New energy power supply box charging device for rail car

Abstract

The new energy power supply box charging device for rail vehicles provided in this application has copper brush blocks and copper-carbon electrode carbon brushes installed on a flat on-board connector and a ground connector, respectively. The ground connector is installed next to the track with the direction facing the track, and the on-board connector is installed on the side wall of the rail vehicle with the direction facing the ground connector. When the rail vehicle stops next to the ground device while traveling along the track, the copper brush blocks and copper-carbon electrode carbon brushes can be directly connected based on the on-board connector and the ground connector, eliminating the need for manual dragging of the charging connector, reducing manual operation steps, and improving the charging efficiency of the rail vehicle.

Description

Technical Field

[0001] This utility model relates to the field of charging device technology, specifically a charging device for a new energy power supply box for rail vehicles. Background Technology

[0002] Railcars in the metallurgical industry are primarily used for transportation during the steelmaking process. They carry ladles of molten iron, ladles of molten steel, slag ladle, slabs, etc., and transport them along fixed rail lines to their respective production locations. With the advancement of new energy technologies, many railcars are powered by new energy sources, requiring charging from ground-based chargers during operation. For example... Figure 1 This is a schematic diagram of the vehicle plug connection interface and contact arrangement in a DC charging interface as defined in the national standard charging standard. Based on the national standard DC charging interface, the charging sequence is as follows: a1: Complete the physical connection; After the charging gun is inserted, a physical connection is established between the charging gun and the vehicle charging head. This process is achieved based on the charging connection signals CC1 and CC2. a2: Low-voltage auxiliary power-on, the ground charger wakes up the BMS (BATTERYMANAGEMENT SYSTEM) through low-voltage auxiliary power signals (A+ and A-). a3: Establish communication connection based on CAN bus and complete charging handshake; this step is completed based on the charging communication signals CAN_H(S+) and CAN_H(S-); a4: Configure charging parameters; The BMS sends a charging request to the ground charger, which then determines whether charging can begin. a5: Charging process; BMS sends a charging request to the ground charger to complete the charging process; a6: Charging complete; When charging is complete, the BMS sends a charging end command to the charger to complete the charging process. based on Figure 1 The charging principle diagram of the interface is as follows Figure 2 As shown in the diagram, resistors R2, R3, and R4 are all 1kΩ resistors. The specific implementation process of step a1 is as follows: The on-site operator manually inserts the charging gun into the vehicle. After insertion, the resistance on CC1 of the ground charger changes from resistor R2 to a parallel connection of R2 and R4, thus the resistance changes from 1kΩ to 500Ω. Simultaneously, resistor R3 (1kΩ) is also connected to CC2 of the BMS. The ground charger and BMS determine the completion of the insertion action by detecting the resistance changes on CC2 and CC1, respectively, and then begin executing the subsequent charging processes a2~a6.

[0003] In existing technology, when a railcar needs charging, as the track moves near the ground charging area, the on-site operator manually inserts the charging gun into the vehicle's onboard plug to complete step a1. After step a6, the charging gun still needs to be manually removed. However, this requires a dedicated worker in the charging area to assist the railcar in the charging process. But in actual operation, this position is not fully staffed, and the overall efficiency is low due to manual operation. Utility Model Content

[0004] To address the issue of low charging efficiency in existing railcar technologies, this invention provides a new energy power supply box charging device for railcars, which can effectively reduce the degree of manual intervention in the docking process between railcars and ground charging equipment, thereby improving the charging efficiency of railcars.

[0005] The structure of this utility model is as follows: a new energy power box charging device for rail vehicles, characterized in that it includes: a charging power supply, an on-board connection device, and a ground connection device. The charging power supply is located in the charging area beside the track; the vehicle-mounted connection device is located on the railcar, and the ground connection device is installed in the charging area beside the track. The ground connection device includes: a ground support frame, a ground connector, and copper-carbon electrode carbon brushes. The ground connector is flat, and the copper-carbon electrode carbon brushes are disposed on one of the plates of the ground connector. Each copper-carbon electrode carbon brush is connected to the charging line of the charging power supply. The ground connector is installed beside the track via the ground support frame, facing the track. The vehicle-mounted connection device includes: a vehicle-mounted support frame, a vehicle-mounted connector, and copper brush blocks. The vehicle-mounted connector is flat, and the copper-carbon electrode carbon brushes are disposed on the plate surface of the vehicle-mounted connector. Each copper brush block is electrically connected to the charging line of the railcar's new energy power supply box. The vehicle-mounted connector is mounted on the side wall of the railcar via the vehicle-mounted support frame, facing the ground connector. The installation heights of the ground connector and the vehicle connector are adapted to each other; the number and type of the copper-carbon electrode carbon brush are set accordingly to the copper-carbon electrode carbon brush, and the copper-carbon electrode carbon brush and the copper brush block are installed in a mutually corresponding manner.

[0006] Its further features are: It also includes: a connection confirmation module, a vehicle-mounted connection signal generation module, and a ground connection signal generation module; The connection confirmation module includes: a ground sensor module, a vehicle-mounted sensor module, a first reflector, and a second reflector; The vehicle-mounted sensor module and the first reflector are mounted on the vehicle-mounted connection device, and the ground sensor module and the second reflector are mounted on the ground connection device. When the railcar arrives at the charging position and the copper-carbon electrode carbon brush and the copper brush block are successfully docked, the ground sensor module and the first reflector work together to emit a ground feedback position signal; the vehicle-mounted sensor module and the second reflector work together to emit a vehicle-mounted feedback position signal. The ground connection signal generation module generates a CC1 gun insertion signal analog signal based on the ground feedback position signal; The vehicle connection signal generation module generates a CC2 charging gun insertion simulation signal and a low-voltage auxiliary power supply simulation signal based on the vehicle feedback position signal. Both the ground sensor module and the vehicle-mounted sensor module are based on photoelectric sensors, namely photoelectric sensor SE1 and photoelectric sensor SE2, respectively. The second reflector is disposed on the plate surface of the copper-carbon electrode carbon brush on the ground connector; the second reflector is disposed parallel to the copper-carbon electrode carbon brush; the second reflector is disposed symmetrically in the horizontal direction with the center line connecting all the copper-carbon electrode carbon brushes as the center line; The vehicle-mounted sensor module is mounted on the vehicle-mounted connector and is located on the extension line of the line connecting the center points of all the copper brush blocks; the light signal emission direction of the vehicle-mounted sensor module is towards the second reflector. In the direction of travel of the railcar, the length of the second reflector is less than the length of the copper-carbon electrode carbon brush; the lengths of the first reflector and the second reflector are the same. The ground sensor module is mounted on the ground connector. The light signal emission direction of the ground sensor module is parallel to the line connecting the center points of all the copper-carbon electrode carbon brushes and is located in the direction perpendicular to the line connecting the center points of the copper-carbon electrode carbon brushes. The signal emission direction of the ground sensor module is towards the first reflector. The first reflector is parallel to the insertion direction of the copper brush block and is mounted on the vehicle support frame; the first reflector is symmetrically arranged on both sides of the horizontal direction of the line connecting the center points of all the copper brush blocks. The ground connection signal generation module includes: relay K1, resistor R2 and resistor R4; One end of resistor R2 is connected to the negative terminal of the DC power supply, and the other end of resistor R2 is connected to pin 30 of relay K2 as the CC1 signal output pin. One end of resistor R4 is connected to the negative terminal of the DC power supply, and the other end of resistor R4 is connected to pin 87 of relay K1. Pin 86 of relay K1 is connected to the signal output pin of photoelectric sensor SE1. Pin 85 of relay K1 is connected to the positive terminal of the power supply. The positive terminal pin of photoelectric sensor SE1 is connected to the positive terminal of the DC power supply, and the negative terminal pin of photoelectric sensor SE1 is connected to the negative terminal of the DC power supply. The vehicle connection signal generation module includes: resistor R3, relay K2, and relay K3; One end of resistor R3 is connected to the negative terminal of the DC power supply, and the other end of resistor R3 is connected to pin 87 of relay K3. Pin 30 of relay K3 is the CC2 signal output pin. Pin 85 of relay K3 is connected to pin 30 of relay K2, and pin 85 of relay K2 is then connected to the positive terminal of the DC power supply. Pin 86 of relay K3 is connected to pin 86 of relay K2 and the signal output pin of photoelectric sensor SE2. Pin 87 of relay K2 is the output pin of signal A+. The positive power supply pin of photoelectric sensor SE2 is connected to the positive terminal of the DC power supply, and the negative power supply pin of photoelectric sensor SE2 is connected to the negative terminal of the DC power supply. The connection methods between the copper-carbon electrode carbon brush and the copper brush block include: vertical connection and horizontal connection. The copper brush block is configured as 4 pieces, which are respectively connected to DC+, DC-, S+, and S- of the new energy power supply box; the copper-carbon electrode carbon brush is configured as 4 pieces, which are respectively connected to DC+, DC-, S+, and S- of the charging power supply. The width of the copper-carbon electrode carbon brush is greater than the width of the spring block, and the length of the copper-carbon electrode carbon brush is greater than the length of the spring block; The copper brush block includes: a housing, a spring block, a wire, a spring, a wire connector, and a base plate; the base plate is mounted on the mounting surface of the vehicle-mounted connector; the housing is a hollow structure with openings at both ends, the spring block is inserted into the inner cavity of the housing from one opening, and the other opening of the housing is mounted on the base plate; the spring is installed in the inner cavity of the spring block, and the two ends of the spring block respectively press against the spring block and the base plate; the wire connector is fixedly connected to the spring block, and the two ends of the wire are respectively connected to the wire connector and the charging line of the new energy battery box of the railcar; The housing includes: a base housing, trapezoidal guide plates, and limiting sliders. The inner cavity dimensions of the base housing are adapted to the length and width of the spring block, and the height is lower than the height of the spring block. The two trapezoidal guide plates are arranged on the base housing along the running direction of the spring block track vehicle, and the limiting sliders are arranged on the inner wall of the guide plates adjacent to the spring block. The spring block includes: a block body, a spring guide cavity, a limiting groove, and an insertion guide surface. One end of the block body is inserted into the inner cavity of the housing, and the other end is provided with the insertion guide surface. The spring guide cavity is opened at one end of the block body located in the inner cavity of the housing. One end of the spring is inserted into the spring guide cavity, and the other end is pressed against the base plate. The limiting groove is opened on two side walls adjacent to the block body and the guide plate. The position and width of the limiting groove are adapted to the position and size of the limiting slider.

[0007] The new energy power supply box charging device for rail vehicles provided in this application has copper brush blocks and copper-carbon electrode carbon brushes installed on a flat on-board connector and a ground connector, respectively. The ground connector is installed next to the track with the direction facing the track, and the on-board connector is installed on the side wall of the rail vehicle with the direction facing the ground connector. When the rail vehicle stops next to the ground device while traveling along the track, the copper brush blocks and copper-carbon electrode carbon brushes can be directly connected based on the on-board connector and the ground connector, eliminating the need for manual dragging of the charging connector, reducing manual operation steps, and improving the charging efficiency of the rail vehicle. Attached Figure Description

[0008] Figure 1 A diagram showing the layout of DC charging vehicle plugs as defined in the national standard for charging. Figure 2 A schematic diagram of the charging connection interface as defined in the national standard; Figure 3 A schematic diagram of the overall structure of a charging device for a new energy power supply box for rail vehicles; Figure 4 A schematic diagram showing the electrical connections of various components in the charging device for a new energy power supply box for rail vehicles. Figure 5 A schematic diagram of the structure when the ground connection device and the vehicle-mounted connection device are docked. Figure 6 This is a schematic diagram of the ground connection device. Figure 7 This is a structural schematic diagram of the vehicle-mounted connection device; Figure 8 This is a schematic diagram of the overall structure of the copper brush block; Figure 9 This is a schematic diagram of the shell structure; Figure 10 This is a schematic diagram of the spring block structure; Figure 11 A schematic diagram of the circuit structure for the ground connection signal generation module; Figure 12 This is a schematic diagram of the circuit structure of the vehicle-mounted connection signal generation module. Detailed Implementation

[0009] like Figure 3 and Figure 4 As shown, this application includes a charging device for a new energy power supply box for rail vehicles, comprising: a charging power supply (not marked in the figure), a controller (not marked in the figure), a ground connection device 3, and an on-board connection device 4. The charging power supply is located in the charging area beside the track 2; the rail vehicle 1 runs on the track 2, the on-board connection device 4 is located on the rail vehicle 1, and the ground connection device 3 is installed in the charging area beside the track 2.

[0010] like Figure 5 and Figure 6 As shown, the ground connection device 3 includes: a ground support frame 31, a ground connector 32, and copper-carbon electrode carbon brushes 33. The ground connector 32 is flat, and the copper-carbon electrode carbon brushes 33 are disposed on one surface of the ground connector 32. Each copper-carbon electrode carbon brush 33 is connected to the charging circuit of the charging power supply. A brush plate PE substrate and other related structural components are disposed between the copper-carbon electrode carbon brushes 33. The specific connection method can be implemented based on existing technology. The ground connector 32 is mounted beside the track 2 via the ground support frame 31, facing the track 2.

[0011] like Figure 5 and Figure 7 As shown, the vehicle-mounted connection device 4 includes: a vehicle-mounted connector 41, copper brush blocks 42, and a vehicle-mounted support frame 44. The vehicle-mounted connector 41 is flat, and the copper-carbon electrode carbon brush 33 is disposed on the plate surface of the vehicle-mounted connector 41. A PE substrate and related structural components are disposed between the copper brush blocks 42, and the specific connection method is based on the technology of the national standard charging socket. Each copper brush block 42 is electrically connected to the charging line of the new energy power supply box (not marked in the figure) of the railcar 1; the vehicle-mounted connector 41 is mounted on the side wall of the railcar 1 via the vehicle-mounted support frame 44, facing the ground connector 32.

[0012] Depending on the connection configuration of the vehicle-mounted connector 41 and the ground connector 32, the docking methods of the copper-carbon electrode carbon brush 33 and the copper brush block 42 include: vertical docking and horizontal docking. When both the ground connector 32 and the vehicle-mounted connector 41 are set vertically, the docking method of the copper-carbon electrode carbon brush 33 and the copper brush block 42 is horizontal docking; when both the ground connector 32 and the vehicle-mounted connector 41 are set horizontally, the docking method of the copper-carbon electrode carbon brush 33 and the copper brush block 42 is vertical docking. In this embodiment, the docking method of the copper-carbon electrode carbon brush 33 and the copper brush block 42 is set to vertical docking. The copper brush block 42 can be on top, or the copper-carbon electrode carbon brush 33 can be on top; in this embodiment, the copper-carbon electrode carbon brush 33 is positioned on top.

[0013] During installation, the ground connector 32 and the vehicle connector 41 are installed at the same height. The number and type of copper-carbon electrode carbon brushes 33 are set accordingly. The copper-carbon electrode carbon brushes 33 are set on the lower end face of the ground connector 32, and the copper brush block 42 is set on the upper end face of the vehicle connector 41. When the railcar 1 stops at the preset position next to the ground device 3 along the track 2, the copper-carbon electrode carbon brushes 33 and the copper brush block 42 installed on the vehicle connector 32 and the ground connector 41 can be directly connected without manual adjustment of the position.

[0014] When the vehicle needs charging, the remote control platform controls the railcar to move to the charging area, connecting the onboard connection device 4 to the ground connection device 3. This completes the connection between the power supply box's DC+, DC-, S+, and S- terminals and the charging base's DC+, DC-, S+, and S- terminals, thus initiating charging. During charging, the onboard PLC can disable the railcar's operation. After charging is complete, the existing electrical control system in the railcar can send a charging completion command to the remote control platform, simultaneously releasing the onboard PLC's control over the railcar's operation.

[0015] The specific preset parking position can be determined manually or based on the position sensor 5 to determine the current vehicle position. This application includes a position sensor 5, which is mounted on the body of the railcar 1. The position sensor 5 is implemented using a position-determining sensor module from the prior art, such as a laser sensor or a radar positioning module. Assuming it is based on a laser sensor, the laser sensor is positioned on... Figure 3 As shown in the diagram, a laser reflector (not marked) is installed outside the track at the preset parking position. When the railcar reaches the preset position, the laser emitted by the laser sensor is reflected at close range, and the position sensor module sends a stop signal. After the stop signal is issued, the railcar 1 can be stopped manually or by controlling the controller. The system collects the real-time position of the railcar 1 based on position sensor 5.

[0016] To ensure more accurate control of the railcar's position, another ground position sensor (not marked in the figure) can be installed near the ground connection device 3 in the charging area. Once both the ground position sensor and the on-vehicle position sensor 5 transmit position signals simultaneously, the accuracy of the railcar 1's stopping position can be determined. This prevents signal mistransmission problems caused by the on-vehicle position sensor 5 during operation.

[0017] Meanwhile, to ensure compatibility with structural errors between different railcars 1 and rails 2, the width of the copper-carbon electrode carbon brush 33 is greater than the width of the spring block 422, and the length of the copper-carbon electrode carbon brush 33 is greater than the length of the spring block 422. Even if the parking position of the railcar 1 has a slight error, the spring block 422 can still establish a connection with the copper-carbon electrode carbon brush 33. The specific length and width of the copper-carbon electrode carbon brush 33 are set according to historical data on the parking position error of the railcar 1.

[0018] To ensure compatibility with height errors during vertical docking and lateral distance errors during horizontal docking of the ground connector 32 and the vehicle connector 41, the copper brush block 42 is designed with elastic features in this application. The structure of the copper brush block 42 can be based on any existing structure capable of achieving the same function. In this embodiment, it is based on... Figures 8-10 The structure shown is implemented.

[0019] like Figure 8 As shown, the copper brush block 42 includes: a housing 421, a spring block 422, a wire 423, a spring 424, a wire connector 425, and a base plate 426; the base plate 426 is mounted on the mounting surface of the vehicle connector 41; the housing 421 is a hollow structure with openings at both ends, the spring block 422 is inserted into the inner cavity of the housing 421 from one opening, and the other opening of the housing 421 is mounted on the base plate 426; the housing 421 is provided with bolt holes 4214, and is fixedly mounted on the base plate 426 by bolts; the spring 424 is installed in the inner cavity of the spring block 422, and the two ends of the spring press against the spring block 422 and the base plate 426 respectively; the wire connector 425 is fixedly connected to the spring block 422 to prevent the wire from falling off during vehicle operation, and the two ends of the wire 423 are connected to the wire connector 425 and the charging line of the new energy power box of the railcar 1 respectively. When there is an error in the distance between the ground connector 32 and the vehicle connector 41, the position of the spring block 422 can be flexibly adjusted by the spring 424 installed between the spring block 422 and the base plate 426 during the process of inserting the spring block 422 between the ground connector 32 and the vehicle connector 41 to adapt to various errors.

[0020] like Figure 9As shown, the housing 421 includes a rectangular base housing 4211, trapezoidal guide plates 4212, and limiting sliders 4213. The inner dimensions of the base housing 4211 are adapted to the length and width of the spring block 422, and its height is lower than the height of the spring block 422. Two trapezoidal guide plates 4212 are arranged on the base housing 4211 along the running direction of the spring block track vehicle, and the limiting sliders 4213 are arranged on the inner wall of the guide plates 4212 adjacent to the side of the spring block 422. The guide plates 4212, which are low at both ends and high in the middle, can ensure that the spring block 422 can smoothly enter narrow spaces. Arranging the two trapezoidal guide plates 4212 on both sides of the spring block 422 along the running direction of the spring block track vehicle can ensure that the spring block 422 will not wobble significantly during the docking process with the copper-carbon electrode carbon brush 33, ensuring successful charging.

[0021] like Figure 10 As shown, the spring block 422 includes: a block body 4222, a spring guide cavity 424, a limiting slide groove 4224, and an insertion guide surface 4221. One end of the block body 4222 is inserted into the inner cavity of the housing 421, and the other end is provided with the insertion guide surface 4221. The insertion guide surface 4221 can be an arc or a slope. In this embodiment, it is set as a slope. When the distance between the ground connector 32 and the vehicle connector 41 is small, the spring block 422 can be inserted between the ground connector 32 and the vehicle connector 41 based on the insertion guide surface 4221. As the spring block 422 is inserted, the spring 424 is gradually compressed into the spring guide cavity 424. The force of the spring 424 makes the spring block 422 and the copper-carbon electrode carbon brush 33 closely connected during the charging process.

[0022] The limiting groove 4224 is formed on the two side walls adjacent to the block 4222 and the guide plate 4212. The position and width of the limiting groove 4224 are adapted to the position and size of the limiting slider 4213. During assembly, the bottom end of the block 4222 is set in the inner cavity of the base shell 4211, between the two guide plates 4212. The limiting slider 4213 is inserted into the limiting groove 4224. The end of the limiting groove 4224 adjacent to the bottom plate 426 is closed. Through the cooperation of the limiting groove 4224 and the limiting slider 4213, the spring block 422 can slide smoothly in the inner cavity of the shell 421, while ensuring that the spring block 422 will not fall out of the inner cavity of the shell 421.

[0023] The spring guide cavity 424 is located at one end of the block 4222 within the cavity of the housing 421. The size of the spring guide cavity 424 is adapted to the spring 424. When the housing 421 is fixedly installed on the base plate 426, one end of the spring 424 is inserted into the spring guide cavity 424, and the other end is pressed against the base plate 426. The setting of the spring guide cavity 424 ensures that the spring 424 will not shift during compression.

[0024] Since the railcar 1 operates in the processing workshop, in order to protect the on-board connector 41, this application also provides an on-board protection device. The on-board protection device includes a protective cover and a heat insulation layer (not marked in the figure). The heat insulation layer is set on the protective cover, and the protective cover is set on the on-board support frame 44 on the side of the on-board connector 41 away from the railcar 1 body; reducing the probability of the on-board connector 41 being damaged by splashes other than debris during the operation of the railcar.

[0025] The specific electrical connection relationship between the vehicle-mounted connection device 4 and the ground connection device 3 is as follows: Figure 4 As shown. The connection pins between the charging power supply and the ground charging device include: T1+\T1-, DC+, S+, S-, DC-, T2+\T2-, PE. The connection pins between the on-board charging device and the new energy power supply box on the railcar 1 are DC+, S+, S-, DC-. The on-board connector 41 contains four copper brush blocks 42, which are connected to the DC+, DC-, S+, and S- pins of the new energy power supply box, respectively. The ground connector 32 contains four copper-carbon electrode brushes 33, which are connected to the DC+, DC-, S+, and S- pins of the charging power supply, respectively. The specific connection method is based on existing technology to ensure effective connection when the copper brush blocks and copper-carbon electrode brushes are connected. The S+ and S- pins transmit communication data, while the DC+ and DC- pins are positive and negative power supply pins, providing charging power. In this application, the connection of these four pins is guaranteed at a minimum during charging. In the national standard, the other pins, such as A+, A- (BMS charging wake-up), CC1-2 (charging gun inserted into charging socket signal), and CC1-1 (charging gun inserted into charging socket signal), are implemented in the form of analog signals based on the cooperation of the connection confirmation module, the vehicle connection signal generation module, and the ground connection signal generation module.

[0026] The connection confirmation module includes: a ground sensor module 35, a vehicle-mounted sensor module 45, a first reflector 46, and a second reflector 34; the vehicle-mounted sensor module 45 and the first reflector 46 are mounted on the vehicle-mounted connection device 4, and the ground sensor module 35 and the second reflector 34 are mounted on the ground connection device 3.

[0027] When the railcar arrives at the charging position and the copper-carbon electrode carbon brush 33 and the copper brush block 42 are successfully docked, the ground sensor module 35 and the first reflector 46 work together to send a ground feedback position signal; the vehicle-mounted sensor module 45 and the second reflector 34 work together to send a vehicle-mounted feedback position signal.

[0028] The ground connection signal generation module is installed in the ground connection device 3, and generates a CC1 gun insertion signal analog signal based on the ground feedback position signal.

[0029] The vehicle connection signal generation module is set in the vehicle connection device 4, and generates the CC2 charging gun insertion analog signal and the A+ low voltage auxiliary power supply analog signal based on the vehicle feedback position signal.

[0030] like Figure 6 As shown, the second reflector 34 is disposed on the plate surface of the ground connector 32 where the copper-carbon electrode carbon brush 33 is located; the second reflector 34 is disposed parallel to the copper-carbon electrode carbon brush 33, and the second reflector 34 is horizontally symmetrically disposed with the center line L2 connecting all the copper-carbon electrode carbon brushes 33 as the center line.

[0031] like Figure 7 As shown, the vehicle-mounted sensor module 45 is mounted on the vehicle-mounted connector 41, and the vehicle-mounted sensor module 45 is located on the extension line L1 of the line connecting the center points of all the copper brush blocks 42; the light signal emission direction of the vehicle-mounted sensor module 45 is towards the second reflector 34.

[0032] The ground sensor module 35 is mounted on the ground connector 32. The light signal emission direction of the ground sensor module 35 is parallel to the line L2 connecting the center points of all the copper-carbon electrode brushes 33, and is located in the vertical direction of the line L2 connecting the center points of the copper-carbon electrode brushes 33. The ground sensor module 35 can be positioned above or below the line L2 connecting the center points. In this embodiment, the ground sensor module 35 is positioned above the line L1 connecting the center points, and correspondingly, the position of the first reflector 46 is also positioned above the copper-carbon electrode brushes 33. The signal emission direction of the ground sensor module 35 is towards the first reflector 46.

[0033] The first reflector 46 is parallel to the insertion direction of the copper brush block 42 and is mounted on the vehicle support frame; the first reflector 46 is symmetrically arranged on both sides of the line L1 connecting the center points of all the copper brush blocks 42 in the horizontal direction.

[0034] Figure 7 The image shows the state after the copper-carbon electrode carbon brush 33 and the copper brush block 42 are aligned, with the center points of lines L2 and L3 coinciding. This is to clearly visualize the structure after the connection. Figure 7 The ground connector 32 and the copper-carbon electrode carbon brush 33 are both cut off in half with the center line L2 of the copper-carbon electrode carbon brush 33 as the boundary. Therefore, the cross-sections of the ground connector 32 and the copper-carbon electrode carbon brush 33 can be seen, and the ground sensor module 35 is installed above the cross-section.

[0035] In this application, the first reflector 46 and the second reflector 34 are of the same length and are both arranged along the direction of travel of the railcar. In the direction of travel of the railcar, the length of the second reflector 34 is less than the length of the copper-carbon electrode carbon brush 33. Specifically, in this embodiment, the length of the copper-carbon electrode carbon brush 33 is 700mm, while the lengths of the first reflector 46 and the second reflector 34 are set between 300mm and 600mm.

[0036] The first reflector 46 is configured symmetrically in the horizontal direction with the line L1 connecting the center points of the copper brush block 42 as the axis, and the second reflector 34 is configured symmetrically in the horizontal direction with the line L2 connecting the center points of the copper-carbon electrode brush 33 as the axis. At the same time, the ground sensor module 35 is placed above the line L1 connecting the center points of the copper-carbon electrode brush 33, and the vehicle sensor module 45 is placed on the extension line L1 of the line connecting the center points of the copper brush block 42. With the length settings of the first reflector 46 and the second reflector 34, it is ensured that the vehicle sensor module 45 and the ground sensor module 35 can detect the corresponding reflector and send a signal of successful physical docking after the copper-carbon electrode brush 33 and the copper brush block 42 have a certain contact surface.

[0037] The specific lengths of the first reflector 46 and the second reflector 34 are determined based on the docking area required for successful charging of the copper-carbon electrode carbon brush 33 and the copper brush block 42. Assuming successful charging is achieved with a 50mm docking between the copper-carbon electrode carbon brush 33 and the copper brush block 42, the lengths of the first reflector 46 and the second reflector 34 can be set to 600mm. Since both reflectors are symmetrically arranged around the horizontal points of the center lines L1 and L2, when the copper-carbon electrode carbon brush 33 and the copper brush block 42 are docked 50mm apart, the vehicle-mounted sensor module 45 and the ground sensor module 35 can receive the infrared signal reflected by the corresponding reflector and simultaneously issue a docking signal.

[0038] The ground sensor module 35 and the vehicle-mounted sensor module 45 can be implemented based on any existing sensor capable of position detection. In this embodiment, both the ground sensor module 35 and the vehicle-mounted sensor module 45 are implemented based on an NPN normally open photoelectric sensor switch. Specifically, it is implemented based on an infrared diffuse reflection proximity photoelectric sensor switch of model E3F-DS30C, which supports transparent or opaque objects such as metal, plastic, peeled wood, paper, or magnets, and supports connection to PLC, servo controller, controller, etc. for input signals. The photoelectric sensor switch in this embodiment is a three-wire sensor, with one positive power line (24V), one negative power line (0V), and the other a signal output line. When the NPN normally open photoelectric sensor switch does not detect the light signal reflected by the reflector, there is no output; when it detects the light signal reflected by the reflector, the output becomes low, i.e., a docking signal is issued.

[0039] Figure 11 and Figure 12 In this embodiment, the ground sensor module is labeled as photoelectric sensor SE1, and the vehicle-mounted sensor module is labeled as photoelectric sensor SE2. Relays K1, K2, and K3 in this embodiment are based on a vehicle-grade five-pin relay DC24 / 20A, specifically model ZTV4 / 024-1Z from Chint.

[0040] like Figure 11 As shown, the ground connection signal generation module includes: relay K1, resistor R2 and resistor R4; One end of resistor R2 is connected to the negative terminal of the DC power supply, and the other end of resistor R2 is connected to pin 30 of relay K2 as the CC1 signal output pin. One end of resistor R4 is connected to the negative terminal of the DC power supply, and the other end of resistor R4 is connected to pin 87 of relay K1. Pin 86 of relay K1 is connected to the signal output pin of photoelectric sensor SE1. Pin 85 of relay K1 is connected to the positive terminal of the power supply. The positive power supply pin of photoelectric sensor SE1 is connected to the positive terminal of the DC power supply, and the negative power supply pin of photoelectric sensor SE1 is connected to the negative terminal of the DC power supply.

[0041] In this embodiment, the operating power supply is 24V. Inside relay K1, pin 1 of switch S1 is connected to relay pin 30, pin 2 of switch S1 is connected to relay pin 87a, and pin 3 of switch S1 is connected to relay pin 87. By default, pins 1 and 2 of switch S1 are connected, while pin 3 of switch S1 is disconnected. Pin CC1-2, which sends the CC1 signal, is also disconnected and has no resistance.

[0042] After the power supply is turned on, the photoelectric sensor SE1 starts working. The photoelectric sensor SE1 emits light waves. When the copper carbon electrode carbon brush 33 and the copper brush block 42 are properly aligned, the photoelectric sensor SE1 receives the feedback light wave. The signal output pin of the photoelectric sensor SE1 emits a low level, so pin 86 of the relay K1 is connected to the charging command 24V- power supply. The 24V+ power supply goes from pin 85 of the relay K1 through the box (coil) and then through pin 86 to the power supply V-, forming a circuit. The coil generates magnetic force, which attracts switch S1 from pin 87a to pin 87. Then pins 1 and 3 of switch S1 are connected, connecting pin 30 of the relay K1 to pin 87 of the relay K1. R4 and R2 are then connected in parallel. R2 and R4 are both 1KΩ, and when connected in parallel, they become 500Ω. The ground charging device detects that the resistance value of CC1-2 has changed from 1kΩ to 500Ω, and determines that the charging gun has been inserted into the charging socket. Subsequently, a handshake message CRM (Charger Identification Message) can be sent to wait for a response from the BMS.

[0043] like Figure 12 As shown, the vehicle connection signal generation module includes: resistor R3, relay K2 and relay K3.

[0044] One end of resistor R3 is connected to the negative terminal of the DC power supply, and the other end of resistor R3 is connected to pin 87 of relay K3. Pin 30 of relay K3 is the CC2 signal output pin. Pin 85 of relay K3 is connected to pin 30 of relay K2. Pin 85 of relay K2 is then connected to the positive terminal of the DC power supply. Pin 86 of relay K3 is connected to pin 86 of relay K2 and the signal output pin of photoelectric sensor SE2. Pin 87 of relay K2 is the output pin of signal A+. The positive power supply pin of photoelectric sensor SE2 is connected to the positive terminal of the DC power supply, and the negative power supply pin of photoelectric sensor SE2 is connected to the negative terminal of the DC power supply.

[0045] Similar to relay K1, pins 1 of switches S2 and S3 inside relays K2 and K3 are connected to pin 30 of relay K2, pin 2 of switch S1 is connected to pin 87a of relay K2, and pin 3 of switch S1 is connected to pin 87 of relay K2. By default, pins 1 and 2 of switch S1 are connected, while pin 3 is disconnected. Pin 30 of relay K3 is the CC2 signal output pin, and pin 87 of relay K2 is the A+ signal output pin; both pins are disconnected.

[0046] After the copper-carbon electrode carbon brush 33 and the copper brush block 42 are properly aligned, the photoelectric sensor SE2 receives the feedback light wave. The signal output pin of the photoelectric sensor SE2 emits a low level, and the switches inside relays K2 and K3 are also attracted by the magnetic force of the coil, simultaneously turning on pins 30 and 87 of both relays. Signal A- uses the 24V operating power supply as its signal source. Figure 4 As shown, when the new energy battery box detects CC2-2, it indicates that it has received the CC2 charging gun insertion analog signal from the on-board device, signifying successful docking. The new energy battery box determines that the charging gun has been inserted into the charging socket and wakes up the BMS via low-voltage auxiliary power signals (A+ and A-). Subsequently, the BMS can send a BHM (BMS Vehicle Identification Message) and wait for the charger's response to execute the subsequent charging process at any time. At this time, the BMS is in a charging preparation state and proceeds with the subsequent charging process. The specific charging process is implemented based on existing technology.

[0047] In this application, by setting a ground sensor module 35 and a vehicle-mounted sensor module 45 on the ground connection device 3 and the vehicle-mounted connection device 4 respectively, the docking position of the copper-carbon electrode carbon brush 33 and the copper brush block 42 is confirmed from both the ground connection device 3 and the vehicle-mounted connection device 4, effectively preventing misjudgment. This application implements the ground sensor module 35 and the vehicle-mounted sensor module 45 based on photoelectric sensors, and designs the circuit structures in the vehicle-mounted connection signal generation module and the ground connection signal generation module. When the ground sensor module 35 and the vehicle-mounted sensor module 45 detect successful docking and both sensors emit signals, the docking is considered successful. Then, the docking signals CC1 and CC2 are sent to the ground charging device and the new energy battery box. The controller will only issue a charging command when it receives the positioning signals from both the ground charging device and the new energy battery box simultaneously, effectively increasing the probability of successful charging.

[0048] This application's technical solution achieves the hardware docking process through the copper brush block 42 in the on-board connector 41 and the copper-carbon electrode carbon brush 33 on the ground connector 32. Based on the ground sensor module 35 and the on-board sensor module 45, the resistance changes on CC2 and CC1 are simulated through the on-board connection signal generation module and the ground connection signal generation module, realizing the generation of the simulated signal for the physical connection of the charging gun to the on-board charging head. The entire process follows the national standard charging workflow, avoiding modifications to the charger and battery management system. The docking action replaces the plugging action, effectively achieving unmanned operation of the docking process in the railcar charging process, thus improving the railcar charging efficiency. In specific applications, the controller is electrically connected to the railcar 1, the charging power supply, and the position sensor 5 based on PLC technology. The hardware structure in this application, combined with existing PLC technology, enables remote control of the charger's start and stop via a local area network. When the vehicle reaches the charging position, it connects to the charger, and subsequent operations are performed remotely. The specific control method can be implemented based on existing technology.

Claims

1. A charging device for a new energy power supply box for rail vehicles, characterized in that, It includes: Charging power supply, vehicle-mounted connection device, and ground connection device; The charging power supply is located in the charging area next to the track; The vehicle-mounted connection device is installed on the railcar, and the ground connection device is installed in the charging area beside the track; The ground connection device includes: a ground support frame, a ground connector, and copper-carbon electrode carbon brushes. The ground connector is flat, and the copper-carbon electrode carbon brushes are disposed on one of the plates of the ground connector. Each copper-carbon electrode carbon brush is connected to the charging line of the charging power supply. The ground connector is installed beside the track via the ground support frame, facing the track. The vehicle-mounted connection device includes: a vehicle-mounted support frame, a vehicle-mounted connector, and copper brush blocks. The vehicle-mounted connector is flat, and the copper-carbon electrode carbon brushes are disposed on the plate surface of the vehicle-mounted connector. Each copper brush block is electrically connected to the charging line of the railcar's new energy power supply box. The vehicle-mounted connector is mounted on the side wall of the railcar via the vehicle-mounted support frame, facing the ground connector. The installation heights of the ground connector and the vehicle connector are adapted to each other; the number and type of the copper-carbon electrode carbon brush are set accordingly to the copper-carbon electrode carbon brush, and the copper-carbon electrode carbon brush and the copper brush block are installed in a mutually corresponding manner.

2. The charging device for a new energy power supply box for rail vehicles according to claim 1, characterized in that, It also includes: a connection confirmation module, a vehicle-mounted connection signal generation module, and a ground connection signal generation module; The connection confirmation module includes: a ground sensor module, a vehicle-mounted sensor module, a first reflector, and a second reflector; The vehicle-mounted sensor module and the first reflector are mounted on the vehicle-mounted connection device, and the ground sensor module and the second reflector are mounted on the ground connection device. When the railcar arrives at the charging position and the copper-carbon electrode carbon brush and the copper brush block are successfully docked, the ground sensor module and the first reflector work together to emit a ground feedback position signal; the vehicle-mounted sensor module and the second reflector work together to emit a vehicle-mounted feedback position signal. The ground connection signal generation module generates a CC1 gun insertion signal analog signal based on the ground feedback position signal; The vehicle connection signal generation module generates a CC2 charging gun insertion simulation signal and a low-voltage auxiliary power supply simulation signal based on the vehicle feedback position signal.

3. The charging device for the new energy power supply box of the railcar according to claim 2, characterized in that: Both the ground sensor module and the vehicle-mounted sensor module are based on photoelectric sensors, namely photoelectric sensor SE1 and photoelectric sensor SE2, respectively.

4. The charging device for the new energy power supply box of the railcar according to claim 2, characterized in that: The second reflector is disposed on the plate surface of the copper-carbon electrode carbon brush on the ground connector; the second reflector is disposed parallel to the copper-carbon electrode carbon brush; the second reflector is disposed symmetrically in the horizontal direction with the center line connecting all the copper-carbon electrode carbon brushes as the center line; The vehicle-mounted sensor module is mounted on the vehicle-mounted connector and is located on the extension line of the line connecting the center points of all the copper brush blocks; the light signal emission direction of the vehicle-mounted sensor module is towards the second reflector. In the direction of travel of the railcar, the length of the second reflector is less than the length of the copper-carbon electrode carbon brush; the lengths of the first reflector and the second reflector are the same. The ground sensor module is mounted on the ground connector. The light signal emission direction of the ground sensor module is parallel to the line connecting the center points of all the copper-carbon electrode carbon brushes and is located in the direction perpendicular to the line connecting the center points of the copper-carbon electrode carbon brushes. The signal emission direction of the ground sensor module is towards the first reflector. The first reflector is parallel to the insertion direction of the copper brush block and is mounted on the vehicle support frame; the first reflector is symmetrically arranged on both sides of the line connecting the center points of all the copper brush blocks in the horizontal direction.

5. The charging device for a new energy power supply box for rail vehicles according to claim 3, characterized in that: The ground connection signal generation module includes: relay K1, resistor R2 and resistor R4; One end of resistor R2 is connected to the negative terminal of the DC power supply, and the other end of resistor R2 is connected to pin 30 of relay K2 as the CC1 signal output pin. One end of resistor R4 is connected to the negative terminal of the DC power supply, and the other end of resistor R4 is connected to pin 87 of relay K1. Pin 86 of relay K1 is connected to the signal output pin of photoelectric sensor SE1. Pin 85 of relay K1 is connected to the positive terminal of the power supply. The positive power supply pin of photoelectric sensor SE1 is connected to the positive terminal of the DC power supply, and the negative power supply pin of photoelectric sensor SE1 is connected to the negative terminal of the DC power supply.

6. The charging device for a new energy power supply box for rail vehicles according to claim 3, characterized in that: The vehicle connection signal generation module includes: resistor R3, relay K2, and relay K3; One end of resistor R3 is connected to the negative terminal of the DC power supply, and the other end of resistor R3 is connected to pin 87 of relay K3. Pin 30 of relay K3 is the CC2 signal output pin. Pin 85 of relay K3 is connected to pin 30 of relay K2, and pin 85 of relay K2 is then connected to the positive terminal of the DC power supply. Pin 86 of relay K3 is connected to pin 86 of relay K2 and the signal output pin of photoelectric sensor SE2. Pin 87 of relay K2 is the output pin of signal A+. The positive power supply pin of photoelectric sensor SE2 is connected to the positive terminal of the DC power supply, and the negative power supply pin of photoelectric sensor SE2 is connected to the negative terminal of the DC power supply.

7. The charging device for a new energy power supply box for rail vehicles according to claim 1, characterized in that: The connection methods between the copper-carbon electrode carbon brush and the copper brush block include: vertical connection and horizontal connection.

8. The charging device for a new energy power supply box for rail vehicles according to claim 1, characterized in that: The copper brush block is configured as 4 pieces, which are respectively connected to DC+, DC-, S+, and S- of the new energy power supply box; the copper-carbon electrode carbon brush is configured as 4 pieces, which are respectively connected to DC+, DC-, S+, and S- of the charging power supply.

9. The charging device for a new energy power supply box for rail vehicles according to claim 1, characterized in that: The copper brush block includes: a housing, a spring block, a wire, a spring, a wire connector, and a base plate; the base plate is mounted on the mounting surface of the vehicle-mounted connector; the housing is a hollow structure with openings at both ends, the spring block is inserted into the inner cavity of the housing from one opening, and the other opening of the housing is mounted on the base plate; the spring is installed in the inner cavity of the spring block, and the two ends of the spring block respectively press against the spring block and the base plate; the wire connector is fixedly connected to the spring block, and the two ends of the wire are respectively connected to the wire connector and the charging line of the new energy battery box of the railcar; The housing includes: a base housing, trapezoidal guide plates, and limiting sliders. The inner cavity dimensions of the base housing are adapted to the length and width of the spring block, and the height is lower than the height of the spring block. The two trapezoidal guide plates are arranged on the base housing along the running direction of the spring block track vehicle, and the limiting sliders are arranged on the inner wall of the guide plates adjacent to the spring block. The spring block includes: a block body, a spring guide cavity, a limiting groove, and an insertion guide surface. One end of the block body is inserted into the inner cavity of the housing, and the other end is provided with the insertion guide surface. The spring guide cavity is opened at one end of the block body located in the inner cavity of the housing. One end of the spring is inserted into the spring guide cavity, and the other end is pressed against the base plate. The limiting groove is opened on two side walls adjacent to the block body and the guide plate. The position and width of the limiting groove are adapted to the position and size of the limiting slider.

10. The charging device for a new energy power supply box for rail vehicles according to claim 9, characterized in that: The width of the copper-carbon electrode carbon brush is greater than the width of the spring block, and the length of the copper-carbon electrode carbon brush is greater than the length of the spring block.

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