A mobile power supplementing device

Abstract

The application discloses a mobile power supply device, which mainly comprises a high-voltage box, a battery module, a direct-current discharging module, a direct-current charging module, an alternating-current charging and discharging module and an EMS control module. The high-voltage box is internally provided with a copper bar, a first fuse, a contactor, a first relay, a direct-current circuit breaker, a switching power supply and a Hall sensor, and protection and control of a circuit are realized through reasonable connection. The direct-current charging module has an input source from a high-voltage output interface, and the voltage and current of the output direct-current electricity can be adjusted as required, and is suitable for different load devices. The alternating-current charging and discharging module can interact with an alternating-current power grid, realizes battery charging and alternating-current discharging for a load. The speed of a cooling fan module is automatically adjusted by the EMS control module, so that the charging module can work within a preset temperature. The device has the advantages of high integration, flexible charging, high safety, intelligent management and control and optimized heat dissipation, and the performance and efficiency of mobile power supply are improved.

Description

Technical Field

[0001] This application belongs to the field of battery control technology, and in particular relates to a mobile charging device. Background Technology

[0002] With the rapid development of the electric vehicle industry, the demand for convenient and efficient charging facilities is increasing daily. Mobile charging vehicles, as a flexible charging solution, can provide emergency charging services when electric vehicles are low on power and cannot reach fixed charging stations in time, showing great promise for application. However, existing mobile charging vehicle technology has significant shortcomings in several key aspects, severely restricting its further development and widespread application.

[0003] Currently, charging piles and energy storage technologies in mobile charging vehicle technology are fragmented. Traditional design approaches often develop and apply charging piles and energy storage systems as two independent components, lacking effective integration and coordination. This results in severe deficiencies in the reliability and compatibility of the entire mobile charging vehicle system. In actual operation, poor communication and collaboration between the charging pile and the energy storage system can easily lead to problems such as unstable energy transmission and low charging efficiency. For example, when the power output of the energy storage system does not match the charging demand of the charging pile, it may cause charging interruptions or excessively slow charging speeds, failing to meet the actual needs of users. Furthermore, due to the lack of unified standards and specifications, seamless interoperability between charging piles and energy storage devices from different manufacturers is difficult to achieve, further limiting the versatility and scalability of mobile charging vehicle systems.

[0004] Furthermore, mobile charging vehicles face severe electromagnetic interference problems during operation. Interference from high-voltage systems, in particular, significantly impacts the charging process and system stability. High-voltage interference frequently leads to charging interruptions and false alarms. During charging, high-voltage interference may cause malfunctions in the charging control circuit, resulting in sudden interruptions in charging current and affecting charging continuity and efficiency. Simultaneously, interference signals may trigger the system's alarm devices, generating false alarms and causing unnecessary inconvenience to users and maintenance personnel. Moreover, existing mobile charging vehicles exhibit poor physical integration and lack effective modular design. The low integration between functional modules and the complex connections and communication between them result in an overall system structure that is neither compact nor simple. Utility Model Content

[0005] This application proposes a mobile power replenishment device with a plug-and-play design, reducing the difficulty of technical integration. It integrates a high-voltage box, battery module, charging module, AC charging and discharging module, and EMS control module into a single, complete mobile power replenishment system. This integrated design reduces the size and footprint of the device, improving the overall compactness and portability of the system, facilitating movement and deployment, and allowing for flexible application in various scenarios such as parking lots and roadside assistance. Furthermore, the modules work independently yet collaboratively, simplifying system installation, maintenance, and upgrades. For example, if a module malfunctions, it can be quickly replaced, reducing maintenance costs and time, and improving system availability and reliability.

[0006] Specifically, this application proposes a mobile power supply device, comprising: a high-voltage box, a battery module, a DC discharge module, a DC charging module, an AC charging and discharging module, and an EMS control module. The high-voltage box includes a copper busbar, a first fuse, a contactor, a first relay, a DC circuit breaker, a switching power supply, and a Hall sensor. The switching power supply is connected to the DC circuit breaker and the contactor, and is also connected to the relay. The contactor is also connected to the copper busbar or the fuse side to control the switching of the contactor according to different operating conditions.

[0007] The high-pressure box also includes: The high-voltage box is equipped with a battery connector base, a DC power supply connector base, a DC discharge connector base, a PCS connector base, a liquid cooling unit connector base, a low-voltage control connector base, and a 24V power supply connector base.

[0008] The battery module is connected in series to the battery connector base on the high-voltage box, and after passing through the circuit breaker, it is output to the DC bus inside the high-voltage box.

[0009] The DC discharge module includes: a second relay, a second fuse, and a shunt. The input terminal of the second relay is connected to the control circuit, and the output terminal is connected to the second fuse and the shunt. The shunt is connected in series between the second relay and the load.

[0010] The mobile power supply device further includes: a DC-DC module; the input terminal of the DC-DC module is connected to the base of the DC discharge connector of the high-voltage box; The output of the DC-DC module is connected to the input of the DC discharge module, and after passing through the second power distribution relay, it is connected to the second fuse, and finally connected to the charging gun through the second relay.

[0011] The DC charging module includes: a charging gun socket, a BMS, and / or an EVCC; The charging gun holder is connected to the DC power supply connector base of the high-voltage box after being connected to an external charging pile. The BMS communicates with the external charging pile and interacts with the charging pile for data.

[0012] The AC charging and discharging module includes a concealed socket, a concealed plug, an AC interlock contactor, a leakage current detection device, a current transformer, and lightning protection. Both the concealed socket and the concealed plug are connected to the PCS AC test. The concealed socket is used to supply power to the external load, and the concealed plug is used to charge the battery from the external power grid. The AC interlock contactor is connected to the charging and discharging circuit to ensure that only one circuit is working.

[0013] The EMS control module includes EMS, CCU, and BMS; The EMS is responsible for real-time data collection and monitoring of all devices, as well as security protection and fault handling. The BMS is responsible for collecting various data from the battery cells and uploading them to the EMS. It also needs to communicate with external charging piles and exchange data. The CCU mainly communicates with external vehicles and exchanges data. Compared with the prior art, this application has the following beneficial effects: The fuses in the high-voltage box of this application will quickly melt and disconnect the circuit when the circuit current abnormally increases, preventing irreversible damage to critical components such as battery modules and charging modules due to overcurrent. The contactor and relay work together; the relay controls the energization and de-energization of the contactor coil, thereby controlling the on / off state of the main circuit, enabling remote and automated circuit control. The circuit breaker can automatically trip in the event of serious faults such as short circuits and overloads, providing comprehensive protection for equipment and personnel, and reducing the risk of electrical accidents.

[0014] The EMS control module continuously monitors the operating status of each device within the system, enabling rapid and accurate diagnosis of faults. Upon detecting an anomaly, appropriate measures can be taken immediately, such as issuing alarms or disconnecting relevant circuits, to prevent further escalation of the fault and ensure the stable operation of the entire mobile power supply device.

[0015] Furthermore, the charging module's input power is drawn from the high-voltage output interface, and the voltage and current of its output DC power can be flexibly adjusted according to the specific needs of different load devices. This allows the mobile charging device to adapt to various types of loads, providing suitable charging parameters for electric vehicles, electric motorcycles, and other DC-powered devices, greatly expanding the device's application range. The AC charging and discharging modules enable bidirectional energy exchange with the AC power grid. When the battery module's power is insufficient, it can draw power from the AC power grid for charging; when needed, it can release the power from the battery module in AC form to power different AC load devices, meeting diverse power consumption scenarios and enhancing the device's practicality and emergency power supply capabilities. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the mobile power supply device of this application.

[0017] Figure 2 This is a schematic diagram of the interior of the high-voltage box in this application.

[0018] Figure 3 This is a front view of the high-voltage box of this application.

[0019] Figure 4 This is a schematic diagram of the back of the high-voltage box in this application.

[0020] Figure 5 This is a front view of the charging module of this application.

[0021] Figure 6 This is a schematic diagram of the internal structure of the charging module in this application.

[0022] Figure 7 This is a schematic diagram of the AC charging and AC discharging module interface of this application.

[0023] Figure 8 This is a schematic diagram of the internal structure of the AC charging and AC discharging module of this application.

[0024] In the diagram, 1-fuse; 2-relay; 3-terminal block; 4-circuit breaker; 5-Hall effect sensor; 6-PCS negative terminal; 7-DC-DC negative terminal; 8-PCS positive terminal; 9-DC-DC positive terminal; 10-high voltage acquisition port; 11-24V output port; 12-battery positive terminal; 13-low voltage connection; 14-battery negative terminal; 15-liquid cooling unit power supply; 16-DC power supply positive terminal (charging pile); 17-DC power supply negative terminal. 18 - Negative terminal of charging gun B; 19 - Positive terminal of charging gun B; 20 - Positive terminal of DC-DC module; 21 - Negative terminal of DC-DC module; 22 - Pre-charge resistor; 23 - Negative terminal of charging gun A; 24 - Positive terminal of charging gun A; 25 - Output 125A; 26 - Output 63A; 27 - Output 32A; 28 - Input 125A; 29 - Input 63A; 30 - Leakage detection; 31 - AC interlock contactor; 32 - Lightning protection. Detailed Implementation

[0025] The following description is intended to disclose this application so that those skilled in the art can implement it. The preferred embodiments described below are merely examples, and other obvious variations will occur to those skilled in the art.

[0026] like Figure 1-4 As shown, this application proposes a mobile power supply device, including: a high-voltage box, a battery module, a DC discharge module, a DC charging module, an AC charging and discharging module, and an EMS control module.

[0027] The high-voltage box includes a copper busbar, a first fuse, a contactor, a first relay, a DC circuit breaker, a switching power supply, and a Hall sensor. The switching power supply is connected to the DC circuit breaker and the contactor, and is also connected to the relay. The contactor is also connected to the copper busbar or the fuse side to control the switching of the contactor according to different operating conditions.

[0028] The high-pressure box also includes: The high-voltage box is equipped with a battery connector base, a DC power supply connector base, a DC discharge connector base, a PCS connector base, a liquid cooling unit connector base, a low-voltage control connector base, and a 24V power supply connector base.

[0029] The high-voltage box, a crucial component of the mobile power supply vehicle, is responsible for the distribution and management of high-voltage power. Its outer casing is made of high-strength aluminum alloy, treated with a special anodizing process, providing excellent corrosion resistance and electromagnetic shielding performance. The high-voltage busbars are made of high-purity copper, with a silver-plated surface to reduce resistance and improve conductivity. The busbar specifications are designed based on the system's rated current and voltage to ensure stable power transmission.

[0030] The first fuse is a fast-acting type, and its rated current is configured according to different load requirements. When an overcurrent occurs in the circuit, the first fuse can cut off the circuit in a very short time, protecting other equipment from damage.

[0031] The contactor uses a high-performance DC contactor, possessing excellent arc-extinguishing capability and reliability. Signals sent via the EMS control module enable the switching control of the high-voltage circuit.

[0032] Preferably, the high-voltage input interface uses a dedicated high-voltage connector, which features anti-mismating properties and excellent insulation. The connector contacts are gold-plated to improve contact performance and oxidation resistance.

[0033] The high-voltage output interface is designed with multiple output ports of different specifications to accommodate different load devices, such as battery modules and charging modules. Each output port is equipped with an independent fuse and contactor for easy fault isolation and maintenance.

[0034] The battery module is connected in series to the battery connector base on the high-voltage box, and after passing through the circuit breaker, it is output to the DC bus inside the high-voltage box.

[0035] The DC discharge module includes: a second relay, a second fuse, and a shunt. The input terminal of the second relay is connected to the control circuit, and the output terminal is connected to the second fuse and the shunt. The shunt is connected in series between the second relay and the load.

[0036] The mobile power supply device also includes a DC-DC module; the input terminal of the DC-DC module is connected to the base of the DC discharge connector of the high-voltage box. The output of the DC-DC module is connected to the input of the DC discharge module, and after passing through the second power distribution relay, it is connected to the second fuse, and finally connected to the charging gun through the second relay.

[0037] The DC charging module includes: a charging gun socket, a BMS, and / or an EVCC; The charging gun holder is connected to the DC power supply connector base of the high-voltage box after being connected to an external charging pile. The BMS communicates with the external charging pile and interacts with the charging pile for data.

[0038] The AC charging and discharging module includes a concealed socket, a concealed plug, an AC interlock contactor, a leakage current detection device, a current transformer, and lightning protection. Both the concealed socket and the concealed plug are connected to the PCS AC test. The concealed socket is used to supply power to the external load, and the concealed plug is used to charge the battery from the external power grid. The AC interlock contactor is connected to the charging and discharging circuit to ensure that only one circuit is working.

[0039] The EMS control module includes EMS, CCU, and BMS; The EMS is responsible for real-time data collection and monitoring of all devices, as well as security protection and fault handling. The BMS is responsible for collecting various data from the battery cells and uploading them to the EMS. It also needs to communicate with external charging piles and exchange data. The CCU mainly communicates with external vehicles and exchanges data. Preferably, the high-pressure box as shown in the figure further includes: On the front of the high-voltage box, there are circuit breaker switches, high-voltage acquisition ports, low-voltage connection ports, battery positive and negative terminals, PCS positive and negative terminals, and DC positive and negative terminals. The high-voltage acquisition port is connected to the high-voltage busbar and each high-voltage circuit node to acquire circuit parameters and send the circuit parameters to the EMS control module. The positive and negative terminals of the battery are connected to the positive and negative terminals of the battery module through a high-voltage busbar and a high-voltage connector. The positive terminal of the PCS is connected to the output terminal of the high-voltage busbar or circuit breaker switch to receive high-voltage electrical energy; the negative terminal of the PCS is connected to the negative terminal of the battery module or the common ground to form a current loop. The DC positive terminal is connected to the high-voltage busbar or a DC power supply that has undergone step-down and voltage regulation to provide positive voltage to the DC load; the DC negative terminal is connected to the negative terminal of the battery module or to the common ground to form a current loop.

[0040] The high-pressure box also includes: On the back of the high-voltage box, a power supply interface for the liquid cooler unit and positive and negative DC power supply ports are provided; The input end of the power supply interface of the liquid chiller is connected to the high-voltage busbar inside the high-voltage box, and the output end of the interface is connected to the power input end of the liquid chiller.

[0041] like Figure 5-6 As shown, multiple charging module connection ports and a charging gun connection port are provided on the front of the charging module.

[0042] The AC charging and discharging module enables the mobile charging vehicle to interact with the AC power grid, achieving charging and discharging functions to other devices. The AC charging and discharging module includes: 1. AC charging section The AC charging module uses advanced bidirectional inverter technology, which can convert AC grid power into DC power to charge the battery module.

[0043] During the charging process, the charging strategy is automatically adjusted by detecting parameters such as voltage, frequency, and phase of the power grid to ensure charging safety and efficiency.

[0044] The AC charging interface uses a charging socket that conforms to national standards and has functions such as leakage protection and overcurrent protection.

[0045] 2. AC discharge section The AC discharge module also utilizes bidirectional inverter technology to convert the DC power in the battery module into AC power to supply power to other devices.

[0046] During the discharge process, the output voltage and frequency can be automatically adjusted according to the load requirements to ensure the stability of the power supply.

[0047] The AC discharge interface can be designed with multiple output ports of different specifications according to different load types, such as 220V / 50Hz, 380V / 50Hz, etc.

[0048] Specifically, such as Figure 7-8 As shown, the AC charging and AC discharging module includes an AC interlock contactor and a Hall sensor; The input terminal of the AC interlock contactor is connected to the AC power supply, and the output terminal is connected to the AC port of the charging or discharging equipment; the control terminal is connected to the EMS control module. The Hall sensor is connected to an AC interlock contactor.

[0049] Preferably, the EMS control module is the brain of the mobile charging vehicle, responsible for the comprehensive management and control of the energy flow, equipment status and fault diagnosis of the entire system.

[0050] Hardware components of the EMS control module: It uses a high-performance microcontroller as its core processor, possessing powerful computing and data processing capabilities.

[0051] It is equipped with multiple sensor interfaces for real-time acquisition of parameters such as voltage, current, and temperature of the battery module, as well as the working status information of devices such as the charging module and high-voltage box PDU.

[0052] It has communication interfaces, such as CAN bus and Ethernet, which enable it to communicate and exchange information with other modules.

[0053] Software functions of the EMS control module: Energy management strategy: Based on the battery module's SOC (State of Charge), the needs of the charged device, and the grid conditions, formulate a reasonable energy allocation strategy to achieve optimal energy utilization.

[0054] Equipment control: By sending control signals, the charging module, high-voltage box PDU, AC charging and AC discharging module and other equipment are controlled in real time to ensure their normal operation.

[0055] Fault diagnosis and protection: Real-time monitoring of the system's operating status; when a fault is detected, timely signaling and corresponding protective measures are taken, such as cutting off the circuit or reducing power.

[0056] Preferably, the charging module generates a large amount of heat during operation. If it cannot be dissipated in time, it will affect the performance and lifespan of the charging module. Therefore, the design of the cooling fan module is crucial.

[0057] Cooling fan selection: Choose a suitable cooling fan based on the power and heat dissipation requirements of the charging module. The cooling fan should have characteristics such as high air volume, low noise, and long lifespan.

[0058] The system employs a dual-fan design, ensuring that if one fan fails, the other can still meet basic cooling requirements, thus improving system reliability.

[0059] Cooling duct design: A well-designed cooling duct ensures that the airflow generated by the cooling fan effectively removes the heat generated by the charging module. The cooling duct adopts a streamlined design to reduce airflow resistance and improve heat dissipation efficiency.

[0060] A temperature sensor is installed in the heat dissipation duct to monitor the temperature inside the duct in real time. When the temperature is too high, the speed of the cooling fan is automatically adjusted by the EMS control module to ensure that the charging module operates within a suitable temperature range.

[0061] In this application, the charging gun and charging base are the connecting components between the mobile charging vehicle and the device being charged, and their design directly affects the safety and convenience of charging.

[0062] Charging gun design: The outer shell of the charging gun is made of high-strength engineering plastic, possessing excellent insulation properties and mechanical strength. The handle is ergonomically designed for a comfortable grip and easy operation.

[0063] The charging gun's contacts are made of a special alloy material, possessing excellent conductivity and wear resistance. The shape and size of the contacts conform to national standards, ensuring a good match with the charging interface of the device being charged.

[0064] The charging gun is equipped with both mechanical and electronic locking devices to ensure a reliable connection between the charging gun and the device being charged during the charging process, preventing accidental disconnection.

[0065] Charging stand design: The charging stand is mounted on the body of the mobile charging vehicle, featuring an embedded design that integrates seamlessly with the vehicle's appearance. The surface of the charging stand has a non-slip treatment to prevent the charging gun from slipping during use.

[0066] The charging dock is equipped with a charging interface detection circuit that can detect the insertion and removal status of the charging gun in real time and feed the information back to the EMS control module.

[0067] The charging dock also features dustproof, waterproof, and leakage-proof functions, ensuring normal use in various harsh environments.

[0068] Through the meticulous design and coordinated operation of the various modules, this mobile charging vehicle can achieve efficient, safe, and convenient charging and discharging functions, meeting the needs of different users. In practical applications, each module can be further optimized and improved according to specific usage scenarios and user requirements.

[0069] The foregoing has shown and described the basic principles, main features, and advantages of this application. Those skilled in the art should understand that this application is not limited to the above embodiments. The embodiments and descriptions in the specification are merely the principles of this application. Various changes and modifications can be made to this application without departing from the spirit and scope thereof, and all such changes and modifications fall within the scope of the claims. The scope of protection claimed by this application is defined by the appended claims and their equivalents.

[0070] The above embodiments are merely illustrative of the principles and effects of this utility model and are not intended to limit the scope of this utility model. Any person skilled in the art can modify or alter the above embodiments without departing from the spirit and scope of this utility model. Therefore, all equivalent modifications or alterations made by those skilled in the art without departing from the spirit and technical concept disclosed in this utility model should still be covered by the claims of this utility model.

Claims

1. A mobile power supplementing device, characterized by, include: High-voltage box, battery module, DC discharge module, DC charging module, AC charging and discharging module and EMS control module; The high-voltage box includes a copper busbar, a first fuse, a contactor, a first relay, a DC circuit breaker, a switching power supply, and a Hall sensor. The switching power supply is connected to the DC circuit breaker and the contactor, and is also connected to the relay. The contactor is also connected to the copper busbar or the fuse side to control the switching of the contactor according to different operating conditions.

2. The mobile power supplementing device according to claim 1, wherein The high-pressure box also includes: The high-voltage box is equipped with a battery connector base, a DC power supply connector base, a DC discharge connector base, a PCS connector base, a liquid cooling unit connector base, a low-voltage control connector base, and a 24V power supply connector base.

3. The mobile power supplementing device according to claim 2, wherein Also includes: The battery module is connected in series to the battery connector base on the high-voltage box, and after passing through the circuit breaker, it is output to the DC bus inside the high-voltage box.

4. The mobile power supplementing device according to claim 3, wherein The DC discharge module includes: a second relay, a second fuse, and a shunt. The input terminal of the second relay is connected to the control circuit, and the output terminal is connected to the second fuse and the shunt. The shunt is connected in series between the second relay and the load.

5. A mobile power supplementing device according to claim 4, characterized in that Also includes: DC-DC module; The input terminal of the DC-DC module is connected to the base of the DC discharge connector in the high-voltage box. The output of the DC-DC module is connected to the input of the DC discharge module, and after passing through the second power distribution relay, it is connected to the second fuse, and finally connected to the charging gun through the second relay.

6. The mobile power supplementing device of claim 5, wherein, The DC charging module includes: a charging gun socket, a BMS, and / or an EVCC; The charging gun holder is connected to the DC power supply connector base of the high-voltage box after being connected to an external charging pile. The BMS communicates with the external charging pile and interacts with the charging pile for data.

7. The mobile power supplementing device of claim 6, wherein, The AC charging and discharging module includes a concealed socket, a concealed plug, an AC interlock contactor, a leakage current detection device, a current transformer, and lightning protection. Both the concealed socket and the concealed plug are connected to the PCS AC test. The concealed socket is used to supply power to the external load, and the concealed plug is used to charge the battery from the external power grid. The AC interlock contactor is connected to the charging and discharging circuit to ensure that only one circuit is working.

8. The mobile power supplementing device of claim 7, wherein, The EMS control module includes EMS, CCU, and BMS; The EMS is responsible for real-time data collection and monitoring of all devices, as well as security protection and fault handling. The BMS is responsible for collecting various data from the battery cells and uploading them to the EMS. It also needs to communicate with external charging piles and exchange data. The CCU mainly communicates with external vehicles and exchanges data.

Images