Integrated direct current charger

Abstract

The utility model discloses an integrated direct current charger, which is characterized by comprising a power module bin, a power distribution contactor matrix bin and an independent air duct system, power distribution contactor groups arranged in a rectangular matrix are arranged in the power distribution contactor matrix bin, each group of power distribution contactors is correspondingly connected with the output end of a single power module, the matrix arrangement direction is consistent with the output direction of the power module, and the power distribution contactor matrix bin and the power module bin are separated by a partition plate; the compact and modularized integrated direct current charger provided by the utility model solves the problems of low heat dissipation efficiency, difficult maintenance and inflexible power distribution in the prior art by optimizing the matrix layout of the power distribution contactors, the independent air duct heat dissipation system and the intelligent temperature control technology.

Description

Technical Field

[0001] This utility model relates to the field of electric vehicle charging equipment technology, specifically to an integrated DC charger. Background Technology

[0002] With the rapid development of the electric vehicle industry, high-power DC fast charging technology has become a core requirement for improving user experience. However, existing charging equipment still faces the following technical bottlenecks in terms of heat dissipation design and temperature control systems for power distribution modules:

[0003] 1. Low heat dissipation efficiency and thermal management deficiencies:

[0004] Traditional chargers typically use a linear or distributed arrangement of power distribution contactor matrices, leading to the following problems:

[0005] Simple airflow design: Most equipment uses unidirectional airflow (e.g., only front intake and rear exhaust), resulting in a single airflow path and a tendency to create a heat island effect in the contactor matrix area. Especially when multiple modules are operating in parallel, local temperatures can exceed 85°C, accelerating component aging. Inadequate heat dissipation structure: The contactor matrix airflow outlet lacks a guiding design, causing airflow to directly impact the cabinet casing, leading to energy loss. Although some products use a straight-plate guiding structure, the airflow direction is not optimized, and the heat dissipation fins are perpendicular to the airflow angle, resulting in a heat exchange efficiency of less than 60%. High copper busbar connection losses: The copper busbar length between the contactor and the power module generally exceeds 300mm, increasing line impedance and causing an overall efficiency decrease of approximately 3%-5% in the power distribution module.

[0006] 2. Delayed temperature control system and energy waste:

[0007] The existing temperature control solutions for chargers have the following shortcomings:

[0008] Limited monitoring scope: Only a few temperature sensors are installed at the duct outlet, failing to cover high-temperature areas such as contactor contacts and copper busbar connection points. Experimental data shows that traditional monitoring networks can have a response delay of over 30 seconds to localized overheating (such as contactor contact temperature exceeding limits); Inefficient fan control: Fixed-speed fans or segmented speed regulation are used, failing to dynamically match the actual load. For example, in low-temperature environments or with low power output, the fan still operates at its rated speed, resulting in energy waste of over 40%; Lack of PID control: Although some products incorporate temperature feedback, they lack closed-loop control algorithms, leading to temperature fluctuations of ±5℃, impacting component lifespan.

[0009] 3. Insufficient ease of maintenance and modularity:

[0010] Traditional designs have the following limitations in terms of maintenance and scalability:

[0011] Contactor maintenance is complex: the entire housing or power module needs to be disassembled to repair the contactor matrix, and a single maintenance takes more than 2 hours; Electromagnetic interference (EMI) problems: the contactor matrix and power module compartment are not effectively isolated, resulting in control signal interference and an increased malfunction rate; Poor frame scalability: the main power module and auxiliary equipment (such as the control board) are integrated into one design, and the entire equipment needs to be replaced during upgrades, increasing user costs.

[0012] To address the aforementioned issues, this invention proposes a compact, modular integrated DC charger. By optimizing the power distribution contactor matrix layout, the independent airflow cooling system, and intelligent temperature control technology, it solves the problems of low heat dissipation efficiency, difficult maintenance, and inflexible power distribution in existing technologies. Utility Model Content

[0013] The purpose of this utility model is to provide an integrated DC charger that addresses the aforementioned problems by optimizing the power distribution contactor matrix layout, the independent air duct heat dissipation system, and intelligent temperature control technology, thereby solving the problems of low heat dissipation efficiency, difficult maintenance, and inflexible power distribution in the prior art.

[0014] The technical solution of this utility model is as follows:

[0015] This utility model discloses an integrated DC charger, comprising a power module compartment, a power distribution contactor matrix compartment, and an independent air duct system; the power distribution contactor matrix compartment is provided with a rectangular matrix arrangement of power distribution contactor groups, each group of power distribution contactors being connected to the output terminal of a single power module, the matrix arrangement direction being consistent with the output direction of the power module, and the power distribution contactor matrix compartment and the power module compartment being separated by a partition.

[0016] The power module compartment and the contactor matrix compartment are physically separated by a partition, which reduces the impact of electromagnetic interference generated by the power module during operation on the contactor signal transmission and improves equipment stability. The power module and contactor matrix are arranged in separate zones to avoid heat cross-transfer, reduce the ambient temperature of the contactor matrix area and extend the life of components. The contactor matrix adopts a rectangular matrix arrangement with the direction consistent with the output direction of the power module, which minimizes the copper busbar connection path and reduces line impedance and power loss.

[0017] Furthermore, the independent air duct system includes a left-side power module air duct and a right-side power distribution contactor matrix air duct. The power module air duct inlet is located at the bottom front of the cabinet, and the outlet is located at the top rear of the cabinet. The power distribution contactor matrix air duct inlet is located at the bottom rear of the cabinet, and the outlet is located at the top front of the cabinet, forming a cross-convective air duct structure. Air enters from the bottom front and exits from the top rear, utilizing the natural rising characteristics of cold air to form a vertical airflow covering the module surface and directly carrying away the heat from the core heat source. The contactor matrix inlets from the bottom rear and exits from the top front, forming cross-convective airflow with the left-side air duct, creating a negative pressure zone at the top front of the cabinet to accelerate the exhaust of hot air and prevent hot air recirculation. The cross-duct design breaks the problem of hot air stagnation in traditional unidirectional air ducts.

[0018] Furthermore, an S-shaped airflow guide plate is provided at the air duct outlet of the power distribution contactor matrix. The surface of the airflow guide plate is arrayed with fish-fin-shaped heat dissipation fins. These fins form an angle of 15°-30° with the airflow direction. The S-shaped airflow guide plate transforms the turbulent flow at the air duct outlet into laminar flow, ensuring uniform airflow coverage of the contactor matrix surface and avoiding localized airflow dead zones. The fish-fin-shaped heat dissipation fin array increases the surface area by 40% compared to traditional straight-plate fins. Combined with the 15°-30° airflow angle design, it enhances airflow disturbance and improves the convective heat transfer coefficient. Simultaneously, the S-shaped structure reduces vibration noise generated by direct airflow impacting the cabinet casing.

[0019] Furthermore, the power distribution contactor matrix includes at least nine groups of contactor units arranged side by side, each group of contactor units having a rated switching power of 40kW. The contactor units are directly connected to the output terminals of the corresponding power modules via copper busbars, the length of which is ≤200mm. The nine groups of side by side contactor units support a rated switching power of 40kW, and dynamic combination of multiple power modules can be achieved through independent control to meet different charging needs. With a copper busbar length of ≤200mm, the line impedance is reduced to below 0.1mΩ, reducing energy loss during power distribution. The short copper busbar also reduces thermal expansion and contraction deformation, lowers the risk of contactor contact arcing, and improves electrical connection reliability.

[0020] Additionally, the front of the cabinet has an independent maintenance window corresponding to the power distribution contactor matrix compartment. The contactor units can be plugged in and out for maintenance via a detachable side door. The inside of the side door has an EMI shielding layer. The independent window on the front allows direct plugging and unplugging of the contactor units without disassembling the power module or air duct system, reducing maintenance time per operation. The EMI shielding layer inside the detachable side door effectively isolates the contactor matrix from electromagnetic interference from external equipment, ensuring the stability of the control signal.

[0021] Furthermore, the independent air duct system comprises 20 independently controlled axial flow fans. The fan array is divided into power module cooling groups and contactor cooling groups. The power module cooling group fans are installed at the outlet of the module air duct, and the contactor cooling group fans are installed at the inlet of the matrix air duct. The 20 fan groups are divided into power module cooling groups (12 groups) and contactor cooling groups (8 groups). Airflow is dynamically allocated according to the load, and each fan group operates independently; a failure in a single group does not affect overall heat dissipation.

[0022] Furthermore, each of the axial flow fans is equipped with a PWM speed control interface, which is connected to the control board inside the cabinet. The control board has a built-in PID temperature regulation module. The module compares the contactor temperature value collected in real time with the preset temperature difference threshold and outputs a speed regulation signal. The PID module collects data from 12 NTC sensors in real time and dynamically adjusts the fan speed. The three-dimensional monitoring network covers the contactor contacts, copper busbar connection points, and air duct inlets and outlets. By analyzing historical temperature curves, potential fault points can be warned in advance.

[0023] Furthermore, a three-dimensional temperature monitoring network is set up in the power distribution contactor matrix compartment, including at least 12 NTC temperature sensors. The sensors are respectively arranged at the contactor contact points, copper busbar connection points, and air duct inlet and outlet positions. The sampling period of the monitoring network is ≤500ms. The three-dimensional monitoring network covers the contactor contacts, copper busbar connection points, and air duct inlet and outlet. By analyzing historical temperature curves, potential fault points can be predicted in advance.

[0024] Furthermore, the cabinet adopts a split frame design, including a main power frame and an auxiliary equipment frame. The main power frame integrates power modules, contactor matrix and air duct system, while the auxiliary equipment frame includes charging control board, switching power supply and circuit breaker. The two frames are connected by quick-release connectors. The main power frame and auxiliary equipment frame are separate, and users can upgrade the power module or control board separately as needed, reducing later maintenance costs.

[0025] Furthermore, the bottom of the main power frame is provided with adjustable support feet, which include shock-absorbing rubber pads and horizontal adjustment screws. The overall dimensions of the cabinet meet the following requirements: length × width × height = 1200mm × 800mm × 1800mm. The adjustable support feet, through the horizontal adjustment screws (adjustment range ±20mm) and shock-absorbing rubber pads, adapt to uneven ground and reduce the impact of vibration on the contactor contacts.

[0026] In summary, due to the adoption of the above technical solution, the beneficial effects of this utility model are:

[0027] 1. This utility model discloses an integrated DC charger that effectively reduces the temperature of the contactor matrix area and the fan load by combining a cross-convection air duct with an S-shaped guide plate.

[0028] 2. This utility model achieves precise temperature control through three-dimensional temperature monitoring and PID speed-regulating fan, effectively reducing energy consumption.

[0029] 3. The power module and contactor matrix of this utility model are integrated into one design, which reduces space occupation. Attached Figure Description

[0030] Figure 1 This is a schematic diagram of an integrated DC charger according to the present invention;

[0031] Figure 2 This is a schematic diagram of the fan unit of this utility model.

[0032] Attached reference numerals: 1-Power module compartment, 2-Power distribution contactor matrix compartment, 3-Power distribution contactor, 4-Temperature sensor, 5-Fan, 6-Air duct, 7-Air duct outlet, 8-Hot air flow direction. Detailed Implementation

[0033] It should be noted that relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0034] The features and performance of this utility model will be further described in detail below with reference to the embodiments.

[0035] like Figures 1-2 As shown, the following are the usage steps of the integrated DC charger of this utility model:

[0036] Example 1: Equipment Installation and Basic Commissioning

[0037] 1. Frame assembly and support adjustment:

[0038] S1.1: The main power frame and the auxiliary equipment frame are connected via quick-release connectors. The main power frame has a built-in power module compartment, contactor matrix compartment, and independent air duct system, while the auxiliary equipment frame integrates the charging control board, switching power supply, and circuit breaker.

[0039] S1.2: Adjust the adjustable support feet at the bottom of the main power frame. By rotating the leveling screw, the entire cabinet is leveled, and the shock-absorbing rubber pads are in contact with the ground, eliminating the vibration caused by uneven installation environment.

[0040] 2. Connection between power module and contactor matrix:

[0041] S2.1: Insert the power module into the preset slot in the power module compartment and connect it to the corresponding contactor unit in the contactor matrix compartment via a copper busbar. The copper busbar adopts a short direct connection design, with its length controlled within 200mm to reduce line impedance.

[0042] S2.2: Confirm that the contactor matrix is ​​arranged in a rectangular matrix, with the arrangement direction consistent with the output direction of the power module. Each group of contactor units corresponds to the output terminal of the power module through independent contacts, ensuring the uniqueness of the power distribution path.

[0043] 3. Duct system and fan installation:

[0044] S3.1: Install an independent air duct system. The left power module air duct inlet is located at the bottom front of the cabinet, and the outlet is located at the top rear; the right contactor matrix air duct inlet is located at the bottom rear of the cabinet, and the outlet is located at the top front, forming a cross-convection structure.

[0045] S3.2: Install power module cooling fans (12 sets in total) at the power module air duct outlet and contactor cooling fans (8 sets in total) at the contactor matrix air duct inlet. Each fan is equipped with a PWM speed control interface and is connected to the control board inside the cabinet via a wiring harness.

[0046] 4. Temperature monitoring network deployment:

[0047] S4.1: Arrange a three-dimensional temperature monitoring network within the power distribution contactor matrix compartment. Attach 12 NTC temperature sensors to the contactor contacts, copper busbar connection points, and air duct inlet and outlet positions, ensuring close contact between the sensors and the surface being measured.

[0048] S4.2: Connect the sensor signal line to the control board, set the sampling period to 500ms, and verify the synchronization between the sensor data and the value displayed on the control board.

[0049] Example 2: Equipment Operation and Function Verification

[0050] 1. Initial power-on test:

[0051] S1.1: Close the circuit breaker inside the cabinet to start the switching power supply of the auxiliary equipment frame, and supply power to the charging control board and the fan.

[0052] S1.2: Initialize the PID temperature regulation module parameters through the control board interface, set the contactor contact temperature threshold to 75℃, and the temperature difference threshold to ±2℃.

[0053] 2. Verification of heat dissipation and temperature control functions:

[0054] S2.1: Start the axial flow fan. The power module cooling group runs at the default speed, and the contactor cooling group dynamically adjusts its speed according to the temperature of the contactor matrix compartment.

[0055] S2.2: Simulate a high-power output scenario and observe the temperature change in the contactor matrix compartment. When the contact temperature approaches 75℃, the PID module outputs a speed regulation signal, increasing the speed of the contactor cooling fan until the temperature stabilizes within the threshold range.

[0056] S2.3: Verify the effectiveness of the cross-convection air duct. Infrared thermal imagers were used to detect the air outlet temperature at the front and rear sides of the top of the cabinet, confirming that effective convection was achieved in the air ducts on both sides, with no hot air stagnation.

[0057] 3. Power distribution and contactor switching test:

[0058] S3.1: Set multiple power output requirements via the charging control board (e.g., 120kW for a single gun, 60kW for dual guns).

[0059] S3.2: Observe the contactor matrix operation logic. When the required power changes, the corresponding contactor unit switches in a preset order, and the copper busbar connection path is dynamically adjusted to ensure that the power module output matches the charging gun's requirements.

[0060] Example 3: Equipment Maintenance and Troubleshooting

[0061] 1. Contactor unit replacement:

[0062] S1.1: Open the independent maintenance window on the front of the cabinet and remove the removable side door of the corresponding contactor matrix compartment. The EMI shielding layer on the inside of the side door is removed along with the door, exposing the contactor unit.

[0063] S1.2: Pull out the copper busbar connection terminal of the faulty contactor unit, release the locking mechanism of the quick-release connector, and remove the faulty unit.

[0064] S1.3: Insert the new contactor unit, reconnect the copper busbar and lock the connector, then close the maintenance window.

[0065] 2. Airflow cleaning and heat dissipation optimization:

[0066] S2.1: Clean the air duct system regularly. Remove the air deflector at the air duct outlet of the power module and remove dust from the surface of the S-shaped air deflector and between the fish fin-shaped heat sink fins.

[0067] S2.2: Check the angle of the heat dissipation fins to ensure that the fins maintain an angle of 15°-30° with the airflow direction and are free from deformation or blockage.

[0068] S2.3: After reinstalling the air deflector, verify the recovery of heat dissipation performance through a fan speed adjustment test.

[0069] 3. Temperature control system calibration:

[0070] S3.1: Use a high-precision temperature source to simulate the contactor contact temperature and verify the deviation between the NTC sensor reading and the actual temperature.

[0071] S3.2: Adjust the PID parameters through the control board interface to optimize the temperature regulation response speed and stability, and ensure that the speed regulation signal and the fan speed are linearly matched.

[0072] Example 4: Extended Applications and Modular Upgrades

[0073] 1. Power module expansion:

[0074] S1.1: Disconnect the main power frame from the auxiliary equipment frame and remove the front cover of the main frame.

[0075] S1.2: Insert the new power module into the empty slot and connect it to the reserved interface of the contactor matrix via the copper busbar.

[0076] S1.3: Update the power allocation logic of the control board to enable the newly added modules to participate in dynamic power combination.

[0077] 2. Control board upgrade:

[0078] S2.1: Disconnect the signal line and power line of the charging control board inside the auxiliary equipment frame.

[0079] S2.2: Remove the old control board, insert the new generation board, reconnect the wiring harness and secure it.

[0080] S2.3: Load the latest control algorithm through the host computer software and enable enhanced functions (such as remote diagnostics and power prediction).

[0081] The embodiments described above merely illustrate specific implementation methods of this application, and while the descriptions are detailed and specific, they should not be construed as limiting the scope of protection of this application. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the technical solution of this application, and these modifications and improvements all fall within the scope of protection of this application.

Claims

1. An integrated DC charger, installed inside a cabinet, characterized in that: It includes a power module compartment, a power distribution contactor matrix compartment, and an independent air duct system; the power distribution contactor matrix compartment is equipped with a rectangular matrix of power distribution contactor groups, each group of power distribution contactors is connected to the output end of a single power module, the matrix arrangement direction is consistent with the output direction of the power module, and the power distribution contactor matrix compartment and the power module compartment are separated by a partition.

2. The charger according to claim 1, characterized in that: The independent air duct system includes a left power module air duct and a right power distribution contactor matrix air duct. The inlet of the power module air duct is located at the bottom front of the cabinet, and the outlet is located at the top rear of the cabinet. The inlet of the power distribution contactor matrix air duct is located at the bottom rear of the cabinet, and the outlet is located at the top front of the cabinet, forming a cross-flow air duct structure.

3. The charger according to claim 2, characterized in that: The power distribution contactor matrix has an S-shaped guide plate at the air duct outlet. The surface of the guide plate is arranged with fish fin-shaped heat dissipation fins, and the heat dissipation fins are at an angle of 15°-30° with the airflow direction of the air duct.

4. The charger according to claim 2, characterized in that: The power distribution contactor matrix includes at least 9 groups of contactor units arranged side by side. Each group of contactor units has a rated switching power of 40kW. The contactor units are directly connected to the output terminals of the corresponding power modules via copper busbars, and the length of the copper busbars is ≤200mm.

5. The charger according to claim 1, characterized in that: The cabinet includes a cabinet body and a side door. An independent maintenance window is provided on the front, which corresponds to the position of the power distribution contactor matrix compartment. The contactor unit can be plugged in and out for maintenance through the detachable side door. An EMI shielding layer is provided on the inside of the side door.

6. The charger according to claim 2, characterized in that: The independent air duct system includes 20 independently controlled axial flow fans. The fan array is divided into a power module cooling group and a contactor cooling group. The fans are installed at the outlet of the module air duct, and the contactor cooling group fans are installed at the inlet of the matrix air duct.

7. The charger according to claim 6, characterized in that: Each fan is equipped with a PWM speed control interface, which is connected to the control board inside the cabinet. The control board has a built-in PID temperature regulation module, which outputs a speed control signal by comparing the contactor temperature value collected in real time with a preset temperature difference threshold.

8. The charger according to claim 7, characterized in that: The power distribution contactor matrix compartment is equipped with a three-dimensional temperature monitoring network, which includes at least 12 NTC temperature sensors. The temperature sensors are respectively arranged at the contactor contact points, copper busbar connection points, and air duct inlet and outlet positions. The sampling period of the monitoring network is ≤500ms.

9. The charger according to claim 1, characterized in that: The cabinet adopts a split frame design, which includes a main power frame and an auxiliary equipment frame. The main power frame integrates power modules, contactor matrix and air duct system. The auxiliary equipment frame includes charging control board, switching power supply and circuit breaker. The main power frame and auxiliary equipment frame are connected by quick-release connectors.

10. The charger according to claim 9, characterized in that: The main power frame is equipped with adjustable support feet at the bottom. The support feet include shock-absorbing rubber pads and horizontal adjustment screws. The overall dimensions of the cabinet meet the following requirements: length × width × height = 1200mm × 800mm × 1800mm.

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