Intelligent charger

Abstract

The utility model discloses an intelligent charger comprising a control module, an input protection module and an output processing module, a power conversion module is arranged between the input protection module and the output processing module, and the power conversion module comprises a PFC control unit, a rectification unit and a detection unit. An alternating current voltage sampling circuit is arranged between the input protection module and the PFC control unit, and the alternating current voltage sampling circuit comprises a slow start circuit and a high-voltage rectification circuit. According to the utility model, not only is the adaptability and maintainability of the charger improved by adopting a modular architecture, but also the power conversion can be detected and controlled; and closed-loop feedback is realized, an autonomous decision-making capability and a man-machine interaction function are realized, and the control precision and the flexibility of the control system are improved.

Description

Technical Field

[0001] This utility model relates to a charger, and more particularly to an intelligent charger. Background Technology

[0002] With the large-scale application of autonomous mobile robots and collaborative robots in logistics warehousing and industrial manufacturing, traditional charging methods, due to their low energy replenishment efficiency and short battery life, are no longer sufficient to meet the demands of high-frequency operations. This has spurred the development of intelligent fast charging technology centered on a 48V system. The 48V voltage balances energy density and safety, and is compatible with the lithium iron phosphate battery packs commonly used in robots. Its charger technology exhibits three main characteristics: intelligent dynamic control, high-efficiency energy conversion, and scenario-based integration capabilities. Current mainstream solutions are trending towards higher power, standardized protocols, and lightweight integration, while also facing challenges such as the diversity of battery chemistry systems and long-term stability under complex operating conditions. Some products have obtained CE / UL certification, becoming a key supporting technology for cost reduction and efficiency improvement in the robotics industry.

[0003] Chinese patent application number "2018216015250" discloses an intelligent charger. This utility model discloses an intelligent charger that, by setting a power factor correction circuit and a phase-shifted full-bridge zero-voltage switching circuit, adjusts the output voltage by ensuring the difference between the conduction angles of the leading and lagging bridge arms falls within a preset range. The switching transistors can be turned on or off under zero voltage or zero current conditions, thereby reducing switching losses and noise and improving the switching efficiency of the phase-shifted full-bridge zero-voltage switching circuit. However, in actual products, there are still some substantial technical defects. For example, while this intelligent charger improves switching efficiency, it only focuses on the power conversion stage, lacking a systematic design for input voltage detection, PFC control, and auxiliary power supply. The control accuracy and flexibility of the control system are very limited in actual operation, and the circuit architecture is concentrated in the power conversion stage, resulting in high coupling between modules, poor scalability, and difficulty in adapting to the charging needs of different battery specifications. Utility Model Content

[0004] The purpose of this invention is to provide an intelligent charger that not only adopts a modular architecture to improve the adaptability and maintainability of the charger, but also can detect and control power conversion and realize closed-loop feedback. Furthermore, it has autonomous decision-making capabilities and human-computer interaction functions, thereby improving the control accuracy and flexibility of the control system and solving the problems in the prior art.

[0005] To achieve the above objectives, this utility model employs the following technical solution:

[0006] A smart charger includes a control module, an input protection module connected to the control module, and an output processing module connected to the input protection module. The input protection module includes a surge protection circuit and an EMI filter. The output processing module includes an output rectification and filtering circuit, an output EMI circuit, and a battery reverse connection protection circuit. A power conversion module is provided between the input protection module and the output processing module. The power conversion module includes a PFC control unit electrically connected to the input protection module, a rectifier unit for rectifying and converting the input AC power to DC power, and a detection unit for the PFC output voltage. An AC voltage sampling circuit for sampling the input AC signal is provided between the input protection module and the PFC control unit. The AC voltage sampling circuit includes a soft-start circuit and a high-voltage rectification circuit.

[0007] Furthermore, the PFC control unit is electrically connected to an auxiliary power supply unit at its rear end. The auxiliary power supply unit includes a power control circuit and a buck circuit for converting the voltage boosted by the PFC rectifier unit to supply power to the control circuit and control chip of the low-voltage system.

[0008] Furthermore, the detection unit is electrically connected to a DC-DC converter circuit at its rear end to step down the high-voltage DC power to a low-voltage DC power.

[0009] Furthermore, the control module includes an LLC control unit and a charging management control unit. The control module is electrically connected to the rectifier unit, the DC-DC converter circuit, and the battery reverse connection protection circuit, respectively, and is used to collect voltage and current signals and output control commands.

[0010] Furthermore, the control module is connected to a display device for displaying the device status of the charger.

[0011] Furthermore, the PFC control unit includes a PFC control circuit and a drive circuit.

[0012] The beneficial effects of this utility model are as follows: This utility model uses standardized interface connections for input protection, power conversion, output processing, and control modules. Each module can be independently replaced or upgraded to adapt to different power requirements or battery specifications, improving the adaptability of the charger. Through power factor correction technology, the distilled DC voltage is boosted to a stable high-voltage DC, ensuring that the input current and voltage are in phase, significantly reducing grid harmonic pollution and improving energy utilization. The soft-start circuit in the AC voltage sampling circuit suppresses the surge current at the moment of power-on, avoiding impact on power devices such as the rectifier unit and PFC control unit. The high-voltage rectifier circuit ensures stable rectification of high-voltage input, improving the charger's adaptability to a wide range of input voltages. Attached Figure Description

[0013] Figure 1 A system principle block diagram of an intelligent charger provided by this utility model;

[0014] Figure 2 Circuit diagram of the input protection module of the intelligent charger provided by this utility model;

[0015] Figure 3 Circuit diagram of the AC voltage sampling circuit provided by this utility model;

[0016] Figure 4 The high-voltage rectifier circuit diagram provided by this utility model;

[0017] Figure 5 The overall circuit diagram of the PFC control unit provided by this utility model;

[0018] Figure 6 The overall circuit diagram of the rectifier unit provided by this utility model;

[0019] Figure 7 Overall circuit diagram of the auxiliary power supply unit provided by this utility model;

[0020] Figure 8 The overall circuit diagram of the detection unit provided by this utility model;

[0021] Figure 9 The overall circuit diagram of the LLC control unit provided by this utility model;

[0022] Figure 10 The overall circuit diagram of the charging management control unit provided by this utility model.

[0023] The diagram shows the following labels: 100, Control Module; 200, Input Protection Module; 210, Surge Protection Circuit; 220, EMI Filter; 300, Output Processing Module; 310, Rectifier and Filter Circuit; 320, Output EMI Circuit; 330, Battery Reverse Connection Protection Circuit; 400, Power Conversion Module; 410, PFC Control Unit; 411, PFC Control Circuit; 412, Drive Circuit; 420, Rectifier Unit; 430, Detection Unit; 500, AC Voltage Sampling Circuit; 510, Soft Start Circuit; 520, High Voltage Rectifier Circuit; 600, Auxiliary Power Supply Unit; 700, DC-DC Conversion Circuit. Detailed Implementation

[0024] To make the above-mentioned objectives, features, and advantages of this utility model more apparent and understandable, the specific embodiments of this utility model are described in detail below with reference to the accompanying drawings. Many specific details are set forth in the following description to provide a full understanding of this utility model. However, this utility model can be implemented in many other ways different from those described herein, and those skilled in the art can make similar modifications without departing from the spirit of this utility model. Therefore, this utility model is not limited to the specific embodiments disclosed below.

[0025] Example: Figures 1 to 10 The smart charger shown includes a control module 100, an input protection module 200 connected to the control module 100, and an output processing module 300 connected to the input protection module 200. The input protection module 200 includes a surge protection circuit 210 and an EMI filter 220. The output processing module 300 includes an output rectifier filter circuit 310, an output EMI circuit 320, and a battery reverse connection protection circuit 330. A power conversion module 400 is provided between the input protection module 200 and the output processing module 300. The power conversion module 400 includes components electrically connected to the input protection module 200. The PFC control unit 410, which is connected to the PFC control unit 410, the rectifier unit 420 which rectifies and converts the input AC power into DC power, and the detection unit 430 for the PFC output voltage are connected. An AC voltage sampling circuit 500 for sampling the input AC signal is provided between the input protection module 200 and the PFC control unit 410. The AC voltage sampling circuit 500 includes a soft start circuit 510 and a high voltage rectifier circuit 520. The output rectifier filter circuit 310, the output EMI circuit 320 and the battery reverse connection protection circuit 330 are conventional prior art circuit protection module designs, which will not be described in detail here.

[0026] Among them, such as Figure 2 In the surge protection circuit 210 shown, RV1, RV2, and RV3 are zinc oxide varistors. RV1 absorbs the differential-mode surge voltage between L and N. RV2, RV3, and the gas discharge tube X1 form common-mode surge protection between L and N and ground. At the mains input terminal of the EMI filter 220, a 1000pF Y1 capacitor is added to both L and N lines to ground to eliminate high-frequency interference. The X2 capacitors C3, C6, and C32 in the EMI filter 220 eliminate differential-mode interference, while C4 and C5 are common-mode capacitors used to eliminate common-mode interference.

[0027] The input protection module integrates surge protection circuitry (suppressing differential-mode / common-mode surge impacts) and EMI filter (filtering out high-frequency differential-mode / common-mode interference). This not only prevents damage to the charger's internal circuitry from power grid surges (such as lightning strikes or instantaneous high voltage caused by switching operations), but also reduces the charger's electromagnetic interference to the power grid and surrounding equipment, significantly improving reliability in complex power grid environments.

[0028] like Figure 3 The AC voltage sampling circuit shown samples and judges the input AC signal. The sampled signal is sent to the subsequent monitoring circuit to prevent the system input voltage from being too high or too low. When it is too high or too low, the subsequent charging circuit is shut down. Diodes VD2 and VD3 are connected in parallel with diodes VD4 and VD5, and then in series with resistors R9, R10, R12, and R13. Finally, it is connected with resistor R33, C22, and diode VD25 to form the input voltage sampling circuit. It samples the average value. The sampling voltage is 2.80V when the input voltage is 178V, 3.45V when the rated input voltage is 220V, and 4.45V when the input voltage is 285V. The soft-start circuit 510 is composed of R78, K1, and VD7. In addition, R31, R56, R57, and R58 are discharge resistors to ensure that the rectified voltage reaches zero at the zero-crossing point, thereby improving the sampling accuracy of the average voltage.

[0029] like Figure 4 The high-voltage rectifier circuit 520 shown is a bridge rectifier circuit used to rectify the input 220V AC power into 310V high-voltage DC power. Specifically, the AC power is input from pins 2 and 3 of the rectifier bridge BD2, and after rectification, 310V high-voltage DC power is output from pins 1 and 4.

[0030] like Figure 5 The PFC control unit 410 shown includes a PFC control circuit 411 and a drive circuit 412. The chip of the PFC control circuit 411 is a continuous conduction mode power factor correction controller chip of model ICE3PCS01G. In addition to controlling the input current, this chip also has functions such as input undervoltage, input overvoltage, and PFC output overvoltage protection. The PFC control unit is equipped with a drive circuit 412. The chip of the drive circuit 412 is a non-isolated gate driver chip of model 2EDN7524. The 13th pin of the controller chip of the PFC control unit is connected to the second pin of the driver chip through resistor R19.

[0031] like Figure 6 The rectifier unit 420 shown is a boost circuit used to further boost the rectified DC310V output to DC400V. The rectified DC310V is input from POWER and AGND, boosted to DC400V by PFC, and then output from PFC+ and AGND and connected to PFC control unit 410.

[0032] The PFC control unit 410 uses power factor correction technology to boost the rectified DC voltage to a stable high-voltage DC, making the input current and voltage in phase and the power factor close to 1. This significantly reduces grid harmonic pollution and improves energy utilization by 10%-15% compared to traditional chargers. The detection unit 430 monitors the PFC output voltage in real time and works with the control module to achieve closed-loop feedback, ensuring stable high-voltage DC output and preventing damage to the downstream DC-DC conversion circuit due to voltage fluctuations, thus extending the equipment's lifespan.

[0033] In this embodiment, as Figure 7 The PFC control unit 410 shown is electrically connected to an auxiliary power supply unit 600 at its rear end. The auxiliary power supply unit 600 includes a power control circuit and a buck circuit for converting the voltage boosted by the PFC rectifier unit 420 to power the control circuit and control chip of the low-voltage system. Specifically, the chip D1 of the auxiliary power supply unit 600 is a power control chip of model ICE3AR1080VJZ. This chip has a built-in 800V MOSFET. The auxiliary power supply is set to start working when the output is 100Vac. VCC powers the PFC control circuit with an output of 12V / 0.2A, VCC-F powers the fan with an output of 12V / 0.5A, and VCC-D powers the output control circuit and battery management hardware circuit with an output of 12V / 0.3A.

[0034] In this embodiment, as shown in FIG8, the detection unit 430 is electrically connected to a DC-DC converter circuit 700 at its rear end to step down 400V high voltage DC to 60V low voltage DC.

[0035] In addition, such as Figure 9 , Figure 10 The control module 100 shown includes an LLC control unit and a charging management control unit. The control module 100 is electrically connected to the rectifier unit 420, the DC-DC converter circuit, and the battery reverse connection protection circuit 330, respectively. It is used to collect voltage and current signals and output control commands. The LLC control unit chip D2 is a 32-bit microcontroller of model TMS320F28035. The LLC control unit is driven by a second drive circuit. The second drive circuit chip D1J is a driver chip of model 2EDN7524. Pin 11 of D2 is connected to pin 2 of D1J through resistor R11, and pin 14 of D2 is connected to pin 4 of D1J through resistor R12. The charging management control unit chip is a control chip of model TMS320F28035.

[0036] The control module 100, through electrical connection with the input protection module 200, the power conversion module 400, and the output processing module 300, realizes real-time acquisition and analysis of input voltage, PFC output voltage, DC-DC output voltage / current, and battery status, dynamically adjusts charging parameters (such as constant current-constant voltage mode switching), and supports functions such as automatic shutdown (battery fully charged) and standby mode (battery disconnected), thereby improving the intelligence level of the charging process and the user experience.

[0037] This intelligent charger's technical solution significantly improves the charger's safety, energy efficiency, and reliability through end-to-end protection, high-efficiency energy conversion, and intelligent control. It is suitable for scenarios with high requirements for charging stability, such as industrial robots and energy storage devices, and has outstanding practical value.

[0038] The foregoing has shown and described the basic principles, main features, and advantages of this utility model. It will be apparent to those skilled in the art that this utility model is not limited to the details of the exemplary embodiments described above, and that it can be implemented in other specific forms without departing from the spirit or basic characteristics of this utility model. Therefore, the embodiments should be considered exemplary and non-limiting in all respects. The scope of this utility model is defined by the appended claims rather than the foregoing description. Therefore, it is intended that all variations falling within the meaning and scope of equivalents of the claims be included within this utility model, and no reference numerals in the claims should be construed as limiting the scope of the claims.

[0039] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A smart charger, comprising a control module, an input protection module connected to the control module, and an output processing module connected to the input protection module, wherein the input protection module includes a surge protection circuit and an EMI filter, and the output processing module includes an output rectification and filtering circuit, an output EMI circuit, and a battery reverse connection protection circuit, characterized in that: A power conversion module is provided between the input protection module and the output processing module. The power conversion module includes a PFC control unit electrically connected to the input protection module, a rectifier unit that rectifies and converts the input AC power into DC power, and a detection unit for the PFC output voltage. An AC voltage sampling circuit for sampling the input AC signal is provided between the input protection module and the PFC control unit. The AC voltage sampling circuit includes a soft-start circuit and a high-voltage rectifier circuit.

2. The intelligent charger according to claim 1, characterized in that: The PFC control unit is electrically connected to an auxiliary power supply unit at its rear end. The auxiliary power supply unit includes a power control circuit and a buck circuit for converting the voltage boosted by the PFC rectifier unit to supply power to the control circuit and control chip of the low-voltage system.

3. The intelligent charger according to claim 1, characterized in that: The detection unit is electrically connected to a DC-DC converter circuit at its rear end to step down the high-voltage DC power to a low-voltage DC power.

4. The intelligent charger according to claim 3, characterized in that: The control module includes an LLC control unit and a charging management control unit. The control module is electrically connected to the rectifier unit, the DC-DC converter circuit and the battery reverse connection protection circuit, respectively, and is used to collect voltage and current signals and output control commands.

5. The intelligent charger according to claim 4, characterized in that: The control module is connected to a display device to display the device status of the charger.

6. The intelligent charger according to claim 1, characterized in that: The PFC control unit includes a PFC control circuit and a drive circuit.

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