of each DC output copper busbar is connected to the positive and negative output terminals of the first power conversion module and the second power conversion module. The second end of each DC output copper busbar extends to the rear end of the cabinet (100) to form a copper busbar wiring area for wiring the charging terminal. The top-layer rear crossbeam (110) is provided with a first cable management section corresponding to the positive terminal of the first power conversion module, the first-layer rear crossbeam (120) is provided with a second cable management section corresponding to the negative terminal of the first power conversion module and the positive terminal of the second power conversion module, and the second-layer rear crossbeam (130) is provided with a third cable management section corresponding to the negative terminal of the second power conversion module.

2. The wiring structure of the 480kW split-type charging stack as described in claim 1, characterized in that, The top rear crossbeam (110) is a C-shaped steel. The rear end of the top rear crossbeam (110) is provided with a tail cap plate. The tail cap plate is arranged parallel to the rear end face of the top rear crossbeam (110). The first cable management part is a first cable management groove opened on the tail cap plate. The front end of the tail cap plate has a first contact surface for contacting the positive terminal output of the first power conversion module. The first cable management groove is connected to the first contact surface.

3. The wiring structure of the 480kW split-type charging stack as described in claim 2, characterized in that, The first layer rear crossbeam (120) is a C-shaped steel, and the second cable management part is a second cable management groove (121) opened in the middle of the first layer rear crossbeam (120). The front end of the first layer rear crossbeam (120) has a second contact surface for contacting the negative terminal output of the first power conversion module and the positive terminal output of the second power conversion module. The second cable management groove (121) is connected to the second contact surface.

4. The wiring structure of the 480kW split-type charging stack as described in claim 3, characterized in that, The second-layer rear crossbeam (130) is a C-shaped steel. The rear end of the second-layer rear crossbeam (130) is provided with an L-shaped line support plate (200). The first end of the L-shaped line support plate (200) is connected to the second-layer rear crossbeam (130). The second end face of the L-shaped line support plate (200) is parallel to the rear end face of the second-layer rear crossbeam (130). The upper end of the L-shaped line support plate (200) has a third contact surface for contacting the negative terminal output of the second power conversion module.

5. The wiring structure of the 480kW split-type charging stack as described in claim 4, characterized in that, Cable tie fixing holes (300) are provided on the first, second and third bonding surfaces.

6. The wiring structure of the 480kW split-type charging stack as described in claim 4, characterized in that, The cabinet (100) has side panels (180) on both sides. The inner side of the side panels (180) is provided with a first side beam (181), a second side beam (182) and a third side beam (183) from top to bottom along the height direction of the cabinet (100). The first side beam (181) is connected to the end of the top layer rear beam (110), the second side beam (182) is connected to the end of the first layer rear beam (120), and the third side beam (183) is connected to the end of the second layer rear beam (130).

7. The wiring structure of the 480kW split-type charging stack as described in claim 6, characterized in that, A wire guide plate (400) is provided below the third side beam (183). The wire guide plate (400) is arranged parallel to the lower end face of the third side beam (183). A third wire channel (410) is formed between the outer side of the wire guide plate (400) and the inner side of the side plate (180). The third mating surface is connected to the third wire channel (410).

8. The wiring structure of the 480kW split-type charging stack as described in claim 7, characterized in that, The lower end face of the third side beam (183) is connected to a limiting plate (500). The limiting plate (500) extends along the height direction of the cabinet (100) and is spaced apart from the inner side of the side plate (180). The cable guide plate (400) is connected to the limiting plate (500). The upper end of the cable guide plate (400) and the rear end of the limiting plate (500) form a receiving space (510) for accommodating the negative terminal output of the second power conversion module.

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