Intelligent alternating current charging control system

Abstract

The utility model provides a kind of intelligent alternating current charging control system, the intelligent alternating current charging control system includes charging socket, charger, junction box, battery pack, load, networking controller, server and background control terminal;Wherein, charging socket sets three groups of power cable;Three groups of power cable are connected with the alternating current side one end of charger, and the other end of charger is connected with junction box;Junction box passes through multiple switch control sub-battery access quantity, so that sub-battery parallel access charging system, provides different charging power for load;In addition, charger and battery pack establish wireless communication with networking controller, and charging data can be transmitted to cloud server by flow card, realize remote access and control entire charging system.The intelligent alternating current charging control system, can be compatible with new and old battery parallel use, meet the different charging parameter needs of user, also can be monitored charging state in real time by cloud server, to improve the stability and reliability of system operation.

Description

Technical Field

[0001] This utility model relates to the field of electric vehicle charging technology, specifically to an AC charging system with multi-mode power supply, intelligent remote control and modular expansion functions, which is suitable for the power replenishment needs of electric vehicles, energy storage devices and other scenarios. Background Technology

[0002] With the widespread adoption of electric vehicles, the demand for efficient, intelligent, and highly compatible charging systems is becoming increasingly urgent. Existing AC charging systems have several limitations. Some systems only support single-phase power supply, failing to fully utilize the advantages of three-phase power, resulting in low charging efficiency. In terms of charging current control, they lack the ability to flexibly adjust according to the characteristics of external charging equipment, easily causing charging power mismatch, affecting charging speed and battery life. Furthermore, most existing AC charging systems are high-voltage (250-750VDC) series systems, unable to solve the problem of rapid charging when multiple low-voltage batteries are connected in parallel. Moreover, existing AC charging systems cannot read charging system status information, remotely upgrade the internal controller program, or control the start / stop function of the entire charging system, making system maintenance inconvenient and requiring significant manpower for monitoring and management. Therefore, developing a comprehensive and high-performance AC charging system is of significant practical importance. Utility Model Content

[0003] In order to overcome the shortcomings of the existing technology, the purpose of this utility model is to provide an intelligent AC charging control system that has sufficient power to meet the charging needs of the battery pack, and realizes intelligent management and control of the charging process, thereby improving the reliability, stability and safety of the entire charging system.

[0004] The technical solution used in this utility model is: an intelligent AC charging control system, characterized in that it includes a charging socket, a charger, a junction box, a battery pack, a load, a network controller, a server, and a back-end control terminal; The charging socket has several plug holes, which are connected to other electrical devices via wire harnesses. The output end of the charging socket is connected to the input end of the charger. The wiring harness includes a power wiring harness and a communication wiring harness; The output terminal of the charger is connected to the input terminal of the junction box; The first end of the battery pack is connected to the output end of the junction box, the second end of the battery pack is connected to the load, and the battery pack, the charger and the network controller establish wireless communication. The network controller establishes wireless communication with the server; The server establishes wireless communication with the back-end control terminal.

[0005] The power cable harness includes a first power cable L1, a second power cable L2, a third power cable L3, a neutral wire N, and a ground wire PE; the communication cable harness includes a first control line PP and a second control line CP. The first power cable L1, the second power cable L2, and the third power cable L3 are interconnected to form a three-phase power supply, and together with the neutral wire N, form a single-phase power supply. The first control line PP and the second control line CP are connected separately to form a closed-loop control transmission path. The first power cable L1, the second power cable L2, and the third power cable L3 are all AC power transmission lines, typically used in three-phase AC power systems. They carry different phase currents in the three-phase power supply, providing the necessary AC power to the charging equipment. During the charging process, these power cables transmit AC power from the grid to the charger, which then converts it into DC power to charge the battery pack. The neutral wire is the return path in the AC power system, used in conjunction with the power cables (L1, L2, L3) to form a complete AC circuit. It provides a path for current return, ensuring that current flows normally in the circuit. In a charging system, the neutral wire, along with the power cable, transmits AC power from the power grid to the charger. The ground wire (PE) is used for electrical safety, connecting the metal casing of the charging equipment or vehicle to the earth. In the event of leakage or a fault, the ground wire provides a path for current discharge, preventing electric shock or equipment damage. The ground wire is an indispensable safety protection measure in a charging system. In an intelligent AC charging system, the first control line (PP, Proximity Pilot) and the second control line (CP, Control Pilot) form a closed-loop control relationship through physical connection and signal interaction, jointly realizing connection status detection, parameter coordination, and safety protection during the charging process.

[0006] Moreover, the first power cable L1, the second power cable L2, and the third power cable L3 are three key cables in the three-phase AC charging system. They together form a three-phase power supply through a specific interconnection method, which can be a star connection or a delta connection. A star connection is more common in charging systems.

[0007] Furthermore, the charging socket is an AC charging socket. AC charging sockets typically employ a seven-hole design, their function being to transmit external AC power to the on-board charger, which then converts the AC power to charge the power battery. Simultaneously, safety protection and communication functions ensure a stable and safe charging process, meeting daily on-board low-voltage charging needs.

[0008] Furthermore, the first control line PP is a charging connection confirmation line. The first control line PP is used to confirm whether the physical connection between the charging gun and the charging socket is intact. When the charging gun is correctly inserted into the charging socket, the PP line transmits a confirmation signal, informing the charging system that the charging process can begin. This is a crucial step in charging safety, preventing the risk of arcing or fire due to poor connection.

[0009] Furthermore, the second control line CP is a charging control guide line. The second control line CP is used for communication and control during the charging process. It transmits information between the charger and the vehicle's battery management system (BMS), such as charging current, voltage requests, and charging status. Through the second control line CP, the charger can adjust charging parameters according to the BMS's requirements, ensuring a safe and efficient charging process.

[0010] Furthermore, the junction box also includes a quick-connect interface. The quick-connect interface is used for hot-plugging and parallel connection of the battery pack.

[0011] Furthermore, the junction box is equipped with a battery pack communication interface. This interface can be directly connected to a PC terminal, allowing the host computer to read charging status information and flash the BMS program.

[0012] Furthermore, the battery pack consists of multiple sub-cells. There is no need to set up a separate charger for each battery pack; the overall system capacity is increased by adaptively expanding the number of sub-cells, thereby extending the load's operating time.

[0013] Furthermore, the load is a load with an LCD screen. Preferably, the load provided in this solution is an LCD display screen, which can interact well with the user and obtain charging information. For example, the LCD display screen can intuitively display the charging progress of the electric vehicle, can display the calculation method and details of charging fees, and users can query past charging records through the LCD display screen, which helps users understand their charging habits and electricity consumption, and make reasonable electricity planning, etc.

[0014] Furthermore, the network controller includes a data SIM card and a GPS positioning module. The network controller reads CAN bus data from the charger and BMS, and transmits the data to the cloud server via the data SIM card (4G or 5G card). End users can access and control the entire charging system via mobile phone or computer (PC).

[0015] The advantages of this utility model compared with the prior art are: This system ensures sufficient power to meet the charging needs of the battery packs while also enabling intelligent management and control of the charging process, thus improving the reliability, stability, and safety of the entire system. The AC charging socket connects to both the power and communication wiring harnesses, supporting both single-phase and three-phase AC power inputs, with a maximum power output of 11kW, significantly reducing terminal charging time and improving charging efficiency. Furthermore, the charger output connects to the junction box input, which plays a crucial role in aggregating and distributing electrical energy. Multiple switches within the junction box allow for different numbers of sub-batteries to be connected to different loads, meeting varying voltage charging and discharging requirements and facilitating parallel use of both new and old batteries. Each battery pack is connected in parallel to the junction box, ensuring stable current distribution and enhancing system fault tolerance. Even if one battery pack fails, it will not affect the normal operation of other battery packs, improving the overall stability and reliability of the charging system. Additionally, the built-in intelligent control module and communication interface enable real-time reading of the charging system status, remote upgrades of the control program, and remote start / stop control, enhancing system safety and ease of maintenance.

[0016] Other features and advantages of this invention will be set forth in the following description, and will be apparent in part from the description, or may be learned by practicing the technical solutions of this invention. The objects and other advantages of this invention may be realized and obtained by means of the structures and / or processes particularly pointed out in the description, claims, and drawings. Attached Figure Description

[0017] Figure 1 Overall architecture diagram of the intelligent AC charging control system provided by this utility model;

[0018] Figure 2 This is a diagram of the charging information interaction control flow architecture of this utility model. Detailed Implementation

[0019] The following detailed description of the embodiments of this utility model, in conjunction with the accompanying drawings, will provide a thorough understanding of how this utility model uses technical means to solve technical problems and achieve technical effects, enabling its implementation. It should be noted that these specific descriptions are merely intended to facilitate a clearer understanding of this utility model by those skilled in the art, and are not intended to limit its scope. For example, the use of "first" and "second" in the embodiments of this utility model is not intended to limit its application, but merely to indicate the sequence numbers of multiple identical or similar devices or mechanisms. Those skilled in the art can rearrange these sequence numbers for ease of description or during the organization of technical solutions. Furthermore, alternative solutions are described for some mechanisms in different embodiments, and these alternatives can be applied to other identical or similar devices or mechanisms. As long as there is no conflict, the various embodiments and features in each embodiment of this utility model can be combined with each other, and the resulting technical solutions are all within the protection scope of this utility model.

[0020] The technical solution of this utility model will be described in detail below with reference to the accompanying drawings and specific embodiments.

[0021] like Figure 1 As shown, an intelligent AC charging control system includes a charging socket, a charger, a junction box, a battery pack, a load, a network controller, a server, and a back-end control terminal. The charging socket has several plug holes, which are connected to other electrical devices through wire harnesses. The output end of the charging socket is connected to the input end of the charger. Wiring harnesses include power wiring harnesses and communication wiring harnesses; The charger's output terminal is connected to the junction box's input terminal; The first end of the battery pack is connected to the output end of the junction box, and the second end of the battery pack is connected to the load. The battery pack, charger and network controller establish wireless communication. The network controller establishes wireless communication with the server; The server establishes wireless communication with the back-end control terminal.

[0022] The power wiring harness includes a first power cable L1, a second power cable L2, a third power cable L3, a neutral wire N, and a ground wire PE. The communication wiring harness includes a first control wire PP and a second control wire CP.

[0023] It should be noted that the first power cable L1, the second power cable L2, and the third power cable L3 are interconnected to form a three-phase power supply, which, together with the neutral line N, forms a single-phase power supply; the first control line PP and the second control line CP are connected separately to form a closed-loop control transmission path.

[0024] Understandably, in single-phase power supply mode, any one of the power cables L1, L2, and L3 is combined with the neutral wire N to form three independent single-phase power supplies. The internal or external circuit layout of the AC charging socket contains dedicated switches or switching devices. When single-phase power is needed, these switches are controlled automatically by the system. For example, if L1 and N are chosen to form a single-phase power supply, the switch connected to L1 is closed, while ensuring that the switches connected to L2 and L3 are open. At this time, current flows in from the L1 line, passes through the charger, and then flows back to the power source through the N line, forming a complete single-phase power supply circuit. Similarly, L2 and N, and L3 and N can be chosen to form single-phase power supplies separately; simply close the corresponding switch and open the switches of the other power cables.

[0025] Understandably, when using three-phase power supply, closing the switches connecting L1, L2, and L3 ensures that the three power cables form a complete three-phase circuit. In a three-phase power supply system, a star (Y) or delta (Δ) connection is generally used. In a star connection, the ends of the three power cables are connected together to form a common point (neutral point), while the beginnings are led out as the output terminals of the three-phase power supply. In a delta connection, the end of L1 is connected to the beginning of L2, the end of L2 is connected to the beginning of L3, and the end of L3 is connected to the beginning of L1, forming a closed delta circuit. The output terminals of the three-phase power supply are led out from the three connection points. In actual charging systems, a star connection is usually used, and the neutral point is connected to the neutral wire N.

[0026] It should be noted that the first control line PP is the charging connection confirmation line, and the second control line CP is the charging control guide line.

[0027] Understandably, the first control line PP and the second control line CP detect the RC resistance of the external charging gun and feed back different charging currents to the charger. For example, when a user inserts a 16A charging gun into the vehicle's charging port, the first control line PP confirms that the charging gun is connected and has a current carrying capacity of 16A, and detects that the RC resistance inside the gun is 680Ω. The CP signal initially outputs 12V. After voltage division by the vehicle's internal resistors, the CP voltage drops to 9V, indicating "inserted but not ready to charge." After the user starts charging, the CP voltage drops to 6V, and the charging station notifies the vehicle of the maximum allowable current of 16A via a PWM duty cycle (e.g., 30%). The charger output is adjusted according to the second control line CP to ensure that the current does not exceed 16A, preventing cable overheating or damage.

[0028] It should be noted that the junction box also includes a quick connector interface.

[0029] Understandably, the junction box, as the core hub for power distribution and connection, can flexibly adapt to the parallel connection needs of different numbers of battery packs by setting up multiple sets of quick connector interfaces, meeting the different needs of fast charging, slow charging, and peak charging under low-voltage charging. For example, during off-peak electricity prices at night, six battery packs can be connected to store energy, while during peak daytime hours, two battery packs can be connected to quickly replenish the energy of electric vehicles, with the remaining battery packs serving as backups. This increases the utilization rate of the charging station by 30% and reduces operating costs.

[0030] It should be noted that a battery pack communication interface is provided on the junction box.

[0031] Understandably, the junction box, by integrating a standardized communication interface (such as RS485), can directly connect to a PC (Personal Computer) terminal. This design allows maintenance personnel to monitor the charging status in real time via host computer software. Because the junction box integrates a CAN (Controller Area Network) interface, after connecting to a PC and reading data from a vehicle's battery pack via the host computer, maintenance personnel can quickly diagnose battery pack faults and update BMS policies using UDS (Unified Diagnostic Services).

[0032] It should be noted that the battery pack consists of multiple sub-cells. It possesses sufficient power to meet the charging needs of the battery pack, and also achieves intelligent management and control of the charging process, thus improving the reliability, stability, and safety of the entire charging system.

[0033] The specific principle is as follows: After the user inserts the charging gun, the system detects the power supply type (single-phase or three-phase) through the charging connection confirmation signal. Furthermore, PP and CP, as control signals, identify different RC resistance values ​​in the external charging gun head circuit to request different charging current requirements. The system reads the power supply voltage / frequency and adjusts the PFC (Power Factor Correction) circuit parameters (such as switching frequency and duty cycle) to match the input characteristics.

[0034] The charger converts AC power into DC power required by the load and battery pack. The DC power output from the charger, through the DC+ and DC- ports of the junction box, can provide specific charging power to the load according to different charging voltage requirements. Specifically, the battery pack includes multiple sub-cells such as module1, module2, module3...module36. The junction box controls the number of sub-cells connected through multiple sets of switches, allowing the sub-cells to be connected in parallel to the charging system. This meets the user's requirements for using different numbers of battery packs in parallel for different charging efficiencies of the load. The charging power of this intelligent AC charging control system reaches up to 11kW, greatly shortening the terminal charging time and effectively improving charging efficiency.

[0035] In addition, the power harness and communication harness of this intelligent AC charging control system use shielded twisted-pair cables.

[0036] Understandably, using shielded twisted pair (STP) cable for power / communication wiring harnesses is a key design feature to ensure the electromagnetic compatibility (EMC) of the charging system, especially in environments with strong electromagnetic interference (EMI), where its anti-interference capability directly affects the reliability of data transmission and equipment safety. Preferably, the shielded twisted pair cable has an interference immunity level ≥20V / m.

[0037] It should be noted that the load is a load with an LCD screen.

[0038] Understandably, the optimal load for a charging system is an LCD screen, which allows for effective user interaction and the acquisition of charging information. The LCD screen can be used for software management, including load balancing management software, remote monitoring and maintenance software, and data encryption software. For example, load balancing management software automatically allocates charging tasks based on the real-time load of charging piles, preventing overload of individual piles. Similarly, cloud-based fast charging systems use algorithms to guide vehicles with high power demands to available high-power charging piles, balancing the load on the charging stations.

[0039] It should be noted that the network controller includes a data SIM card and a GPS positioning module. The battery pack, charger, load, and network controller establish wireless communication.

[0040] Understandably, this intelligent AC charging control system is used in unattended guidance or display systems. The network controller communicates with the server via a data SIM card network and uploads log data such as device charging status, charging power, and charging time, enabling remote monitoring of the charging system. Display information can be remotely modified, facilitating operation and maintenance. A GPS positioning module determines the charging status of different charging stations, allowing for timely charging maintenance and providing users with the optimal charging location.

[0041] When charging power is abnormal, an alarm is triggered and transmitted to the mobile app via the cloud. Maintenance personnel can view the device's operating status in real time and receive push notifications. Simultaneously, maintenance personnel can also remotely update the BMS (Battery Management System), thereby enhancing system security and ease of maintenance.

[0042] like Figure 2 The diagram illustrates the charging information interaction control flow architecture of this patent. The network controller is at the core, enabling data interaction and remote control of the charging equipment via the CAN bus communication protocol and cellular network. Specifically, the three key devices—BMS (Battery Management System), charger, and LCD load—are all connected to the network controller via the CAN bus. The BMS collects key parameters such as battery voltage, current, and temperature in real time and transmits this data accurately to the network controller via the CAN bus. The charger is responsible for charging the battery, sending charging parameters such as charging voltage, charging current, and charging progress to the network controller via the CAN bus. The LCD load feeds back its display content or load operating status data to the network controller via the CAN bus.

[0043] The network controller acts as an information hub, integrating and initially processing various types of data received. Subsequently, it connects to the cellular network via a data SIM card, utilizing 4G / 5G high-speed transmission technology to upload the data to a cloud platform / server. The cloud platform performs in-depth analysis and storage of this data, allowing users to view the charging system's operational status and effectively monitor the charging equipment anytime, anywhere via a terminal (App / Web).

[0044] When a user needs to remotely control the charging equipment, they send a command through the terminal. The command travels via the cloud platform and cellular network to the network controller. The network controller then transmits the command precisely to the BMS, charger, or LCD load via the CAN bus, enabling operations such as adjusting charging parameters and emergency power cut-off in case of fault.

[0045] In this intelligent AC charging system, the network controller interaction method enables efficient data exchange and convenient remote control between devices, improving the intelligence level of the charging system and the user experience.

[0046] Finally, it should be noted that the above description is merely the preferred embodiment of this utility model and is not intended to limit the utility model in any way. Any person skilled in the art can make many possible changes and simple substitutions to the technical solution of this utility model using the disclosed methods and technical content without departing from the scope of the technical solution of this utility model, and these all fall within the protection scope of the technical solution of this utility model.

Claims

1. An intelligent AC charging control system, characterized in that, include: Charging sockets, chargers, junction boxes, battery packs, loads, network controllers, servers, and back-end control terminals, among which, The charging socket has several plug holes, which are connected to other electrical devices via wire harnesses. The output end of the charging socket is connected to the input end of the charger. The wiring harness includes a power wiring harness and a communication wiring harness; The output terminal of the charger is connected to the input terminal of the junction box; The first end of the battery pack is connected to the output end of the junction box, the second end of the battery pack is connected to the load, and the battery pack, the charger and the network controller establish wireless communication. The network controller establishes wireless communication with the server; The server establishes wireless communication with the back-end control terminal.

2. The intelligent AC charging control system according to claim 1, characterized in that, The power harness includes a first power cable (L1), a second power cable (L2), a third power cable (L3), a neutral wire (N), and a ground wire (PE); the communication harness includes a first control line (PP) and a second control line (CP). The first power cable (L1), the second power cable (L2), and the third power cable (L3) are interconnected to form a three-phase power supply, which, together with the neutral wire (N), forms a single-phase power supply. The first control line (PP) and the second control line (CP) are connected separately to form a closed-loop control transmission path.

3. The intelligent AC charging control system according to claim 1, characterized in that, The charging socket is an AC charging socket.

4. The intelligent AC charging control system according to claim 2, characterized in that, The first control line (PP) is the charging connection confirmation line.

5. The intelligent AC charging control system according to claim 2, characterized in that, The second control line (CP) is the charging control guide line.

6. The intelligent AC charging control system according to claim 1, characterized in that, The junction box also includes a quick connector interface.

7. The intelligent AC charging control system according to claim 1, characterized in that, The junction box is equipped with a battery pack communication interface.

8. The intelligent AC charging control system according to claim 1, characterized in that, The battery pack consists of multiple sub-cells.

9. The intelligent AC charging control system according to claim 1, characterized in that, The load is a load with an LCD screen.

10. The intelligent AC charging control system according to claim 1, characterized in that, The network controller includes a data SIM card and a GPS positioning module.

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