Power switching module and commercial vehicle battery swap station

Abstract

This utility model provides a power switching module and a commercial vehicle battery swapping station, comprising: a base plate; a tray fixedly supported by several support columns disposed in the base plate; a PCB board disposed in the center of the tray and terminal blocks at the edges; several first contactors distributed on the base plate; a second copper busbar, a fourth copper busbar, and a second contactor sequentially connected to the first contactors; a third copper busbar connected to the second copper busbar; a charging terminal interface connected to the first contactors through the third copper busbar; and a battery charging copper busbar connected to the second copper busbar through wires. The first and second contactors, through their internal contacts and arc-extinguishing devices, can effectively limit the magnitude of the inrush current, protecting the safety of the entire electrical system. The orderly arrangement of the PCB board, terminal blocks, copper busbars, and connectors effectively isolates and manages the circuit, reducing the risk of electrical faults and significantly improving the electrical safety of the commercial vehicle battery swapping station.

Description

Technical Field

[0001] This utility model relates to the field of commercial vehicle battery swapping station technology, specifically to a power switching module and a commercial vehicle battery swapping station. Background Technology

[0002] With the rapid development of the new energy vehicle industry, battery swapping stations for commercial vehicles, as key facilities for ensuring the range of electric vehicles, have become a focus of industry attention due to their efficient operation and intelligent management. Traditional new energy battery swapping station charging systems typically employ a design where each battery compartment is assigned a fixed charging module. Each battery compartment can only use its dedicated charging module for charging. When a battery in one compartment is charging, even if the charging modules in other compartments are idle, cross-compartment power sharing or parallel charging cannot be achieved, thus limiting the flexible allocation and efficient utilization of charging power. This not only affects the overall charging efficiency of the battery swapping station but also increases operating costs and wastes resources.

[0003] Chinese patent CN118214110A discloses a power switching method based on a new energy battery swapping station. The method uses a control board to control a contactor, which in turn controls the opening and closing of the power switching circuit. This allows two charging modules to be interconnected and then distributed to two battery compartments and four charging piles for charging. When the battery swapping station is idle, the module can charge other charging piles. Although this power switching method can theoretically improve charging efficiency, the interconnection of multiple charging modules and battery compartments, as well as the parallel connection of the charging pile outputs, increases the risk of electrical safety issues. The moment of power switching may generate large current and voltage fluctuations, posing a threat to the safety and stability of the system. Utility Model Content

[0004] This utility model provides a power switching module and a power swapping station for commercial vehicles to solve the electrical safety problem of the power switching module in commercial vehicle power swapping stations.

[0005] To solve the above problems, this utility model provides a power switching module, including: a base plate, a tray fixedly supported by a plurality of support columns disposed in the base plate, a PCB board disposed in the middle of the tray and a terminal block at the edge position, a plurality of first contactors distributed on the base plate, a second copper busbar, a fourth copper busbar, and a second contactor sequentially connected to the first contactors, a third copper busbar connected to the second copper busbar, a charging terminal interface connected to the first contactors through the third copper busbar, and a battery charging copper busbar connected to the second copper busbar through a wire;

[0006] By implementing the above scheme, the first and second contactors, through their internal contacts and arc-extinguishing devices, can effectively limit the magnitude of the inrush current, thereby protecting the circuit and equipment from damage, ensuring stable power supply to the load, and protecting the safety of the entire electrical system. The orderly arrangement of the PCB board, terminal blocks, contactors, and copper busbars effectively isolates and manages the circuit, reduces the risk of electrical faults, and further significantly improves the electrical safety of the commercial vehicle battery swapping station.

[0007] According to one embodiment of this utility model, eight second contactors are provided, arranged in a single row, and connected in pairs through a U-shaped fourth copper busbar; six first contactors are provided, divided into two groups, each group distributed in a triangular pattern on both sides of the middle of the substrate; the first and second contactors extend to the left and right through a cross-connected second and third copper busbar to form two independent branches connecting to the charging terminal interface; the first and second contactors are connected to the battery charging copper busbars of the two independent branches through the second copper busbar and wires. Through the above scheme, the current path is optimized, the current distribution is more uniform, and the electrical performance is improved. At the same time, the cross-connection of the copper busbars increases the heat dissipation area, which helps to dissipate heat quickly and prevents equipment damage due to overheating.

[0008] According to one embodiment of the present invention, the copper busbars are all connected to the contactors by bolts, which ensures tight contact between the copper busbars and the contactors, reduces contact resistance, improves the stability of electrical connection, effectively prevents current fluctuations and electrical faults caused by poor contact, and improves the reliability and safety of the power switching module.

[0009] This utility model also provides a commercial vehicle battery swapping station, including the aforementioned power switching module; it further includes: a housing, charging terminal areas opened on the left and right sides of the housing, a battery charging area opened on the rear right side of the housing, a multi-layer substrate vertically fixed inside the housing and equipped with the power switching module, a connecting plate located below the charging terminal area and fixed at one end to the inner wall of the housing, the other end of the connecting plate being fixed to a corner piece bent downwards from the substrate, a support piece fixed to the inner walls of the left and right sides of the bottom of the housing, a plurality of first copper busbars connected to the power switching module, a connector connected to the first copper busbars, and a Z-shaped charging module access copper busbar fixed to the bottom of the connector.

[0010] According to one embodiment of this utility model, the bottom of the first copper busbar, the second copper busbar, the third copper busbar, the Z-type charging module access copper busbar, and the battery charging copper busbar are all provided with a plurality of first insulating support columns and second insulating support columns. The bottom of the second insulating support column is provided with corrugated steel. Through the above scheme, the electrical insulation of the copper busbar is enhanced, effectively preventing direct contact between the copper busbar and other metal parts, thereby avoiding short circuits and electric shock accidents, and improving electrical safety performance. The corrugated steel further enhances the mechanical stability of the second insulating support column, preventing insulation failure caused by vibration or impact, and providing more stable support for the copper busbar.

[0011] According to one embodiment of the present invention, three sets of first insulating support columns are provided at the rear of the connector. Through the above scheme, the electrical insulation of the connector is enhanced, effectively preventing direct contact between the connector and other metal parts, avoiding short circuits and electric shock accidents, thereby improving the electrical safety performance of the power switching module.

[0012] According to one embodiment of the present invention, the substrate has N+2 layers, the power switching module is located in the middle of the substrate with a total of N layers, and the Z-type charging module is connected to the copper busbar on the N+2 layer of the substrate. Through the above scheme, the multi-layer design of the substrate enhances the overall structural stability of the power switching module, so that the module can maintain stable performance under long-term high-load operation. At the same time, the modular design allows each component to be replaced and upgraded independently, reducing maintenance costs and time.

[0013] According to one embodiment of the present invention, the substrate with the power switching module is provided with U-shaped through slots on both the left and right sides. The above solution facilitates the installation and output of the battery charging copper busbar and the charging terminal interface, and makes it convenient for maintenance and replacement.

[0014] According to one embodiment of the present invention, the above-mentioned connector is connected to the first copper busbar and the Z-type charging module access copper busbar by bolts.

[0015] According to one embodiment of the present invention, the first copper busbar is an L-shaped copper busbar, the second copper busbar is a straight copper busbar, and the third copper busbar is a wavy copper busbar. The above scheme helps to optimize the current path, so that the current flows more smoothly inside the power switching module, reduces the loss of current during transmission, and thus improves electrical performance. At the same time, the design of the wavy copper busbar increases the contact area between the copper busbar and the air, which is conducive to the rapid dissipation of heat.

[0016] The technical advantages of this application are as follows:

[0017] 1. The power switching module and commercial vehicle battery swapping station provided in this application improve the stability and reliability of electrical connections and reduce the risk of electrical faults by setting first and second contactors, optimizing the contactor arrangement and copper busbar connection structure.

[0018] 2. The multi-layer substrate and modular design facilitate the installation, maintenance and expansion of the equipment.

[0019] 3. By connecting the output circuit of the charging terminal in parallel through multiple power switching modules, the charging power of the charging pile is improved.

[0020] 4. By integrating multiple power switching modules into a single integrated power switching module, the design of the charging system for the battery swapping station is simplified. Only the power distribution and charging module power supply circuits need to be designed, and the placement position of the power switching module needs to be reserved. The external interface of the power switching module is unified, which can achieve direct installation and replacement. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the overall structure of a power switching module and a commercial vehicle battery swapping station provided by this utility model.

[0022] Figure 2 This is a front view structural diagram of a power switching module and a commercial vehicle battery swapping station provided by this utility model.

[0023] Figure 3 This is a rear-view structural diagram of a power switching module and a commercial vehicle battery swapping station provided by this utility model.

[0024] Figure 4 This is a schematic diagram of the box structure of a power switching module and a commercial vehicle battery swapping station provided by this utility model.

[0025] Figure 5 This utility model provides Figure 2 Schematic diagram of section AA.

[0026] Figure 6 This utility model provides Figure 2 Schematic diagram of the BB section.

[0027] Figure 7 This utility model provides Figure 2 Schematic diagram of the middle CC section

[0028] Figure 8 This utility model provides Figure 1 A magnified view of the details at point D.

[0029] Explanation of reference numerals in the attached figures:

[0030] 1. Housing; 2. Base plate; 3. Power switching module; 301. Terminal block; 302. PCB board; 303. Tray; 304. First contactor; 305. Second copper busbar; 306. Third copper busbar; 307. Charging terminal interface; 308. Battery charging copper busbar; 309. Second contactor; 310. Support column; 311. Wire; 312. Fourth copper busbar; 4. Charging terminal area; 5. Connecting plate; 6. Support component; 7. Z-type charging module access copper busbar; 8. Battery charging area; 9. First copper busbar; 10. Connector; 11. First insulating support column; 12. Second insulating support column; 13. Corrugated steel. Detailed Implementation

[0031] The following will be combined with the appendix Figures 1-8 The embodiments of the technical solution of this application are described in detail below. The following embodiments are only used to illustrate the technical solution of this application more clearly, and are therefore only examples and should not be used to limit the scope of protection of this application.

[0032] Reference Figures 1-8 This utility model provides a power switching module 3, including: a base plate 2, a tray 303 fixedly supported by a plurality of support columns 310 disposed in the base plate 2, a PCB board 302 disposed in the middle of the tray 303 and a terminal block 301 disposed at the edge position, a plurality of first contactors 304 distributed on the base plate 2, a second copper busbar 305, a fourth copper busbar 312 and a second contactor 309 sequentially connected to the first contactors 304, a third copper busbar 306 connected to the second copper busbar 305, a charging terminal interface 307 connected to the first contactors 304 through the third copper busbar 306, and a battery charging copper busbar 308 connected to the second copper busbar 305 through a wire 311;

[0033] The above scheme, by setting up the first and second contactors 309, can effectively limit the magnitude of the inrush current through their internal contacts and arc-extinguishing devices, thereby protecting the circuit and equipment from damage, ensuring stable power supply to the load, and protecting the safety of the entire electrical system. The orderly arrangement of the PCB board 302, terminal block 301, contactors, and copper busbars effectively isolates and manages the circuit, reduces the risk of electrical faults, and further significantly improves the electrical safety of the commercial vehicle battery swapping station.

[0034] The aforementioned second contactor 309 comprises eight units arranged in a single row, and the second contactors 309 are connected in pairs via a U-shaped fourth copper busbar 312. The first contactor 304 comprises six units, divided into two groups, each group being triangularly distributed on both sides of the middle of the substrate 2. The first contactor 304 and the second contactor 309 extend to the left and right respectively through the cross-connected second copper busbar 305 and third copper busbar 306, forming two independent branches that connect to the charging terminal interface 307. The first contactor 304 and the second contactor 309 are connected to the battery charging copper busbar 308 of the two independent branches via the second copper busbar 305 and wire 311. Through the above scheme, the current path is optimized, the current distribution is more uniform, and the electrical performance is improved. At the same time, the cross-connection of the copper busbars increases the heat dissipation area, which helps to dissipate heat quickly and prevents equipment damage due to overheating.

[0035] All of the copper busbars are connected to the contactors by bolts, which ensures tight contact between the copper busbars and the contactors, reduces contact resistance, improves the stability of electrical connections, effectively prevents current fluctuations and electrical faults caused by poor contact, and improves the reliability and safety of the power switching module 3.

[0036] This utility model also provides a commercial vehicle battery swapping station, including the aforementioned power switching module 3; it also includes: a charging terminal area 4 made of metal with good sealing and electromagnetic shielding performance, with charging terminal areas 4 on the left and right sides of the housing 1, and a battery charging area 8 on the rear right side of the housing 1. Seven layers of substrate 2 are vertically fixedly installed inside the housing 1, with the power switching module 3 located on the middle five layers of substrate 2, and the Z-shaped charging module access copper busbar 7 located on the seventh layer of substrate 2. U-shaped through slots are provided on both the left and right sides of the substrate 2 where the power switching module 3 is located, facilitating the installation and output of the battery charging copper busbar and charging terminal interface, and making maintenance and replacement convenient.

[0037] A connecting plate 5 located below the charging terminal area 4 and fixed at one end to the inner wall of the housing 1, the other end of the connecting plate 5 fixed to the corner piece bent downward on the base plate 2, a support piece 6 fixed to the inner walls of the left and right sides of the bottom of the housing 1, several first copper busbars 9 connected to the power switching module 3, a connecting piece 10 connected to the first copper busbars 9, and a Z-shaped charging module access copper busbar 7 fixed to the bottom of the connecting piece 10.

[0038] The bottom of the aforementioned first copper busbar 9, second copper busbar 305, third copper busbar 306, Z-type charging module access copper busbar 7, and battery charging copper busbar 308 are all equipped with several first insulating support columns 11 and second insulating support columns 12. The bottom of the second insulating support column 12 is provided with corrugated steel 13. Three sets of first insulating support columns 11 are provided behind the aforementioned connector 10. Through the above scheme, the electrical insulation of the copper busbar is enhanced, effectively preventing direct contact between the copper busbar and other metal parts, thereby avoiding short circuits and electric shock accidents.

[0039] The aforementioned substrate 2 has seven layers. The power switching module 3 is located in the middle of substrate 2, comprising five layers, and the Z-shaped charging module access copper busbar 7 is located on the seventh layer of substrate 2. This multi-layer design of substrate 2 enhances the overall structural stability of the power switching module 3, enabling the module to maintain stable performance even under prolonged high-load operation. Simultaneously, the modular design allows for independent replacement and upgrades of individual components, reducing maintenance costs and time. U-shaped through slots are provided on both the left and right sides of the substrate 2 housing the power switching module 3. This design facilitates the installation and output of the battery charging copper busbar 308 and the charging terminal interface 307, making maintenance and replacement easier.

[0040] The aforementioned connector 10 is bolted to the first copper busbar 9 and the Z-type charging module access copper busbar 7. The first copper busbar 9 is an L-shaped copper busbar, the second copper busbar 305 is a straight copper busbar, and the third copper busbar 306 is a wavy copper busbar. This design helps to optimize the current path, allowing the current to flow more smoothly inside the power switching module 3, reducing current loss during transmission, and thus improving electrical performance. At the same time, the wavy copper busbar design increases the contact area between the copper busbar and the air, which is beneficial for the rapid dissipation of heat.

[0041] Working principle:

[0042] At the start of charging, the Z-type charging module connects to copper busbar 7 as the current input, responsible for introducing the electrical energy provided by the external power supply into the power switching module 3. Connector 10 acts as a bridge for current transmission, connecting the Z-type charging module to copper busbar 7 and the first copper busbar 9. The current then passes through connector 10 and the first copper busbar 9. After the current reaches the core control section of the power switching module, PCB board 302, as the control center of the power switching module, sends control signals according to the charging demand, causing the second contactor 309 and the first contactor 304 to close sequentially. After the contactors close, the current is distributed sequentially through the second contactor 309, the second copper busbar 305, the first contactor 304, and the third copper busbar 306. The second copper busbar 305 guides the current to the battery charging copper busbar 308, providing charging current for the commercial vehicle battery; the third copper busbar 306 guides the current to the charging terminal copper busbar 307, providing charging current for the charging pile. The power switching module 3 thus achieves synchronous charging of the battery and the charging pile. Once the battery and charging station are fully charged, the PCB board 302 will send a control signal to disconnect the first contactor 304 and the second contactor 309 in sequence, thereby cutting off the current path and ending the charging process.

[0043] The above embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this application.

Claims

1. A power switching module, characterized in that, include: The substrate (2), a tray (303) fixedly supported by a plurality of support columns (310) provided in the substrate (2), a PCB board (302) in the middle of the tray (303) and a terminal block (301) at the edge position, a plurality of first contactors (304) distributed on the substrate (2), a second copper busbar (305), a fourth copper busbar (312) and a second contactor (309) sequentially connected to the first contactors (304), a third copper busbar (306) connected to the second copper busbar (305), a charging terminal interface (307) connected to the first contactor (304) through the third copper busbar (306), and a battery charging copper busbar (308) connected to the second copper busbar (305) through a wire (311).

2. The power switching module according to claim 1, characterized in that, There are eight second contactors (309), which are arranged in a single row and connected in pairs by the U-shaped fourth copper busbar (312); there are six first contactors (304), which are divided into two groups, each group being triangularly distributed on both sides of the middle part of the substrate (2); The first contactor (304) and the second contactor (309) are connected by a cross-shaped second copper busbar (305) and a third copper busbar (306), which extend to the left and right respectively to form two independent branches that connect to the charging terminal interface (307). The first contactor (304) and the second contactor (309) are connected to the battery charging copper busbar (308) of the two independent branches through the second copper busbar (305) and the wire (311).

3. The power switching module according to claim 2, characterized in that, All copper busbars are connected to the contactors by bolts.

4. A battery swapping station for commercial vehicles, characterized in that, Includes the power switching module as described in any one of claims 1 to 3; It also includes: a housing (1), charging terminal areas (4) opened on the left and right sides of the housing (1), a battery charging area (8) opened on the right side of the rear of the housing (1), a multi-layer substrate (2) vertically fixed inside the housing (1) and equipped with the power switching module (3), a connecting plate (5) located below the charging terminal area (4) and fixed at one end to the inner wall of the housing (1), the other end of the connecting plate (5) fixed to the corner piece bent downward on the substrate (2), a support member (6) fixed to the inner wall of the left and right sides of the bottom of the housing (1), a plurality of first copper busbars (9) connected to the power switching module (3), a connector (10) connected to the first copper busbars (9), and a Z-shaped charging module access copper busbar (7) fixed at the bottom of the connector (10).

5. The commercial vehicle battery swapping station according to claim 4, characterized in that, The bottom of the first copper busbar (9), the second copper busbar (305), the third copper busbar (306), the Z-type charging module access copper busbar (7), and the battery charging copper busbar (308) are provided with several first insulating support columns (11) and second insulating support columns (12), and the bottom of the second insulating support column (12) is provided with corrugated steel (13).

6. The commercial vehicle battery swapping station according to claim 5, characterized in that, Three sets of the first insulating support columns (11) are provided behind the connector (10).

7. The commercial vehicle battery swapping station according to claim 4, characterized in that, The substrate (2) has N+2 layers, the power switching module (3) is located in the middle of the substrate (2) with a total of N layers, and the Z-type charging module access copper busbar (7) is located in the N+2 layer of the substrate (2).

8. The commercial vehicle battery swapping station according to claim 7, characterized in that, The substrate (2) equipped with the power switching module (3) has U-shaped through slots on both the left and right sides.

9. The commercial vehicle battery swapping station according to claim 4, characterized in that, The connector (10) is connected to the first copper busbar (9) and the Z-type charging module access copper busbar (7) by bolts.

10. The commercial vehicle battery swapping station according to claim 4, characterized in that, The first copper busbar (9) is an L-shaped copper busbar, the second copper busbar (305) is a straight copper busbar, and the third copper busbar (306) is a wavy copper busbar.

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