A 1180kW liquid-cooled super-fast port charging pile for ships

Abstract

The utility model discloses a kind of liquid-cooled superfast wharf charging pile of 1180kW, belong to the technical field of marine charging equipment. The charging pile includes cabinet, three-level NPC charging module, water-cooling heat dissipation system, charging interface assembly and control system;Three-level NPC charging module is composed of four sub-modules in parallel, adopts silicon carbide IGBT device, and output current total harmonic distortion is smaller;Water-cooling system is integrated in module bottom, and cooling liquid is glycol aqueous solution, and heat dissipation efficiency is high;Cabinet has salt fog resistance, moisture resistance. The utility model is suitable for wharf high salt fog, high humidity environment, with the advantages of high power density, good heat dissipation performance, strong reliability, easy maintenance etc.

Description

Technical Field

[0001] This utility model relates to the technical field of marine charging equipment, specifically to a 1180kW liquid-cooled ultra-fast marine charging pile for dock use. Background Technology

[0002] With the development of electric ship technology, the demand for charging power on ships is increasing, and 1180kW-class ultra-fast charging has become a core requirement for large electric ships. Traditional marine charging piles mostly adopt a two-level topology, which has problems such as large switching losses, high output harmonics, and the need for complex filtering devices, making it difficult to adapt to high-power fast charging scenarios. At the same time, the heat dissipation problem of high-power charging modules is prominent, and air cooling is limited by heat dissipation efficiency and cannot meet the requirements of continuous high-power operation.

[0003] In existing technologies, although the three-level NPC midpoint clamping topology has been used in high-power converters, its adaptability design in the field of marine charging piles is insufficient, especially lacking protection design for the high salt spray and high humidity environment of docks. In addition, the integration of the liquid cooling system and the three-level topology module is low, resulting in the charging pile being bulky and having poor reliability. Therefore, a 1180kW ultra-fast marine charging pile for docks based on the three-level NPC topology and integrating a high-efficiency liquid cooling system is designed to solve the above problems. Summary of the Invention

[0004] The purpose of this invention is to provide a 1180kW liquid-cooled ultra-fast marine charging pile for docks, aiming to solve the problems of low power density, insufficient heat dissipation, high output harmonics, and poor environmental adaptability of traditional charging piles.

[0005] To solve the above-mentioned technical problems, the technical solution of this utility model is as follows: A 1180kW liquid-cooled ultra-fast marine charging pile for dock use, comprising: The cabinet is made of 316L stainless steel with an IP66 protection rating. The interior is divided into an equipment cavity, a heat dissipation cavity, and an interface cavity. The three-level NPC charging module is located inside the device cavity and consists of four 295kW sub-modules connected in parallel. Each sub-module includes a three-level NPC topology circuit, a pre-charging circuit, and a filtering unit. The water-cooled heat dissipation system includes a water-cooled plate embedded at the bottom of the submodule, a main circulation pump, a plate heat exchanger, and an expansion tank. The water-cooled plate is provided with a serpentine flow channel with a flat circular cross-section. A charging interface assembly, disposed in the interface cavity, includes a liquid-cooled charging gun and an interface socket with an anti-misinsertion structure; The control system includes a main controller with a DSP+FPGA architecture, a sampling module, a communication module, and a protection unit.

[0006] Preferably, the three-level NPC topology circuit includes four 1200V / 600A silicon carbide IGBT switches, two clamping diodes, and two voltage divider capacitors.

[0007] Preferably, the coolant in the water-cooled heat dissipation system is a 50% ethylene glycol aqueous solution with a conductivity ≤10μS / cm.

[0008] Preferably, the total harmonic distortion rate of the output current of the three-level NPC charging module is ≤3%.

[0009] Preferably, the submodule supports hot-swapping, and the weight of a single module is ≤30kg.

[0010] Preferably, the charging gun has a rated current of 800A and a built-in liquid cooling channel and an 8-core signal control line.

[0011] Preferably, the protection unit of the control system has a response time of ≤10μs and has overvoltage, overcurrent, overtemperature and insulation fault protection functions.

[0012] Preferably, the charging pile includes a cabinet, a three-level NPC charging module, a water-cooling system, a charging interface assembly, and a control system. The cabinet is made of 316L stainless steel with an IP66 protection rating and is internally divided into an equipment cavity, a heat dissipation cavity, and an interface cavity. The three-level NPC charging module consists of four 295kW sub-modules connected in parallel. Each sub-module includes a three-level NPC circuit, a pre-charging circuit, and an LC filter unit. The water-cooling system is integrated at the bottom of the sub-module, using an ethylene glycol aqueous solution as the coolant, with a flat circular flow channel cross-section. The charging interface assembly includes a liquid-cooled charging gun and an anti-misinsertion interface socket. The control system adopts a DSP+FPGA architecture to implement SVPWM modulation and multiple protection functions.

[0013] The beneficial effects of this utility model are as follows: 1. High power and high efficiency: When the power output is 1180kW, the conversion efficiency is ≥96%, which is 2% higher than that of the traditional two-level topology.

[0014] 2. Reliable heat dissipation: The water cooling system can withstand the heat dissipation requirements of power density ≥20kW / L and is suitable for the high-temperature environment of the dock.

[0015] 3. Long lifespan: Service life ≥ 10 years in salt spray environment, 50% longer than ordinary charging piles; Easy maintenance: Modular design reduces maintenance time to less than 30 minutes, reducing operation and maintenance costs. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the structure of this utility model; Figure 2 This is a schematic diagram of the three-level NPC submodule circuit topology in this utility model; In the diagram: 1. Cabinet; 2. Three-level NPC charging module; 3. Water cooling system; 4. Charging interface assembly; 5. Water-cooled plate; 6. Plate heat exchanger; 7. Control system; 8. Expansion tank; 11. Equipment cavity; 12. Heat dissipation cavity; 13. Interface cavity. Detailed Implementation

[0017] Example 1: like Figure 1-2 As shown, a 1180kW liquid-cooled ultra-fast marine charging pile for dock use includes: Cabinet 1 is made of 316L stainless steel with an IP66 protection rating. The interior is divided into equipment cavity 11, heat dissipation cavity 12 and interface cavity 13. The three-level NPC charging module 2 is located in the device cavity 11 and consists of four 295kW sub-modules connected in parallel. Each sub-module includes a three-level NPC topology circuit, a pre-charging circuit and a filtering unit. The water-cooled heat dissipation system 3 includes a water-cooled plate 5 embedded at the bottom of the submodule, a main circulation pump, a plate heat exchanger 6, and an expansion tank 8. The water-cooled plate 5 is provided with a serpentine flow channel with a flat circular cross-section. The charging interface assembly 4 is located in the interface cavity 13 and includes a liquid-cooled charging gun and an interface socket with an anti-misinsertion structure. The control system 7 includes a main controller with a DSP+FPGA architecture, a sampling module, a communication module, and a protection unit.

[0018] Preferably, the three-level NPC topology circuit includes four 1200V / 600A silicon carbide IGBT switches, two clamping diodes, and two voltage divider capacitors.

[0019] Preferably, the coolant in the water-cooled heat dissipation system 3 is a 50% ethylene glycol aqueous solution with a conductivity ≤10μS / cm.

[0020] Preferably, the total harmonic distortion rate of the output current of the three-level NPC charging module 2 is ≤3%.

[0021] Preferably, the submodule supports hot-swapping, and the weight of a single module is ≤30kg.

[0022] Preferably, the charging gun has a rated current of 800A and a built-in liquid cooling channel and an 8-core signal control line.

[0023] Preferably, the protection unit of the control system 7 has a response time of ≤10μs and has overvoltage, overcurrent, overtemperature and insulation fault protection functions.

[0024] Preferably, the charging pile includes a cabinet 1, a three-level NPC charging module 2, a water-cooling system 3, a charging interface assembly 4, and a control system 7. The cabinet 1 is made of 316L stainless steel with an IP66 protection rating, and its interior is divided into an equipment cavity 11, a heat dissipation cavity 12, and an interface cavity 13. The three-level NPC charging module 2 consists of four 295kW sub-modules connected in parallel. Each sub-module includes a three-level NPC circuit, a pre-charging circuit, and an LC filter unit. The water-cooling system is integrated at the bottom of the sub-modules, using an ethylene glycol aqueous solution as the coolant, with a flat, round flow channel cross-section. The charging interface assembly 4 includes a liquid-cooled charging gun and an anti-misinsertion interface socket. The control system 7 adopts a DSP+FPGA architecture to implement SVPWM modulation and multiple protection functions.

[0025] The working principle of this utility model is as follows: The AC power from the grid is connected to the three-level NPC charging module 2 via the inlet terminal of cabinet 1, and the voltage divider capacitor is charged through the pre-charging circuit. The main controller controls the IGBT switching transistor to conduct, realizing the three-level voltage output, and outputs stable DC power after passing through the filter unit. During the charging process, the heat generated by the IGBT is transferred to the coolant through the water-cooled plate 5. The main circulation pump drives the coolant into the plate heat exchanger 6, where it exchanges heat with the outside air and then flows back to achieve continuous heat dissipation. The control system 7 monitors the charging parameters in real time. When the ship's BMS sends a full charge signal or a fault occurs, the charging circuit is immediately cut off.

Claims

1. A 1180kW liquid-cooled ultra-fast marine charging pile for dock use, characterized in that, include: The cabinet is made of 316L stainless steel with an IP66 protection rating. The interior is divided into an equipment cavity, a heat dissipation cavity, and an interface cavity. The three-level NPC charging module is located inside the device cavity and consists of four 295kW sub-modules connected in parallel. Each sub-module includes a three-level NPC topology circuit, a pre-charging circuit, and a filtering unit. The water-cooled heat dissipation system includes a water-cooled plate embedded at the bottom of the submodule, a main circulation pump, a plate heat exchanger, and an expansion tank. The water-cooled plate is provided with a serpentine flow channel with a flat circular cross-section. A charging interface assembly, disposed in the interface cavity, includes a liquid-cooled charging gun and an interface socket with an anti-misinsertion structure; The control system includes a main controller with a DSP+FPGA architecture, a sampling module, a communication module, and a protection unit.

2. The 1180kW liquid-cooled ultra-fast marine charging pile for dock use according to claim 1, characterized in that, The three-level NPC topology circuit includes four 1200V / 600A silicon carbide IGBT switches, two clamping diodes, and two voltage divider capacitors.

3. The 1180kW liquid-cooled ultra-fast marine charging pile for dock use according to claim 1, characterized in that, The coolant in the water-cooled heat dissipation system is a 50% ethylene glycol aqueous solution with a conductivity ≤10μS / cm.

4. A 1180kW liquid-cooled ultra-fast marine charging pile for dock use according to claim 1, characterized in that, The total harmonic distortion (THD) of the output current of the three-level NPC charging module is ≤3%.

5. A 1180kW liquid-cooled ultra-fast marine charging pile for dock use according to claim 1, characterized in that, The submodules support hot-swapping, and the weight of a single module is ≤30kg.

6. A 1180kW liquid-cooled ultra-fast marine charging pile for dock use according to claim 1, characterized in that, The charging gun has a rated current of 800A and features a built-in liquid cooling channel and an 8-core signal control line.

7. A 1180kW liquid-cooled ultra-fast marine charging pile for dock use according to claim 1, characterized in that, The protection unit of the control system has a response time of ≤10μs and is equipped with overvoltage, overcurrent, overtemperature and insulation fault protection functions.

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