Modular high-power lithium battery charging power supply with intelligent temperature control module

Abstract

The utility model relates to electronic circuit technical field, concretely is a kind of modularization high-power lithium battery charging power supply with intelligent temperature control module, including power supply main module, intelligent temperature control module, MCU control module and battery management module, each module is assembled through 2.54mm pitch gold-plated plug-in interface;Power supply main module contains EMI filter, rectification filter, staggered PFC, high-frequency boost and TL494 closed-loop voltage stabilizing unit, wherein staggered PFC is with TEA2376 as core, power factor is greater than or equal to 0.98, can realize the conversion of commercial power to stable direct current;Intelligent temperature control module is with TMP20 temperature sensor temperature measurement, temperature measurement accuracy ±0.5 DEG C, temperature control is passed through two levels threshold value;MCU control module is sampled by ADC, and power is dynamically controlled by PID regulation, with the aid of MAX485 transmission parameter;Battery management module contains MOS tube array, SOC detection and millisecond level overvoltage and overcurrent protection, wherein SOC detection accuracy ±3%.The power supply temperature control is accurate, charging is stable, power factor is high, operation and maintenance are convenient, applicable to multiple scene high-power lithium battery charging.

Description

Technical Field

[0001] This utility model relates to the field of electronic circuit technology, specifically a modular high-power lithium battery charging power supply with an intelligent temperature control module. Background Technology

[0002] With the development of the new energy industry, high-power lithium batteries are increasingly widely used in new energy vehicles, energy storage systems, industrial equipment and other fields, which puts forward higher requirements for the power level, stability, safety and adaptability of charging power supplies.

[0003] Current traditional high-power lithium battery charging power supplies suffer from several technical defects: First, they lack sufficient temperature control capabilities, often employing simple temperature switches or single-point temperature measurement, which cannot accurately capture temperature changes in critical heat-generating components such as high-frequency transformers and MOSFETs. This can easily lead to component aging and burnout due to insufficient heat dissipation, or excessive heat dissipation resulting in energy waste. In extreme cases, temperature control failure may even cause charging interruptions. Second, they have low modularity, with most power supplies using an integrated structure. If a functional unit, such as the PFC unit or voltage regulator unit, fails, the entire unit must be disassembled for repair or replacement, resulting in high maintenance costs and difficulty in adapting to different lithium battery specifications. First, the charging requirements cannot be flexibly adjusted according to module configuration, resulting in poor versatility. Second, the charging efficiency and power quality are subpar. Some power factor correction units are simply designed, with power factors often below 0.9, easily causing harmonic pollution to the power grid. Simultaneously, the output voltage ripple is large, and the voltage regulation accuracy is insufficient, easily leading to overcharging and undercharging of lithium batteries, shortening battery cycle life. Third, the battery management mechanism is imperfect. The SOC detection accuracy is mostly above ±5%, unable to accurately determine the battery's state of charge. Furthermore, the overvoltage and overcurrent protection response delays are long, often exceeding 100μs, easily causing safety risks such as battery bulging, leakage, and even fire. In addition, traditional power supplies lack reliable remote parameter monitoring capabilities, making it difficult to meet the unattended operation and maintenance needs of industrial scenarios. These shortcomings restrict the adaptability and safety of high-power lithium battery charging power supplies, failing to fully match the current high-efficiency and safe charging requirements of high-power lithium batteries. Utility Model Content

[0004] The purpose of this invention is to provide a modular high-power lithium battery charging power supply with an intelligent temperature control module, so as to solve the problems of low temperature control accuracy, poor modularity, and insufficient charging safety and efficiency of traditional charging power supplies mentioned in the background art.

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

[0006] A modular high-power lithium battery charging power supply with an intelligent temperature control module, comprising:

[0007] The main power module is connected in series with an EMI filter unit, a rectifier filter unit, an interleaved PFC power factor correction unit, a high-frequency boost converter unit, and an output voltage regulation feedback unit. It is used to convert 220V AC mains power into stable DC power adapted to lithium batteries. The high-frequency boost converter unit is equipped with an OSG60R200FS MOSFET and a high-frequency transformer.

[0008] The intelligent temperature control module includes a temperature acquisition unit, a signal amplification unit, and a heat dissipation execution unit. The temperature acquisition unit is attached to the surface of key heat-generating components such as high-frequency transformers and MOSFETs. The heat dissipation execution unit includes a cooling fan and a temperature control switch.

[0009] The MCU control module uses a CW32F03F4 series microcontroller and is equipped with an ADC sampling interface, a PWM output interface and a USART communication interface. The ADC sampling interface is electrically connected to the intelligent temperature control module and the battery management module, and the PWM output interface is connected to the power regulation circuit of the main power supply module.

[0010] The battery management module consists of a battery interface, a charge / discharge MOSFET array, a SOC detection unit, and a protection circuit. The protection circuit includes an overvoltage detection resistor network and an overcurrent sampling sensor.

[0011] The MCU control module receives the temperature signal from the intelligent temperature control module and dynamically adjusts the switching frequency of the high-frequency boost converter unit through the PWM signal, while triggering the start and stop of the heat dissipation execution unit. The power supply module, intelligent temperature control module, MCU control module and battery management module are modularly assembled through pluggable electrical interfaces, and each module integrates an independent over-temperature protection circuit.

[0012] Preferably, the rectifier and filter unit of the main power supply module includes a GBU5006 rectifier bridge, an LF1 common-mode inductor, and CY1 / CY2 X capacitors, wherein CY1 and CY2 are both 104pF / 275V X capacitors, which are symmetrically connected in parallel at the input of the rectifier bridge, and the inductance of the LF1 common-mode inductor is 10mH, forming a two-stage EMI filtering and rectification integrated structure.

[0013] Preferably, the interleaved PFC power factor correction unit of the main power supply module is based on a TEA2376 dual-phase interleaved PFC controller, and is equipped with two independent boost inductors, each with an inductance of 220μH, and Q2 / Q4 type N-channel MOSFETs, with a power factor correction accuracy ≥0.98; the output voltage regulation feedback unit uses a TL494 pulse width modulation chip and an LM358 operational amplifier to form a closed-loop regulation circuit, with an output voltage ripple ≤50mV and a voltage regulation accuracy of ±1%.

[0014] Preferably, the temperature acquisition unit of the intelligent temperature control module adopts a TMP20 high-precision temperature sensor, which is attached to the heat sink surface of the high-frequency transformer core and the OSG60R200FS MOS transistor via a thermally conductive silicone sheet. The temperature measurement range is -40℃ to 125℃, and the temperature measurement accuracy is ±0.5℃ within the working range of 25℃ to 85℃.

[0015] Preferably, the signal amplification unit of the intelligent temperature control module is composed of an LM358 operational amplifier forming a non-inverting proportional amplifier circuit, wherein the feedback resistor R9 is 10kΩ, the input resistor R7 is 1kΩ, and the amplification factor is fixed at 10 times; the heat dissipation execution unit is set with two-level temperature control thresholds: when the detected temperature is ≥55℃, the cooling fan is started (speed 3000rpm), and when it is ≥75℃, the power output power is reduced to 50% of the rated value through the MCU control module.

[0016] Preferably, the USART communication interface of the MCU control module supports asynchronous communication at a baud rate of 9600bps, and differential signal transmission is achieved through the MAX485 chip for uploading temperature, voltage, and current parameters to an external monitoring terminal; the ADC sampling interface is configured with 12-bit resolution and a sampling frequency ≥1kHz, and simultaneously acquires the total battery voltage, individual cell voltage, charging current, and temperature signals of 6 key components; it has a built-in power regulation program based on a PID algorithm, with a power regulation response delay ≤100ms.

[0017] Preferably, the charging and discharging MOSFET array of the battery management module uses two 2N7002 N-channel MOSFETs connected in parallel, and is electrically isolated from the MCU control module through a 4N35 optocoupler; the SOC detection unit uses the voltage integration method, combined with a temperature compensation algorithm based on the capacity decay curve of the lithium battery from -20℃ to 60℃, and the SOC calculation accuracy is ≤±3%; the overvoltage protection threshold of the protection circuit is 1.15 times the rated battery voltage, the overcurrent protection threshold is 1.2 times the rated charging current, and the protection response time is ≤50μs.

[0018] Preferably, the pluggable electrical interfaces between modules use 2.54mm pitch gold-plated terminals, each with a rated current ≥50A and a contact resistance ≤10mΩ; it also includes an auxiliary power supply module, which consists of an LTV1007 optocoupler and a BCX56 PNP transistor forming a linear voltage regulator circuit, outputting dual-channel regulated power supplies of 5V / 1A and 3.3V / 0.5A, respectively, to power the MCU control module and the temperature sensor; it is equipped with an LED status indicator module, where a solid red LED1 indicates charging in progress, a flashing LED indicates a charging fault, and a solid green LED2 indicates charging complete.

[0019] Compared with existing technologies, the advantages of this utility model are as follows: This modular high-power lithium battery charging power supply with intelligent temperature control module achieves modular assembly of the main power supply module, intelligent temperature control module, MCU control module and battery management module through pluggable electrical interfaces. This not only greatly simplifies the disassembly and maintenance process of the equipment, but also facilitates flexible adjustment of module configuration according to different lithium battery specifications or usage scenarios, reducing the later operation and maintenance costs. At the same time, the intelligent temperature control module monitors the temperature of key heat-generating components such as high-frequency transformers and MOSFETs in real time through the temperature acquisition unit. Combined with the dynamic response mechanism of the MCU control module, it can adjust the switching frequency of the high-frequency boost converter unit and trigger the start and stop of the heat dissipation execution unit through PWM signals, effectively avoiding the aging or damage of components due to high temperature, extending the overall service life of the power supply, and preventing charging interruption caused by overheating, ensuring the continuity of the charging process. Furthermore, the combination of the interleaved PFC power factor correction unit and the output voltage regulation feedback unit in the main power module can significantly improve the power factor (correction accuracy ≥0.98) and reduce output voltage ripple (≤50mV), ensuring stable and efficient DC power for the lithium battery and reducing power loss. The SOC detection unit and overvoltage and overcurrent protection circuits in the battery management module, combined with the MCU's parameter acquisition and logic control, can accurately monitor the lithium battery's health status and provide multiple safety protections, preventing damage to the lithium battery due to overcharging, overcurrent, etc., thus improving charging safety. In addition, the USART communication interface of the MCU control module enables external uploading and monitoring of charging parameters. Combined with the independent over-temperature protection circuits of each module, this further balances the convenience and reliability of the equipment, comprehensively meeting the efficient, safe, and stable charging needs of high-power lithium batteries in different scenarios. Attached Figure Description

[0020] The accompanying drawings are provided to further illustrate the present invention and form part of the specification. They are explained in detail together with the embodiments of the present invention, but do not constitute a limitation thereof.

[0021] Figure 1 This is a circuit diagram of the main power module for power conversion and auxiliary control in this utility model;

[0022] Figure 2 This is a circuit diagram of the MCU control and battery management in this utility model. Detailed Implementation

[0023] The technical solutions of the present utility model will be clearly and completely described below with reference to the embodiments and accompanying drawings. 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 protection scope of the present utility model.

[0024] A modular high-power lithium battery charging power supply with an intelligent temperature control module, such as... Figure 1 and Figure 2As shown, the system includes: a main power supply module, which sequentially connects an EMI filter unit, a rectifier filter unit, an interleaved PFC power factor correction unit, a high-frequency boost converter unit, and an output voltage regulation feedback unit to convert 220V AC mains power into stable DC power suitable for lithium batteries. The high-frequency boost converter unit is equipped with an OSG60R200FS MOSFET and a high-frequency transformer; an intelligent temperature control module, which includes a temperature acquisition unit, a signal amplification unit, and a heat dissipation execution unit. The temperature acquisition unit is attached to the surface of key heat-generating components such as the high-frequency transformer and MOSFET. The heat dissipation execution unit includes a cooling fan and a temperature control switch; and an MCU control module, which uses a CW32F03F4 series microcontroller and is equipped with an ADC sampling interface and PWM output. The system includes an interface and a USART communication interface, an ADC sampling interface electrically connected to the intelligent temperature control module and the battery management module, and a PWM output interface connected to the power regulation circuit of the main power supply module. The battery management module consists of a battery interface, a charging / discharging MOSFET array, a SOC detection unit, and a protection circuit, which includes an overvoltage detection resistor network and an overcurrent sampling sensor. The MCU control module receives the temperature signal from the intelligent temperature control module and dynamically adjusts the switching frequency of the high-frequency boost converter unit through the PWM signal, while simultaneously triggering the start and stop of the heat dissipation execution unit. The main power supply module, intelligent temperature control module, MCU control module, and battery management module are modularly assembled through pluggable electrical interfaces, and each module integrates an independent over-temperature protection circuit.By modularly assembling the main power supply module, intelligent temperature control module, MCU control module, and battery management module using pluggable electrical interfaces, the disassembly and maintenance process is significantly simplified. This allows for flexible adjustment of module configurations based on different lithium battery specifications or usage scenarios, reducing subsequent maintenance costs. Simultaneously, the intelligent temperature control module monitors the temperature of key heat-generating components such as the high-frequency transformer and MOSFETs in real time through a temperature acquisition unit. Combined with the dynamic response mechanism of the MCU control module, it can adjust the switching frequency of the high-frequency boost converter unit and trigger the start / stop of the heat dissipation execution unit via PWM signals, effectively preventing components from aging or being damaged due to high temperatures, extending the overall lifespan of the power supply, and preventing charging interruptions caused by overheating, ensuring continuous charging. Furthermore, the interleaved PFC power factor correction unit in the main power supply module... When paired with the output voltage regulation feedback unit, it can significantly improve the power factor (correction accuracy ≥0.98) and reduce output voltage ripple (≤50mV), ensuring a stable and efficient DC power supply for the lithium battery and reducing power loss. Furthermore, the SOC detection unit and overvoltage / overcurrent protection circuits of the battery management module, combined with the parameter acquisition and logic control of the MCU, can accurately monitor the health status of the lithium battery and achieve multiple safety protections, preventing damage to the lithium battery due to overcharging, overcurrent, etc., thus improving charging safety. In addition, the USART communication interface of the MCU control module can realize external uploading and monitoring of charging parameters. Combined with the independent over-temperature protection circuits of each module, it further balances the convenience and reliability of the equipment, comprehensively meeting the efficient, safe, and stable charging needs of high-power lithium batteries in different scenarios.

[0025] Furthermore, the rectifier and filter unit of the main power supply module includes a GBU5006 rectifier bridge, an LF1 common-mode inductor, and CY1 / CY2 X capacitors. Both CY1 and CY2 are 104pF / 275V X capacitors, symmetrically connected in parallel at the input of the rectifier bridge. The LF1 common-mode inductor has an inductance of 10mH, forming a two-stage EMI filtering and rectification integrated structure. The interleaved PFC power factor correction unit of the main power supply module is based on a TEA2376 dual-phase interleaved PFC controller and is equipped with two... Independent boost inductors (all with an inductance of 220μH) and Q2 / Q4 type N-channel MOSFETs are used, with a power factor correction accuracy ≥0.98. The output voltage regulation feedback unit uses a TL494 pulse width modulation chip and an LM358 operational amplifier to form a closed-loop regulation circuit, with an output voltage ripple ≤50mV and a voltage regulation accuracy of ±1%. The rectification and filtering unit uses a GBU5006 type rectifier bridge, a 10mH LF1 type common mode inductor, and a 104pF / 275V CY1 / CY2 type X capacitor to form a two-stage EMI filter. The integrated rectifier and rectifier structure efficiently filters out common-mode interference, differential-mode interference, and high-frequency noise from the mains power supply, preventing interference signals from damaging downstream PFC and boost units. It also improves the purity of the rectified DC power, providing a stable input for subsequent power conversion. The interleaved PFC power factor correction unit, based on the TEA2376 controller and equipped with two independent 220μH boost inductors and Q2 / Q4 N-channel MOSFETs, achieves a power factor correction accuracy of ≥0.98, significantly reducing grid harmonic pollution, meeting national power quality standards, and reducing power loss (e.g., avoiding additional grid energy consumption due to low power factor). It also improves the power supply's adaptability to mains voltage fluctuations. The output voltage regulation feedback unit uses a TL494 chip and an LM358 operational amplifier to form a closed-loop regulation circuit, achieving an output voltage ripple of ≤50mV and a voltage regulation accuracy of ±1%. This provides a continuous and stable charging voltage for the lithium battery, preventing overcharging, undercharging, or decreased charging efficiency due to voltage fluctuations, effectively extending the battery's cycle life.

[0026] Specifically, the temperature acquisition unit of the intelligent temperature control module uses a TMP20 high-precision temperature sensor, which is attached to the surface of the heat sink of the high-frequency transformer core and the OSG60R200FS MOSFET via a thermally conductive silicone pad. The temperature measurement range is -40℃ to 125℃, with a measurement accuracy of ±0.5℃ within the operating range of 25℃ to 85℃. The signal amplification unit of the intelligent temperature control module uses an LM358 operational amplifier to form a non-inverting proportional amplifier circuit, where the feedback resistor R9 is 10kΩ, the input resistor R7 is 1kΩ, and the amplification factor is fixed at 10 times. The heat dissipation execution unit has two temperature control thresholds: when the detected temperature is ≥55℃, the cooling fan is activated (3000rpm); when the temperature is ≥75℃, the power output is reduced to 50% of the rated value via the MCU control module. The temperature acquisition unit of the intelligent temperature control module uses a TMP20 high-precision temperature sensor, which is attached to the surface of the heat sink of the high-frequency transformer core and the OSG60R200FS MOSFET via a thermally conductive silicone pad. The measurement accuracy is ±0.5℃ within the operating range of 25℃ to 85℃. With an internal temperature measurement accuracy of ±0.5℃, it can accurately capture the true temperature of key heat-generating components, avoiding untimely or excessive heat dissipation due to temperature measurement errors. The temperature measurement range covers -40℃ to 125℃, adapting to extreme high and low temperature usage scenarios, such as outdoor low-temperature charging and high-temperature environments during high-power charging, improving the power supply's environmental adaptability. The signal amplification unit uses a 10kΩ R9 resistor and a 1kΩ R7 resistor to form a 10x fixed amplification factor in a non-inverting proportional circuit, which can amplify the weak temperature signal output by the sensor to a range that the MCU control module can accurately recognize, avoiding temperature control delays caused by signal attenuation. The heat dissipation execution unit is set with two threshold levels: fan activation at 55℃ and power reduction to 50% at 75℃. This not only allows for timely heat dissipation through the fan when the component temperature is slightly high, preventing the temperature from continuing to rise, but also actively reduces power when the temperature approaches the dangerous threshold, reducing heat generation from the source. This dual protection prevents key components from aging or burning out due to high temperatures, while also preventing charging interruptions caused by component overheating, ensuring the continuity and safety of the charging process.

[0027] The MCU control module's USART communication interface supports 9600bps baud rate asynchronous communication, using a MAX485 chip for differential signal transmission to upload temperature, voltage, and current parameters to an external monitoring terminal. The ADC sampling interface is configured with 12-bit resolution and a sampling frequency ≥1kHz, simultaneously acquiring total battery voltage, individual cell voltage, charging current, and temperature signals from six key components. A built-in PID-based power regulation program ensures a power regulation response delay ≤100ms. The MCU control module's USART communication interface uses a MAX485 chip for differential signal transmission, supporting 9600bps baud rate asynchronous communication. This differential transmission method effectively resists external electromagnetic interference (such as motor interference and interference from other electronic devices in industrial settings), ensuring stable uploading of charging parameters such as temperature, voltage, and current to the external monitoring terminal. The control terminal allows users to remotely monitor the charging status in real time without on-site supervision. The ADC sampling interface features 12-bit resolution and a sampling frequency ≥1kHz, simultaneously acquiring total battery voltage, individual cell voltage, charging current, and temperature signals from six key components. High resolution ensures data accuracy (e.g., individual cell voltage sampling error ≤1mV), while the high sampling frequency ensures rapid capture of parameter changes (e.g., sudden overcurrent, rapid temperature rise), providing real-time and accurate data support for MCU control decisions. A built-in power regulation program based on a PID algorithm has a response delay ≤100ms, quickly adjusting the power output based on sampling parameters (e.g., temperature rise, battery voltage near full charge) to avoid excessive parameter fluctuations and achieve dynamic optimization of the charging process. This ensures charging efficiency while preventing safety risks caused by adjustment delays (e.g., failure to cut off overcurrent in time).

[0028] It is worth noting that the charging and discharging MOSFET array of the battery management module uses two 2N7002 N-channel MOSFETs connected in parallel, and is electrically isolated from the MCU control module through a 4N35 optocoupler. The SOC detection unit uses the voltage integration method, combined with a temperature compensation algorithm based on the capacity decay curve of lithium batteries from -20℃ to 60℃, achieving an SOC calculation accuracy of ≤±3%. The overvoltage protection threshold of the protection circuit is 1.15 times the rated battery voltage, and the overcurrent protection threshold is 1.2 times the rated charging current, with a protection response time ≤50μs. The charging and discharging MOSFET array of the battery management module uses two 2N7002 N-channel MOSFETs connected in parallel, which improves the current carrying capacity compared to a single-tube design (e.g., a single tube with a maximum current of 100mA can carry 200mA after parallel connection), meeting the charging and discharging current requirements of high-power lithium batteries. Electrical isolation from the MCU control module is achieved through a 4N35 optocoupler. The independent drive can block grounding interference between the MCU side and the battery side, preventing high voltage and high current from the battery side from entering the MCU module and causing controller damage, thus improving system stability. The SOC detection unit adopts the voltage integration method combined with the temperature compensation algorithm of the capacity decay curve from -20℃ to 60℃, making the SOC calculation accuracy ≤±3%. It can accurately determine the state of charge of the lithium battery, avoiding overcharging (such as continuing to charge when it shows full charge) and undercharging (such as stopping charging when it is not fully charged) caused by misjudgment of SOC, thus extending battery life. The overvoltage protection threshold of the protection circuit is set to 1.15 times the rated voltage of the battery and the overcurrent protection threshold is set to 1.2 times the rated charging current. The protection response time is ≤50μs. It can quickly cut off the charging and discharging circuit when the lithium battery has overvoltage or overcurrent faults (such as a sudden increase in current caused by an internal short circuit in the battery), avoiding safety accidents such as battery bulging and fire. At the same time, the short response time reduces the damage range of the fault to the battery and power supply.

[0029] In addition, the pluggable electrical interfaces between modules use 2.54mm pitch gold-plated terminals, each with a rated current ≥50A and a contact resistance ≤10mΩ. An auxiliary power supply module is also included, consisting of an LTV1007 optocoupler and a BCX56 PNP transistor forming a linear voltage regulator circuit, outputting dual regulated power supplies of 5V / 1A and 3.3V / 0.5A to power the MCU control module and temperature sensor, respectively. An LED status indicator module is also included, with a solid red LED1 indicating charging in progress, a flashing LED indicating a charging fault, and a solid green LED2 indicating charging completion. The pluggable electrical interfaces between modules use 2.54mm pitch gold-plated terminals, each with a rated current ≥50A and a contact resistance ≤10mΩ. The gold plating reduces contact resistance and improves oxidation resistance (preventing poor contact due to terminal oxidation after long-term use). The high rated current meets the current transmission requirements during high-power charging, and the low contact resistance reduces heat loss during current transmission (preventing terminal overheating and burnout). The pluggable design also facilitates module removal and replacement. (If the main power module fails, it can be quickly disassembled and replaced without the need for complete scrapping), reducing maintenance costs; the auxiliary power module consists of an LTV1007 optocoupler and a BCX56 PNP transistor forming a linear voltage regulator circuit, outputting dual-channel regulated power supplies of 5V / 1A and 3.3V / 0.5A, respectively powering the MCU control module and the temperature sensor. The linear voltage regulator circuit can provide a stable output voltage (low ripple), avoiding MCU crashes and sensor sampling errors caused by power supply voltage fluctuations. The dual outputs adapt to the voltage requirements of different devices (MCU requires 5V, sensor requires 3.3V), eliminating the need for additional voltage conversion modules and simplifying the circuit structure; in the LED status indicator module, a solid red LED1 indicates charging in progress, a flashing LED indicates a charging failure, and a solid green LED2 indicates charging complete. The intuitive light indicators allow users to quickly determine the charging status (e.g., seeing a flashing red LED indicates a fault, without needing to check complex parameters), facilitating timely troubleshooting (e.g., in case of a charging failure, it can quickly locate whether the problem is with the power supply or the battery), improving ease of use.

[0030] The working principle of this modular high-power lithium battery charging power supply with intelligent temperature control module:

[0031] (1) Conversion process from mains power to adapted power

[0032] The 220V AC mains power first enters the EMI filter unit of the main power module. An LF1 common-mode inductor (10mH) filters out common-mode interference from the mains. Combined with CY1 / CY2 type X capacitors (104pF / 275V) symmetrically connected in parallel at the rectifier bridge input, differential-mode interference is further suppressed. Then, the AC-to-DC rectification is completed by a GBU5006 rectifier bridge, forming a two-stage EMI filtering and rectification pre-processing. The pre-processed DC power then enters the interleaved PFC power factor correction unit, with a TEA2376 dual-phase interleaved PFC controller at its core, driving Q... The 2 / Q4 type N-channel MOSFET, together with two 220μH independent boost inductors, adjusts the current phase to correct the power factor to ≥0.98, reducing grid harmonic pollution. Then, the DC power enters the high-frequency boost converter unit, where the OSG60R200FS type MOSFET and the high-frequency transformer work together to realize voltage boosting and high-frequency conversion. Finally, through the output voltage regulation feedback unit—a closed-loop circuit consisting of a TL494 pulse width modulation chip and an LM358 operational amplifier—the output voltage ripple is controlled to ≤50mV and the voltage regulation accuracy is controlled to ±1%, ultimately generating stable DC power suitable for lithium batteries.

[0033] (2) Real-time adjustment mechanism of intelligent temperature control

[0034] The temperature acquisition unit of the intelligent temperature control module uses a thermally conductive silicone pad to attach a TMP20 high-precision temperature sensor to the high-frequency transformer core and the OSG60R200FS MOSFET heatsink. It acquires temperature data in real-time within the range of -40℃ to 125℃, achieving a high-precision measurement of ±0.5℃, particularly within the 25℃ to 85℃ operating range. The weak temperature signal (millivolt level) output by the sensor is amplified by a signal amplification unit composed of an LM358 operational amplifier. After processing by a 10x fixed amplification circuit consisting of feedback resistor R9 (10kΩ) and input resistor R7 (1kΩ), it is converted into a voltage signal that the MCU control module can accurately recognize. Upon receiving the signal, the MCU determines the temperature threshold: when the detected temperature is ≥55℃, it triggers the cooling execution unit to start a 3000rpm cooling fan, reducing the device temperature through forced air cooling; if the temperature continues to rise to ≥75℃, it adjusts the switching frequency of the high-frequency boost converter unit through the PWM output interface, reducing the power output to 50% of the rated value, thus reducing heat generation at the source and achieving dual temperature control protection through active cooling and power regulation.

[0035] (3) Core control and battery safety management logic

[0036] The MCU control module (CW32F03F4 series) serves as the core coordination unit. Through a 12-bit resolution ADC sampling interface with a sampling frequency ≥1kHz, it synchronously acquires the total battery voltage, individual cell voltage, charging current, and temperature signals from six key components. Based on its built-in PID algorithm (response delay ≤100ms), it dynamically adjusts the output power of the main power supply module. Simultaneously, its USART communication interface uses a MAX485 chip to achieve differential signal transmission (9600bps baud rate), uploading charging parameters to an external monitoring terminal for remote monitoring. In the battery management module, two 2N7002 N-channel MOSFETs are connected in parallel to form a charging / discharging MOSFET array. Electrical isolation between the MOSFET and the MCU is achieved through a 4N35 optocoupler to prevent high-voltage interference and damage. The controller is faulty; the SOC detection unit uses the voltage integration method, combined with a temperature compensation algorithm based on the lithium battery capacity decay curve from -20℃ to 60℃, to control the SOC calculation accuracy within ≤±3%, accurately judging the battery's state of charge; the protection circuit uses 1.15 times the battery's rated voltage as the overvoltage threshold and 1.2 times the rated charging current as the overcurrent threshold, and quickly cuts off the charging and discharging circuit within ≤50μs when an abnormality is detected. In addition, the auxiliary power module (LTV1007 optocoupler + BCX56 transistor) outputs 5V / 1A and 3.3V / 0.5A dual-channel regulated power to power the MCU and sensors. The LED status indicator module (red for charging, red for fault, green for completion) provides intuitive feedback on the working status, forming a complete management system of precise control + multiple protections + status visibility.

[0037] The foregoing has shown and described the basic principles, main features, and advantages of this utility model. Those skilled in the art should understand that this utility model is not limited to the above embodiments. The embodiments and descriptions in the specification are merely preferred examples and are not intended to limit the utility model. Various changes and modifications can be made to this utility model without departing from its spirit and scope, and all such changes and modifications fall within the scope of the claimed utility model. The scope of protection of this utility model is defined by the appended claims and their equivalents.

Claims

1. A modular high-power lithium battery charging power supply with an intelligent temperature control module, characterized in that, include: The main power module is connected in series with an EMI filter unit, a rectifier filter unit, an interleaved PFC power factor correction unit, a high-frequency boost converter unit, and an output voltage regulation feedback unit. It is used to convert 220V AC mains power into stable DC power adapted to lithium batteries. The high-frequency boost converter unit is equipped with an OSG60R200FS MOSFET and a high-frequency transformer. The intelligent temperature control module includes a temperature acquisition unit, a signal amplification unit, and a heat dissipation execution unit. The temperature acquisition unit is attached to the surface of key heat-generating components such as high-frequency transformers and MOSFETs. The heat dissipation execution unit includes a cooling fan and a temperature control switch. The MCU control module uses a CW32F03F4 series microcontroller and is equipped with an ADC sampling interface, a PWM output interface and a USART communication interface. The ADC sampling interface is electrically connected to the intelligent temperature control module and the battery management module, and the PWM output interface is connected to the power regulation circuit of the main power supply module. The battery management module consists of a battery interface, a charge / discharge MOSFET array, a SOC detection unit, and a protection circuit. The protection circuit includes an overvoltage detection resistor network and an overcurrent sampling sensor. The MCU control module receives the temperature signal from the intelligent temperature control module and dynamically adjusts the switching frequency of the high-frequency boost converter unit through the PWM signal, while triggering the start and stop of the heat dissipation execution unit. The power supply module, intelligent temperature control module, MCU control module and battery management module are modularly assembled through pluggable electrical interfaces, and each module integrates an independent over-temperature protection circuit.

2. The modular high-power lithium battery charging power supply with intelligent temperature control module according to claim 1, characterized in that: The rectifier and filter unit of the main power supply module includes a GBU5006 rectifier bridge, an LF1 common-mode inductor, and CY1 / CY2 X capacitors. CY1 and CY2 are both 104pF / 275V X capacitors, which are symmetrically connected in parallel at the input of the rectifier bridge. The inductance of the LF1 common-mode inductor is 10mH, forming a two-stage EMI filtering and rectification integrated structure.

3. The modular high-power lithium battery charging power supply with intelligent temperature control module according to claim 2, characterized in that: The interleaved PFC power factor correction unit of the main power module is based on the TEA2376 dual-phase interleaved PFC controller, and is equipped with two independent boost inductors, each with an inductance of 220μH, and Q2 / Q4 type N-channel MOSFETs, with a power factor correction accuracy of ≥0.98; the output voltage regulation feedback unit uses a TL494 pulse width modulation chip and an LM358 operational amplifier to form a closed-loop regulation circuit, with an output voltage ripple of ≤50mV and a voltage regulation accuracy of ±1%.

4. The modular high-power lithium battery charging power supply with intelligent temperature control module according to claim 1, characterized in that: The temperature acquisition unit of the intelligent temperature control module adopts a TMP20 high-precision temperature sensor, which is attached to the heat sink surface of the high-frequency transformer core and the OSG60R200FS MOS transistor via a thermally conductive silicone sheet. The temperature measurement range is -40℃ to 125℃, and the temperature measurement accuracy is ±0.5℃ within the working range of 25℃ to 85℃.

5. The modular high-power lithium battery charging power supply with intelligent temperature control module according to claim 4, characterized in that: The signal amplification unit of the intelligent temperature control module consists of an LM358 operational amplifier forming a non-inverting proportional amplifier circuit, wherein the feedback resistor R9 is 10kΩ, the input resistor R7 is 1kΩ, and the amplification factor is fixed at 10 times; the heat dissipation execution unit is set with two-level temperature control thresholds: when the detected temperature is ≥55℃, the cooling fan with a speed of 3000rpm is started; when the temperature is ≥75℃, the power output power is reduced to 50% of the rated value through the MCU control module.

6. The modular high-power lithium battery charging power supply with intelligent temperature control module according to claim 1, characterized in that: The MCU control module's USART communication interface supports 9600bps baud rate asynchronous communication and uses the MAX485 chip to implement differential signal transmission, which is used to upload temperature, voltage, and current parameters to an external monitoring terminal. The ADC sampling interface is configured with 12-bit resolution and a sampling frequency ≥1kHz, and simultaneously collects the total battery voltage, individual cell voltage, charging current, and temperature signals of 6 key components. It has a built-in power regulation program based on a PID algorithm, with a power regulation response delay ≤100ms.

7. The modular high-power lithium battery charging power supply with intelligent temperature control module according to claim 1, characterized in that: The battery management module's charge / discharge MOSFET array uses two 2N7002 N-channel MOSFETs connected in parallel, and is electrically isolated from the MCU control module via a 4N35 optocoupler. The SOC detection unit uses the voltage integration method, combined with a temperature compensation algorithm based on the lithium battery's capacity decay curve from -20℃ to 60℃, achieving an SOC calculation accuracy of ≤±3%. The protection circuit's overvoltage protection threshold is 1.15 times the battery's rated voltage, its overcurrent protection threshold is 1.2 times the rated charging current, and its protection response time is ≤50μs.

8. The modular high-power lithium battery charging power supply with intelligent temperature control module according to claim 1, characterized in that: The pluggable electrical interfaces between modules use 2.54mm pitch gold-plated terminals, each with a rated current ≥50A and a contact resistance ≤10mΩ. An auxiliary power supply module is also included, consisting of an LTV1007 optocoupler and a BCX56 PNP transistor forming a linear voltage regulator circuit, outputting dual regulated power supplies of 5V / 1A and 3.3V / 0.5A to power the MCU control module and temperature sensor, respectively. An LED status indicator module is also included, with a solid red LED1 indicating charging in progress, a flashing LED indicating a charging fault, and a solid green LED2 indicating charging complete.

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