Alternating-current and direct-current integrated charging system

Abstract

An alternating-current and direct-current (DC) integrated charging system, comprising an alternating-current and DC charging socket, a cable, a current identification module, a control module, an on-board charger and a traction battery, wherein the alternating-current and DC charging socket comprises an alternating-current interface (11) and a DC interface (12); an output end of an alternating-current terminal is connected to an output end of a DC terminal to form a common output end, and the common output end is then connected to the current identification module, the control module, the on-board charger and the traction battery by means of the cable; the on-board charger comprises a DC-DC converter and an alternating-current charging management unit; and the control module is configured to acquire a current waveform by means of the current identification module, and execute an alternating-current charging mode or a DC charging mode on the basis of the current waveform. Since an alternating current and a DC at an output end of the alternating-current and DC charging socket share the same cable, the consumption of charging wire harness and the number of accessories on the wire harness are reduced, thereby reducing the costs.

Description

An AC / DC integrated charging system

[0001] Related applications

[0002] This application claims priority to the Chinese utility model patent application number 202322294815.2 filed on August 25, 2023, and cites the entire disclosure of the above patent application as part of this application. Technical Field

[0003] The present disclosure relates to the technical field of automobile connectors, and in particular to an AC / DC integrated charging system. Background Art

[0004] With the rapid development of new energy technologies, electric vehicles are becoming increasingly popular. Currently, charging sockets on the market have a wide range of charging interface standards, including national, European, and American standards, as well as DC and AC charging interfaces. Therefore, to accommodate these multiple charging interfaces, electric vehicles typically have integrated AC and DC interfaces. The AC and DC interfaces are connected to the vehicle battery via cables. Due to the high charging currents, the charging harness cables are thicker and require numerous accessories to assist assembly, significantly increasing their weight and cost.

[0005] Therefore, a new technical solution is urgently needed to solve the above problems.

[0006] Summary of the Invention

[0007] The purpose of the present disclosure is to provide an AC / DC integrated charging system, which can solve the problem of large usage of charging harnesses and a large number of accessories on the harnesses, which wastes costs.

[0008] The present disclosure provides an AC / DC integrated charging system, including an AC / DC charging station, a cable, a current identification module, a control module, an on-board charger, and a power battery;

[0009] The AC / DC charging station includes an AC interface and a DC interface. The AC interface is provided with at least one AC terminal for receiving AC power, and the DC interface is provided with at least one DC terminal for receiving DC power. The output ends of the AC terminal and the output ends of the DC terminal are respectively connected to form a common output end. The common output end is connected to the input end of the current identification module via a cable. The output end of the current identification module is connected to the input end of the control module. The output end of the control module is connected to the input end of the vehicle charger. The output end of the vehicle charger is connected to the power battery.

[0010] The on-board charger includes a DCDC converter and an AC charging management unit;

[0011] The control module is configured to obtain the current waveform from the current identification module and execute the AC charging mode or the DC charging mode according to the current waveform, wherein the AC charging mode or the DC charging mode is to power the power battery through the AC charging management unit or through the DCDC converter.

[0012] Exemplarily, the DCDC converter is connected in parallel with the AC charging management unit, the output end of the control module is connected to the input end of the DCDC converter and the AC charging management unit respectively, and the output end of the DCDC converter and the output end of the AC charging management unit are connected to the input end of the power battery.

[0013] Exemplarily, the AC terminal includes an AC negative terminal, an AC PE terminal and an AC positive terminal, and the DC terminal includes a DC negative terminal, a DC PE terminal and a DC positive terminal. The output end of the AC positive terminal is transferred to the output end of the DC positive terminal through a first transfer structure, the output end of the AC negative terminal is transferred to the output end of the DC negative terminal through a second transfer structure, and the output end of the AC PE terminal is transferred to the output end of the DC PE terminal through a third transfer structure. The output end of the DC positive terminal, the output end of the DC negative terminal and the output end of the DC PE terminal together form a common output end.

[0014] Exemplarily, the connection between the first adapter structure and the AC positive terminal and the DC positive terminal is any one of crimping, screwing or welding; and / or

[0015] The connection between the second adapter structure and the AC negative terminal and the DC negative terminal is any one of crimping, screwing or welding; and / or

[0016] The connection between the third adapter structure and the AC PE terminal and the DC PE terminal is any one of crimping, screwing or welding.

[0017] Illustratively, the first adapter structure, the second adapter structure, and the third adapter structure are any one or a combination of adapter bars or adapter lines.

[0018] Exemplarily, the AC terminal includes an AC negative terminal, an AC PE terminal and an AC positive terminal, the DC terminal includes a DC negative terminal, a DC PE terminal and a DC positive terminal, the output end of the AC positive terminal and the output end of the DC positive terminal are connected through a first output structure, the output end of the AC negative terminal and the output end of the DC negative terminal are connected through a second output structure, the output end of the AC PE terminal and the DC PE terminal are connected through a third output structure, and the first output structure, the second output structure and the third output structure together form a common output end.

[0019] Exemplarily, the first output structure, the second output structure, and the third output structure are any one or a combination of adapter bars or adapter cables.

[0020] Exemplarily, a high-voltage distribution unit and a BMS are connected in series between the AC and DC charging stations and the power battery.

[0021] Exemplarily, the AC charging management unit is integrated with a rectifier and converts the AC power output from the common output terminal into DC power through the rectifier.

[0022] Exemplarily, the control module and the current identification module are both integrated into the AC / DC charging base.

[0023] Exemplarily, the current identification module is integrated with the control module.

[0024] Exemplarily, the control part of the AC charging management unit, the control part of the DCDC converter and the control module are integrated together.

[0025] Beneficial effects of the present disclosure:

[0026] The AC / DC charging station disclosed herein has an AC terminal output end in the AC interface and a DC terminal output end in the DC interface connected to form a common output end. The common output end is sequentially connected to a current identification module, a control module, an onboard charger, and a power battery via cables. Output cables for the AC terminal output end or the DC terminal output end are eliminated, and cables are connected only at the common output end. The AC and DC are connected on the same line, which reduces the amount of charging harnesses and the number of harness accessories such as cable ties, tapes, and brackets used for the harnesses. This significantly reduces costs, and also reduces the weight and space of the charging harness, contributing to lightweighting of the device.

[0027] The on-board charger integrates a DCDC converter and an AC charging management unit. The control module obtains the current waveform of the common output terminal based on the current identification module and controls the on-board charger to execute AC charging mode or DC charging mode. The on-board charger disclosed in the present invention has the two-in-one charging management function of the DCDC converter and the AC charging management unit.

[0028] Other features and advantages of the present disclosure will become apparent from the following detailed description of exemplary embodiments of the present disclosure with reference to the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the present disclosure and, together with the description, serve to explain the principles of the present disclosure.

[0030] FIG1 is a block diagram showing the structural principle of the AC / DC integrated charging system disclosed herein.

[0031] FIG2 is a connection diagram of the AC / DC integrated charging system disclosed in the present invention.

[0032] FIG3 is a schematic structural diagram of a common output terminal formed by connecting the output end of the AC terminal and the output end of the DC terminal of the present invention.

[0033] FIG4 is another structural schematic diagram showing that the output end of the AC terminal and the output end of the DC terminal of the present disclosure are respectively connected to form a common output end. DETAILED DESCRIPTION

[0034] Various exemplary embodiments of the present disclosure will now be described in detail with reference to the accompanying drawings. It should be noted that unless otherwise specifically stated, the relative arrangement of components and steps, numerical expressions and numerical values ​​set forth in these embodiments do not limit the scope of the present disclosure.

[0035] The following description of at least one exemplary embodiment is merely illustrative in nature and is in no way intended to limit the present disclosure, its application, or uses.

[0036] Technologies, methods, and equipment known to ordinary technicians in the relevant art may not be discussed in detail, but where appropriate, the technologies, methods, and equipment should be considered part of the specification.

[0037] In all examples shown and discussed herein, any specific values ​​should be interpreted as merely exemplary and not limiting. Therefore, other examples of the exemplary embodiments may have different values.

[0038] As shown in Figures 1 to 4, the present disclosure provides an AC / DC integrated charging system, including an AC / DC charging station, a cable, a current identification module, a control module, an onboard charger, and a power battery;

[0039] The AC / DC charging station includes an AC interface and a DC interface. The AC interface is provided with at least one AC terminal for receiving AC power, and the DC interface is provided with at least one DC terminal for receiving DC power. The output of the AC terminal and the output of the DC terminal are respectively connected to form a common output terminal. The common output terminal is connected to the input terminal of the current identification module via a cable. The output terminal of the current identification module is connected to the input terminal of the control module. The output terminal of the control module is connected to the input terminal of the vehicle charger. The output terminal of the vehicle charger is connected to the power battery.

[0040] The on-board charger includes a DCDC converter (i.e., a DC-DC converter or DC / DC converter, which is used to convert one DC voltage (input) to another DC voltage (output)) and an AC charging management unit;

[0041] The control module is configured to obtain the current waveform from the current identification module and execute the AC charging mode or the DC charging mode according to the current waveform, wherein the AC charging mode or the DC charging mode is to power the power battery through the AC charging management unit or through the DCDC converter.

[0042] With the rapid development of new energy technologies, electric vehicles are becoming increasingly popular. Currently, charging sockets on the market have a wide range of charging interface standards, including national, European, and American standards, as well as DC and AC charging interfaces. Therefore, to accommodate these multiple charging interfaces, electric vehicles typically have integrated AC and DC interfaces. The AC and DC interfaces are connected to the vehicle battery via cables. Due to the high charging currents, the charging harness cables are thicker and require numerous accessories to assist assembly, significantly increasing their weight and cost.

[0043] The output ends of the AC terminals in the AC interface of the AC / DC charging stand disclosed herein and the output ends of the DC terminals in the DC interface are respectively connected to form a common output end. The common output end is sequentially connected to the current identification module, the control module, the on-board charger, and the power battery via cables. The output cables of the AC terminal output end or the DC terminal output end are eliminated. Cables are only connected at the common output end. The AC and DC are connected on the same line, which reduces the amount of charging wiring harness and the number of all wiring harness accessories such as cable ties, tapes, and brackets used for the wiring harness, greatly reducing costs.

[0044] The on-board charger integrates a DCDC converter and an AC charging management unit. The control module obtains the current waveform of the common output terminal based on the current identification module and controls the on-board charger to execute AC charging mode or DC charging mode. The on-board charger disclosed in the present invention has the two-in-one charging management function of the DCDC converter and the AC charging management unit.

[0045] In some embodiments, the DCDC converter is connected in parallel with the AC charging management unit, the output end of the control module is connected to the input end of the DCDC converter and the AC charging management unit respectively, and the output end of the DCDC converter and the output end of the AC charging management unit are connected to the input end of the power battery.

[0046] It can be understood as follows: the current identification module identifies the current waveform of the common output end, and the on-board charger executes the charging mode according to the current waveform. If it is an AC waveform, the power battery is charged through the AC charging management unit. If it is an AC waveform, the power battery is charged through the DCDC converter.

[0047] In some embodiments, the AC terminal includes an AC negative terminal 112, an AC PE terminal 113, and an AC positive terminal 111; the DC terminal includes a DC negative terminal 122, a DC PE terminal 123, and a DC positive terminal 121; the output end of the AC positive terminal 111 is transferred to the output end of the DC positive terminal 121 through a first transfer structure 13; the output end of the AC negative terminal 112 is transferred to the output end of the DC negative terminal 122 through a second transfer structure 14; the output end of the AC PE terminal 113 is transferred to the output end of the DC PE terminal 123 through a third transfer structure 15; the output end of the DC positive terminal 121, the output end of the DC negative terminal 122, and the output end of the DC PE terminal 123 together form a common output end.

[0048] The output end of the AC terminal is transferred to the output end of the DC terminal through a transfer structure. Only the output end of the DC positive terminal 121, the output end of the DC negative terminal 122 and the output end of the DC PE terminal 123 of the DC terminal form a common output end, which is connected to the on-board charger through a cable. The output end of the on-board charger is connected to the power battery. This can reduce the number of AC cables connected to the output end of the AC terminal and all accessories such as cable ties, tapes, brackets, etc. used for the cables, thereby greatly reducing costs.

[0049] In some embodiments, the connection between the first adapter structure 13 and the AC positive terminal 111 and the DC positive terminal 121 is any one of crimping, screwing or welding; and / or

[0050] The connection between the second adapter structure 14 and the AC negative terminal 112 and the DC negative terminal 122 is any one of crimping, screwing or welding; and / or

[0051] The third adapter structure 15 and the AC PE terminal 113 and the DC PE terminal 123 are connected by any one of crimping, screwing or welding.

[0052] Crimping involves assembling the adapter and terminal, then using a crimping machine to press the two together. The advantage of crimping is its high production efficiency. Automatic crimping machines enable rapid, high-quality production.

[0053] A threaded connection is a removable connection that uses threaded parts to connect the adapter structure and the terminal. Common threaded connection parts include bolts, studs, screws, and set screws, most of which are standard parts.

[0054] Welding generally uses resistance welding, friction welding, ultrasonic welding and arc welding. Resistance welding refers to a method of welding that uses a strong current to pass through the contact point between the electrode and the workpiece, generating heat due to the contact resistance.

[0055] Friction welding refers to a method of welding that uses the heat generated by friction between the contact surfaces of the workpieces as a heat source to cause the workpieces to undergo plastic deformation under pressure.

[0056] Ultrasonic welding uses high-frequency vibration waves to transmit to the surfaces of two objects to be welded. Under pressure, the two surfaces of the objects rub against each other to form a fusion between the molecular layers.

[0057] Arc welding refers to the use of electric arc as a heat source and the physical phenomenon of air discharge to convert electrical energy into the thermal energy and mechanical energy required for welding, thereby achieving the purpose of connecting metals. The main methods include arc welding, submerged arc welding, gas shielded welding, etc.

[0058] In some embodiments, the first adapter structure 13 , the second adapter structure 14 , and the third adapter structure 15 are any one or a combination of adapter bars or adapter wires.

[0059] The first transfer structure 13, the second transfer structure 14 and the third transfer structure 15 all use conductive transfer bars or transfer wires.

[0060] The transfer bar can be a copper bar or an aluminum bar. The copper bar, also known as the copper busbar or copper busbar, is made of copper and has a long conductor with a rectangular or chamfered (rounded) rectangular cross-section (generally rounded copper bars are used to avoid tip discharge). It is a high-current conductive product that plays the role of transmitting current and electrical connection in the circuit.

[0061] Aluminum busbar: A long aluminum product with a rectangular cross-section made of aluminum or aluminum alloy, sometimes also called a busbar.

[0062] The adapter cable is a conductive cable used to connect the conductive components between the AC terminal and the DC terminal.

[0063] In some embodiments, the AC terminal includes an AC negative terminal 112, an AC PE terminal 113, and an AC positive terminal 111; the DC terminal includes a DC negative terminal 122, a DC PE terminal 123, and a DC positive terminal 121; the output end of the AC positive terminal 111 and the output end of the DC positive terminal 121 are connected through a first output structure 16; the output end of the AC negative terminal 112 and the output end of the DC negative terminal 122 are connected through a second output structure 17; the output end of the AC PE terminal 113 and the DC PE terminal 123 are connected through a third output structure 18; the first output structure 16, the second output structure 17, and the third output structure 18 together form a common output end.

[0064] The output end of the AC terminal and the output end of the DC terminal are connected through the first output structure 16, the second output structure 17 and the third output structure 18. The first output structure 16, the second output structure 17 and the third output structure 18 together form a common output end, which is then connected to the on-board charger through a cable. The output end of the on-board charger is connected to the power battery, which can reduce the number of cables connected to the output ends of the AC terminal or the DC terminal and all accessories such as cable ties, tapes, brackets, etc. used for the cables, thereby greatly reducing costs.

[0065] In some embodiments, the first output structure 16 , the second output structure 17 , and the third output structure 18 are any one or a combination of patch cords or patch cables.

[0066] The first output structure 16, the second output structure 17, and the third output structure 18 all utilize conductive adapter bars or cables. These adapter bars can be copper or aluminum. Copper busbars, also known as copper busbars or busbars, are long conductors made of copper with rectangular or chamfered (rounded) rectangular cross-sections (generally copper busbars with rounded corners are used to prevent tip discharges). These are high-current conductive products that carry current and provide electrical connections within circuits. Aluminum busbars are long, rectangular aluminum bars made of aluminum or aluminum alloys, sometimes also called busbars. Adapter cables are conductive cables used to connect the conductive components between AC and DC terminals.

[0067] Exemplarily, a high-voltage distribution unit and a BMS are connected in series between the AC and DC charging stations and the power battery.

[0068] The high-voltage distribution unit (HDU) is a control unit that distributes energy from the power battery and is a key component in electric vehicles. It primarily distributes power, provides short-circuit and overload protection, and provides power to the power battery and onboard electrical components.

[0069] A BMS (Battery Management System) is a battery management system. Its primary function is to intelligently manage and maintain individual battery cells, prevent overcharging and over-discharging, extend battery life, and monitor battery status. As the battery management system for electric vehicles, the BMS is the crucial link between the onboard power battery and the electric vehicle. The BMS collects, processes, and stores important information about the battery pack's operation in real time, exchanging information with external devices such as the vehicle controller. This information addresses key issues in lithium-ion battery systems, including safety, availability, usability, and service life.

[0070] In some embodiments, the AC charging management unit is integrated with a rectifier and converts the AC power output from the common output terminal into DC power through the rectifier.

[0071] The rectifier integrated into the AC charge management unit is an electrical device that converts alternating current, which periodically reverses direction, into direct current, which flows in only one direction.

[0072] In some embodiments, the control module and the current identification module are both integrated into the AC / DC charging station.

[0073] This can be understood as follows: the AC / DC charging station integrates a control module and a current identification module. The control module can execute AC charging mode or DC charging mode based on the current waveform type obtained by the current identification module. The AC charging mode or DC charging mode is to power the power battery through the AC charging management unit or the DC-DC converter. For example, the AC charging mode powers the power battery through the AC / DC management unit. The DC charging mode powers the power battery through the DC-DC converter.

[0074] In some embodiments, the current identification module is integrated with the control module.

[0075] The current identification module is integrated with the control module, which is more conducive to transmitting the current waveform identified by the current identification module from the common output terminal to the control module. The control module then controls the on-board charger to execute AC charging mode or DC charging mode according to the current waveform.

[0076] In some embodiments, the control part of the AC charging management unit, the control part of the DCDC converter and the control module are integrated together.

[0077] The control part of the AC charging management unit and the control part of the DCDC converter are integrated with the control module, which can save overall layout space, reduce manufacturing costs, facilitate information interaction and transmission between the control parts, and make the control time of the entire system more efficient.

[0078] Although some specific embodiments of the present disclosure have been described in detail through examples, those skilled in the art will understand that the above examples are for illustration only and are not intended to limit the scope of the present disclosure. Those skilled in the art will understand that the above embodiments may be modified without departing from the scope and spirit of the present disclosure. The scope of the present disclosure is defined by the appended claims.

Claims

1. An AC / DC integrated charging system, characterized in that: include: AC and DC charging stations, cables, current identification modules, control modules, on-board chargers and power batteries; The AC / DC charging seat comprises an AC interface and a DC interface, wherein the AC interface is provided with at least one AC terminal for receiving AC power, and the DC interface is provided with at least one DC terminal for receiving DC power, and the output end of the AC terminal and the output end of the DC terminal are respectively connected to form a common output end, and the common output end is connected to the input end of the current identification module through the cable, the output end of the current identification module is connected to the input end of the control module, the output end of the control module is connected to the input end of the on-board charger, and the output end of the on-board charger is connected to the power battery; The on-board charger includes a DCDC converter and an AC charging management unit; The control module is configured to obtain a current waveform from the current identification module and execute an AC charging mode or a DC charging mode according to the current waveform, wherein the AC charging mode or the DC charging mode is to power the power battery through the AC charging management unit or to power the power battery through the DCDC converter.

2. The AC / DC integrated charging system according to claim 1, characterized in that: The DCDC converter is connected in parallel with the AC charging management unit, the output end of the control module is connected to the input end of the DCDC converter and the AC charging management unit respectively, and the output end of the DCDC converter and the output end of the AC charging management unit are connected to the input end of the power battery.

3. The AC / DC integrated charging system according to claim 1, characterized in that: The AC terminal includes an AC negative terminal, an AC PE terminal and an AC positive terminal, and the DC terminal includes a DC negative terminal, a DC PE terminal and a DC positive terminal. The output end of the AC positive terminal is transferred to the output end of the DC positive terminal through a first transfer structure, the output end of the AC negative terminal is transferred to the output end of the DC negative terminal through a second transfer structure, the output end of the AC PE terminal is transferred to the output end of the DC PE terminal through a third transfer structure, and the output end of the DC positive terminal, the output end of the DC negative terminal and the output end of the DC PE terminal together form the common output end.

4. The AC / DC integrated charging system according to claim 3, characterized in that: The connection between the first adapter structure and the AC positive terminal and the DC positive terminal is any one of crimping, screwing or welding; and / or The connection between the second adapter structure and the AC negative terminal and the DC negative terminal is any one of crimping, screwing or welding; and / or The third adapter structure is connected to the AC PE terminal and the DC PE terminal by any one of crimping, screwing or welding.

5. The AC / DC integrated charging system according to claim 3, characterized in that: The first adapter structure, the second adapter structure and the third adapter structure are any one or a combination of adapter bars or adapter lines.

6. The AC / DC integrated charging system according to claim 1, characterized in that: The AC terminal includes an AC negative terminal, an AC PE terminal and an AC positive terminal, and the DC terminal includes a DC negative terminal, a DC PE terminal and a DC positive terminal. The output end of the AC positive terminal and the output end of the DC positive terminal are connected through a first output structure, the output end of the AC negative terminal and the output end of the DC negative terminal are connected through a second output structure, the output end of the AC PE terminal and the DC PE terminal are connected through a third output structure, and the first output structure, the second output structure and the third output structure together form the common output end.

7. The AC / DC integrated charging system according to claim 6, characterized in that: The first output structure, the second output structure and the third output structure are any one or a combination of adapter bars or adapter wires.

8. The AC / DC integrated charging system according to claim 1, characterized in that: A high voltage distribution unit and a BMS are connected in series between the AC / DC charging station and the power battery.

9. The AC / DC integrated charging system according to claim 1, characterized in that: The AC charging management unit is integrated with a rectifier and converts the AC power output from the common output terminal into DC power through the rectifier.

10. The AC / DC integrated charging system according to claim 1, characterized in that: The control module and the current identification module are both integrated in the AC / DC charging base.

11. The AC / DC integrated charging system according to claim 1, characterized in that: The current identification module is integrated with the control module.

12. The AC / DC integrated charging system according to claim 1, characterized in that: The control part of the AC charging management unit and the control part of the DCDC converter are integrated with the control module.

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