High-power dc charging gun

Abstract

This utility model discloses a high-power DC charging gun. The high-power DC charging gun includes: a gun housing and multiple liquid-cooled power modules mounted on the front end of the gun housing, and liquid-cooled cables mounted on the rear end of the gun housing. Each liquid-cooled power module includes two liquid-cooled power terminals and a liquid-cooled box. The two liquid-cooled power terminals are sleeved through shaft holes on both sides of the liquid-cooled box, forming a one-inlet, two-outlet non-isolated cooling structure between the liquid-cooled box and the two liquid-cooled power terminals. The liquid-cooled cables include multiple inlet pipes, outlet pipes, and power wires. Each inlet pipe connects to an inlet port, and each outlet pipe has a power wire inserted through a gap. Each power wire is electrically connected to a liquid-cooled power terminal, and the corresponding outlet pipe connects to the outlet port of that liquid-cooled power terminal, forming a high-power liquid-cooled DC charging gun with a shunt structure. This utility model has the advantages of meeting megawatt-level charging requirements, small component size and low weight, and stable and safe charging.

Description

Technical Field

[0001] This utility model relates to the field of high-power charging, and in particular to a high-power DC charging gun. Background Technology

[0002] With the development of new energy vehicle technology, charging applications for large transportation vehicles such as electric heavy-duty trucks have emerged. These vehicles have higher requirements for driving range and energy storage, requiring longer charging times when using the charging power of ordinary electric vehicles. Therefore, increasing charging power has become a key focus. For example, conventional electric heavy-duty trucks require charging currents of up to 3000A and charging power of several MW. Current methods for increasing charging current require the use of ultra-large diameter cables, which have several drawbacks: First, ultra-large diameter cables are not only expensive and technically difficult to manufacture, but also significantly increase the weight of the charging gun; second, high-power, long-term charging generates a large amount of heat, causing excessively high charging temperatures, which degrades the performance of the charging device, leads to frequent interruptions and unstable operation, resulting in low charging efficiency and long charging times. This can seriously affect the lifespan of the device and create safety hazards. Utility Model Content

[0003] To address one or more of the aforementioned problems, this utility model provides a high-power DC charging gun.

[0004] According to one aspect of the present invention, the high-power DC charging gun includes: a gun housing and a plurality of liquid-cooled power modules installed at the front end of the gun housing, and a liquid-cooled cable installed at the rear end of the gun housing.

[0005] Each liquid-cooled power module includes two liquid-cooled power terminals and a liquid-cooled box. The liquid-cooled power terminals are provided with axial liquid cooling channels with closed front and rear ports. The middle section of the outer peripheral wall is provided with a drainage hole that connects to the liquid cooling channel, and the rear end of the outer peripheral wall is provided with a liquid outlet that connects to the liquid cooling channel. The first axial holes on both sides of the liquid-cooled box are connected to the middle sections of the two liquid-cooled power terminals. The middle of the liquid-cooled box is provided with a liquid inlet with an open rear opening. Two symmetrical liquid outlets at the end of the liquid inlet are respectively connected to the drainage holes of the two liquid-cooled power terminals, forming a non-isolated cooling structure with one inlet and two outlets.

[0006] The liquid-cooled cable includes multiple inlet pipes, outlet pipes, and power wires. Each inlet pipe is connected to an inlet port, and a power wire is threaded through the gap inside each outlet pipe. Each power wire is electrically connected to a liquid-cooled power terminal, and the corresponding outlet pipe is connected to the outlet port of the liquid-cooled power terminal, thus forming a high-power liquid-cooled DC charging gun with a shunt structure.

[0007] In some embodiments, the first shaft hole and the middle section of the liquid-cooled power terminal are fitted together with a gap, and the two ends of the gap are sealed by two sealing rings to form a sealed cavity through which the coolant passes; the liquid outlet and the drainage hole are directly opposite the sealed cavity.

[0008] In some embodiments, the middle section of the liquid cooling channel is symmetrically provided with two radial through-hole structures for drainage holes, and the end of the liquid inlet of the liquid cooling box is symmetrically provided with two backward-inclined liquid distribution ports to form a Y-shaped flow channel, with each inner drainage hole facing a liquid distribution port.

[0009] In some embodiments, the first shaft hole is a stepped hole structure, the middle section of the liquid-cooled power terminal is a stepped shaft that mates with the stepped hole, and the front small diameter end and the rear large diameter end of the stepped shaft are respectively provided with a sealing groove for an interference fit sealing ring, and the drainage hole is located at the small diameter end of the stepped shaft.

[0010] Alternatively, a positioning block for positioning and preventing rotation may be provided on the inner wall of the front end of the first shaft hole.

[0011] In some embodiments, the liquid cooling channel is a central blind hole of the liquid cooling power terminal, and a power wire is crimped to a fixed bushing at the rear end of the central blind hole to form a liquid cooling channel closed at both ends;

[0012] The liquid outlet pipe is connected to the rear end of the liquid cooling power terminal through a gap, and its end is fixedly sleeved to the middle section of the liquid cooling power terminal. The liquid outlet is a vertical arc cut at the rear end of the liquid cooling channel.

[0013] In some embodiments, the liquid-cooled power terminal is provided with an outlet section, a locking truncated cone, and a threaded section with progressively larger diameters from back to middle. The end of the outlet pipe is interference-fitted to the locking truncated cone, and a quick-tightening nut is connected to the threaded section and fixes the outlet pipe to the locking truncated cone.

[0014] In some embodiments, the liquid inlet of the liquid cooling box extends outward to form a pagoda connector; the liquid inlet pipe is interference-fitted into the pagoda connector and the connection is fixedly connected by a metal clamp.

[0015] In some embodiments, the front port of the gun housing is fixedly fitted with an insert housing, and the rear end of the insert housing is threadedly connected to a front mounting plate.

[0016] The liquid cooling box is fixedly fitted with the positioning groove of the front mounting plate. The two liquid cooling power terminals of the liquid cooling power module are inserted into the two insertion pipe holes of the insertion end of the insertion shell. The middle section passes through the second shaft hole in the positioning groove and is fitted to the front wall of the front mounting plate by a C-shaped retaining ring to achieve pre-fixation and anti-retraction.

[0017] The liquid cooling cable is fixedly connected to the rear port of the gun casing by a cable clamp.

[0018] In some implementations, there are two liquid-cooled power modules; the liquid-cooled cable includes an outer sheath and two liquid inlet pipes, four liquid outlet pipes, and four power wires passing through the outer sheath;

[0019] The charging gun has a charging power in the megawatt range.

[0020] In some implementations, the coolant is cooling oil.

[0021] This high-power DC charging gun employs multiple liquid-cooled power modules and liquid-cooled cables, with multiple sets of power conductors connected in parallel to shunt the current, reducing the charging power and current of each charging module. Each charging module also features liquid cooling. Its advantages are: First, the shunt structure of this high-power DC charging gun can meet megawatt-level charging requirements, solving the problem of excessively large wire diameters, effectively reducing costs, simplifying production technology and assembly, and significantly reducing the weight of the charging gun. Second, each liquid-cooled power module has a cooling structure, ensuring the charging gun operates at a suitable temperature for extended periods, resulting in stable and uninterrupted charging performance, and safe and fast charging. Third, the one-in-two-out non-isolated cooling structure provides equal cooling for both the liquid-cooled power terminals and power conductors. Compared to the traditional one-in-one-out cooling mode, which results in a low inlet temperature and a high outlet temperature, the new structure's inlet temperature at the terminals is almost unaffected by cable heating, resulting in higher cooling efficiency. Fourth, the one-in-two-out structure is simple, with fewer components, facilitating assembly and reducing costs. Attached Figure Description

[0022] Figure 1 This is a three-dimensional schematic diagram of a high-power DC charging gun according to one embodiment of the present invention.

[0023] Figure 2 for Figure 1 A three-dimensional exploded view of a high-power DC charging gun is shown.

[0024] Figure 3 for Figure 2 A three-dimensional schematic diagram of the liquid-cooled power module shown;

[0025] Figure 4 for Figure 3 A three-dimensional exploded view of the liquid-cooled power module shown.

[0026] Figure 5 for Figure 3 A cross-sectional schematic diagram of the liquid-cooled power module shown (I);

[0027] Figure 6 for Figure 3 Schematic diagram of cross-section of the liquid-cooled power module shown (II);

[0028] Figure 7 for Figure 2 A cross-sectional view of the liquid-cooled cable shown.

[0029] Gun casing 1, locking assembly 11, grip 12;

[0030] Liquid-cooled power module 2, liquid-cooled power terminal 20, liquid-cooled channel 200, drain hole 201, liquid outlet 202, liquid outlet section 203, threaded section 204, locking frustum 205, sealing groove 206, liquid-cooled box 21, first shaft hole 210, liquid inlet 211, liquid distribution port 212, positioning block 213, pagoda connector 214, quick-tightening nut 22, sealing ring 23;

[0031] Liquid-cooled cable 3, outer sheath 30, liquid inlet pipe 31, liquid outlet pipe 32, power wire 33;

[0032] Insert housing 4, insertion terminal 40, rear end ring 41;

[0033] Front mounting plate 5, positioning groove 51, second shaft hole 52;

[0034] 6. C-type retaining ring; 7. Wire locking clip; 8. Signal terminal. Detailed Implementation

[0035] The present invention will now be described in further detail with reference to the accompanying drawings. It should be noted that the terms "front," "rear," "left," "right," "up," and "down" used in the following description refer to the directions in the accompanying drawings, while the terms "inner" and "outer" refer to the directions toward or away from the geometric center of a specific component, respectively.

[0036] Figures 1 to 7 A high-power DC charging gun according to one embodiment of the present invention is schematically shown. As shown in the figure, the high-power DC charging gun includes: a gun housing 1 and a plurality of liquid-cooled power modules 2 installed at the front end of the gun housing 1, and a liquid-cooled cable 3 installed at the rear end of the gun housing 1;

[0037] Each liquid-cooled power module 2 includes two liquid-cooled power terminals 20 and a liquid-cooled box 21. The liquid-cooled power terminal 20 is provided with an axial liquid-cooled channel 200 with closed front and rear ports. The middle section of its outer peripheral wall is provided with a drain hole 201 that connects to the liquid-cooled channel 200, and the rear end of its outer peripheral wall is provided with a liquid outlet 202 that connects to the liquid-cooled channel 200.

[0038] The first shaft holes 210 on both sides of the liquid cooling box 21 are fitted with the middle sections of two liquid cooling power terminals 20. The liquid cooling box 21 has a rear-opening liquid inlet 211 in the middle. Two symmetrical liquid outlets 212 at the end of the liquid inlet 211 are respectively connected to the drainage holes 201 of the two liquid cooling power terminals 20, forming a non-isolated cooling structure with one inlet and two outlets. A preferred connection structure between the drainage holes 201 and the liquid outlets 212 is as follows: the first shaft holes 210 and the middle sections of the liquid cooling power terminals 20 are fitted with a gap, and the two ends of the gap are press-fitted by two sealing rings 23 to form a sealed cavity through which the coolant passes; the liquid outlets 212 and the drainage holes 201 are directly opposite the sealed cavity.

[0039] The liquid-cooled cable 3 includes multiple inlet pipes 31, outlet pipes 32, and power wires 33. Each inlet pipe 31 is connected to an inlet port 211, and each outlet pipe 32 has a power wire 33 inserted through a gap. The annular hole between the outlet pipe 32 and the power wire 33 is a coolant outlet channel. Each power wire 33 is electrically connected to a liquid-cooled power terminal 20, and the corresponding outlet pipe 32 is connected to the outlet port 202 of the liquid-cooled power terminal 20, forming a high-power liquid-cooled DC charging gun with a shunt structure.

[0040] This high-power DC charging gun employs multiple liquid-cooled power modules 2 and liquid-cooled cables 3, with multiple sets of power conductors 33 connected in parallel to shunt the current, reducing the charging power and charging current of each charging module. Each charging module also features liquid cooling. Its advantages are: First, the shunt structure of this high-power DC charging gun can meet megawatt-level charging requirements, solving the problem of excessively large wire diameters, effectively reducing costs, simplifying production technology and assembly, and significantly reducing the weight of the charging gun. Second, each liquid-cooled power module 2 has a cooling structure, ensuring the charging gun operates at a suitable temperature for extended periods, resulting in stable and uninterrupted charging performance, and safe and fast charging. Third, the one-in-two-out non-isolated cooling structure provides equal cooling for both the liquid-cooled power terminals 20 and the power conductors 33. Compared to the traditional one-in-one-out cooling mode, which results in a low inlet temperature and a high outlet temperature, the inlet temperature at the terminals of the one-in-two-out non-isolated cooling structure is almost unaffected by cable heating, resulting in higher cooling efficiency. Fourth, the one-in-two-out structure is simple, with fewer components, facilitating assembly and reducing costs.

[0041] Preferably, the middle section of the liquid cooling channel 200 is symmetrically provided with two radially through-hole drainage holes 201, and the end of the liquid inlet 211 of the liquid cooling tank 21 is symmetrically provided with two backward-sloping liquid distribution ports 212 to form a Y-shaped flow channel, with each inner drainage hole 201 directly opposite a liquid distribution port 212. The beneficial effect is that the Y-shaped flow channel ensures that the liquid flow rate and velocity of the two liquid cooling channels 200 are the same, resulting in the same liquid cooling effect.

[0042] Preferably, the first shaft hole 210 has a stepped hole structure, and the middle section of the liquid-cooled power terminal 20 is a stepped shaft that mates with the stepped hole. A sealing groove 206 is provided at the front small-diameter end and the rear large-diameter end of the stepped shaft. Each sealing ring 23 has its outer end interference-fitted with a sealing groove 206 and its inner end interference-fitted with either the small-diameter or large-diameter end. The drainage hole 201 is located at the small-diameter end of the stepped shaft. The beneficial effect is that this arrangement can prevent the burrs of the drainage hole 201 from scratching the rear sealing ring 23, ensuring a good sealing and leak-proof effect.

[0043] Preferably, the inner wall of the front end of the first shaft hole 210 is provided with a positioning block 213 for flat positioning and anti-rotation. The rear end of the liquid-cooled power terminal 20 is fixedly sleeved into the first shaft hole 210 and the corresponding flat end is sleeved through the positioning block 213. Its beneficial effect is that this setting can achieve a constant terminal position and achieve anti-rotation connection.

[0044] Furthermore, the liquid cooling channel 200 is a central blind hole of the liquid cooling power terminal 20, and the power wire 33 is crimped to the rear end of the central blind hole by a fixed bushing, forming a liquid cooling channel 200 closed at both ends;

[0045] The outlet pipe 32 is gapped and connected to the rear end of the liquid-cooled power terminal 20, with its end fixedly sleeved to the middle section of the liquid-cooled power terminal 20. The outlet 202 is a vertical arc cut at the rear end of the liquid-cooled channel 200, which penetrates the rear end of the outer peripheral wall of the liquid-cooled power terminal 20 and connects to the outlet pipe 32. Its advantages are: the structure is simple, it achieves effective and rapid fluid flow, avoids interference between connecting parts, and facilitates the installation and layout of other components.

[0046] Preferably, the liquid-cooled power terminal 20 is provided with, from rear to center, an outlet section 203 containing an outlet 202 with progressively larger diameters, a locking truncated cone 205, and a threaded section 204. The end of the outlet pipe 32 is interference-fitted to the locking truncated cone 205, and the quick-release nut 22 connects to the threaded section 204 and fixes the outlet pipe 32 to the locking truncated cone 205. The advantage of this design is that it enables a secure fixation between the terminal and the outlet pipe 32, preventing loosening and leakage.

[0047] Preferably, the liquid inlet 211 of the liquid cooling tank 21 extends outward to form a pagoda connector 214; the liquid inlet pipe 31 is interference-fitted to the pagoda connector 214 and the connection is fixed by a metal clamp. The advantage of this design is that the connection is firm and will not loosen during long-term use.

[0048] Furthermore, the gun casing 1 is a hollow shell with open front and rear ends. The front port of the gun casing 1 is connected to the rear end ring 41 of the insert shell 4 by a sleeve of the same size, and the front threaded post of the inner cavity of the gun casing 1 and the insert shell 4 are connected as one piece by a threaded component.

[0049] The two liquid cooling power terminals 20 of each liquid cooling power module 2 are connected to the two insertion holes of the insertion end 40 of the insertion housing 4.

[0050] The front mounting plate 5 is fitted onto the rear end ring 41 of the insert housing 4, and the ring and the axial threaded hole of the front mounting plate 5 are fixedly connected by a threaded component. The liquid cooling box 21 is fitted into the positioning groove 51 of the front mounting plate 5, and the middle section of the liquid cooling power terminal 20 passes through the second axial hole 52 of the positioning groove 51 and is attached to the front end wall of the front mounting plate 5 by a C-shaped retaining ring 6, thereby achieving pre-fixation and anti-retraction of the terminal and the liquid cooling box 21.

[0051] The rear port of the gun casing 1 and the front ring of the locking cable clamp 7 are fixedly sleeved and connected by threaded parts; the outer sheath 30 of the liquid-cooled cable 3 is fitted to the front ring and the internal tubing is sleeved and connected to the clamping hole of the locking cable clamp 7. Its advantages are: the overall structure of this device is compact, the size is small, and the installation accuracy is high.

[0052] Preferably, the upper end of the gun casing 1 is also equipped with a locking assembly 11 and a grip 12.

[0053] Preferably, there are two liquid-cooled power modules 2;

[0054] The liquid-cooled cable 3 includes an outer sheath 30 and two inlet pipes 31, four outlet pipes 32, and four power wires 33, all housed within the outer sheath 30. The two inlet pipes 31 connect to the inlet pipes 31 of the two liquid-cooled power modules 2. The tails of the four power wires 33 are crimped to the four liquid-cooled power terminals 20. The four outlet pipes 32 connect to the outlets 202 of the four liquid-cooled power terminals 20. The charging gun has a charging power of megawatts. Its advantages are: this setup effectively achieves megawatt-level charging, enabling the application of high-power DC charging guns in charging large vehicles such as electric heavy trucks, with a charging current reaching 3000A, a charging voltage reaching 1500A, and a charging power reaching 4.5MW.

[0055] Preferably, the liquid-cooled cable 3 also includes a signal cable sheathed within an outer sheath 30, and the inner wall of the outer sheath 30 is further provided with a shielding layer. The insert housing 4 also has a bushing connection to a signal terminal 8, which is electrically connected to the signal cable of the liquid-cooled cable 3.

[0056] Preferably, the coolant is cooling oil. The cooling oil can be E4 rechargeable cooling oil. Rechargeable cooling oil has a better cooling effect and is suitable for non-enclosed cavities formed by sealing rings.

[0057] Preferably, the liquid cooling box 2 is made of a composite plastic of PA66 and 30% glass fiber.

[0058] The above descriptions are merely some embodiments of this utility model. For those skilled in the art, various modifications and improvements can be made without departing from the inventive concept of this utility model, and all such modifications and improvements fall within the protection scope of this utility model.

Claims

1. A high-power DC charging gun, characterized in that, Includes: a gun housing (1) and multiple liquid-cooled power modules (2) installed at the front end of the gun housing (1), and liquid-cooled cables (3) installed at the rear end of the gun housing (1); Each of the liquid-cooled power modules (2) includes two liquid-cooled power terminals (20) and a liquid-cooled box (21). The liquid-cooled power terminals (20) are provided with axial liquid-cooled channels (200) with closed front and rear ports. The middle section of the outer peripheral wall is provided with a drain hole (201) that connects to the liquid-cooled channel (200), and the rear end of the outer peripheral wall is provided with a liquid outlet (202) that connects to the liquid-cooled channel (200). The first axial holes (210) on both sides of the liquid-cooled box (21) are sleeved with the middle section of the two liquid-cooled power terminals (20). The liquid-cooled box (21) is provided with a liquid inlet (211) with a rear open opening in the middle. The two liquid outlets (212) at the end of the liquid inlet (211) are symmetrically connected to the drain holes (201) of the two liquid-cooled power terminals (20) respectively, forming a non-isolated cooling structure with one inlet and two outlets. The liquid-cooled cable (3) includes multiple inlet pipes (31), outlet pipes (32) and power wires (33). Each inlet pipe (31) is connected to an inlet port (211). Each outlet pipe (32) has a power wire (33) inserted through a gap. Each power wire (33) is electrically connected to a liquid-cooled power terminal (20) and the corresponding outlet pipe (32) is connected to the outlet port (202) of the liquid-cooled power terminal (20), thus forming a high-power liquid-cooled DC charging gun with a shunt structure.

2. The high-power DC charging gun according to claim 1, characterized in that, The first shaft hole (210) and the middle section of the liquid cooling power terminal (20) are fitted together with a gap, and the two ends of the gap are sealed by two sealing rings (23) to form a sealed cavity through which the coolant passes; the liquid outlet (212) and the drainage hole (201) are directly opposite the sealed cavity.

3. The high-power DC charging gun according to claim 2, characterized in that, The liquid cooling channel (200) has two radial through-hole drainage holes (201) symmetrically arranged in the middle section. The liquid inlet (211) of the liquid cooling box (21) has two backward inclined distribution ports (212) symmetrically arranged at the end to form a Y-shaped flow channel. Each inner drainage hole (201) is directly opposite one of the distribution ports (212).

4. The high-power DC charging gun according to claim 3, characterized in that, The first shaft hole (210) is a stepped hole structure. The middle section of the liquid-cooled power terminal (20) is a stepped shaft that matches the stepped hole. The front end of the stepped shaft and the rear end of the stepped shaft are respectively provided with a sealing groove (206) of an interference fit sealing ring (23). The drainage hole (201) is located at the small diameter end of the stepped shaft. Alternatively, a positioning block (213) may be provided on the inner wall of the front end of the first shaft hole (210) to prevent rotation.

5. The high-power DC charging gun according to claim 2, characterized in that, The liquid cooling channel (200) is a central blind hole of the liquid cooling power terminal (20), and the power wire (33) is pressed into the rear end of the central blind hole by a fixed bushing, forming the liquid cooling channel (200) which is closed at both ends; The liquid outlet pipe (32) is connected to the rear end of the liquid cooling power terminal (20) through a gap, and its end is fixedly sleeved to the middle section of the liquid cooling power terminal (20). The liquid outlet (202) is a vertical arc cut at the rear end of the liquid cooling channel (200).

6. The high-power DC charging gun according to claim 5, characterized in that, The liquid-cooled power terminal (20) is provided with an outlet section (203) with an increasing diameter from back to middle, a locking truncated cone (205) and a threaded section (204). The end of the outlet pipe (32) is interference-fitted to the locking truncated cone (205), and the quick-tight nut (22) is connected to the threaded section (204) and fixes the outlet pipe (32) to the locking truncated cone (205).

7. The high-power DC charging gun according to claim 1, characterized in that, The liquid inlet (211) of the liquid cooling box (21) extends outward to form a pagoda connector (214); the liquid inlet pipe (31) is interference-fitted to the pagoda connector (214) and the connection is fixedly connected by a metal clamp.

8. The high-power DC charging gun according to claim 1, characterized in that, The gun casing (1) is fixedly sleeved with the insert shell (4) at the front port, and the insert shell (4) is threadedly connected to the front mounting plate (5) at the rear end; The liquid cooling box (21) is fixedly fitted into the positioning groove (51) of the front mounting plate (5). The two liquid cooling power terminals (20) of the liquid cooling power module (2) are inserted into the two insertion pipe holes of the insertion end (40) of the insertion shell (4). The middle section passes through the second shaft hole (52) in the positioning groove (51) and is attached to the front wall of the front mounting plate (5) by a C-shaped retaining ring (6) to achieve pre-fixation and anti-retraction. The rear port of the gun casing (1) is fixedly connected to the liquid cooling cable (3) by a wire clamp (7).

9. The high-power DC charging gun according to any one of claims 1 to 8, characterized in that, The liquid-cooled power module (2) consists of two units; the liquid-cooled cable (3) includes an outer sheath (30) and two inlet pipes (31), four outlet pipes (32), and four power wires (33) that pass through the outer sheath (30); the charging power of the charging gun is in the megawatt range.

10. The high-power DC charging gun according to claim 9, characterized in that, The coolant is cooling oil.

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