Extensible split charging pile

Abstract

The utility model relates to the technical field of charging piles, in particular to an extensible split charging pile, which comprises a cabinet body, a left cavity and a right cavity are arranged in the cabinet body, the left cavity is provided with a first power conversion module mounting position and a second power conversion module mounting position along the height direction of the cabinet body, and the right cavity is provided with a third power conversion module mounting position and a fourth power conversion module mounting position along the height direction of the cabinet body. A power distribution assembly mounting position is arranged below the left cavity and the right cavity; the power conversion modules in the first to fourth power conversion module mounting positions are spliced and mounted through pluggable high-voltage connectors; a support body is arranged in the power distribution assembly installation position, each power conversion module is correspondingly provided with a set of contactors and a set of direct current outlet copper bars, all the contactors are arranged on the support body and correspondingly connected in series through bridging copper bars to form an annular loop, and all the direct current outlet copper bars are connected into the annular loop through the bridging copper bars. According to the utility model, the modular layout and flexible expansion of the power conversion module and the power distribution assembly can be realized, and the expandability of the charging pile is improved.

Description

Technical Field

[0001] This utility model relates to the field of charging pile technology, and more specifically, to an expandable split charging stack. Background Technology

[0002] In the current field of charging piles, traditional charging piles generally adopt an integrated design architecture. This design mode, with its highly integrated and tightly interconnected functional modules, exposes significant shortcomings in practical applications. On the one hand, when users have power expansion needs, the rigid internal structure and compact module layout make it difficult to flexibly expand key components such as the power conversion module, failing to effectively cope with the ever-increasing charging load demands and greatly limiting the upgrade potential of the charging pile. On the other hand, if a part of the charging pile malfunctions, its integrated structure necessitates a complete shutdown for repair. Repair requires checking, disassembling, and replacing all modules, resulting in a cumbersome, time-consuming, and labor-intensive repair process, as well as prolonged charging service interruptions, severely impacting user experience and operational efficiency.

[0003] With the rapid development of the new energy industry, the market has placed higher demands on the flexibility, scalability, and ease of maintenance of charging stacks. The traditional integrated charging stack design is no longer able to meet the industry's development trends, thus necessitating a solution that can support the rapid expansion of charging stack functional modules. Utility Model Content

[0004] The purpose of this invention is to provide an expandable split charging stack. By dividing the cabinet cavity and setting multiple mounting positions, the power conversion modules are spliced ​​using pluggable high-voltage connectors. A ring circuit is formed using the bracket body, contactor, DC output copper busbar, and bridging copper busbar. This not only realizes the modular layout and flexible expansion of the power conversion modules, but also provides a convenient foundation for the expansion of the DC output modules. When expanding the DC output modules, they can be directly connected to the ring circuit through the bridging copper busbar without large-scale modification of the overall circuit, greatly reducing the difficulty and cost of expansion. This solves the technical problem of how to improve the flexibility, expandability, and maintenance convenience of the charging stack.

[0005] This utility model is achieved through the following technical solution: an expandable split charging stack, including a cabinet, wherein a left cavity and a right cavity are spaced apart along the length direction inside the cabinet, a first power conversion module mounting position and a second power conversion module mounting position are arranged sequentially along the height direction of the cabinet in the left cavity, a third power conversion module mounting position and a fourth power conversion module mounting position are arranged sequentially along the height direction of the cabinet in the right cavity, and a power distribution component mounting position is arranged below the left cavity and the right cavity;

[0006] Each of the first to fourth power conversion module mounting positions is provided with multiple accommodating spaces for accommodating power conversion modules, and each power conversion module is spliced ​​and installed through a pluggable high-voltage connector;

[0007] The power distribution component mounting position is provided with a bracket body. Each power conversion module is provided with a set of contactors and DC output copper busbars. Each contactor is arranged on the bracket body and connected in series with a bridging copper busbar to form a loop. Each DC output copper busbar is connected to the loop through the bridging copper busbar.

[0008] According to a preferred embodiment, a middle cavity is provided between the left cavity and the right cavity, and the middle cavity has two mounting surfaces, one on the front and one on the back.

[0009] According to a preferred embodiment, the first mounting surface of the central cavity is provided with a leakage protection and surge protection plate mounting position and an AC wiring board mounting position arranged sequentially along the height direction of the cabinet, and the second mounting surface of the central cavity is provided with a power supply board mounting position and a control main board mounting position arranged sequentially along the height direction of the cabinet.

[0010] According to a preferred embodiment, the leakage protection surge protector, power supply board, AC terminal block, and control main board are all installed in their respective mounting positions using a slide rail mounting method.

[0011] According to a preferred embodiment, the cabinet is provided with a top-level crossbeam, a first-level crossbeam, and a second-level crossbeam at intervals from top to bottom along the cabinet height direction. A first partition and a second partition extending along the cabinet height direction are provided between the top-level crossbeam and the second-level crossbeam. The first partition and the second partition are spaced apart, dividing the space between the top-level crossbeam and the first-level crossbeam into a first power conversion module installation position, a leakage protection and surge protection board installation position, a power supply board installation position, and a third power conversion module installation position. The space between the first-level crossbeam and the second-level crossbeam is divided into a second power conversion module installation position, an AC junction box installation position, a control motherboard installation position, and a fourth power conversion module installation position.

[0012] According to a preferred embodiment, the front end of the top beam has a first contact surface that is in contact with the positive terminal of the first power conversion module in the mounting position of the first power conversion module; the front end of the first beam has a second contact surface that is in contact with the negative terminal of the first power conversion module and the positive terminal of the second power conversion module in the mounting position of the second power conversion module; and the rear end of the second beam has a third contact surface that is in contact with the negative terminal 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, each group of contactors consists of a first contactor connected to the positive output terminal of the power conversion module and a second contactor connected to the negative output terminal of the power conversion module. The support body consists of a first support body and a second support body arranged in parallel at intervals. Each first contactor is arranged on the first support body, and each second contactor is arranged on the second support body. Contactors located on the same first support body or second support body and adjacent to each other are connected sequentially by bridging copper busbars.

[0015] According to a preferred embodiment, the bridging copper busbar has a first main body region and first ends located at both ends of the first main body region;

[0016] The first end has a first mounting hole adapted to the contactor;

[0017] The first main body area is provided with a plurality of first connection holes that are adapted to the first end of the DC output copper busbar at intervals along its length.

[0018] According to a preferred embodiment, the ring circuit includes an upper circuit formed on a first support body and a lower circuit formed on a second support body. Both the upper circuit and the lower circuit include a forward section, a transition section, and a return section formed by a contactor and a bridging copper busbar. The forward section and the return section are arranged in parallel, and the transition section connects the forward section and the return section.

[0019] The DC output copper busbar includes a first output copper busbar connected to the outgoing section and a second output copper busbar connected to the return section, with the first output copper busbar and the second output copper busbar arranged alternately.

[0020] The scalable split charging stack provided by this utility model has at least the following advantages and beneficial effects: By dividing the cabinet cavity and setting multiple installation positions, this utility model uses pluggable high-voltage connectors to splice power conversion modules, and uses the bracket body, contactor, DC output copper busbar and bridging copper busbar to form a ring circuit. This not only realizes the modular layout and flexible expansion of the power conversion module, but also provides a convenient foundation for the expansion of the DC output module. When expanding the DC output module, it can be directly connected to the ring circuit through the bridging copper busbar without large-scale modification of the overall circuit, which greatly reduces the difficulty and cost of expansion. Attached Figure Description

[0021] Figure 1 Rear view of the expandable split charging stack provided in Embodiment 1 of this utility model;

[0022] Figure 2 A front view of the expandable split charging stack provided in Embodiment 1 of this utility model;

[0023] Figure 3 Rear view of the power distribution component provided in Embodiment 1 of this utility model;

[0024] Reference numerals: 1-First power conversion module mounting position, 2-Second power conversion module mounting position, 3-Third power conversion module mounting position, 4-Fourth power conversion module mounting position, 5-Power distribution component mounting position, 6-Residual current protection and surge protection board mounting position, 7-AC junction box mounting position, 8-Power supply board mounting position, 9-Control main board mounting position, 10-Top beam, 11-First floor beam, 12-Second floor beam, 13-First partition, 14-Second partition, 15-First support body, 16-Second support body, 17-First contactor, 18-Second contactor, 19-Bridging copper busbar, 20-First outgoing busbar, 21-Second outgoing busbar. Detailed Implementation

[0025] 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.

[0026] Example 1

[0027] To improve the flexibility, scalability, and ease of maintenance of the charging stack, this utility model provides a scalable split charging stack.

[0028] The expandable split charging stack provided in this embodiment includes a cabinet, and the cabinet has a left cavity and a right cavity spaced apart along its length.

[0029] Among them, see Figure 1 and Figure 2 As shown, the left cavity has a first power conversion module mounting position 1 and a second power conversion module mounting position 2 arranged sequentially along the height of the cabinet, and the right cavity has a third power conversion module mounting position 3 and a fourth power conversion module mounting position 4 arranged sequentially along the height of the cabinet. The first power conversion module mounting position 1 and the second power conversion module mounting position 2, and the third power conversion module mounting position 3 and the fourth power conversion module mounting position 4 are all separated by partitions.

[0030] Furthermore, each of the first to fourth power conversion module mounting positions 4 is provided with multiple accommodating spaces for accommodating power conversion modules, and each power conversion module is spliced ​​and installed via a pluggable high-voltage connector.

[0031] The power distribution component mounting positions 5 are arranged below the left cavity and the right cavity; in some embodiments, the power distribution component mounting positions 5 are provided with a bracket body, and each power conversion module is provided with a set of contactors and DC output copper busbars respectively. Each contactor is arranged on the bracket body and connected in series through the bridging copper busbar 19 to form a ring circuit. Each DC output copper busbar is connected to the ring circuit through the bridging copper busbar 19.

[0032] Specifically, this embodiment divides the cabinet cavity, sets multiple mounting positions, uses pluggable high-voltage connectors to splice power conversion modules, and uses the bracket body, contactor, DC output copper busbar and bridging copper busbar 19 to form a ring circuit. This not only realizes the modular layout and flexible expansion of the power conversion module, but also provides a convenient foundation for the expansion of the DC output module. When expanding the DC output module, it can be directly connected to the ring circuit through the bridging copper busbar 19 without large-scale modification of the overall circuit, which greatly reduces the difficulty and cost of expansion.

[0033] Example 2

[0034] This embodiment, based on the technical solution provided in Embodiment 1, further explains the expandable structure provided by the cabinet:

[0035] In this embodiment, a middle cavity is provided between the left cavity and the right cavity, and the middle cavity has two mounting surfaces, one on the front and one on the back. The first mounting surface of the middle cavity is arranged with a leakage protection and surge protection plate mounting position 6 and an AC wiring board mounting position 7 along the height direction of the cabinet. The second mounting surface of the middle cavity is arranged with a power supply board mounting position 8 and a control main board mounting position 9 along the height direction of the cabinet. Preferably, the leakage protection and surge protection plate, the power supply board, the AC wiring board and the control main board are all installed in their respective mounting positions using a sliding rail mounting method.

[0036] Specifically, the use of a sliding rail mounting method for the leakage protection and surge protection board, power supply board, AC wiring board, and control main board enables rapid positioning and installation of functional modules, improving installation efficiency and shortening maintenance time. When it is necessary to expand the power conversion module or power distribution component, the sliding rail mounting method facilitates the rapid relocation and adjustment of the relevant modules, further enhancing the scalability of the charging stack.

[0037] In some embodiments, the cabinet is provided with a top-level crossbeam 10, a first-level crossbeam 11, and a second-level crossbeam 12 at intervals from top to bottom along the cabinet height direction. A first partition 13 and a second partition 14 extending along the cabinet height direction are provided between the top-level crossbeam 10 and the second-level crossbeam 12. The first partition 13 and the second partition 14 are spaced apart, dividing the space between the top-level crossbeam 10 and the first-level crossbeam 11 into a first power conversion module installation position 1, a leakage protection and surge protection board installation position 6, a power supply board installation position 8, and a third power conversion module installation position 3. The space between the first-level crossbeam 11 and the second-level crossbeam 12 is divided into a second power conversion module installation position 2, an AC junction box installation position 7, a control motherboard installation position 9, and a fourth power conversion module installation position 4.

[0038] Furthermore, the front end of the top beam 10 has a first contact surface that is in contact with the positive terminal output of the first power conversion module in the first power conversion module mounting position 1, providing a directional cable management channel and a contact fixing surface for the positive terminal output of the first power conversion module.

[0039] The front end of the first-layer crossbeam 11 has a second contact surface that is in contact with the negative terminal output of the first power conversion module and the positive terminal output of the second power conversion module in the mounting position 2 of the second power conversion module, 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; the rear end of the second-layer crossbeam 12 has a third contact surface that is in contact with the negative terminal output of the second power conversion module, providing a directional cable management channel and a contact fixing surface for the negative terminal output of the second power conversion module.

[0040] Specifically, in this embodiment, cable tie fixing holes are provided on the first, second, and third bonding surfaces. The cable tie fixing holes on the first, second, and third bonding surfaces provide standardized fixing points for cable bundling, achieving rigid fixing of flexible cables. This design can effectively suppress the risk of cable wear caused by electromagnetic vibration during fuel cell operation, while facilitating 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.

[0041] Example 3

[0042] This embodiment further illustrates the scalable design of the power distribution component based on the technical solutions provided in any one of Embodiments 1 to 2:

[0043] In this embodiment, see Figure 3As shown, each group of contactors consists of a first contactor 17 connected to the positive output terminal of the power conversion module and a second contactor 18 connected to the negative output terminal of the power conversion module. The support body consists of a first support body 15 and a second support body 16 arranged in parallel at intervals. Each first contactor 17 is arranged on the first support body 15, and each second contactor 18 is arranged on the second support body 16. The contactors located on the same first support body 15 or second support body 16 and adjacent to each other are connected sequentially by bridging copper busbars 19.

[0044] Specifically, in this embodiment, the first contactor 17 and the second contactor 18 are arranged on the upper and lower brackets respectively, so that the positive and negative circuits are separated in the vertical space, avoiding the staggered arrangement of positive and negative contactors in the same plane, reducing the electrical spacing requirements between adjacent contactors, thereby enabling more contactors to be expanded in a unit area, thereby increasing the total power.

[0045] Furthermore, the bridging copper busbar 19 has a first main body area and first ends located at both ends of the first main body area; wherein, the first ends are provided with first mounting holes adapted to the contactor; and a plurality of first connection holes adapted to the first ends of the DC output copper busbar are provided at intervals along the length direction of the first main body area.

[0046] This embodiment forms a standardized interface by opening mounting holes adapted to the contactor at the first end of the bridging copper busbar 19 and connection holes adapted to the outgoing copper busbar in the first main body area. This allows for quick and easy fixing of the contactor to the copper busbar and the outgoing copper busbar to the loop circuit through pre-drilled holes, avoiding on-site measurement and custom wiring, thus improving assembly accuracy and efficiency. In addition, multiple connection holes are set at intervals along the length of the bridging copper busbar 19, allowing outgoing copper busbars to be led out at different positions according to power distribution requirements. This adapts to the power distribution of multiple charging terminals, enabling flexible configuration of multiple outgoing lines in one circuit, and improving the flexibility, scalability, and adaptability of power distribution to cabinet space.

[0047] In some preferred embodiments, the annular circuit includes an upper circuit formed on the first support body 15 and a lower circuit formed on the second support body 16. Both the upper and lower circuits include a forward section, a transition section, and a return section formed by a contactor and a bridging copper busbar 19. The forward section and the return section are arranged in parallel, and the transition section connects the forward section and the return section. The DC output copper busbar includes a first output copper busbar connected to the forward section and a second output copper busbar connected to the return section. The first output copper busbar and the second output copper busbar are arranged alternately.

[0048] Specifically, in this embodiment, both the upper and lower circuits include a parallel symmetrical structure with outgoing, transition, and return segments, which ensures that positive and negative currents are evenly distributed between the upper and lower layers, reducing circuit inductance and electromagnetic interference. At the same time, the parallel outgoing and return segments can form a low-impedance path, improving the stability of high-current transmission. In addition, the first and second outgoing copper busbars are arranged alternately, forming an orderly copper busbar wiring area in the wiring area, which can avoid the spatial overlap of positive and negative outgoing copper busbars, reduce wiring difficulty and short-circuit risk, and facilitate cable differentiation during later maintenance.

[0049] 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 scalable, modular charging stack, characterized in that, The cabinet includes a left cavity and a right cavity spaced apart along its length. The left cavity has a first power conversion module mounting position (1) and a second power conversion module mounting position (2) arranged sequentially along the height of the cabinet. The right cavity has a third power conversion module mounting position (3) and a fourth power conversion module mounting position (4) arranged sequentially along the height of the cabinet. The power distribution component mounting position (5) is arranged below the left and right cavities. Each of the first to fourth power conversion module mounting positions (4) is provided with multiple accommodating spaces for accommodating power conversion modules, and each power conversion module is spliced ​​and installed by plug-in high voltage connectors; The power distribution component mounting position (5) is provided with a bracket body. Each power conversion module is provided with a set of contactors and DC output copper busbars. Each contactor is arranged on the bracket body and connected in series with the bridging copper busbar (19) to form a ring circuit. Each DC output copper busbar is connected to the ring circuit through the bridging copper busbar (19).

2. The scalable split-type charging stack as described in claim 1, characterized in that, A middle cavity is provided between the left cavity and the right cavity, and the middle cavity has two mounting surfaces, one on the front and one on the back.

3. The scalable split-type charging stack as described in claim 2, characterized in that, The first mounting surface of the middle cavity is provided with a leakage protection and surge protection plate mounting position (6) and an AC wiring board mounting position (7) arranged sequentially along the height direction of the cabinet. The second mounting surface of the middle cavity is provided with a power supply board mounting position (8) and a control main board mounting position (9) arranged sequentially along the height direction of the cabinet.

4. The scalable split-type charging stack as described in claim 3, characterized in that, The leakage protection surge protector, power supply board, AC junction box, and control main board are all installed in their respective mounting positions using a sliding rail method.

5. The scalable split-type charging stack as described in claim 3, characterized in that, The cabinet is provided with a top-level crossbeam (10), a first-level crossbeam (11), and a second-level crossbeam (12) at intervals from top to bottom along the height direction of the cabinet. A first partition (13) and a second partition (14) extending along the height direction of the cabinet are provided between the top-level crossbeam (10) and the second-level crossbeam (12). The first partition (13) and the second partition (14) are spaced apart, dividing the space between the top-level crossbeam (10) and the first-level crossbeam (11) into a first power conversion module installation position (1), a leakage protection and lightning protection board installation position (6), a power supply board installation position (8), and a third power conversion module installation position (3). The space between the first-level crossbeam (11) and the second-level crossbeam (12) is divided into a second power conversion module installation position (2), an AC wiring board installation position (7), a control motherboard installation position (9), and a fourth power conversion module installation position (4).

6. The scalable split-type charging stack as described in claim 5, characterized in that, The front end of the top beam (10) has a first contact surface that is in contact with the positive terminal of the first power conversion module in the first power conversion module mounting position (1). The front end of the first layer beam (11) has a second contact surface that is in contact with the negative terminal of the first power conversion module and the positive terminal of the second power conversion module in the second power conversion module mounting position (2). The rear end of the second layer beam (12) has a third contact surface that is in contact with the negative terminal of the second power conversion module.

7. The scalable split-type charging stack as described in claim 6, characterized in that, Cable tie fixing holes are provided on the first, second and third bonding surfaces.

8. The scalable modular charging stack as described in any one of claims 1 to 7, characterized in that, Each group of contactors consists of a first contactor (17) connected to the positive output terminal of the power conversion module and a second contactor (18) connected to the negative output terminal of the power conversion module. The support body consists of a first support body (15) and a second support body (16) arranged in parallel at intervals. Each first contactor (17) is arranged on the first support body (15), and each second contactor (18) is arranged on the second support body (16). Contactors located on the same first support body (15) or second support body (16) and adjacent to each other are connected sequentially by a bridging copper busbar (19).

9. The scalable split-type charging stack as described in claim 8, characterized in that, The bridging copper busbar (19) has a first main body area and first ends located at both ends of the first main body area; The first end has a first mounting hole adapted to the contactor; The first main body area is provided with a plurality of first connection holes that are adapted to the first end of the DC output copper busbar at intervals along its length.

10. The scalable split-type charging stack as described in claim 9, characterized in that, The ring circuit includes an upper circuit formed on the first support body (15) and a lower circuit formed on the second support body (16). The upper circuit and the lower circuit each include a forward section, a transition section and a return section formed by a contactor and a bridging copper busbar (19). The forward section and the return section are arranged in parallel, and the transition section is connected between the forward section and the return section. The DC output copper busbar includes a first output copper busbar connected to the outgoing section and a second output copper busbar connected to the return section, with the first output copper busbar and the second output copper busbar arranged alternately.

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