An isolated super capacitor energy injection system with wide input voltage

Abstract

The utility model discloses a kind of wide input voltage's isolated super capacitor energy injection system, comprising: DSP signal processing and control circuit, display module, communication and external control input circuit, alternating current input and rectification filter circuit, high frequency phase-shift H bridge inverter circuit, high frequency overcurrent protection and direct-coupled circuit, high frequency isolation resonant open transformer, high frequency bridge rectifier filter circuit, output current detection circuit, output voltage detection circuit, secondary high frequency filter circuit, differential voltage detection circuit;The utility model can be according to the characteristic curve of super super capacitor by communication mode real-time input characteristic data, let charging characteristic more adapt to the characteristic demand of super capacitor, or implant super capacitor charging characteristic curve to local equipment in advance, system automatically tracks characteristic curve.

Description

Technical Field

[0001] This utility model relates to the field of supercapacitor module technology, specifically to an isolated supercapacitor power injection system with a wide input voltage range. Background Technology

[0002] With the increasing application of supercapacitors in various fields such as new energy, transportation, industry, military, and medical equipment, the demand for intelligent analysis and comprehensive prediction of supercapacitor system performance is gradually emerging in these fields.

[0003] In existing large-scale supercapacitor application projects, all supercapacitor balancing systems and management systems can only monitor the voltage of individual supercapacitor cells or modules, perform different forms of balancing, and monitor charging and discharging current. Currently, there is no equipment on the market capable of dynamically testing the capacity, internal resistance, and other performance characteristics of supercapacitor energy storage systems during system application, nor is there any equipment capable of dynamically and intelligently analyzing the health status of supercapacitor energy storage systems. Utility Model Content

[0004] The purpose of this invention is to provide an isolated supercapacitor energy injection system with a wide input voltage range, in order to solve the technical problems in the background art.

[0005] To achieve the above objectives, the present invention adopts the following technical solution:

[0006] A wide-input-voltage isolated supercapacitor power injection system includes: a DSP signal processing and control circuit, a display module, a communication and external control input circuit, an AC input and rectification filtering circuit, a high-frequency phase-shifting H-bridge inverter circuit, a high-frequency overcurrent protection and DC blocking coupling circuit, a high-frequency isolated resonant open transformer, a high-frequency bridge rectification filtering circuit, an output current detection circuit, an output voltage detection circuit, a secondary high-frequency filtering circuit, and a differential voltage detection circuit; wherein:

[0007] The AC input and the input terminal of the rectifier and filter circuit are connected to a three-phase or single-phase AC mains voltage;

[0008] The AC input and the DC output of the rectifier and filter circuit are connected in two separate paths.

[0009] The PWM signal output of the DSP signal processing and control circuit is amplified by an isolated drive and then connected to the control terminal of the high-frequency phase-shifting H-bridge inverter circuit.

[0010] The high-frequency square wave output terminal of the high-frequency phase-shifting H-bridge inverter circuit is connected to the input terminal of the high-frequency overcurrent protection and DC blocking coupling circuit.

[0011] The output terminal of the high-frequency overcurrent protection and DC blocking coupling circuit is connected to the primary side of the high-frequency isolation resonant open transformer;

[0012] The secondary winding of the high-frequency isolation resonant open transformer is connected to the input terminal of the high-frequency bridge rectifier filter circuit.

[0013] The output of the high-frequency bridge rectifier filter circuit is connected in three ways.

[0014] The signal output terminal of the output current detection circuit is connected to the current feedback input terminal of the DSP signal processing and control circuit;

[0015] The signal output terminal of the output voltage detection circuit is connected to the voltage feedback input terminal of the DSP signal processing and control circuit;

[0016] The output of the secondary high-frequency filter circuit is connected to the positive terminal of an external supercapacitor energy storage unit;

[0017] The detection terminal of the differential voltage detection circuit is connected in parallel to the positive and negative terminals of the external supercapacitor energy storage unit, and its signal output terminal is connected to the differential voltage input terminal of the DSP signal processing and control circuit.

[0018] The display signal output terminal of the DSP signal processing and control circuit is connected to the input terminal of the display module;

[0019] The communication terminal of the DSP signal processing and control circuit is connected to the communication and external control input circuit.

[0020] In some embodiments, the AC input and the DC output of the rectifier and filter circuit are connected in two separate paths: including:

[0021] The first connection is to the input terminal of the system power module;

[0022] The second path connects to the DC bus input of the high-frequency phase-shifting H-bridge inverter circuit.

[0023] In some embodiments, the output of the high-frequency bridge rectifier filter circuit is connected in three ways: including:

[0024] The first path connects to the input terminal of the output current detection circuit;

[0025] The second path connects to the input terminal of the secondary high-frequency filter circuit;

[0026] The third path connects to the input terminal of the output voltage detection circuit.

[0027] In some embodiments, the high-frequency overcurrent protection and DC blocking coupling circuit includes an isolation current signal output terminal connected to the overcurrent protection signal input terminal of the DSP signal processing and control circuit.

[0028] In some embodiments, the output current detection circuit uses a series sampling resistor or a Hall effect device connected to the negative terminal of the output, and the sampled signal is amplified and fed back to the DSP signal processing and control circuit.

[0029] In some embodiments, the differential voltage detection circuit employs opto-isolation or magneto-electric isolation, and its isolation signal output terminal is connected to the DSP signal processing and control circuit.

[0030] In some embodiments, the communication and external control input circuitry is connected to external devices via isolated digital I / O or CAN / RS485 bus, and inputs external control signals to the DSP signal processing and control circuitry.

[0031] In some embodiments, the magnetic core of the high-frequency isolation resonant open transformer adopts an EE-type ferrite stacked structure or a toroidal magnetic core structure.

[0032] When using EE-type ferrite, the magnetic core has physical openings to increase leakage inductance;

[0033] When using a toroidal core, its inherent leakage inductance characteristics are directly utilized.

[0034] In some embodiments, the rectifier device of the high-frequency bridge rectifier filter circuit is a silicon carbide high-voltage diode, a fast recovery diode, or an ultra-fast recovery diode; the filter device is a high-voltage film capacitor, an electrolytic capacitor, or a combination thereof.

[0035] The system power supply module is a wide input voltage switching power supply or a power frequency transformer linear power supply, and its output terminal is connected to the power supply terminal of all sub-modules.

[0036] In some embodiments, the system performs the following operations in the DSP signal processing and control circuitry:

[0037] Calculate the internal resistance of the supercapacitor based on the differential voltage detection value:

[0038]

[0039] Where U1 is the voltage at the end of constant current, U2 is the voltage after 5 seconds of wave blocking, and I is the charging current;

[0040] Calculate the capacity based on the current curve, voltage curve, and constant current time:

[0041]

[0042] Where C represents the actual capacitance of the supercapacitor energy storage unit in the current state, T represents the duration of constant current charging, and ΔU represents the voltage change of the supercapacitor during charging.

[0043] Compare the internal resistance / capacitance with the initial value, and output the health assessment result to the display module or communication circuit.

[0044] This utility model has the following beneficial effects:

[0045] 1. This utility model can input characteristic data in real time through communication based on the characteristic curve of the supercapacitor, so that the charging characteristics are more adapted to the characteristic requirements of the supercapacitor, or pre-embed the supercapacitor charging characteristic curve into the device, and the system automatically tracks the characteristic curve.

[0046] 2. This utility model can detect and evaluate the actual capacity of the external target supercapacitor energy storage unit in stages during use.

[0047] 3. This utility model can assess and predict the total internal resistance of the external target supercapacitor energy storage unit at the end of each constant current.

[0048] 4. This utility model adopts a modular design and has flexible communication methods, which can be applied to various supercapacitor application projects. Attached Figure Description

[0049] Figure 1 This is a block diagram of the system components. Detailed Implementation

[0050] To make the objectives, technical solutions, and advantages of this application clearer, the technical solutions in the embodiments of this application will be described in more detail below with reference to the accompanying drawings. In the drawings, the same or similar reference numerals denote the same or similar components or components having the same or similar functions throughout. The described embodiments are some, but not all, of the embodiments of this application. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain this application, and should not be construed as limiting this application. All other embodiments obtained by those skilled in the art based on the embodiments of this application without creative effort are within the scope of protection of this application.

[0051] The embodiments of this application will now be described in detail with reference to the accompanying drawings.

[0052] In the description of this application, it should be noted that, unless otherwise expressly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, an indirect connection through an intermediate medium, or the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0053] In the description of this application, it should be understood that the terms "upper", "lower", "front", "back", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the accompanying drawings, and are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this application.

[0054] Furthermore, the terms “comprising” and “having”, and any variations thereof, are intended to cover non-exclusive inclusion, such that a process, method, system, product, or display that includes a series of steps or units is not necessarily limited to those steps or units that are explicitly listed, but may include other steps or units that are not explicitly listed or that are inherent to such process, method, product, or display.

[0055] The following will combine Figure 1 This application provides a detailed description of a wide-input-voltage isolated supercapacitor power supply system according to its embodiments. It is important to note that the following embodiments are merely illustrative of this application and do not constitute a limitation thereof.

[0056] This invention can change the existing charging methods and approaches in current supercapacitor application industries (especially in the fields of new energy, transportation, industry, military, and medical equipment), thereby further ensuring the safety of application systems. Simultaneously, it can automatically analyze and evaluate the overall capacity and internal resistance of the target supercapacitor energy storage system through the process data recorded by this invention. Furthermore, it can predict the lifespan of the supercapacitor, providing data to the upper-level management system of the specific application system, enabling more accurate safety assessments of the overall system, timely system maintenance, and reducing the occurrence of safety accidents in existing high-voltage, high-capacity, or high-energy energy storage systems.

[0057] Example 1:

[0058] like Figure 1 As shown, this utility model discloses a wide input voltage isolated supercapacitor power supply system. It includes a DSP signal processing and control circuit, a display module, a communication and external control input circuit, an AC input and rectification / filtering circuit, a system power supply module, a high-frequency phase-shifting H-bridge inverter circuit, a high-frequency overcurrent protection and DC blocking coupling circuit, a high-frequency isolated resonant open-type transformer, a high-frequency bridge rectification / filtering circuit, an output current detection circuit, an output voltage detection circuit, a secondary high-frequency filter circuit, and a differential voltage detection circuit. Wherein:

[0059] The AC input and the input terminal of the rectifier and filter circuit are connected to a three-phase or single-phase AC mains voltage;

[0060] The AC input and the DC output of the rectifier and filter circuit are connected in two separate paths:

[0061] The first connection is to the input terminal of the system power module;

[0062] The second path connects to the DC bus input of the high-frequency phase-shifting H-bridge inverter circuit.

[0063] The PWM signal output of the DSP signal processing and control circuit is amplified by an isolated drive and then connected to the control terminal of the high-frequency phase-shifting H-bridge inverter circuit.

[0064] The high-frequency square wave output terminal of the high-frequency phase-shifting H-bridge inverter circuit is connected to the input terminal of the high-frequency overcurrent protection and DC blocking coupling circuit.

[0065] The output terminal of the high-frequency overcurrent protection and DC blocking coupling circuit is connected to the primary side of the high-frequency isolation resonant open transformer;

[0066] The secondary winding of the high-frequency isolation resonant open transformer is connected to the input terminal of the high-frequency bridge rectifier filter circuit.

[0067] The output of the high-frequency bridge rectifier filter circuit is connected in three ways:

[0068] The first path connects to the input terminal of the output current detection circuit;

[0069] The second path connects to the input terminal of the secondary high-frequency filter circuit;

[0070] The third path connects to the input terminal of the output voltage detection circuit.

[0071] The signal output terminal of the output current detection circuit is connected to the current feedback input terminal of the DSP signal processing and control circuit;

[0072] The signal output terminal of the output voltage detection circuit is connected to the voltage feedback input terminal of the DSP signal processing and control circuit;

[0073] The output of the secondary high-frequency filter circuit is connected to the positive terminal of an external supercapacitor energy storage unit;

[0074] The detection terminal of the differential voltage detection circuit is connected in parallel to the positive and negative terminals of the external supercapacitor energy storage unit, and its signal output terminal is connected to the differential voltage input terminal of the DSP signal processing and control circuit.

[0075] The display signal output terminal of the DSP signal processing and control circuit is connected to the input terminal of the display module;

[0076] The communication terminal of the DSP signal processing and control circuit is connected to the communication and external control input circuit.

[0077] The three-phase or single-phase AC mains voltage is input from the AC input and rectifier filter circuit. The input AC power is rectified into a DC fluctuating voltage and then smoothed and filtered. The filtered DC voltage is sent to the system power module to be converted into low-voltage power supply with different voltage values ​​required by each sub-module of the system, so as to ensure the normal operation of each sub-module.

[0078] On the other hand, the DC bus of the high-frequency phase-shifted H-bridge inverter circuit is fed by the phase-shifted PWM signal generated by the DSP digital signal processor. After being isolated and amplified, the signal drives the four power MOSFETs in the H-bridge inverter circuit to continuously switch and work interactively according to the design logic. A high-frequency alternating high-voltage square wave of a specific frequency is used. The signal is then coupled to the high-frequency isolation resonant open transformer through the high-frequency overcurrent protection and DC blocking coupling circuit. A corresponding high-frequency pulse voltage is generated on the secondary side of the transformer. After being rectified and filtered by the high-frequency bridge rectifier and filter circuit, the output DC current is detected by the output current detection circuit. After being discharged, the current signal is sent to the DSP digital signal processor. Through software calculation, a closed-loop constant current logic is formed to control the phase shift of the phase-shifted square wave. The output DC voltage is then filtered again by the secondary high-frequency filter circuit and sent to the external supercapacitor energy storage unit.

[0079] Meanwhile, the differential voltage detection circuit will monitor the differential voltage of the external supercapacitor energy storage unit in real time throughout the process. When the system finishes constant current charging of the external supercapacitor energy storage unit, the system automatically records the differential voltage of the energy storage unit. Then, the bridge inverter circuit is blocked for 5 seconds, and the system automatically records the differential voltage of the energy storage unit again. The absolute values ​​of the two recorded differential values ​​are calculated by the program inside the DSP to obtain the difference between the two. The difference is then divided by the most recently detected effective current to calculate the relative overall internal resistance of the external supercapacitor energy storage unit.

[0080] The system performs the following operations in the DSP signal processing and control circuit:

[0081] Calculate the internal resistance of the supercapacitor based on the differential voltage detection value:

[0082]

[0083] Where U1 is the voltage at the end of constant current, U2 is the voltage after 5 seconds of wave blocking, and I is the charging current;

[0084] Next, the system retrieves the previously recorded real-time current curve data, voltage curve data, and effective constant current time data. The program then uses formulas...

[0085] Calculate the capacity based on the current curve, voltage curve, and constant current time:

[0086]

[0087] Where C represents the actual capacitance of the supercapacitor energy storage unit in its current state, T represents the duration of constant current charging, and ΔU represents the voltage change of the supercapacitor during charging. The current comprehensive capacity of the external supercapacitor energy storage unit is calculated. By comparing this series of calculations with the initial system values, the health level of the supercapacitor energy storage unit under test is deduced. This achieves the innovative effect of this invention: enabling special charging based on the characteristics of supercapacitors, and simultaneously testing the overall capacity and internal resistance of the supercapacitor energy storage unit.

[0088] The DSP signal processing and control circuit, the core unit of the system control and signal processing of this utility model, is mainly composed of TMS320F280025 and its peripheral devices.

[0089] The display module, mainly composed of OLEDs, is responsible for displaying system parameters.

[0090] The communication and external control input circuit is responsible for data communication between the local unit and the upper management system, as well as for isolating I / O control inputs and status outputs.

[0091] The AC input and rectification filter circuit is mainly responsible for AC input common-mode filtering, AC-CDC rectification and conversion, DC filtering and other functions.

[0092] The system power module converts the rectified AC DC voltage into various low-voltage DC voltages required for the normal operation of each sub-module of the system.

[0093] The high-frequency phase-shifting H-bridge inverter circuit converts the stable DC bus voltage into a corresponding high-frequency high-voltage alternating square wave based on the logic timing and phase-shifting angle issued by the DSP control system.

[0094] The high-frequency overcurrent protection and DC blocking coupling circuit isolates, collects, filters, and amplifies the high-frequency alternating current before sending it to the analog signal input pin of the DSP control unit. On the other hand, it provides DC isolation for the high-frequency main current sent to the power transformer.

[0095] The high-frequency isolation resonant open transformer realizes the high-frequency conversion of power energy into electromagnetic energy, and increases leakage inductance by opening the transformer core in its physical structure, thereby achieving the effect of frequency domain resonance.

[0096] The high-frequency bridge rectifier and filter circuit is responsible for DC rectification and filtering of the high-frequency pulse voltage of the transformer secondary.

[0097] The output current detection circuit is responsible for detecting the output current using the negative terminal current, filtering and amplifying the current signal, and sending it to the analog signal input pin of the DSP control unit. This signal serves as the basis for output current, output power, and control, as well as for calculating parameters such as capacity and internal resistance of the target supercapacitor energy storage unit.

[0098] The output voltage detection circuit is used to detect the output voltage of the local system in real time.

[0099] The secondary high-frequency filter circuit filters the output voltage again for high-frequency components, minimizing the impact on the stability of the output voltage caused by the sampling resistor of the current detection circuit.

[0100] The differential voltage detection circuit is the core of this invention for monitoring the internal resistance of the target supercapacitor energy storage unit. It is mainly responsible for real-time detection of the differential voltage of the target supercapacitor energy storage unit, sending the differential voltage to the DSP system unit in real time for process data analysis, and using it as the basis for calculating the internal resistance of the target supercapacitor energy storage unit.

[0101] Preferably, the DSP signal processing and control circuit adopts a digital signal processing and control circuit with TMS320F280025 as the core device.

[0102] Preferably, the display module uses an OLED display screen, which is suitable for a wide range of high and low temperature environments.

[0103] Preferably, the communication and external control input circuit adopts a CAN-isolated communication method and an optocoupler-isolated IO digital signal input / output method.

[0104] Preferably, the AC input and rectifier filter circuit adopts a combination of a PCB-welded three-phase rectifier bridge and a thin-film capacitor.

[0105] Preferably, the system power module adopts a high-frequency switching power supply with a wide voltage range.

[0106] Preferably, the high-frequency phase-shifting H-bridge inverter circuit uses silicon carbide MOSFETs as switching devices.

[0107] Preferably, the high-frequency overcurrent protection and DC blocking coupling circuit uses a ferrite current transformer for signal coupling and multiple high-voltage thin-film capacitors connected in parallel for energy coupling.

[0108] Preferably, the high-frequency isolation resonant open transformer is designed with four or more EE50 ferrite chips stacked together.

[0109] Preferably, the high-frequency bridge rectifier filter circuit uses a combination of silicon carbide high-voltage diodes and high-voltage film capacitors.

[0110] Preferably, the output current detection circuit uses a sampling resistor connected in series at the negative terminal for sampling and amplifies the current using a non-inverting operational amplifier.

[0111] Preferably, the output voltage detection circuit uses a series resistor voltage divider method for sampling and performs second-order filtering.

[0112] Preferably, the secondary high-frequency filter circuit uses a high-frequency, high-voltage surface-mount ceramic capacitor.

[0113] Preferably, the differential voltage detection circuit adopts an opto-isolated differential voltage detection method.

[0114] The above description is only a preferred embodiment of the present utility model and is used to limit the present utility model. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.

Claims

1. A wide input voltage isolated supercapacitor energy injection system, characterized in that, include: The circuit includes: DSP signal processing and control circuit, display module, communication and external control input circuit, AC input and rectification filter circuit, high-frequency phase-shifting H-bridge inverter circuit, high-frequency overcurrent protection and DC blocking coupling circuit, high-frequency isolation resonant open transformer, high-frequency bridge rectifier filter circuit, output current detection circuit, output voltage detection circuit, secondary high-frequency filter circuit, and differential voltage detection circuit; among which: The AC input and the input terminal of the rectifier and filter circuit are connected to a three-phase or single-phase AC mains voltage; The AC input and the DC output of the rectifier and filter circuit are connected in two separate paths. The PWM signal output of the DSP signal processing and control circuit is amplified by an isolated drive and then connected to the control terminal of the high-frequency phase-shifting H-bridge inverter circuit. The high-frequency square wave output terminal of the high-frequency phase-shifting H-bridge inverter circuit is connected to the input terminal of the high-frequency overcurrent protection and DC blocking coupling circuit. The output terminal of the high-frequency overcurrent protection and DC blocking coupling circuit is connected to the primary side of the high-frequency isolation resonant open transformer; The secondary winding of the high-frequency isolation resonant open transformer is connected to the input terminal of the high-frequency bridge rectifier filter circuit. The output of the high-frequency bridge rectifier filter circuit is connected in three ways. The signal output terminal of the output current detection circuit is connected to the current feedback input terminal of the DSP signal processing and control circuit; The signal output terminal of the output voltage detection circuit is connected to the voltage feedback input terminal of the DSP signal processing and control circuit; The output of the secondary high-frequency filter circuit is connected to the positive terminal of an external supercapacitor energy storage unit; The detection terminal of the differential voltage detection circuit is connected in parallel to the positive and negative terminals of the external supercapacitor energy storage unit, and its signal output terminal is connected to the differential voltage input terminal of the DSP signal processing and control circuit. The display signal output terminal of the DSP signal processing and control circuit is connected to the input terminal of the display module; The communication terminal of the DSP signal processing and control circuit is connected to the communication and external control input circuit.

2. The system according to claim 1, characterized in that: The AC input and the DC output of the rectifier and filter circuit are connected in two separate paths: including: The first connection is to the input terminal of the system power module; The second path connects to the DC bus input of the high-frequency phase-shifting H-bridge inverter circuit.

3. The system according to claim 1, characterized in that: The output of the high-frequency bridge rectifier filter circuit is connected in three ways: including: The first path connects to the input terminal of the output current detection circuit; The second path connects to the input terminal of the secondary high-frequency filter circuit; The third path connects to the input terminal of the output voltage detection circuit.

4. The system according to claim 1, characterized in that: The high-frequency overcurrent protection and DC blocking coupling circuit includes an isolation current signal output terminal, which is connected to the overcurrent protection signal input terminal of the DSP signal processing and control circuit.

5. The system according to claim 1, characterized in that: The output current detection circuit uses a series sampling resistor or Hall effect device connected to the negative terminal of the output. The sampled signal is amplified and fed back to the DSP signal processing and control circuit.

6. The system according to claim 1, characterized in that: The differential voltage detection circuit uses opto-isolation or magneto-electric isolation, and its isolation signal output terminal is connected to the DSP signal processing and control circuit.

7. The system according to claim 1, characterized in that: The communication and external control input circuits are connected to external devices via isolated digital I / O or CAN / RS485 bus, and external control signals are input to the DSP signal processing and control circuits.

8. The system according to claim 1, characterized in that: The magnetic core of the high-frequency isolation resonant open transformer adopts an EE-type ferrite superimposed structure or a toroidal magnetic core structure; When using EE-type ferrite, the magnetic core has physical openings to increase leakage inductance; When using a toroidal core, its inherent leakage inductance characteristics are directly utilized.

9. The system according to claim 1, characterized in that: The rectifier devices in the high-frequency bridge rectifier filter circuit are silicon carbide high-voltage diodes, fast recovery diodes, or ultra-fast recovery diodes; the filter devices are high-voltage film capacitors, electrolytic capacitors, or combinations thereof.

10. The system according to claim 1, characterized in that: The system power supply module is a wide input voltage switching power supply or a power frequency transformer linear power supply, and its output terminal is connected to the power supply terminal of all sub-modules.

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