A multi-gun direct-current charging power distribution device, a charging pile and a power supply system

Abstract

This utility model discloses a multi-gun DC charging power distribution device, charging pile, and power supply system. It comprises an AC input unit, a charging module group, and a power distribution unit connected in sequence. The power distribution unit includes a positive PDU and a negative PDU, each equipped with a first DC contactor and a second DC contactor. This technical solution adopts a hierarchical architecture of "AC input unit + charging module group + positive / negative PDU," and configures two types of DC contactors with different rated currents (e.g., 600A and 400A) within the PDU according to branch current levels. This allows high-current branches to meet the high-current output requirements of the liquid-cooled guns, while low-current branches can use lower-specification components, significantly reducing contactor material costs and size, minimizing conduction losses, and improving system energy efficiency. Simultaneously, a ring DC bus is introduced to connect each module and each gun in parallel, forming a power-sharing and redundant path. Even in the event of a single module / node failure, the remaining nodes can still continue to supply power.

Description

Technical Field

[0001] This utility model relates to the field of power supply technology, and in particular to a multi-gun DC charging power distribution device, a charging pile and a power supply system. Background Technology

[0002] With the surge in electric vehicle ownership, DC fast charging is gradually replacing traditional AC slow charging, becoming the mainstream direction for public and dedicated energy replenishment infrastructure. High-power DC charging systems typically consist of an AC input, a power conversion module group, and a DC power distribution unit (PDU), which distributes the AC mains power to multiple DC charging guns after rectification / conversion.

[0003] However, most solutions in related technologies still have two prominent problems: First, in order to be compatible with the high current output of liquid-cooled charging guns (commonly 600 A), most PDUs uniformly use high-specification DC contactors (600 A) to cover all branches. Even if some branches only require a small current, they are forced to use high-specification devices, resulting in high material costs, size and power consumption of contactors. Second, V2G (vehicle-to-grid bidirectional) functions are mostly deployed in the form of independent cabinets or independent charging positions, which require an additional gun position and installation space, resulting in a waste of power and site resources, and also increasing the system construction and maintenance costs.

[0004] Therefore, the relevant technologies need to be improved. Utility Model Content

[0005] The main objective of this invention is to provide a multi-gun DC charging power distribution device, a charging pile, and a power supply system, so as to at least solve the technical problems mentioned in the related technologies.

[0006] To achieve the above objectives, the first aspect of this utility model provides a multi-gun DC charging power distribution device, which includes an AC input unit, a charging module group, and a power distribution unit connected in sequence.

[0007] The AC input unit is used to receive AC power from the mains.

[0008] The charging module group is used to receive the AC power and convert it into DC power for transmission to the power distribution unit;

[0009] The power distribution unit includes a positive PDU and a negative PDU, and both the positive PDU and the negative PDU are equipped with a first DC contactor and a second DC contactor.

[0010] The first DC contactor is used to output a first rated output current to the corresponding charging gun through a first current channel, and the second DC contactor is used to output a second rated output current to the corresponding charging gun through a second current channel.

[0011] A second aspect of this utility model provides a charging pile, including a charging pile body and a multi-gun DC charging power distribution device as described in the first aspect, wherein the multi-gun DC charging power distribution device is built into the charging pile body.

[0012] A third aspect of this utility model provides a power supply system, including a power grid and a charging pile as described in the second aspect; the power grid is electrically connected to the charging pile and provides AC power.

[0013] This utility model relates to a multi-gun DC charging power distribution device, charging pile, and power supply system. By adopting a hierarchical architecture of "AC input unit + charging module group + positive / negative PDU", and configuring two types of DC contactors with different rated currents (such as 600A and 400A) in the PDU according to the branch current level, the high current branch can meet the high current output requirements of the liquid-cooled gun, while the low current branch can use low-specification components. This significantly reduces the material cost and volume of the contactors, reduces conduction losses, and improves system energy efficiency without sacrificing output capacity. At the same time, a ring DC bus is introduced to connect each module and each gun in parallel, forming a power sharing and redundancy path. When a single module / node fails, the remaining nodes can still continue to supply power, greatly improving the availability and reliability of the system. Attached Figure Description

[0014] To more clearly illustrate the technical solutions in the embodiments of this utility model or related technologies, the drawings used in the description of the embodiments or related technologies will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0015] Figure 1 This is a schematic diagram of the structure of the multi-gun DC charging power distribution device provided in the embodiments of this application;

[0016] Figure 2 This is a schematic diagram of a power distribution unit in one embodiment of this application;

[0017] Figure 3 This is a schematic diagram of a power distribution unit in one embodiment of this application;

[0018] Figure 4 This is a schematic diagram of the front structure of the charging pile in the embodiments of this application;

[0019] Figure 5 This is a schematic diagram of the rear structure of the charging pile in the embodiments of this application. Detailed Implementation

[0020] To make the inventive objectives, features, and advantages of this application more apparent and understandable, the technical solutions in the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of them. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0021] In this document, the term "embodiment" means that a particular feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment of this application. The appearance of this phrase in various places throughout the specification does not necessarily refer to the same embodiment, nor is it a separate or alternative embodiment mutually exclusive with other embodiments. It will be explicitly and implicitly understood by those skilled in the art that the embodiments described herein can be combined with other embodiments.

[0022] In the description of the embodiments of this application, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. The term "multiple" means two or more, unless otherwise explicitly specified. The term "comprising" indicates the presence of the described feature, whole, step, operation, element, and / or component, but does not exclude the presence or addition of one or more other features, wholes, steps, operations, elements, components, and / or sets thereof. The term "and / or" describes the relationship between related objects, indicating that three relationships may exist. For example, A and / or B may include three cases: A existing alone, A and B existing simultaneously, and B existing alone. The character " / " generally indicates that the related objects before and after are in an "or" relationship.

[0023] Unless otherwise defined, all technical terms used in the embodiments of this application have the same meaning as commonly understood by one of ordinary skill in the art; the terms used in the embodiments of this application are for the purpose of describing specific embodiments only and are not intended to limit this application; the terms "comprising" and "having" and any variations thereof in the specification, claims and foregoing description of the drawings of this application are intended to cover non-exclusive inclusion.

[0024] Furthermore, terms such as "exemplary," "for example," and "optional" are used to indicate illustrative purposes. Any technical solution described by the above terms in the embodiments of this application should not be construed as being more preferred or advantageous than other technical solutions. Specifically, these terms are intended to present the relevant technical concepts in terms of specific implementation methods.

[0025] Please refer to them in order. Figures 1 to 2This application provides a multi-gun DC charging power distribution device, which includes an AC input unit 10, a charging module group 20, and a power distribution unit 30 connected in sequence. The components are described below:

[0026] The AC input unit 10 receives three-phase AC power from the mains and, after processing by an AC switch / contaminator, overvoltage / undervoltage protection devices, and leakage protection devices, provides the controlled AC input to the charging module group 20. Preferably, the AC input unit 10 may be configured with a first AC circuit and a second AC circuit, with each circuit independently supplying power to the charging modules of different subgroups via an AC contactor, thereby achieving input-side redundancy.

[0027] The charging module group 20 can be composed of multiple parallel AC / DC power modules. Each module rectifies and converts the AC input into a controlled DC output. The positive and negative DC terminals of each module are connected in parallel to the positive and negative bus inside the power distribution unit 30, and the converted DC power is transmitted to the subsequent power distribution unit 30.

[0028] The power distribution unit 30 may include a positive PDU 301 and a negative PDU 302. The positive PDU 301 and the negative PDU 302 are respectively equipped with a first DC contactor S2 and a second DC contactor S1, and are matched according to the output level of the charging gun: the first DC contactor (e.g., a model with a rated DC operating current of not less than 600A) is connected in series in the first current channel (high current channel) to connect the DC+ and DC- branches of the corresponding liquid-cooled high current charging gun; the second DC contactor (e.g., a model with a rated DC operating current of not less than 400A) is connected in series in the second current channel (medium and low current channels) to connect the DC+ and DC- branches of the corresponding conventional power charging gun.

[0029] It should be noted that the first DC contactor S2 and the second DC contactor S1 have the following characteristics: 1) Same function: S1 and S2 are essentially DC contactors used to connect / disconnect their respective current channels (similar to "switching devices"). 2) Different channels: S2 is connected in series in a dedicated high-current (600A) channel, located in the high-power branch of the PDU bus, serving liquid-cooled high-current charging guns; S1 is connected in series in a medium-current (400A) channel, located in the conventional power branch of the bus, serving conventional charging guns. 3) Different rated levels: S2 is selected with a 600A rating to handle high-power output, while S1 is selected with a 400A rating to meet medium-power output. 4) Design purpose: By configuring the contactors in layers according to different current channels (S2 in the high-current channel, S1 in the medium-current channel), safety and reliability are ensured while reducing PDU material costs and improving space utilization.

[0030] Therefore, when the first DC contactor S2 is closed, it connects and carries the corresponding first current channel, enabling that channel to have a first rated output current capability (e.g., 600A); when the second DC contactor S1 is closed, it connects and carries the corresponding second current channel, enabling that channel to have a second rated output current capability (e.g., 400A). In other words, the first DC contactor S2 is used to conduct the first current channel by closing, thereby outputting the first rated output current (e.g., 600A) to the corresponding charging gun with a higher power demand; the second DC contactor S1 is used to conduct the second current channel by closing, thereby outputting the second rated output current (e.g., 400A) to the corresponding charging gun with a lower power demand.

[0031] As can be seen, the multi-gun DC charging power distribution device of this application adopts a hierarchical architecture of "AC input unit + charging module group + positive / negative PDU", and configures two types of DC contactors with different rated currents (such as 600A and 400A) in the PDU according to the branch current level. This allows the high current branch to meet the high current output requirements of the liquid-cooled gun, while the low current branch can use low-specification devices. This significantly reduces the material cost and volume of the contactors, reduces conduction losses, and improves system energy efficiency without sacrificing output capacity.

[0032] Please see Figure 2 The power distribution unit also includes a ring DC bus.

[0033] Specifically, the power distribution unit adopts a "ring-shaped DC bus + node contactor" structure. The positive and negative buses BUS+ and BUS- are connected end-to-end to form a closed loop, and the DC output of the charging module group is connected to the bus in a multi-point parallel manner. Multiple "output nodes" are set along the circumference of the bus, each node connected in series with a DC contactor: high-current nodes are equipped with the first contactor (e.g., 600A), and medium-current nodes are equipped with the second contactor (e.g., 400A). When power needs to be supplied to a specific charging gun, only the contactor of the corresponding node is closed, achieving selective disconnection / connection; when multiple guns are working simultaneously, current can reach each node from any direction along the ring bus, achieving power sharing. After any module or node fails and is disconnected, other nodes can still continue to supply power through the bus closed loop, thus balancing cost, distribution flexibility, and reliability. In other words, the "ring-shaped DC bus + node contactor" structure forms a power sharing and redundancy path, ensuring that other nodes can continue to supply power even when a single module / node fails, significantly improving system availability and reliability.

[0034] In addition, the power distribution unit can also be as follows: Figure 3 The “non-ring layout” shown means that under this linear topology, each module still achieves power sharing through parallel connection of corresponding branches. When a branch or node fails, the faulty branch is disconnected by its contactor, and the remaining nodes continue to be powered by the main line, thereby ensuring continuous operation of multiple guns.

[0035] In an optional embodiment of this application, the first DC contactor is set to 5, with a rated DC operating current of not less than 600A; the second DC contactor is set to 7, with a rated DC operating current of not less than 400A; wherein, the 600A-level contactors are respectively connected in series in the DC+ / DC- branch of the corresponding liquid-cooled high-current charging gun, and the 400A-level contactors are respectively connected in series in the DC+ / DC- branch of the corresponding conventional power charging gun.

[0036] It should be understood that the above rated current values ​​can be equivalently replaced based on the system voltage level and the power of the target gun position, and do not constitute a limitation on the protection range. In addition, multiple parallel low-current contactors can be used to replace a single 600A contactor. For example, multiple low-current contactors (such as 300A or 400A) can be connected in parallel to share the total current and reduce the cost of a single contactor.

[0037] Please return and continue reading. Figure 1 The charging module group 20 includes 7 unidirectional AC / DC modules and 1 bidirectional AC / DC module.

[0038] Specifically, 7 unidirectional AC / DC modules (i.e. Figure 1 The seven charging modules (1#-7#) are electrically connected to the DC output ports of the corresponding charging guns (1#-7#) to rectify and convert the AC input for unidirectional charging of the vehicle battery; the bidirectional AC / DC module (i.e. Figure 1 The #8 bidirectional charging module is electrically connected to the DC port of the #8 charging gun. Besides supplying power to the vehicle in charging mode, it can also feed DC energy from the vehicle back to the AC grid in V2G mode. For ease of scheduling, the control unit distributes and limits the output power of each module, prioritizing power balance when multiple charging guns are operating concurrently. When the #8 charging gun requires V2G, the control unit switches the power flow direction and power factor settings of the bidirectional module.

[0039] In an optional embodiment of this application, the AC input unit 10 includes a first AC contactor 101 and a second AC contactor 102.

[0040] Specifically, the first AC contactor is used to electrically connect to four unidirectional AC / DC modules (modules 1#-4#), and the second AC contactor is used to electrically connect to three unidirectional AC / DC modules (modules 5#-7#) and one bidirectional AC / DC module (module 8#). In other words, this embodiment achieves independent power-on / off and fault isolation for two separate power supply circuits by dividing the module group into two AC contactor zones, and supports grouped power scheduling and redundant operation.

[0041] In an optional embodiment of this application, the AC input unit further includes a first AC circuit breaker 103 and a second AC circuit breaker 104.

[0042] Specifically, the first AC circuit breaker 103 is disposed between the first AC mains input and the input terminal of the first AC contactor 101, and is used for overload / short circuit protection and segmented isolation of the first AC power supply circuit; the second AC circuit breaker 104 is disposed between the second AC mains input and the input terminal of the second AC contactor 102, and is used for overload / short circuit protection and segmented isolation of the second AC power supply circuit.

[0043] In an optional embodiment of this application, the power distribution unit is connected to eight charging guns (number 1-8).

[0044] Specifically, the first to seventh guns are unidirectional DC charging guns, and the eighth gun is a DC charging and discharging gun that supports bidirectional energy exchange between the vehicle and the grid. The rated output power of the first, second, third, fifth, and sixth guns is 80 kW, the rated output power of the fourth and seventh guns is 40 kW, and the rated output power of the eighth gun is 60 kW. The rated power of each gun is guaranteed by the number of contactor channels connected in parallel with the upstream AC / DC modules.

[0045] Please see Figure 4 This application also provides a charging pile, including a charging pile body and a multi-gun DC charging power distribution device as described in the above embodiments, wherein the multi-gun DC charging power distribution device is built into the charging pile body.

[0046] The specific structure and installation relationship of the charging pile are as follows:

[0047] The charging station itself is a vertical cabinet with an openable front door for maintenance. The lower part of the cabinet houses the AC input and primary switching unit, including a power supply leakage protection device 41 (1QFP), a terminal power supply miniature circuit breaker 42 (3QFP), a first AC input circuit breaker 103 (1QF) and a first AC contactor 101 (1KMA), and a second AC input circuit breaker 104 (2QF) and a second AC contactor 102 (2KMA). Two AC inputs are respectively introduced and connected to the AC side of the charging module group.

[0048] A power distribution unit is installed in the middle of the cabinet. The power distribution unit includes a positive PDU301 (PDU+) and a negative PDU302 (PDU-). The unit is equipped with a first DC contactor and a second DC contactor as described in the previous embodiment. The power distribution unit is connected to the DC output port 43 (DC+ / DC-) of each charging gun via a ring / non-ring DC bus.

[0049] DC-side protection components include DC surge protectors 1 / 2 / 3 (1SPD / 2SPD / 3SPD, i.e.) Figure 4 Devices labeled 44, 45, and 46 are connected between the DC bus and the chassis ground.

[0050] The safety and human-machine interface includes an emergency stop switch 47 (ESD) installed on the door panel and a power indicator 48 (LED) that displays AC power-on and system status.

[0051] The cabinet has pre-installed air ducts and mounting rails. The charging module group is installed in a drawer-style configuration above or to the side of the PDU, with the AC input unit located below it for easy wiring and heat dissipation.

[0052] During operation, two AC power sources enter the charging module group, and the DC output of the module group is connected in parallel to the PDU+ / PDU-. Different specifications of DC contactors within the PDU are selectively connected to the corresponding DC output ports 43 (DC+ / DC-) of the charging gun positions according to a scheduling strategy, achieving power distribution and fault isolation for each charging gun (numbers 1 to 8). A DC surge protector discharges surges. Upon triggering the emergency stop switch, the control power to the module and PDU is cut off to ensure safety. This charging pile has a compact structure, clear wiring, and is easy to install and maintain. It also enables integrated deployment of multi-gun DC fast charging and V2G functionality within the same cabinet.

[0053] This application also provides a power supply system, including a power grid and a charging pile as described in the above embodiments. The power grid is electrically connected to the charging pile and provides AC power.

[0054] This utility model relates to a multi-gun DC charging power distribution device, charging pile, and power supply system. By adopting a hierarchical architecture of "AC input unit + charging module group + positive / negative PDU", and configuring two types of DC contactors with different rated currents (such as 600A and 400A) in the PDU according to the branch current level, the high current branch can meet the high current output requirements of the liquid-cooled gun, while the low current branch can use low-specification components. This significantly reduces the material cost and volume of the contactors, reduces conduction losses, and improves system energy efficiency without sacrificing output capacity. At the same time, a ring DC bus is introduced to connect each module and each gun in parallel, forming a power sharing and redundancy path. When a single module / node fails, the remaining nodes can still continue to supply power, greatly improving the availability and reliability of the system.

[0055] The specific embodiments of the utility model have been described in detail above, but they are only examples, and the utility model is not limited to the specific embodiments described above. For those skilled in the art, any equivalent modifications or substitutions to the utility model are also within the scope of the utility model. Therefore, all equivalent transformations, modifications, and improvements made without departing from the spirit and principles of the utility model should be covered within the scope of the utility model.

Claims

1. A multi-gun DC charging power distribution device, characterized in that, The multi-gun DC charging power distribution device includes an AC input unit, a charging module group, and a power distribution unit connected in sequence. The AC input unit is used to receive AC power from the mains. The charging module group is used to receive the AC power and convert it into DC power for transmission to the power distribution unit; The power distribution unit includes a positive PDU and a negative PDU, and both the positive PDU and the negative PDU are equipped with a first DC contactor and a second DC contactor. The first DC contactor is used to output a first rated output current to the corresponding charging gun through a first current channel, and the second DC contactor is used to output a second rated output current to the corresponding charging gun through a second current channel.

2. The multi-gun DC charging power distribution device as described in claim 1, characterized in that, The power distribution unit also includes a ring DC bus; The ring-shaped DC bus is connected in parallel with the charging module group. The first DC contactor and the second DC contactor are respectively installed on different output nodes of the ring-shaped DC bus to selectively disconnect the DC output ports of each charging gun.

3. The multi-gun DC charging power distribution device as described in claim 2, characterized in that, The ring-shaped DC bus is used to achieve power sharing among the output nodes; In the event of a failure in any charging module or output node, the remaining modules continue to supply power to other output nodes via the ring DC bus.

4. The multi-gun DC charging power distribution device as described in claim 2, characterized in that, The first DC contactor consists of five 600A DC contactors, and the second DC contactor consists of seven 400A DC contactors; The 600A DC contactor is used for electrical connection with the liquid-cooled charging gun, and the 400A DC contactor is used for electrical connection with the conventional charging gun.

5. The multi-gun DC charging power distribution device as described in any one of claims 1 to 4, characterized in that, The charging module group includes 7 unidirectional AC / DC modules and 1 bidirectional AC / DC module; The unidirectional AC / DC module is connected to the output of each of the seven corresponding charging guns to provide unidirectional charging functionality, and the bidirectional AC / DC module is connected to the output of each of the seven corresponding charging guns to provide charging and V2G functionality.

6. The multi-gun DC charging power distribution device as described in claim 5, characterized in that, The AC input unit includes a first AC contactor and a second AC contactor; The first AC contactor is used to electrically connect to four unidirectional AC / DC modules, and the second AC contactor is used to electrically connect to three unidirectional AC / DC modules and one bidirectional AC / DC module.

7. The multi-gun DC charging power distribution device as described in claim 6, characterized in that, The AC input unit also includes a first AC circuit breaker and a second AC circuit breaker; The first AC circuit breaker is electrically connected to the input terminal of the first AC contactor, and the second AC circuit breaker is electrically connected to the input terminal of the second AC contactor.

8. The multi-gun DC charging power distribution device as described in claim 2, characterized in that, The power distribution unit is connected to eight charging guns; The first to seventh guns are unidirectional DC charging guns, and the eighth gun is a DC charging and discharging gun that supports bidirectional energy interaction between the vehicle and the grid. The rated output power of the first, second, third, fifth, and sixth guns is 80 kW, the rated output power of the fourth and seventh guns is 40 kW, and the rated output power of the eighth gun is 60 kW.

9. A charging pile, characterized in that, The device includes a charging pile body and a multi-gun DC charging power distribution device as described in any one of claims 1 to 8, wherein the multi-gun DC charging power distribution device is built into the charging pile body.

10. A power supply system, characterized in that, Includes the power grid and the charging pile as described in claim 9; The power grid is electrically connected to the charging pile and provides AC power.

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