A high-current, multi-mode intelligent silent charger

Abstract

This application discloses a high-current, multi-mode intelligent silent charger, including a housing, a circuit board, and a cooling fan. The circuit board houses a main control management unit, an internal temperature detection unit, an output current detection unit, a fan drive unit, and a human-machine interface unit. The main control management unit acquires the temperature signal of the NTC thermistor attached to the heatsink and the current sampling signal in the output circuit in real time via an ADC pin, and continuously adjusts the MOSFET of the fan drive unit via a PWM pin, thereby achieving smooth fan speed changes with temperature and load. A long press of the mode button triggers a silent mode, in which the main control unit simultaneously shuts down the fan and reduces the output current limit, achieving a silent effect through low-power operation. When the temperature rises to a safe threshold, the system automatically restarts the fan at a low speed and smoothly increases the speed as the temperature rises, ensuring safety. This invention intelligently balances heat dissipation and noise, offering both a good user experience and reliability.

Description

Technical Field

[0001] This application relates to the field of high-current chargers, and in particular to a high-current multi-mode intelligent silent charger. Background Technology

[0002] Currently, high-power battery chargers are increasingly used in various application scenarios, especially when charging various 12V battery types (such as lithium-ion, lead-acid STD, AGM, GEL, etc.) with high current. In these cases, forced air cooling of power components by a cooling fan is usually required to prevent overheating and damage. Traditional charger cooling control often uses a temperature threshold switch method, where the fan starts and runs at a fixed speed when the internal temperature exceeds a certain fixed value, or the speed is further increased when a higher temperature threshold is reached. This control method is simple in structure but has significant drawbacks: under medium load or low temperature rise conditions, the fan may still operate at a high speed, generating considerable noise, which is detrimental to use in quiet environments.

[0003] Furthermore, existing chargers generally lack intelligent silent operation functions that users can actively trigger, making it impossible to reduce operating noise as needed while simultaneously meeting heat dissipation requirements. Especially in devices with multiple charging modes (such as different current levels like 4A, 16A, 32A, and 50A), if the fan's start / stop and speed cannot be smoothly and steplessly adjusted according to the actual current and temperature signals, it will be difficult to achieve the optimal balance between noise and heat dissipation efficiency at low power output. Utility Model Content

[0004] The purpose of this application is to provide a high-current multi-mode intelligent silent charger that can adjust the fan speed according to real-time temperature and output current, and supports users to actively enable low-noise operation mode.

[0005] To achieve the above objectives, this application provides the following technical solution:

[0006] A high-current multi-mode intelligent silent charger includes a charger housing, a circuit board disposed inside the charger housing, and a cooling fan. The circuit board is provided with a main control management unit, an internal temperature detection unit, an output current detection unit, a fan drive unit, and a human-machine interaction unit.

[0007] The main control management unit has ADC input pins and PWM output pins;

[0008] The internal temperature detection unit includes an NTC thermistor attached to the heat sink of the power component, and the NTC thermistor is electrically connected to the ADC input pin of the main control management unit.

[0009] The output current detection unit includes a sampling resistor or Hall sensor connected in series in the output circuit, and its output terminal is electrically connected to the ADC input pin of the main control management unit.

[0010] The fan drive unit includes a controlled MOSFET or transistor. The control electrode of the MOSFET or transistor is electrically connected to the PWM output pin of the main control management unit, and its output circuit is connected in series with the power input terminal of the cooling fan.

[0011] The human-computer interaction unit includes a mode selection button, and the signal output terminal of the mode selection button is electrically connected to the I / O pin of the main control management unit.

[0012] The main control management unit is configured to steplessly adjust the output of the fan drive unit through its PWM output pin based on the internal temperature signal and output current signal received by its ADC input pin; and in response to a long press signal of the mode selection button, control the fan drive unit to turn off the cooling fan while reducing the current limit of the output circuit.

[0013] Furthermore, a hanging bracket is provided on the back of the charger housing, and the hanging bracket is rotatably mounted on the back of the charger housing.

[0014] Furthermore, the back of the charger housing is provided with a first groove and a second groove corresponding to the hanging bracket. The hanging bracket can be accommodated in the first groove or the second groove. When the charger is to be hung upright, the hanging bracket is located on one side of the first groove. When the charger is to be hung upside down, the hanging bracket is located on one side of the second groove.

[0015] Furthermore, the hanging bracket is provided with hanging grooves at the center symmetrically.

[0016] Furthermore, the back of the charger housing is provided with a recessed groove corresponding to the hanging slot, and the back of the charger housing is provided with multiple protrusions.

[0017] Furthermore, the upper surface of the charger housing is provided with a first heat dissipation groove, a socket, an output terminal wire, and a crystal head interface.

[0018] Furthermore, a second heat dissipation groove is provided on the lower end face of the charger housing.

[0019] Furthermore, the human-computer interaction unit also includes an LCD display screen and / or LED status indicator lights, and the control input terminals of the LCD display screen and / or LED status indicator lights are electrically connected to the I / O pins of the main control management unit.

[0020] Furthermore, the circuit board is also provided with a battery voltage identification circuit, the output of which is electrically connected to the ADC input pin of the main control management unit, for transmitting the detected battery voltage signal to the main control management unit.

[0021] Furthermore, an output relay is also provided on the circuit board. The control coil of the output relay is electrically connected to an I / O pin of the main control management unit through a drive circuit, and its switch contacts are connected in series in the output circuit.

[0022] The beneficial effects of this application are as follows:

[0023] (1) The main control management unit of this application uses PWM technology to steplessly adjust the fan speed by collecting the internal temperature and output current signals in real time. This allows the fan to run at low speed or stop when the load is low and the temperature rise is low, thus eliminating noise from the root. Under high load, the speed can increase smoothly and linearly, ensuring that the heat dissipation efficiency and heat generation are precisely matched, avoiding the noise change problem caused by traditional on / off control, and significantly improving the user experience.

[0024] (2) This application utilizes a function that triggers a forced silent mode by long-pressing the mode selection button. In this mode, the charger performs a dual operation: turning off the fan and simultaneously reducing the output current limit. This proactive reduction in power (reducing the heat source) compensates for the decrease in heat dissipation caused by the fan shutdown, thereby extending the duration of silent operation and meeting the user's high demand for a quiet environment in specific situations, reflecting an intelligent human-computer interaction design.

[0025] (3) Even in forced silent mode, the system continuously monitors the temperature and intelligently restores heat dissipation by "low-speed start and smooth acceleration" when the temperature rises: it starts at a low speed when the temperature reaches 50°C, and then adjusts slowly at a rate of about 100 revolutions per degree Celsius (adjusting only when the temperature changes by ≥3°C) to avoid frequent fluctuations in speed. When the temperature reaches 80°C or other high-heat conditions, it dissipates heat at full capacity to ensure equipment safety. This stepped response mechanism provides a reliable safety net for the equipment while ensuring maximum quietness. Attached Figure Description

[0026] Figure 1 A block diagram provided for one embodiment of this application;

[0027] Figure 2 A circuit block diagram provided for one embodiment of this application;

[0028] Figure 3 This is a three-dimensional view of the front of a charger provided in an embodiment of this application;

[0029] Figure 4This is a three-dimensional structural diagram of the back of a charger provided in an embodiment of this application;

[0030] Figure 5 This is a schematic diagram of the charger housing after it has been opened, according to an embodiment of this application.

[0031] Figure 6 A physical diagram provided for one embodiment of this application.

[0032] Explanation of reference numerals in the attached figures:

[0033] 1. Charger housing; 2. Circuit board; 3. Cooling fan; 4. Hanging bracket; 5. First groove; 6. Second groove; 7. Hanging slot; 8. Alignment groove; 9. Protrusion;

[0034] 11. First heat sink; 12. Socket; 13. Output terminal cable; 14. RJ45 connector; 15. Second heat sink; 16. LCD display screen;

[0035] 21. Main control management unit; 22. Internal temperature detection unit; 23. Output current detection unit; 24. Fan drive unit; 25. Human-machine interaction unit; 27. Output relay; 28. Constant current and constant voltage control circuit; 29. ​​Feedback isolation circuit; 30. EMI filter circuit; 31. High voltage rectifier circuit; 32. Multi-mode PFC+LLC integrated controller;

[0036] 251. Mode selection button; Detailed Implementation

[0037] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of this application.

[0038] In the description of this application, it should be understood that the terms "upper," "lower," "left," "right," etc., are used only for the convenience of describing this application and for 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 on this application. In particular, the understanding of the term "upper" following a noun in the claims should be understood as meaning that the entire inner and outer surfaces of the structure referred to by the noun conform to the definition of "upper."

[0039] The following detailed description, in conjunction with the accompanying drawings and preferred embodiments, describes the specific implementation methods, structures, features, and effects provided in this application.

[0040] like Figure 1 and Figure 5 As shown, a high-current multi-mode intelligent silent charger includes a charger housing 1, a circuit board 2 disposed inside the charger housing 1, and a cooling fan 3. The circuit board 2 is provided with a main control management unit 21, an internal temperature detection unit 22, an output current detection unit 23, a fan drive unit 24, and a human-machine interaction unit 25.

[0041] The main control management unit 21 has an ADC input pin and a PWM output pin;

[0042] The internal temperature detection unit 22 includes an NTC thermistor 34 attached to the power component heat sink 33, and the NTC thermistor is electrically connected to the ADC input pin of the main control management unit 21.

[0043] The output current detection unit 23 includes a sampling resistor or Hall sensor connected in series in the output circuit, and its output terminal is electrically connected to the ADC input pin of the main control management unit 21.

[0044] The fan drive unit 24 includes a controlled MOSFET or transistor. The control terminal of the MOSFET or transistor is electrically connected to the PWM output pin of the main control management unit 21, and its output circuit is connected in series with the power input terminal of the cooling fan 3.

[0045] The human-computer interaction unit 25 includes a mode selection button 251, and the signal output terminal of the mode selection button 251 is electrically connected to the I / O pin of the main control management unit 21.

[0046] The main control management unit 21 is configured to steplessly adjust the output of the fan drive unit 24 through its PWM output pin based on the internal temperature signal and output current signal received by its ADC input pin; and in response to the long press signal of the mode selection button 251, control the fan drive unit 24 to turn off the cooling fan 3 while reducing the current limit of the output circuit.

[0047] like Figure 4 As shown, a bracket 4 is provided on the back of the charger housing 1, and the bracket 4 is rotatably mounted on the back of the charger housing 1.

[0048] like Figure 4 As shown, the back of the charger housing 1 is provided with a first groove 5 and a second groove 6 corresponding to the hanging bracket 4. The hanging bracket 4 can be accommodated in the first groove 5 or the second groove 6. When the charger is to be hung upright, the hanging bracket 4 is located on one side of the first groove 5. When the charger is to be hung upside down, the hanging bracket 4 is located on one side of the second groove 6.

[0049] By setting up a rotatable hanging bracket 4 that can be stored in different grooves, the charger can be hung both upright and upside down, greatly improving the installation adaptability and flexibility of the equipment in different usage scenarios (such as walls, workbenches, and vehicle engine compartments).

[0050] like Figure 4 As shown, the hanging bracket 4 has a hanging groove 7 at a centrally symmetrical location.

[0051] like Figure 4 As shown, the back of the charger housing 1 is provided with a relief groove 8 corresponding to the hanging groove 7, and the back of the charger housing 1 is provided with a plurality of protrusions 9.

[0052] like Figure 4 As shown, the hanging groove 7 on the hanging bracket 4 cooperates with the clearance groove 8 and protrusion 9 on the back of the housing, so that the charger can be securely fastened when suspended to prevent accidental slippage; when laid flat, it can be kept stable by the clearance groove 8 and protected by the anti-slip and shock absorption of the protrusion 9 to protect the surface of the housing.

[0053] like Figure 4 As shown, the upper surface of the charger housing 1 is provided with a first heat dissipation groove 11, a socket 12, an output terminal wire 13, and a crystal head interface 14.

[0054] like Figure 3 As shown, a second heat dissipation groove 15 is provided on the lower end surface of the charger housing 1.

[0055] Heat dissipation grooves are provided on both the upper and lower surfaces of the casing, forming an effective natural airflow channel. Even without relying on a fan or under low-speed operation, effective heat dissipation can be achieved through convection. Combined with the internal active fan cooling, this constitutes a dual cooling system that combines passive and active cooling, improving overall heat dissipation redundancy and reliability, and ensuring the stability of high-power output under high-temperature environments.

[0056] like Figure 3 As shown, the human-computer interaction unit 25 also includes an LCD display screen 16 and / or LED status indicator lights, and the control input terminals of the LCD display screen 16 and / or LED status indicator lights are electrically connected to the I / O pins of the main control management unit 21.

[0057] The addition of an LCD display screen 16 and / or LED status indicators allows for a clear and intuitive display of information such as charging mode, real-time voltage / current, battery status, and fault alarms. This visualizes the complex internal operating status, greatly enhancing the product's usability and user experience, and providing users with a clear overview of the charging process.

[0058] like Figure 2As shown, the circuit board 2 is also provided with a battery voltage identification circuit, the output of which is electrically connected to the ADC input pin of the main control management unit 21, for transmitting the detected battery voltage signal to the main control management unit 21.

[0059] like Figure 2 As shown, the circuit board 2 is also provided with an output relay 27. The control coil of the output relay 27 is electrically connected to an I / O pin of the main control management unit 21 through a drive circuit, and its switch contacts are connected in series in the output circuit.

[0060] Upon initial power-on or detection of battery connection, the battery voltage recognition circuit first determines the battery status. After confirming a normal connection, the output relay 27 is then activated.

[0061] like Figure 2 As shown, the circuit board 2 is also provided with a constant current and constant voltage control circuit 28 and a feedback isolation circuit 29; the feedback signal of the constant current and constant voltage control circuit 28 is transmitted to the main control management unit 21 through the feedback isolation circuit 29 to form a closed-loop control.

[0062] like Figure 2 As shown, the front end of the circuit board 2 is also provided with an EMI filter circuit 30, a high-voltage rectifier circuit 31, and a power conversion circuit controlled by a digitally configured multi-mode PFC+LLC integrated controller 32.

[0063] like Figure 2 As shown, the main control management unit 21 is configured to execute a charging process that includes multiple stages and automatically switch between stages based on feedback signals from the battery voltage identification circuit and the output current detection unit 23.

[0064] like Figure 2 As shown, the battery voltage recognition circuit enables the charger to automatically identify the battery type and initial state, preventing risks such as overcharging and undercharging caused by incorrect connection of incompatible batteries, and achieving safer and more accurate personalized charging management.

[0065] like Figure 2 As shown, output relay 27: its function is to engage only after the main control unit confirms that the battery connection is normal, thus achieving soft start. This completely avoids sparking at the moment of connection, greatly improving operational safety in environments where flammable gases may be present (such as near a car battery), while also protecting the contacts and extending product life.

[0066] like Figure 2 As shown, constant current and constant voltage control with feedback isolation ensures output accuracy and stability, and guarantees charging performance.

[0067] like Figure 2 As shown, the integrated digital control of PFC+LLC improves the conversion efficiency and power factor of the entire power supply, and reduces energy consumption and grid interference.

[0068] The working principle of this application is as follows:

[0069] The core working principle of the high-current multi-mode intelligent silent charger described in this invention lies in the main control management unit 21 (MCU) which comprehensively monitors various sensor signals to perform intelligent closed-loop control on fan speed and output power, thereby achieving a balance between quiet operation, heat dissipation, and safety.

[0070] After power-on, the main control management unit 21 continuously samples two key analog signals through its ADC input pin: the internal temperature signal and the output current signal.

[0071] The internal temperature signal is detected by an NTC thermistor attached to the heat sink of the power components. The resistance of the NTC decreases as the temperature rises, and the voltage signal after voltage division is input to the MCU. The MCU converts the voltage into a real-time temperature value using its internal algorithm.

[0072] The output current signal is detected by a sampling resistor or Hall sensor connected in series in the output circuit. This signal reflects the real-time load of the charger.

[0073] The MCU takes the two signals mentioned above as input parameters and makes a comprehensive judgment. Its output is a PWM signal with a variable duty cycle generated from its PWM output pin. This PWM signal drives the MOSFET (or transistor) in the fan drive unit 24, thereby changing the average voltage applied to the cooling fan 3 to achieve stepless adjustment of its speed.

[0074] Speed ​​control strategy in normal mode: In non-silent mode, the MCU adopts a dual-variable speed control strategy based on temperature and current. The basic control logic is: the higher the output current or the higher the internal temperature, the larger the PWM duty cycle of the MCU output, and the higher the fan speed. This allows the fan speed to smoothly follow the actual operating state of the charger, maintaining low noise at low load and low temperature, and providing strong heat dissipation at high load and high temperature, achieving a dynamic optimal balance between noise and heat dissipation efficiency.

[0075] This invention provides an original manual mute control logic, which is triggered by the user pressing and holding the mode selection button 251 in the human-computer interaction unit 25 for up to 3 seconds.

[0076] When the MCU detects the long press signal, it will perform a predefined double safety operation: turn off the fan. The MCU first reduces the duty cycle of its PWM output pin to 0%, and then cuts off the power supply to the cooling fan 3 through the fan drive unit 24, so that it stops rotating completely and completely eliminates the fan noise.

[0077] The output current limit is reduced. At the same time, the MCU actively reduces the current reference value of the constant current and constant voltage control circuit 28, thereby limiting the current of the output circuit to a preset, lower safety value (e.g., from 50A to 16A or lower).

[0078] This dual operation is crucial for ensuring device safety. Reducing the output current directly decreases the heat generated by the power components, thereby compensating for the heat dissipation lost due to the fan stopping. This significantly slows down the rate of temperature rise inside the device, allowing the charger to operate safely for a period of time without a fan, meeting the temporary needs of users in quiet environments such as at night.

[0079] Even in manual silent mode, the MCU's monitoring of the internal temperature never stops. The system has a progressive temperature protection and recovery mechanism:

[0080] When the MCU detects that the temperature has risen to the first threshold (e.g., 50°C), it will exit the completely silent state for safety reasons. The MCU will restart the fan, but the initial speed will be controlled at a low level (e.g., 1000 RPM). Subsequently, the fan speed will be finely adjusted according to the temperature, typically using a strategy of "increasing the speed by about 100 RPM for every 1°C increase". To avoid frequent changes in speed due to small temperature fluctuations, a speed dead zone is set (e.g., speed adjustment only occurs when the temperature change is greater than or equal to 3°C). If the temperature continues to rise to a second higher threshold (e.g., 80°C), indicating extremely high heat dissipation requirements, the MCU will control the fan to run at the highest speed (e.g., 4000 RPM) to ensure the safety of core power components and prevent overheating damage.

[0081] In addition, the MCU manages the entire charging process: when the battery is first powered on or when it is detected that the battery is connected, the MCU first uses the battery voltage recognition circuit to determine the battery type, connection status and initial voltage. Only after confirming that the connection is normal will it control the output relay 27 to engage and connect the main output circuit to prevent the risk of arcing or hot plugging and unplugging.

[0082] Throughout the entire charging process (including trickle charging, constant current charging, constant voltage charging, and float charging stages), the MCU, through feedback from the output current detection unit 23 and the battery voltage identification circuit, forms a closed-loop control with the constant current and constant voltage control circuit 28 and the feedback isolation circuit 29 to precisely control the charging state and automatically switch between each stage.

[0083] The AC mains power input passes through the EMI filter circuit 30 and the high-voltage rectifier circuit 31 in sequence, and then undergoes high-efficiency power conversion by a multi-mode integrated digital controller that integrates PFC and LLC. Finally, it passes through the subsequent circuit to charge the battery.

[0084] In summary, this invention, through the intelligent decision-making of the main control management unit 21, organically integrates fan control, output power management, charging management, and user interaction, perfectly resolving the contradiction between quiet operation and heat dissipation in high-power chargers.

[0085] The embodiments described above are merely preferred embodiments of this application. It should be noted that those skilled in the art can make several improvements and substitutions without departing from the technical principles of this application, and these improvements and substitutions should also be considered within the scope of protection of this application.

Claims

1. A high-current, multi-mode intelligent silent charger, comprising a charger housing, a circuit board disposed within the charger housing, and a cooling fan, characterized in that: The circuit board is equipped with a main control management unit, an internal temperature detection unit, an output current detection unit, a fan drive unit, and a human-machine interaction unit; The main control management unit has ADC input pins and PWM output pins; The internal temperature detection unit includes an NTC thermistor attached to the heat sink of the power component, and the NTC thermistor is electrically connected to the ADC input pin of the main control management unit. The output current detection unit includes a sampling resistor or Hall sensor connected in series in the output circuit, and its output terminal is electrically connected to the ADC input pin of the main control management unit. The fan drive unit includes a controlled MOSFET or transistor. The control electrode of the MOSFET or transistor is electrically connected to the PWM output pin of the main control management unit, and its output circuit is connected in series with the power input terminal of the cooling fan. The human-computer interaction unit includes a mode selection button, and the signal output terminal of the mode selection button is electrically connected to the I / O pin of the main control management unit. The main control management unit is configured to steplessly adjust the output of the fan drive unit through its PWM output pin based on the internal temperature signal and output current signal received by its ADC input pin; and in response to a long press signal of the mode selection button, control the fan drive unit to turn off the cooling fan while reducing the current limit of the output circuit.

2. The high-current multi-mode intelligent silent charger according to claim 1, characterized in that: A mounting bracket is provided on the back of the charger housing, and the mounting bracket is rotatably mounted on the back of the charger housing.

3. A high-current multi-mode intelligent silent charger according to claim 2, characterized in that: The back of the charger housing is provided with a first groove and a second groove corresponding to the hanging bracket. The hanging bracket can be accommodated in the first groove or the second groove. When the charger is to be hung upright, the hanging bracket is located on one side of the first groove. When the charger is to be hung upside down, the hanging bracket is located on one side of the second groove.

4. A high-current multi-mode intelligent silent charger according to claim 3, characterized in that: The hanging rack has hanging slots at its central symmetrical position.

5. A high-current multi-mode intelligent silent charger according to claim 4, characterized in that: The back of the charger housing has a recessed groove corresponding to the hanging slot, and the back of the charger housing has multiple raised dots.

6. A high-current multi-mode intelligent silent charger according to claim 1, characterized in that: The upper surface of the charger housing is provided with a first heat dissipation groove, a socket, an output terminal wire, and a crystal head interface.

7. A high-current multi-mode intelligent silent charger according to claim 1, characterized in that: The lower end face of the charger housing is provided with a second heat dissipation groove.

8. A high-current multi-mode intelligent silent charger according to claim 1, characterized in that: The human-machine interaction unit also includes an LCD display screen and / or LED status indicators, and the control input terminals of the LCD display screen and / or LED status indicators are electrically connected to the I / O pins of the main control management unit.

9. A high-current multi-mode intelligent silent charger according to claim 1, characterized in that: The circuit board is also equipped with a battery voltage identification circuit, the output of which is electrically connected to the ADC input pin of the main control management unit, for transmitting the detected battery voltage signal to the main control management unit.

10. A high-current multi-mode intelligent silent charger according to claim 1, characterized in that: The circuit board is also equipped with an output relay. The control coil of the output relay is electrically connected to an I / O pin of the main control management unit through a drive circuit, and its switch contacts are connected in series in the output circuit.

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