A high-power fully isolated intelligent charging system

Abstract

This utility model discloses a high-power fully isolated intelligent charging system, including a charging unit and a charging management unit. The charging unit includes: an AC input terminal that sequentially passes through an EMI filter, a PFC boost circuit, a high-voltage filter circuit, an LC resonant buck converter circuit, and an output rectifier filter circuit to the battery charging terminal; the output rectifier filter circuit is connected to an output feedback circuit, which is connected to a power monitoring circuit, which is connected to a power protection circuit and a power monitoring circuit. The charging management unit includes a PFC drive circuit, a PFC feedback circuit, a PFC control circuit, an LC drive circuit, and an LC control circuit. This system integrates the charging management unit and the charging unit. The charging unit provides charging power, while the charging management unit implements charging maintenance control strategies, effectively solving the impact of poor battery charging.

Description

Technical Field

[0001] This utility model relates to a vehicle chassis and superstructure battery charging and maintenance technology, and more particularly to a high-power fully isolated intelligent charging system. Background Technology

[0002] Currently, high-power fully isolated intelligent charging systems mainly consist of charging units and charging management units. They enable the charging and maintenance of the entire vehicle battery pack. Since batteries are inherently consumables, proper maintenance and utilization are crucial for minimizing resource waste.

[0003] A high-power, fully isolated intelligent charging system can properly charge and maintain lead-acid and lithium batteries, extending their lifespan, improving battery performance, and ensuring safe use. Existing charging systems struggle to meet these requirements.

[0004] In view of the above, this utility model is hereby proposed. Utility Model Content

[0005] The purpose of this invention is to provide a high-power, fully isolated intelligent charging system to solve the aforementioned technical problems in the prior art.

[0006] The objective of this utility model is achieved through the following technical solution:

[0007] The high-power fully isolated intelligent charging system of this utility model includes a charging unit and a charging management unit;

[0008] The charging unit includes: an AC input terminal that sequentially passes through an EMI filter, a PFC boost circuit, a high voltage filter circuit, an LC resonant buck converter circuit, and an output rectifier filter circuit to the battery charging terminal;

[0009] The output rectifier and filter circuit is connected to an output feedback circuit, which is connected to a power monitoring circuit. The power monitoring circuit is connected to a power protection circuit and a power monitoring circuit.

[0010] Compared with the prior art, the high-power fully isolated intelligent charging system provided by this utility model integrates a charging management unit and a charging unit. The charging unit provides charging power, and the charging management unit implements charging maintenance control strategies, effectively solving the problem of poor battery charging. Attached Figure Description

[0011] Figure 1 Overall block diagram of the high-power fully isolated intelligent charging system provided in the embodiments of this utility model;

[0012] Figure 2 A diagram illustrating the four-stage charging strategy for a high-power, fully isolated intelligent charging system.

[0013] Figure 3 The diagram shows the constant current output efficiency of a high-power, fully isolated intelligent charging system. Detailed Implementation

[0014] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments, which do not constitute a limitation on the present utility model. Based on the embodiments of the present utility model, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of the present utility model.

[0015] First, the following explanations are provided for the terms that may be used in this article:

[0016] The terms “including,” “contains,” “comprising,” “having,” or other similar semantic descriptions shall be interpreted as non-exclusive inclusion.

[0017] The term "composed of" excludes any technical feature elements not explicitly listed.

[0018] The contents not described in detail in the embodiments of this utility model are existing technologies known to those skilled in the art. Where specific conditions are not specified in the embodiments of this utility model, they shall be performed according to conventional conditions in the art or conditions recommended by the manufacturer. Reagents or instruments used in the embodiments of this utility model whose manufacturers are not specified are all conventional products that can be purchased commercially.

[0019] The high-power fully isolated intelligent charging system of this utility model includes a charging unit and a charging management unit;

[0020] The charging unit includes: an AC input terminal that sequentially passes through an EMI filter, a PFC boost circuit, a high voltage filter circuit, an LC resonant buck converter circuit, and an output rectifier filter circuit to the battery charging terminal;

[0021] The output rectifier and filter circuit is connected to an output feedback circuit, which is connected to a power monitoring circuit. The power monitoring circuit is connected to a power protection circuit and a power monitoring circuit.

[0022] The charging management unit includes:

[0023] The PFC boost circuit is connected to a PFC drive circuit.

[0024] The high-voltage filter circuit is connected to a PFC feedback circuit, and the PFC drive circuit and the PFC feedback circuit are respectively connected to the PFC control circuit.

[0025] The LC resonant step-down converter circuit is connected to an LC drive circuit, which is connected to an LC control circuit.

[0026] The PFC control circuit, LC control circuit, and output feedback circuit are respectively connected to the auxiliary power line.

[0027] The charging management unit uses the EG1155 series microcontroller as the main control chip and integrates operational amplifiers, comparators, and MOS drivers.

[0028] The charging unit employs a symmetrical half-bridge converter.

[0029] In summary, the high-power fully isolated intelligent charging system of this utility model integrates a charging management unit and a charging unit. The charging unit provides charging power, and the charging management unit implements charging maintenance control strategies, effectively solving the problem of poor battery charging.

[0030] To more clearly demonstrate the technical solution and effects provided by this utility model, the following detailed description of the embodiments of this utility model is provided with reference to specific examples.

[0031] The design concept of this utility model is as follows:

[0032] The objective is to provide a charging management strategy module for charging lead-acid and lithium batteries.

[0033] The charging management strategy module adopts a modular design, which can be expanded to charge battery packs of different capacities. It has a wide range of applications and high reliability. At the same time, it uses all domestically produced components and performs sampling functions such as battery pack voltage, charging voltage and charging current. The structural design is simple and easy to assemble, and it can be applied to various integrated power supplies and chargers.

[0034] like Figures 1 to 3 As shown:

[0035] This intelligent charging system uses AC input. Through an EMI filter circuit and a PFC boost circuit, the bus voltage is increased to 360V. The downstream end is connected to an LC resonant isolation converter circuit, which reduces the output voltage to 28.8V. After output rectification and filtering, the battery is charged. The output voltage is detected and fed back to the LC control circuit for voltage regulation.

[0036] The specific charging management strategy module is divided into two parts: the charging unit and the charging management unit.

[0037] 1. Charging Management Unit:

[0038] The charging management unit uses the domestically produced EG1155 series microcontroller, integrating pure digital power control and charging management with a single main control chip. Compared to traditional analog power control, it integrates operational amplifiers, comparators, and MOS drivers, significantly reducing the need for external circuitry and providing flexible parameter configuration. The unit collects AC input voltage, current, and frequency from the charging unit via a fuel gauge and charging current and voltage via a Hall effect sensor. The collected output voltage signal is fed back to the main control chip, which adjusts the duty cycle of the MOS transistor based on the output voltage magnitude, thereby adjusting the output voltage. The unit reports the collected voltage, current, frequency, and temperature data via a serial port and simultaneously receives external control commands. Based on set thresholds, it implements over-temperature, input over-voltage, and output over-voltage and over-current protection functions, and outputs alarm indicator lights for alerts.

[0039] 2. Charging unit:

[0040] The charging unit has an input voltage of 180Vac~260Vac and uses a symmetrical half-bridge converter, supporting a wide input and output range. The secondary high-frequency ripple frequency is twice the primary MOSFET operating frequency, further reducing the size of inductors and capacitors. Both high-frequency and mains-frequency ripple currents are very low, significantly reducing voltage and current stress on power devices and improving the lifespan of the intelligent charging system. It features auxiliary power supply, temperature protection, constant current charging, reverse connection protection, and output current detection. The power board's input circuit uses two-stage common-mode filtering, providing excellent EMC characteristics; the output uses a Π-type filter, effectively suppressing output ripple and noise.

[0041] As can be seen from the technical solution provided by this utility model, the high-power fully isolated intelligent charging system module of this utility model has a simple structure, is easy to assemble, is highly practical, and is aesthetically pleasing.

[0042] Example 1

[0043] like Figures 1 to 3 As shown:

[0044] The high-power fully isolated intelligent charging management strategy module consists of two parts: a charging unit (1 unit) and a charging management unit (1 unit).

[0045] The charging unit can perform AC / DC power conversion, converting AC220V to DC28.8V, and also has the function of changing the output voltage through real-time output voltage acquisition. The charging management unit can implement responsive charging management strategies by collecting charging voltage, charging current, battery voltage, and AC input status.

[0046] The charging management strategy can be divided into four parts: pre-charging stage, constant current stage, constant voltage stage, and float charging stage.

[0047] First, the voltage of the battery to be charged is detected. If the battery voltage is low, pre-charging is performed with a charging current of 1 / 10 of the set maximum charging current. Once the battery voltage rises to a certain value, the standard charging process begins. The standard charging process is as follows: constant current charging is performed at the maximum charging current, and the battery voltage continues to rise steadily. When the battery voltage rises close to the set maximum voltage, constant voltage charging is switched to, and the charging current gradually decreases. When the current drops to 1 / 10 of the maximum charging current, float charging is entered, and charging ends.

[0048] Phase 1: Pre-charge stage – The pre-charge stage is used to pre-charge (recovery charging) the fully discharged battery cells. Trickle charging is used when the battery voltage is below about 10V. The trickle charging current is one-tenth of the constant current charging current, i.e., 0.1C (taking a constant charging current of 1A as an example, the trickle charging current is 100mA).

[0049] Phase 2: Constant Current Phase – When the battery voltage rises above the trickle charging threshold, the charging current is increased for constant current charging. The constant current charging current is between 0.2C and 1.0C. The battery voltage gradually increases during the constant current charging process; this voltage is typically set to 28.8V for the battery.

[0050] Phase 3: Constant Voltage Phase – When the battery voltage rises to 28.8V, constant current charging ends, and constant voltage charging begins. The current decreases gradually from its maximum value as charging continues, depending on the cell's saturation level. Charging is considered complete when the current decreases to 0.01C. (C is a method of expressing current relative to the battery's nominal capacity; for example, if the battery has a capacity of 1000mAh, 1C means a charging current of 1000mA.)

[0051] Phase 4: Float Charge Stage – There are two typical methods for terminating charging: using the minimum charging current or using a timer (or a combination of both). The minimum current method monitors the charging current during the constant voltage charging phase and initiates float charging when the charging current decreases to the range of 0.02C to 0.07C. Charging is terminated after 30 minutes of float charging. The second method starts timing from the beginning of the constant voltage charging phase and terminates the charging process after two hours of continuous charging.

[0052] This high-power, fully isolated intelligent charging system features battery activation and reverse connection protection. The default output activation voltage threshold is 18V. After the charger is powered on, it automatically detects the battery status. When a battery meeting the activation conditions is detected, the output relay automatically opens to begin charging. The output relay automatically disconnects when the battery is removed. When a reverse connection is detected, the output relay will not open, protecting the charger and battery from damage. This high-power, fully isolated intelligent charging system also features temperature protection and seasonal temperature compensation. It provides two temperature protection channels: one monitors the heat sink temperature with a default current reduction threshold of 60℃, an over-temperature threshold of 80℃, and a recovery threshold of 50℃; the other monitors the charger's internal ambient temperature with a default current reduction threshold of 60℃, an over-temperature threshold of 80℃, and a recovery threshold of 50℃. To adapt to the characteristics of lead-acid batteries under different seasonal temperatures, a temperature compensation function is provided. It automatically detects the ambient temperature and increases the output voltage to enhance the charging capacity of lead-acid batteries in winter.

[0053] The above description is merely a preferred embodiment of this utility model, but the scope of protection of this utility model is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in this utility model should be included within the scope of protection of this utility model. Therefore, the scope of protection of this utility model should be determined by the scope of the claims. The information disclosed in the background section is intended only to enhance the understanding of the overall background technology of this utility model and should not be construed as an admission or implication in any way that such information constitutes prior art known to those skilled in the art.

Claims

1. A high-power fully isolated intelligent charging system, characterized in that, Includes a charging unit and a charging management unit; The charging unit includes: an AC input terminal that sequentially passes through an EMI filter, a PFC boost circuit, a high voltage filter circuit, an LC resonant buck converter circuit, and an output rectifier filter circuit to the battery charging terminal; The output rectifier and filter circuit is connected to an output feedback circuit, the output feedback circuit is connected to a power monitoring circuit, and the power monitoring circuit is connected to a power protection circuit and a power monitoring circuit. The charging management unit includes: The PFC boost circuit is connected to a PFC drive circuit. The high-voltage filter circuit is connected to a PFC feedback circuit, and the PFC drive circuit and the PFC feedback circuit are respectively connected to the PFC control circuit. The LC resonant step-down converter circuit is connected to an LC drive circuit, which is connected to an LC control circuit.

2. The high-power fully isolated intelligent charging system according to claim 1, characterized in that, The PFC control circuit, LC control circuit, and output feedback circuit are respectively connected to the auxiliary power line.

3. The high-power fully isolated intelligent charging system according to claim 1 or 2, characterized in that, The charging management unit uses the EG1155 series microcontroller as the main control chip and integrates operational amplifiers, comparators, and MOS drivers.

4. The high-power fully isolated intelligent charging system according to claim 1 or 2, characterized in that, The charging unit employs a symmetrical half-bridge converter.

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