High-voltage direct-drive high-voltage module and mobile storage and charging integrated robot

Abstract

This utility model discloses a high-voltage direct-drive high-voltage module, comprising: a main drive high-voltage pre-charge circuit, the front end of which is connected to both ends of the battery pack, and the rear end of which is connected to the motor via a three-phase inverter, used to limit instantaneous surge current and charge the electric drive bus capacitor; a downstream DC pre-charge circuit, connected between the motor and the DC transformer, providing a pre-charge path for the input capacitor of the downstream DC transformer; a discharge circuit, connected in parallel across the high-voltage bus, used to ensure that the bus capacitor voltage drops rapidly to a safe voltage after the system is powered off; an output anti-backflow circuit, connected between the DC transformer and the output discharge circuit, used to prevent the voltage of the charged object from inverting and affecting the high-voltage system of the mobile energy storage and charging integrated robot; and an output discharge circuit, connected between the output anti-backflow circuit and the charging gun, used to ensure that there is no high-voltage residue when the charging gun or interface is disconnected and to discharge the charge on the output capacitor and cable.

Description

Technical Field

[0001] This utility model relates to the field of energy storage, and in particular to a high-voltage direct-drive high-voltage module; and a mobile integrated energy storage and charging robot having the high-voltage direct-drive high-voltage module. Background Technology

[0002] With the increasing demand for charging new energy vehicles, more and more mobile charging robots are appearing on the market. In the existing high-voltage architecture of mobile charging robots, the voltage requirements of each module—the charging module, chassis electric drive module, high-voltage battery module, and energy storage charging and discharging module—are different for EV vehicles.

[0003] Existing mobile charging robot systems mainly include the following modules:

[0004] ① High-voltage to low-voltage DC-DC module: The DC-DC module converts the high-voltage battery system into low-voltage DC to provide a DC power source for the low-voltage electric drive;

[0005] ②Low-voltage electric drive module: includes a low-voltage motor and motor controller, which controls the chassis movement. Common low-voltage electric drive modules are 36V, 48V and 72V low-voltage electric drive modules;

[0006] ③ Low-voltage battery module: This module serves as an auxiliary drive battery for the low-voltage electric drive module, providing a regulated DC power source for the low-voltage electric drive together with the high-voltage to low-voltage DC-DC converter module. It also absorbs the reverse electromotive force of the low-voltage electric drive, thus acting as a discharge source for the high-voltage to low-voltage DC-DC converter module.

[0007] ④ High-voltage battery module: The high-voltage battery module used for energy storage in the energy storage robot provides DC power to the chassis through a high-voltage to low-voltage DC-DC module;

[0008] ⑤ HVDC module: The battery system uses HVDC to perform buck-boost voltage processing and output constant current or constant voltage control to charge the EV vehicle.

[0009] Existing mobile charging robots use low-voltage electric drive modules, commonly 36V, 48V and 72V, high-voltage to low-voltage DC-DC modules, and low-voltage battery modules to drive the chassis. This system has many components, high cost, low efficiency and high failure rate. Utility Model Content

[0010] The utility model description section introduces a series of simplified concepts, all of which are simplifications of existing technologies in the field, and will be further explained in detail in the detailed description section. This utility model description section is not intended to limit the key features and essential technical features of the claimed technical solution, nor is it intended to determine the scope of protection of the claimed technical solution.

[0011] The technical problem to be solved by this utility model is to provide a high-voltage direct-drive high-voltage module that can reuse the inductor circuit of the chassis electric drive to realize chassis drive.

[0012] And, a mobile integrated storage and charging robot having the aforementioned high-voltage direct-drive high-voltage module.

[0013] To solve the above-mentioned technical problems, the high-voltage direct-drive high-voltage module provided by this utility model includes:

[0014] The main drive high voltage pre-charge circuit is connected to both ends of the battery pack at its front end and to the motor via a three-phase inverter at its rear end. It is used to limit instantaneous surge current and charge the electric drive bus capacitor.

[0015] The downstream DC pre-charge circuit, connected between the motor and the DC transformer, provides a pre-charge path for the input capacitor of the downstream DC transformer, preventing surge current from the high-voltage battery on the downstream capacitor when the HVDC module switches to charging mode.

[0016] The bleed circuit is connected in parallel across the high-voltage busbar and is used to ensure that the busbar capacitor voltage drops rapidly to a safe voltage after the system is powered off.

[0017] The output anti-backflow circuit is connected between the DC transformer and the output discharge circuit. It is used to prevent the voltage of the object being charged from affecting the high voltage system of the mobile storage and charging robot in reverse.

[0018] The output discharge circuit is connected between the output backflow prevention circuit and the charging gun. It is used to ensure that there is no high voltage residue when the charging gun or interface is disconnected and to discharge the charge on the output capacitor and cable.

[0019] Preferably, in a further improvement, the high-voltage direct-drive high-voltage module replaces the DC transformer with a two-phase interleaved bidirectional synchronous Buck / Boost circuit.

[0020] Preferably, the high-voltage direct-drive high-voltage module is further improved, and the main drive high-voltage pre-charge circuit includes:

[0021] The first switch S1 is connected between the positive terminal of the battery and the three-phase inverter;

[0022] The second switch S2 is connected between the negative terminal of the battery and the three-phase inverter;

[0023] The first capacitor C1 is connected in parallel with the three-phase inverter;

[0024] The first resistor R1 is connected between the positive terminal of the battery and the high-voltage side of the three-phase inverter;

[0025] The third switch S3 is connected between the first resistor R1 and the three-phase inverter.

[0026] Preferably, the high-voltage direct-drive high-voltage module is further improved, with the subsequent DC pre-charge circuit including:

[0027] The fourth switch S4 is connected between the motor and the three-phase inverter.

[0028] The second resistor R2 is connected in series with the fifth switch S5 and then in parallel with the fourth switch S4.

[0029] Preferably, the high-voltage direct-drive high-voltage module is further improved, and the discharge circuit includes:

[0030] The third resistor R3 and the sixth switch S6 are connected in series between the rear end of the DC precharge circuit and the low-voltage side of the main side of the DC transformer.

[0031] The second capacitor C2 is connected in parallel between the high-voltage side and the low-voltage side of the main winding of the DC transformer.

[0032] Preferably, the high-voltage direct-drive high-voltage module is further improved to include an output backflow prevention circuit, comprising:

[0033] The anti-backflow diode D1 has its anode connected to the high-voltage side of the secondary winding of the DC transformer, and its cathode connected to the output discharge circuit.

[0034] The third capacitor, C3, is connected between the high-voltage side and the low-voltage side of the secondary winding of the DC transformer.

[0035] Preferably, the output discharge circuit of the high-voltage direct-drive high-voltage module is further improved, including:

[0036] The fourth resistor R4 has its first end connected to the high-voltage side of the output anti-backflow circuit and the seventh switch S7, and its second end connected to the low-voltage side of the output anti-backflow circuit and the ninth switch S9 via the eighth switch S8.

[0037] The other end of the seventh switch S7 is connected to the high-voltage side of the charging gun;

[0038] The other end of the ninth switch S9 is connected to the low-voltage side of the charging gun.

[0039] To solve the above-mentioned technical problems, the present invention provides a mobile integrated storage and charging robot, wherein the high-voltage direct-drive high-voltage module is any of the high-voltage direct-drive high-voltage modules described above.

[0040] The working principle and technical effects of this utility model are as follows;

[0041] During the movement of the mobile charging robot, the electric drive controller acts on the motor to propel the vehicle. However, it does not charge the new energy vehicle while in motion. Furthermore, because different new energy vehicles have different battery voltage ranges, the operating voltage of the charging module generally needs to range from 200V to 1000V. For charging modules with a wide voltage range, a two-stage topology is typically used in the HVDC topology selection to meet the wide voltage operating range of HVDC input and output.

[0042] To reduce the cost of mobile charging robot systems, the circuits of the first, second, and third electric drive arms and the three-phase motor can be reused. The power topology and control circuit of the HVDC charging system for new energy vehicles can be integrated and time-division multiplexed, thereby combining the electric drive controller and HVDC into one, which greatly reduces the size and cost of the system.

[0043] refer to Figure 1 As shown, the first type of high-voltage direct-drive high-voltage module provided by this utility model is used as an example, namely the post-stage isolated DC-DC topology. The working mode is described as follows;

[0044] Operating mode 1: Electric drive mode

[0045] Close the first switch S1 and the second switch S2; open the fourth switch 4, the seventh switch S7, and the ninth switch S9. Put the three-phase bridge arm and the motor into electric drive mode, running the electric drive SVPWM to control the motor torque and speed in a closed-loop control manner.

[0046] Working Mode 2: New Energy Charging HVDC Mode

[0047] Close the first switch S1, the second switch S2, and the fourth switch 4; the seventh switch S7 and the ninth switch S9 are charging relays for new energy vehicles, controlled according to national standards or overseas European / American charging pile protocols and timing sequences. At this time, the three-phase bridge arm and the motor operate in Buck step-down mode (constant voltage control), switching from SVPWM to three-phase interleaved PWM control mode. The subsequent DC-DC converter adopts an isolated LLC or non-isolated interleaved Boost topology, with constant voltage and cross-current closed-loop control to meet the battery voltage range of different new energy vehicles from 200V to 1000V.

[0048] This utility model can achieve at least the following technical effects;

[0049] 1. Good adaptability: It is compatible with a wide range of voltage platforms, with a large voltage adaptation range of 250-1000V for high-voltage electric drives; it can adapt to the electric drive system of the high-voltage platform of the energy storage and charging robot, and improve the operating efficiency of the energy storage and charging robot by cooperating with the voltage platform of the energy storage and charging robot.

[0050] 2. This utility model can replace 36V, 48V and 72V low-voltage electric drive systems.

[0051] 3. High integration: Adopting a highly integrated system architecture, key components are centrally integrated, optimizing the internal structural layout and connection method, reducing wiring complexity and failure points, reusing EV charging power modules and control modules, reducing the size and cost of the device, while improving the reliability and stability of the system, and facilitating installation. It has significant advantages compared with existing technologies.

[0052] 4. Add feedback function: reduce chassis driving power consumption and improve the operating efficiency of the storage and charging robot. Attached Figure Description

[0053] The accompanying drawings are intended to illustrate the general characteristics of the methods, structures, and / or materials used in specific exemplary embodiments of the present invention, supplementing the description in the specification. However, these drawings are schematic diagrams not drawn to scale and may not accurately reflect the precise structural or performance characteristics of any of the given embodiments. The drawings should not be construed as limiting or restricting the range of numerical values ​​or properties covered by the exemplary embodiments of the present invention. The present invention will now be described in further detail with reference to the accompanying drawings and specific embodiments:

[0054] Figure 1 This is a schematic diagram of the architecture of the first embodiment of this utility model.

[0055] Figure 2 This is a schematic diagram of the architecture of the second embodiment of this utility model.

[0056] Explanation of reference numerals in the attached figures

[0057] The first switch S1 is connected between the positive terminal of the battery and the three-phase inverter;

[0058] The second switch S2 is connected between the negative terminal of the battery and the three-phase inverter;

[0059] Third switch S3

[0060] Fourth switch S4

[0061] Fifth switch S5

[0062] Sixth switch S6

[0063] Seventh switch S7

[0064] Eighth switch S8

[0065] Ninth switch S9

[0066] First capacitor C1

[0067] Second capacitor C2

[0068] Third capacitor C3

[0069] First resistor R1

[0070] Second resistor R2

[0071] Third resistor R3

[0072] Fourth resistor R4

[0073] First bridge arm TPB1

[0074] Second bridge arm TPB2

[0075] Third bridge arm TPB3

[0076] Motor

[0077] Charging Gun CG

[0078] First inductor L1

[0079] Second inductor L2

[0080] First NMOS Q1

[0081] Second NMOS Q2

[0082] Third NMOS Q3

[0083] The fourth NMOS Q4. Detailed Implementation

[0084] The following specific embodiments illustrate the implementation of this utility model. Those skilled in the art can fully understand other advantages and technical effects of this utility model from the content disclosed in this specification. This utility model can also be implemented or applied through different specific embodiments, and various details in this specification can also be applied based on different viewpoints, with various modifications or changes made without departing from the overall design concept of the utility model. It should be noted that, in the absence of conflict, the following embodiments and features in the embodiments can be combined with each other. The following exemplary embodiments of this utility model can be implemented in many different forms and should not be construed as limited to the specific embodiments set forth herein. It should be understood that these embodiments are provided to make the disclosure of this utility model thorough and complete, and to fully convey the technical solutions of these exemplary embodiments to those skilled in the art. It should be understood that when an element is referred to as "connected" or "combined" to another element, the element can be directly connected or combined to the other element, or there may be intermediate elements. The difference is that when an element is referred to as "directly connected" or "directly combined" to another element, there are no intermediate elements. Throughout the drawings, the same reference numerals always denote the same elements.

[0085] First embodiment;

[0086] refer to Figure 1As shown, this utility model provides a high-voltage direct-drive high-voltage module, comprising:

[0087] The main drive high voltage pre-charge circuit is connected to both ends of the battery pack at its front end and to the motor via a three-phase inverter at its rear end. It is used to limit instantaneous surge current and charge the electric drive bus capacitor.

[0088] The downstream DC pre-charge circuit is connected between the motor and the DC transformer, and it provides a pre-charge path for the input capacitor of the downstream DC transformer.

[0089] The bleed circuit is connected in parallel across the high-voltage busbar and is used to ensure that the busbar capacitor voltage drops rapidly to a safe voltage after the system is powered off.

[0090] The output anti-backflow circuit is connected between the DC transformer and the output discharge circuit. It is used to prevent the voltage of the object being charged from affecting the high voltage system of the mobile storage and charging robot in reverse.

[0091] The output discharge circuit is connected between the output backflow prevention circuit and the charging gun. It is used to ensure that there is no high voltage residue when the charging gun or interface is disconnected and to discharge the charge on the output capacitor and cable.

[0092] For example, the main drive high-voltage pre-charge circuit includes:

[0093] The first switch S1 is connected between the positive terminal of the battery and the three-phase inverter;

[0094] The second switch S2 is connected between the negative terminal of the battery and the three-phase inverter;

[0095] The first capacitor C1 is connected in parallel with the three-phase inverter;

[0096] The first resistor R1 is connected between the positive terminal of the battery and the high-voltage side of the three-phase inverter;

[0097] The third switch S3 is connected between the first resistor R1 and the three-phase inverter.

[0098] An example, the downstream DC precharge circuit includes:

[0099] The fourth switch S4 is connected between the motor and the three-phase inverter.

[0100] The second resistor R2 is connected in series with the fifth switch S5 and then in parallel with the fourth switch S4.

[0101] An example, a discharge circuit includes:

[0102] The third resistor R3 and the sixth switch S6 are connected in series between the rear end of the DC precharge circuit and the low-voltage side of the main side of the DC transformer.

[0103] The second capacitor C2 is connected in parallel between the high-voltage side and the low-voltage side of the main winding of the DC transformer.

[0104] An example is an output backflow prevention circuit, including:

[0105] The anti-backflow diode D1 has its anode connected to the high-voltage side of the secondary winding of the DC transformer, and its cathode connected to the output discharge circuit.

[0106] The third capacitor, C3, is connected between the high-voltage side and the low-voltage side of the secondary winding of the DC transformer.

[0107] For example, an output bleeder circuit includes:

[0108] The fourth resistor R4 has its first end connected to the high-voltage side of the output anti-backflow circuit and the seventh switch S7, and its second end connected to the low-voltage side of the output anti-backflow circuit and the ninth switch S9 via the eighth switch S8.

[0109] The other end of the seventh switch S7 is connected to the high-voltage side of the charging gun;

[0110] The other end of the ninth switch S9 is connected to the low-voltage side of the charging gun.

[0111] Furthermore, it should be understood that although the terms "first," "second," etc., may be used herein to describe different elements, components, regions, layers, and / or portions, these elements, components, regions, layers, and / or portions should not be limited by these terms. These terms are only used to distinguish one element, component, region, layer, or portion from another element, component, region, layer, or portion. Therefore, without departing from the teachings of exemplary embodiments according to this utility model, the first element, component, region, layer, or portion discussed below may also be referred to as the second element, component, region, layer, or portion.

[0112] Second embodiment;

[0113] refer to Figure 2 As shown, this utility model provides a high-voltage direct-drive high-voltage module, which is a further improvement based on the first embodiment described above. The identical parts will not be repeated. It includes:

[0114] The DC transformer is replaced by a two-phase interleaved bidirectional synchronous Buck / Boost circuit;

[0115] For example, an interleaved bidirectional synchronous Buck / Boost circuit includes:

[0116] One end of the first inductor L1 is connected to the midpoint phase 1 of the first NMOS Q1 and the second NMOS Q2, and the other end is connected to the output positive terminal;

[0117] One end of the second inductor L2 is connected to the midpoint phase 2 of the third NMOS Q3 and the fourth NMOS Q4, and the other end is connected to the output positive terminal;

[0118] Four NMOS transistors, Q1 to Q4, form two half-bridges;

[0119] The bidirectional buck / boost circuit enables bidirectional energy transfer between the high-voltage battery and the new energy vehicle battery.

[0120] Third embodiment;

[0121] This utility model provides a mobile storage and charging integrated robot, whose high-voltage direct-drive high-voltage module is the high-voltage direct-drive high-voltage module described in either the first embodiment or the second embodiment above.

[0122] Unless otherwise defined, all terms used herein (including technical and scientific terms) shall have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. It will also be understood that, unless expressly defined herein, terms such as those defined in a general dictionary shall be interpreted as having the meaning consistent with their meaning in the relevant field context, and not as having an idealized or overly formal meaning.

[0123] The present invention has been described in detail above through specific embodiments and examples, but these are not intended to limit the present invention. Many modifications and improvements can be made by those skilled in the art without departing from the principles of the present invention, and these should also be considered within the scope of protection of the present invention.

Claims

1. A high voltage direct drive high voltage module, characterized in that, include: The main drive high voltage pre-charge circuit is connected to both ends of the battery pack at its front end and to the motor via a three-phase inverter at its rear end. It is used to limit instantaneous surge current and charge the electric drive bus capacitor. The downstream DC pre-charge circuit is connected between the motor and the DC transformer, and it provides a pre-charge path for the input capacitor of the downstream DC transformer. The discharge circuit is connected in parallel across the high-voltage busbar and is used to ensure that the busbar capacitor voltage drops rapidly to a safe voltage after the system is powered off. The output anti-backflow circuit is connected between the DC transformer and the output discharge circuit. It is used to prevent the voltage of the object being charged from affecting the high voltage system of the mobile storage and charging robot in reverse. The output discharge circuit is connected between the output backflow prevention circuit and the charging gun. It is used to ensure that there is no high voltage residue when the charging gun or interface is disconnected and to discharge the charge on the output capacitor and cable.

2. The high voltage direct drive high voltage module of claim 1, wherein: The DC transformer is replaced by a two-phase interleaved bidirectional synchronous Buck / Boost circuit.

3. The high-voltage direct-drive high-voltage module of claim 1 or 2, characterized in that The main drive high-voltage pre-charge circuit includes: The first switch (S1) is connected between the positive terminal of the battery and the three-phase inverter; The second switch (S2) is connected between the negative terminal of the battery and the three-phase inverter; The first capacitor (C1) is connected in parallel with the three-phase inverter; The first resistor (R1) is connected between the positive terminal of the battery and the high-voltage side of the three-phase inverter; The third switch (S3) is connected between the first resistor (R1) and the three-phase inverter.

4. The high voltage direct drive high voltage module of claim 1 or 2, wherein, The downstream DC precharge circuit includes: The fourth switch (S4) is connected between the motor and the three-phase inverter. The second resistor (R2) is connected in series with the fifth switch (S5) and then in parallel with the fourth switch (S4).

5. The high voltage direct drive high voltage module of claim 1 or 2, wherein, The bleeder circuit includes: The third resistor (R3) and the sixth switch (S6) are connected in series between the rear end of the DC precharge circuit and the low-voltage side of the main side of the DC transformer; The second capacitor (C2) is connected in parallel between the high-voltage side and the low-voltage side of the main winding of the DC transformer.

6. The high voltage direct drive high voltage module of claim 1 or 2, wherein, Output backflow prevention circuit, including: The anti-reverse-current diode (D1) has its anode connected to the high-voltage side of the secondary winding of the DC transformer, and its cathode connected to the output discharge circuit. The third capacitor (C3) is connected between the high-voltage side and the low-voltage side of the secondary side of the DC transformer.

7. The high voltage direct drive high voltage module of claim 1 or 2, wherein, The output bleeder circuit includes: The fourth resistor (R4) has its first end connected to the high-voltage side of the output anti-backflow circuit and the seventh switch (S7), and its second end connected to the low-voltage side of the output anti-backflow circuit and the ninth switch (S9) via the eighth switch (S8). The other end of the seventh switch (S7) is connected to the high-voltage side of the charging gun; The other end of the ninth switch (S9) is connected to the low-voltage side of the charging gun.

8. A mobile charging and storing integrated robot, characterized in that: Its high-voltage direct-drive high-voltage module is any one of the high-voltage direct-drive high-voltage modules described in claims 1-7.

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