PDU modules and charging equipment

Abstract

This utility model discloses a PDU module and charging device, relating to the field of power distribution technology. The PDU module includes a control board, a PCB board, a first control group, and a first conductive component. Multiple PCB boards are spaced apart and connected to the control board. The first control group includes multiple first relays forming an n×n triangular matrix, which are fixed to the PCB board. The first conductive component, through first conductive elements, second conductive elements, and bridging busbars, respectively achieves electrical connection and cross-bridging of relays in the same row and column. This solution, through a triangular matrix layout, significantly reduces the total number of relays while achieving the same control functions as a traditional full matrix. Simultaneously, the relays are integrated into the PCB board and uniformly controlled by the control board, eliminating a large number of connectors and wiring harnesses, effectively reducing module size, material and assembly costs, and achieving flexible power distribution functionality.

Description

Technical Field

[0001] This utility model relates to the field of power distribution technology, and in particular to a PDU module and a charging device. Background Technology

[0002] As a key component of the charging pile system, the PDU (Power Distribution Unit) is responsible for the flexible distribution and control of electrical energy. In electric vehicle charging facilities, the performance of the PDU module directly affects the charging efficiency, system reliability and overall cost. Currently, most PDU modules on the market adopt a matrix layout structure, that is, multiple relays are arranged in a matrix, and a large number of connectors and wiring harnesses are used to realize circuit control and signal transmission.

[0003] However, this traditional matrix layout has many drawbacks: First, the large number of relays results in a large overall module size, occupying a lot of space, which is not conducive to the design and integration of compact devices; second, the use of a large number of relays and the corresponding connectors and wiring harnesses significantly increases material and assembly costs; in addition, the complex wiring structure makes the plugging process difficult and the installation efficiency low. Utility Model Content

[0004] The main purpose of this invention is to propose a PDU module and charging device, which aims to reduce costs and assembly difficulty.

[0005] To achieve the above objectives, the PDU module proposed in this utility model includes: Control panel; PCB boards, with multiple PCB boards connected at intervals to the control board; The first control group includes multiple first relays, which are fixedly connected to the PCB board, and the multiple first relays form an n×n triangular matrix. A first conductive component, the first conductive component including a plurality of first conductive elements, a plurality of second conductive elements and a plurality of bridging busbars; The first conductive element electrically connects the first controlled terminals of multiple first relays located in the same row; The second conductive element electrically connects the second controlled terminals of multiple first relays located in the same column; The bridging busbar connects the second controlled terminal of at least one of the first relays located in the same column to the first controlled terminal of at least one of the first relays located in the same row, and the number of the first relays connected is n.

[0006] In one embodiment, the PDU module further includes a first connector and a second connector, both of which are fixedly connected to the PCB board, and the first connector and the second connector are respectively connected to the first controlled terminal and the second controlled terminal of the first relay. Both the first connector and the second connector are provided with an easy-connection part, which is used to connect with the first conductive element, the second conductive element, or the bridging busbar.

[0007] In one embodiment, both the first connector and the second connector are provided with a bending portion, the bending portion of the first connector and the bending portion of the second connector are parallel to each other, and the bending portion is perpendicular to the surface of the PCB board; The bending portion is provided with the easy-connection portion.

[0008] In one embodiment, the bent portion of the first connector and the bent portion of the second connector are respectively located on opposite sides of the first relay; The first conductive element and the second conductive element are located on opposite sides of the first relay.

[0009] In one embodiment, the PDU module further includes a first connection structure and a second connection structure; The first connection structure and the second connection structure correspond to each other, forming n+1 charging channels. The two ends of the charging channels are used to electrically connect the power supply and the electrical equipment, respectively.

[0010] In one embodiment, the first connection structure includes n first connection ends and one second connection end; The n first connection terminals are connected to the first controlled terminals of the first relays located in different rows one by one, and the second connection terminals are connected to the second controlled terminals of the first relays located in the longest column. The second connection structure includes n third connection terminals and one fourth connection terminal; The n third connection terminals are connected to the second controlled terminals of the first relays located in different columns, and the fourth connection terminal is connected to the first controlled terminal of the first relay located in the longest row.

[0011] In one embodiment, the first conductive element and the second conductive element are copper plates.

[0012] In one embodiment, the PDU module further includes a second control group, which includes a plurality of second relays. The second relays are fixedly connected to the PCB board, and the plurality of second relays form an n×n triangular matrix. The second conductive component includes a plurality of third conductive elements, a plurality of fourth conductive elements, and a plurality of bridging busbars; The third conductive element electrically connects the first controlled terminals of multiple second relays located in the same row; The fourth conductive element electrically connects the second controlled terminals of multiple second relays located in the same column; The bridging busbar connects the second controlled terminal of at least one second relay located in the same column to the first controlled terminal of at least one second relay located in the same row, and the number of first relays connected is n.

[0013] In one embodiment, the first relay of the first control group and the second relay of the second control group together form a full matrix.

[0014] This utility model also proposes a charging device, which includes the above-mentioned PDU module.

[0015] The technical solution of this utility model adopts an n×n triangular matrix layout, which, compared with the traditional n×n full matrix layout, effectively reduces the total number of relays required while achieving the same control function. Furthermore, the first relay is integrated into the PCB board, and the coils of all the first relays can be controlled simultaneously through the control board, controlling the on / off state of the controlled terminal of each first relay. This reduces the number of connecting accessories and wiring harnesses, greatly reducing assembly and labor costs. Moreover, power distribution is achieved by controlling the on / off state of different first relays. Attached Figure Description

[0016] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on the structures shown in these drawings without creative effort.

[0017] Figure 1 This is a schematic diagram of the structure of an embodiment of the PDU module provided by this utility model; Figure 2 This is a top view of the PDU module provided by this utility model; Figure 3 This is an assembly diagram of the first connector, the second connector, and the first relay; Figure 4 This is a schematic diagram of the assembly structure of the bridging busbar; Figure 5This is a schematic diagram of another embodiment of the PDU module provided by this utility model.

[0018] Explanation of icon numbers: 1. Control board; 11. PCB board; 121. First relay; 131. First conductive component; 132. Second conductive component; 133. Bridging busbar; 14. First connector; 15. Second connector; 151. Easy-connect part; 152. Bending part; 181. Second relay; 21. First input terminal; 22. Second input terminal; 23. Third input terminal; 24. Fourth input terminal; 25. Fifth input terminal; 26. Sixth input terminal; 27. Seventh input terminal; 28. Eighth input terminal; 31. First output terminal; 32. Second output terminal; 33. Third output terminal; 34. Fourth output terminal; 35. Fifth output terminal; 36. Sixth output terminal; 37. Seventh output terminal; 38. Eighth output terminal.

[0019] The realization of the purpose, functional features and advantages of this utility model will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0020] 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. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present utility model.

[0021] It should be noted that if the embodiments of this utility model involve directional indicators (such as up, down, left, right, front, back, etc.), the directional indicators are only used to explain the relative positional relationship and movement of the components in a specific posture. If the specific posture changes, the directional indicators will also change accordingly.

[0022] Furthermore, if the embodiments of this utility model involve descriptions such as "first" or "second," these descriptions are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined with "first" or "second" may explicitly or implicitly include at least one of those features. Additionally, the use of "and / or" or "and / or" throughout the text includes three parallel solutions. For example, "A and / or B" includes solution A, solution B, or a solution where both A and B are satisfied simultaneously. Furthermore, the technical solutions of the various embodiments can be combined with each other, but this must be based on the ability of those skilled in the art to implement them. When the combination of technical solutions is contradictory or impossible to implement, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection claimed by this utility model.

[0023] As a key component of the charging pile system, the PDU (Power Distribution Unit) is responsible for the flexible distribution and control of electrical energy. In electric vehicle charging facilities, the performance of the PDU module directly affects the charging efficiency, system reliability and overall cost. Currently, most PDU modules on the market adopt a matrix layout structure, that is, multiple relays are arranged in a matrix, and a large number of connectors and wiring harnesses are used to realize circuit control and signal transmission.

[0024] However, this traditional matrix layout has many drawbacks: First, the large number of relays results in a large overall module size, occupying a lot of space, which is not conducive to the design and integration of compact devices; second, the use of a large number of relays and the corresponding connectors and wiring harnesses significantly increases material and assembly costs; in addition, the complex wiring structure makes the plugging process difficult and the installation efficiency low.

[0025] This utility model proposes a PDU module.

[0026] Please see Figures 1 to 5 In one embodiment of this utility model, the PDU module includes: Control panel 1; PCB board 11, multiple PCB boards 11 are connected to the control board 1 at intervals; The first control group includes a plurality of first relays 121, the first relays 121 are fixedly connected to the PCB board 11, and the plurality of first relays 121 form an n×n triangular matrix. The first conductive component includes a plurality of first conductive elements 131, a plurality of second conductive elements 132, and a plurality of bridging busbars 133; The first conductive element 131 electrically connects the first controlled terminals of multiple first relays 121 located in the same row; The second conductive element 132 electrically connects the second controlled terminals of the plurality of first relays 121 located in the same column; The bridging busbar 133 connects the second controlled terminal of at least one first relay 121 located in the same column to the first controlled terminal of at least one first relay 121 located in the same row, and the number of connected first relays 121 is n. The technical solution of this utility model adopts an n×n triangular matrix layout, which, compared with the traditional n×n full matrix layout, effectively reduces the total number of relays required while achieving the same control function. Furthermore, the first relay 121 is integrated into the PCB board 11, and the coils of all the first relays 121 can be controlled simultaneously through the control board 1, controlling the on / off state of the controlled terminal of each first relay 121. This reduces the number of connecting accessories and wiring harnesses, greatly reducing assembly and labor costs. Moreover, power distribution is achieved by controlling the on / off state of different first relays 121.

[0027] It is understood that a single relay includes a coil section and a controlled section. The low-voltage control of the coil section controls the high-voltage control of the controlled section. The first relay 121 of this invention is integrated on the PCB board 11, and multiple PCB boards 11 are connected to the control board 1 at intervals. The multiple PCB boards are integrated with the control board 1, and multiple first relays 121 can be controlled through the control board 1. The distribution adjustment can be achieved by controlling the on / off state of the controlled sections of multiple first relays 121 in conjunction with the first conductive component.

[0028] Understandably, the traditional complex wiring harness has been replaced by a rigid PCB board 11. This eliminates a large number of connection points, resulting in a clear and orderly internal structure, greatly simplifying the operation process, improving installation efficiency, and reducing the risk of human error caused by incorrect or loose wiring harness connections.

[0029] like Figure 3 and Figure 4 As shown, the PDU module also includes a first connector 14 and a second connector 15. The first connector 14 and the second connector 15 are both fixedly connected to the PCB board 11, and the first connector 14 and the second connector 15 are respectively connected to the first controlled terminal and the second controlled terminal of the first relay 121. Both the first connector 14 and the second connector 15 are provided with an easy-connection part 151, which is used to connect with the first conductive element 131, the second conductive element 132 or the bridging busbar 133.

[0030] It is understood that the low-voltage portion (coil portion) of the first relay 121 is integrated into the PCB board 11. Only the high-voltage portion needs to be led out for control. Through the first connector 14 and the second connector 15, and the easy-connection portion 151 provided on both, the connection method between all the first relays 121 and external conductive components such as the first conductive element 131, the second conductive element 132, or the bridging busbar 133 is standardized. Installers no longer need to deal with a large number of scattered and complex cables and terminals; they only need to connect the corresponding accessories to the standardized easy-connection portion 151. This greatly simplifies the plug-in process, making assembly simple, fast, and less prone to errors, thereby significantly improving production efficiency.

[0031] In one embodiment, the easy-connect portion 151 is a through hole to facilitate connection via accessories such as nuts.

[0032] In another embodiment, the easy-connection part 151 is a connecting post to facilitate the insertion of the first conductive element 131, the second conductive element 132 and the bridge busbar 133 bracket. Furthermore, the connecting post is threaded to facilitate the connection of bolts and other accessories.

[0033] It is understood that the easy-connection part 151 may also be other structures that facilitate connection, and this embodiment does not impose specific limitations on it.

[0034] Optionally, both the first connector 14 and the second connector 15 are provided with a bending portion 152. The bending portion 152 of the first connector 14 and the bending portion 152 of the second connector 15 are parallel to each other, and the bending portion 152 is perpendicular to the surface of the PCB board 11. The bending portion 152 is provided with the easy-connection portion 151.

[0035] It is understood that the bending portion 152 can form a uniform mounting plane to facilitate the installation of the first conductive component and reduce the shape requirements of the first conductive element 131, the second conductive element 132 and the bridging busbar 133. For example, the first conductive element 131 and the second conductive element 132 can be assembled by adopting a strip structure, which greatly improves the installation efficiency and quality consistency.

[0036] Optionally, the bent portion 152 of the first connector 14 and the bent portion 152 of the second connector 15 are respectively located on opposite sides of the first relay 121; The first conductive element 131 and the second conductive element 132 are located on opposite sides of the first relay 121.

[0037] It is understandable that the first conductive element 131 and the second conductive element 132 are connected to a large current. By arranging them on both sides of the body of the first relay 121, the main current inflow and outflow paths are physically parallel and separate, dispersing the main heat source to both sides of the first relay 121, avoiding heat concentration, facilitating airflow and overall heat dissipation, and improving the power carrying capacity and long-term reliability of the system.

[0038] Optionally, the PDU module further includes a first connection structure and a second connection structure; The first connection structure and the second connection structure correspond to each other, forming n+1 charging channels. The two ends of the charging channels are used to electrically connect the power supply and the electrical equipment, respectively.

[0039] like Figure 2 As shown, an n×n triangular matrix can form n+1 charging channels. Taking 28 of the first relays 121 forming a 7×7 triangular matrix as an example, it can form 8 charging channels, and different charging channels can be interconnected to achieve power distribution. It should be noted that each of the charging channels is connected to seven of the first relays 121. By connecting different first relays 121, the charging channel can be connected to seven other charging channels, and these seven first relays 121 correspond one-to-one with the other seven charging channels.

[0040] For example, eight charging channels are connected to eight power sources and eight electrical devices at their respective ends. For a single charging channel, one power source and one electrical device are connected to its two ends. When a certain electrical device does not need to be charged, the power corresponding to that electrical device can be allocated to any of the other seven electrical devices to achieve power distribution.

[0041] It is understood that the first connection structure can be used to connect to a power source or an electrical device, and the second connection structure is corresponding to the first connection structure. When the first connection structure is used to connect to a power source, the second connection structure is used to connect to an electrical device; when the first connection structure is used to connect to an electrical device, the second connection structure is used to connect to a power source.

[0042] Optionally, the first connection structure includes n first connection ends and one second connection end; The n first connection terminals are connected to the first controlled terminals of the first relays 121 located in different rows, and the second connection terminals are connected to the second controlled terminals of the first relays 121 located in the longest column. The second connection structure includes n third connection terminals and one fourth connection terminal; The n third connection terminals are connected one by one to the second controlled terminals of the first relay 121 located in different columns, and the fourth connection terminal is connected to the first controlled terminal of the first relay 121 located in the longest row.

[0043] It is understandable that, taking the 28 first relays 121 forming a 7×7 triangular matrix as an example, the 7 first connection terminals and 1 second connection terminal together form the input or output terminals of the 8 charging channels; correspondingly, the 7 third connection terminals and 1 fourth connection terminal together form the input or output terminals of the 8 charging channels.

[0044] Optionally, the first conductive element 131 and the second conductive element 132 are copper plates.

[0045] It should be noted that the first connection structure and the second connection structure are structures for connecting to electrical equipment and power supply. They can be separate structures for easy connection, or they can be the first conductive element 131 and the second conductive element 132 themselves or their outward extensions for easy connection. This embodiment does not impose specific limitations on this.

[0046] by Figure 5 For example, the first input terminal 21 and the first output terminal 31 are directly connected to form the first charging channel; the second input terminal 22 and the second output terminal 32 are directly connected to form the second charging channel; the third input terminal 23 and the third output terminal 33 are directly connected to form the third charging channel; the fourth input terminal 24 and the fourth output terminal 34 are directly connected to form the fourth charging channel; the fifth input terminal 25 and the fifth output terminal 35 are directly connected to form the fifth charging channel; the sixth input terminal 26 and the sixth output terminal 36 are directly connected to form the sixth charging channel; the seventh input terminal 27 and the seventh output terminal 37 are directly connected to form the seventh charging channel; and the eighth input terminal 28 and the eighth output terminal 38 are directly connected to form the eighth charging channel. by Figure 5 For example, define Figure 5 In the diagram, the first relay 121 in the lower left position is at position 1×1, the first relay 121 in the upper left position is at position 7×1, and the first relay 121 in the lower right position is at position 1×7. When the first relay 121 in position 7×1 is connected, the first charging channel is connected to the second charging channel. When the first relay 121 in position 6×1 is connected, the first charging channel is connected to the third charging channel.

[0047] When the first relay 121 located at position 6×2 is connected, the second charging channel is connected to the third charging channel.

[0048] As can be understood from the above, all charging channels can be interconnected to achieve power distribution.

[0049] Understandable, Figure 5 The first input terminal 21 is the second connection terminal, the remaining input terminals are the first connection terminals, the eighth output terminal 38 is the fourth connection terminal, and the remaining output terminals are the third connection terminals.

[0050] Optionally, the PDU module further includes a second control group, which includes a plurality of second relays 181. The second relays 181 are fixedly connected to the PCB board 11, and the plurality of second relays 181 form an n×n triangular matrix. The second conductive component includes a plurality of third conductive elements, a plurality of fourth conductive elements, and a plurality of bridging busbars 133; The third conductive element electrically connects the first controlled terminals of multiple second relays 181 located in the same row; The fourth conductive element electrically connects the second controlled terminals of multiple second relays 181 located in the same column; The bridging busbar 133 connects the second controlled terminal of at least one second relay 181 located in the same column to the first controlled terminal of at least one second relay 181 located in the same row, and the number of first relays 121 connected is n.

[0051] It should be noted that when charging some devices, both positive and negative inputs are required simultaneously, and the first control group and the second control group are used to control the positive input and the negative input, respectively. It is understandable that the number of the second relay 181 is the same as the number of the first relay 121, which can also form n+1 charging channels. Taking the charging of electric vehicles as an example, a charging gun has two ports, one positive and one negative, forming a total of n+1 charging guns. The two ports are controlled by the first control group and the second control group respectively, so as to realize the distribution among different charging guns.

[0052] It should be noted that the second relay 181 of the second control group is also connected to the first connector 14 and the second connector 15, and the connection method and function are similar to those above, so they will not be discussed again here.

[0053] It is understood that the PDU module also includes a third connection structure and a fourth connection structure for connecting to the second control group. The structure is similar to the first connection structure and the second connection structure described above, and will not be discussed again here.

[0054] Optionally, the first relay 121 of the first control group and the second relay 181 of the second control group together form a full matrix.

[0055] It is understood that the first relay 121 of the first control group and the second relay 181 of the second control group can be mounted on the same PCB board 11.

[0056] This utility model also proposes a charging device, which includes a PDU module. The specific structure of the PDU module is as described in the above embodiments. Since this charging device adopts all the technical solutions of all the above embodiments, it has at least all the beneficial effects brought about by the technical solutions of the above embodiments, which will not be described in detail here.

[0057] The above description is merely an exemplary embodiment of the present utility model and does not limit the scope of protection of the present utility model. Any equivalent structural transformations made based on the technical concept of the present utility model and the contents of the present utility model specification and drawings, or direct / indirect applications in other related technical fields, are included within the scope of protection of the present utility model.

Claims

1. A PDU module, characterized in that, include: Control panel; PCB boards, with multiple PCB boards connected at intervals to the control board; The first control group includes multiple first relays, which are fixedly connected to the PCB board, and the multiple first relays form an n×n triangular matrix. A first conductive component, the first conductive component including a plurality of first conductive elements, a plurality of second conductive elements and a plurality of bridging busbars; The first conductive element electrically connects the first controlled terminals of multiple first relays located in the same row; The second conductive element electrically connects the second controlled terminals of multiple first relays located in the same column; The bridging busbar connects the second controlled terminal of at least one of the first relays located in the same column to the first controlled terminal of at least one of the first relays located in the same row, and the number of the first relays connected is n.

2. The PDU module as described in claim 1, characterized in that, The PDU module further includes a first connector and a second connector, both of which are fixedly connected to the PCB board, and the first connector and the second connector are respectively connected to the first controlled terminal and the second controlled terminal of the first relay. Both the first connector and the second connector are provided with an easy-connection part, which is used to connect with the first conductive element, the second conductive element, or the bridging busbar.

3. The PDU module as described in claim 2, characterized in that, Both the first connector and the second connector are provided with a bending portion. The bending portions of the first connector and the second connector are parallel to each other, and the bending portions are perpendicular to the surface of the PCB board. The bending portion is provided with the easy-connection portion.

4. The PDU module as described in claim 3, characterized in that, The bent portions of the first connector and the second connector are located on opposite sides of the first relay, respectively. The first conductive element and the second conductive element are located on opposite sides of the first relay.

5. The PDU module as described in claim 1, characterized in that, The PDU module also includes a first connection structure and a second connection structure; The first connection structure and the second connection structure correspond to each other, forming n+1 charging channels. The two ends of the charging channels are used to electrically connect the power supply and the electrical equipment, respectively.

6. The PDU module as described in claim 5, characterized in that, The first connection structure includes n first connection ends and one second connection end; The n first connection terminals are connected to the first controlled terminals of the first relays located in different rows one by one, and the second connection terminals are connected to the second controlled terminals of the first relays located in the longest column. The second connection structure includes n third connection terminals and one fourth connection terminal; The n third connection terminals are connected to the second controlled terminals of the first relays located in different columns, and the fourth connection terminal is connected to the first controlled terminal of the first relay located in the longest row.

7. The PDU module as described in claim 1, characterized in that, The first conductive element and the second conductive element are copper plates.

8. The PDU module as described in claim 1, characterized in that, The PDU module also includes a second control group, which includes multiple second relays. The second relays are fixedly connected to the PCB board, and the multiple second relays form an n×n triangular matrix. The second conductive component includes a plurality of third conductive elements, a plurality of fourth conductive elements, and a plurality of bridging busbars; The third conductive element electrically connects the first controlled terminals of multiple second relays located in the same row; The fourth conductive element electrically connects the second controlled terminals of multiple second relays located in the same column; The bridging busbar connects the second controlled terminal of at least one second relay located in the same column to the first controlled terminal of at least one second relay located in the same row, and the number of first relays connected is n.

9. The PDU module as described in claim 8, characterized in that, The first relay of the first control group and the second relay of the second control group together form a complete matrix.

10. A charging device, characterized in that, Includes the PDU module as described in any one of claims 1 to 9.

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