Charging early-warning runaway protection apparatus and protection method for electric vehicle

Abstract

A charging early-warning runaway protection apparatus and method for an electric vehicle (1). The apparatus comprises a charging control box arranged on a charging circuit between a charging pile (2) and a vehicle charging port. An indicator light is arranged on a box body of the charging control box to indicate a corresponding state of thermal runaway. The charging control box is used for acquiring vehicle charging information of the electric vehicle (1) during fast charging, the vehicle charging information being used for indicating battery parameter information of the electric vehicle (1) during the fast charging. The charging control box is further used for acquiring pile body charging information of the charging pile (2) during the fast charging, the pile body charging information being used for indicating charging output parameters of the charging pile (2). The charging control box is further used for controlling a display state of the indicator light on the basis of the battery parameter information and the charging output parameters.

Description

A charging early warning and runaway protection device and protection method for electric vehicles

[0001] This application claims priority to Chinese Patent Application No. 202411809763.0, filed on December 10, 2024, entitled "An Electric Vehicle Charging Early Warning and Runaway Protection Device and Protection Method", the entire contents of which are incorporated herein by reference. Technical Field

[0002] This invention relates to the field of electric vehicle charging safety monitoring, and in particular to a method and device for early warning and protection against runaway during charging. Background Technology

[0003] As the market share of electric vehicles increases, the demand for electric vehicle charging is also growing. During the charging process, due to internal short circuits, external short circuits, overcharging, over-discharging, and other reasons, a large amount of heat is generated, leading to battery thermal runaway and frequent accidents that cause electric vehicles to explode. Therefore, the safety of electric vehicles and charging stations during the charging process has attracted great attention from all sectors.

[0004] The current national standard charging process includes: physical connection, low-voltage auxiliary power-on, charging handshake stage, charging parameter configuration stage, charging stage, and charging end stage. During the charging stage, the vehicle sends a battery charging request message to the charging pile according to the BMS requirements. The charging pile adjusts the charging voltage and current in real time based on the message parameters to ensure normal charging. Simultaneously, the two continuously exchange real-time charging status information, such as charging voltage, charging current, battery level, time elapsed, and equipment temperature, mutually monitoring and controlling each other's status. The entire charging process, apart from the signal interaction between the vehicle and the charging pile, stops charging upon detecting a fault, but lacks other runaway protection measures.

[0005] When a short circuit occurs or the battery temperature exceeds its tolerance limit, the electric vehicle may spontaneously combust immediately. Before the charging station can issue a command, there is a high probability of a complete power grid failure, from the vehicle to the charging station, and ultimately to the entire grid. The resulting losses to the charging station and the power grid circuitry are incalculable. Alternatively, a problem with the charging station itself could lead to overheating and a fire during prolonged high-power charging, affecting other electric vehicles and causing even greater losses. Furthermore, if thermal runaway occurs while the charging gun remains connected to the vehicle or the power supply is not severed, it poses a safety risk to rescue efforts and could even increase the overall damage to the charging station. Summary of the Invention

[0006] The purpose of this invention is to overcome the shortcomings of the prior art and provide an electric vehicle charging early warning runaway protection device and protection method. It can monitor the status of electric vehicles and charging piles during the charging process, and will issue an alarm to remind operators when an abnormality occurs. This device can also isolate the chain effect on other equipment when electric vehicles or charging piles spontaneously combust, and intelligently solve the problems mentioned in the background art.

[0007] To achieve the above objectives, the technical solution adopted by the present invention is as follows:

[0008] An electric vehicle charging early warning runaway protection device includes a charging control box installed on the charging circuit between the charging pile and the vehicle charging port; the charging control box is equipped with an indicator light to indicate the corresponding state of thermal runaway.

[0009] The charging control box is used to acquire vehicle charging information of the electric vehicle during the fast charging process. The vehicle charging information is used to indicate the battery parameter information of the electric vehicle during the fast charging process.

[0010] The charging control box is also used to acquire the charging information of the charging pile during the fast charging process, and the charging information is used to indicate the charging output parameters of the charging pile.

[0011] The charging control box is also used to control the display status of the indicator light according to the battery parameter information and the charging output parameters.

[0012] In one optional implementation of this application, the charging control box includes a processor and a cable cutting device; the output of the processor is connected to the cable cutting device, and the processor is used to control whether the charging circuit cable for charging the vehicle is cut off.

[0013] In one optional implementation of this application, a three-color indicator light is provided on the body of the charging control box; the processor inside the charging control box determines the current safe charging status based on the acquired data, and controls the three-color indicator light to light up one of the colors corresponding to the safe status.

[0014] A protection method for an electric vehicle charging early warning runaway protection device, the method being executed by a charging control box installed in the charging circuit between the charging pile and the vehicle charging port; the charging control box is equipped with an indicator light to indicate the corresponding state of thermal runaway; the method includes:

[0015] Acquire vehicle charging information of an electric vehicle during the fast charging process, wherein the vehicle charging information is used to indicate battery parameter information of the electric vehicle during the fast charging process;

[0016] Acquire charging information of the charging pile during the fast charging process, wherein the charging information is used to indicate the charging output parameters of the charging pile;

[0017] The display status of the indicator light is controlled based on the battery parameter information and the charging output parameters.

[0018] In one optional implementation of this application, a three-color indicator light is provided on the casing of the charging control box; controlling the display state of the indicator light according to the battery parameter information and the charging output parameters includes:

[0019] The processor inside the charging control box determines the current safe charging status based on the acquired data, and controls the three-color indicator lights to illuminate one of the colors corresponding to the safe status.

[0020] An electric vehicle charging early warning runaway protection device includes a charging control box installed on the charging circuit between the charging pile and the vehicle charging port; the control box is equipped with three color indicator lights to indicate the corresponding states of thermal runaway; the control box acquires in real time the charging amount of the electric vehicle during fast charging, the temperature sequence of each battery module under dynamic power, and the SOC of the battery, and acquires in real time parameters such as the output power and temperature of the charging pile and the charging interface temperature during fast charging; and controls the lighting state of the three color indicator lights according to the parameters acquired by monitoring.

[0021] The control box includes a processor and a cable cutting device; the output of the processor is connected to the cable cutting device to control whether the charging circuit cable for charging the vehicle is cut off.

[0022] A red, yellow, and green indicator light is installed on the control box. The processor inside the control box determines the current safety status of the charging process based on the data obtained from monitoring, and illuminates one of the red, yellow, or green indicator lights corresponding to the safety status to issue an alarm indication.

[0023] When the processor determines that the current charging is in a normal state, the drive indicator light is lit in green; when it determines that it is in a warning state, the drive indicator light is lit in yellow; when it determines that it is in a thermal runaway abnormal state, the control indicator light is lit in red.

[0024] The protection device also includes a heat dissipation module installed inside the charging pile. The processor of the control box outputs a control signal to the heat dissipation module to control the heat dissipation module to start heat dissipation when the indicator light is in the warning state.

[0025] The control box panel is equipped with a power switch button and a manual cut-off button; the power switch button is used to control whether the control box is powered on; the output of the manual cut-off button is connected to the processor, and the processor controls the working state of the cable cutting device according to the state of the manual switch button.

[0026] The processor of the control box is connected to the CAN network of the charging vehicle via a CAN signal, and is used to issue a cooling command to the charging vehicle in the early warning state to activate the battery cooling system of the charging vehicle.

[0027] The output of the processor in the control box is connected to the controller of the charging pile or the controller of the charging station where the charging pile is located. It is used to upload charging abnormal signals so as to control the charging of the charging pile or the entire charging station and the connection with the power grid based on the abnormal signals.

[0028] A protection method for an electric vehicle charging early warning runaway protection device includes: a control box acquiring in real time the charging capacity of the electric vehicle during fast charging, the temperature sequence of each battery module under dynamic power, and the state of charge (SOC) of the battery; acquiring in real time parameters such as the output power and temperature of the charging pile and the charging interface temperature during fast charging; and performing the following protection control based on the acquired parameters:

[0029] When the signal interaction is normal, the indicator light on the drive control box will be green. If the highest temperature of the electric vehicle battery module group or the internal temperature of the charging pile is detected to exceed the set temperature range, the fan of the charging pile will be started to cool the charging pile or the battery cooling system of the electric vehicle will be started to cool the electric vehicle battery module group. During this process, the indicator light on the control box will be yellow. If the output current of the charging pile is detected to be greater than the current required by the electric vehicle, or if the temperature of the charging interface is abnormal, the indicator light on the control box will be red, an alarm will sound, and the cable will be automatically cut off immediately.

[0030] When all parameters are operating normally within the set working range, i.e., the charging pile temperature ≤ the first pile body temperature threshold, the vehicle battery temperature < the first vehicle temperature threshold, the charging interface temperature ≤ the first interface temperature threshold, and the vehicle charging current < the vehicle demand current, the warning control box indicator light will be green.

[0031] When the parameters are within the set warning temperature range, the control box indicator light turns yellow and the warning protection function is activated. Specifically, when the first charging pile temperature threshold is less than the second charging pile temperature threshold, the control box sends a fan start command to the charging pile, and the fan runs to cool the charging pile. When the first vehicle temperature threshold is less than or equal to the vehicle battery temperature, and less than or equal to the second vehicle temperature threshold, the control box sends a battery cooling system start command to the vehicle, and the coolant circulates to cool the battery. When the charging pile temperature or battery temperature drops to within the threshold of the first charging pile temperature threshold and the first vehicle temperature threshold, the control box indicator light changes from yellow to green.

[0032] When the parameters exceed the set boundary conditions, i.e., the charging pile temperature is greater than or equal to the second pile body temperature threshold, the vehicle battery temperature is greater than the second vehicle temperature threshold, the charging interface temperature is greater than or equal to the first interface temperature threshold, or the vehicle charging current is greater than the vehicle's required current, the control box indicator light will turn red, an alarm sound will be emitted, and the automatic cut-off device will be activated immediately to disconnect the connection between the vehicle and the charging pile.

[0033] The beneficial effects of the technical solution provided in this application include at least the following:

[0034] By monitoring the status of the electric vehicle and charging station during the charging process, an alarm is issued to alert operators when an abnormality occurs. This reduces the cascading effects on other equipment in the event of a spontaneous combustion of the electric vehicle or charging station. Furthermore, in the event of a charging runaway risk, safety risks are mitigated by notifying operators via indicator lights or alarms, cooling the battery module or charging station, or automatically cutting off the cable. This ensures the safety of the charging process and reduces losses should a risk occur. Attached Figure Description

[0035] The following is a brief explanation of the contents of each of the accompanying drawings and the markings in the drawings:

[0036] Figure 1 is a flowchart illustrating an electric vehicle charging early warning and runaway protection method provided in an embodiment of the present invention;

[0037] Figure 2 is a connection diagram of an electric vehicle charging early warning runaway protection device provided in an embodiment of the present invention;

[0038] Figure 3 is a schematic diagram of the control panel of an electric vehicle charging early warning runaway protection device provided in an embodiment of the present invention;

[0039] Figure 4 illustrates the working principle of an electric vehicle charging early warning and runaway protection device provided in an embodiment of the present invention.

[0040] Attached reference numerals: 1-Electric vehicle, 2-Charging pile, 3-220V power supply, 4-Control box, 5-Charging cable connection inlet, 6-Charging cable connection outlet, 7-Charging interface, 8-Control box processor, 9-Air pump, 10-Charging cable inlet sleeve, 11-Charging cable outlet sleeve. Detailed Implementation

[0041] The specific embodiments of the present invention will be further described in detail below with reference to the accompanying drawings and the description of the preferred embodiments.

[0042] Compared to related technologies' charging warning and runaway protection schemes, this embodiment provides an electric vehicle charging warning and runaway protection device, for example, implemented as a control box (also called a charging control box). By specifically monitoring charging runaway and providing at least one of three power-off methods based on the monitoring status—disconnecting charging, disconnecting the charging pile, or disconnecting the charging station—this reduces the safety risk of an accident escalating due to charging runaway of a vehicle connected to a charging pile, which could then spread to other vehicles charging at the same charging pile or even the power grid. The specific implementation of the control box for charging runaway control described above is as follows:

[0043] For example, an electric vehicle charging warning and runaway protection device includes a charging control box installed on the charging circuit between the charging pile and the vehicle charging port. Each charging pile has a control box on its charging gun circuit, which controls the charging circuit. The charging box has a charging cable connection inlet and a charging cable connection outlet. The charging cable of the charging pile is connected to the charging cable connection inlet, and then passes through the inside of the charging box before being led out by the charging cable connection outlet. At the end of the cable is a charging gun for connecting to the charging port of the vehicle to be charged.

[0044] A charging control box is used to acquire vehicle charging information of an electric vehicle during fast charging. The vehicle charging information is used to indicate battery parameter information of the electric vehicle during fast charging. In one optional implementation of this application, the vehicle charging information includes at least one of the following: the charging capacity of the electric vehicle, the temperature sequence of each battery module under dynamic power, and the SOC of the battery.

[0045] The charging control box is also used to acquire the charging information of the charging pile during the fast charging process. The charging information is used to indicate the charging output parameters of the charging pile. In one optional implementation of this application, the charging output parameters include at least one of the charging pile's output power, temperature, and charging interface temperature.

[0046] The charging control box is equipped with indicator lights to indicate the corresponding thermal runaway state. There can be one or more indicator lights, with different display states—such as different numbers of lights, different lighting positions, and different lighting colors—corresponding to different display states. In one example, the control box has three colored indicator lights to indicate the corresponding thermal runaway state. The control box acquires real-time data on the electric vehicle's charging capacity, the temperature sequence of each battery module under dynamic power, and the battery's SOC during the fast charging process. It also acquires real-time parameters such as the charging pile's output power, temperature, and charging interface temperature. Based on these acquired parameters, the control box controls the illumination state of the three colored indicator lights.

[0047] The control box includes a processor and a cable cutting device. The processor's output is connected to the cable cutting device to control whether the charging circuit cable for charging the vehicle is cut. The cable cutting device includes an air pump, a charging cable inlet sleeve, and a charging cable outlet sleeve, used to control the cutting of the charging cable. The air pump is powered by an electrical supply, maintaining or increasing air pressure by compressing air, which acts on the charging cable sleeve to cut the connected charging cables. The charging cables are directly connected, meaning that each signal within the control box is independent and transmitted separately. After the cable is cut, power transmission stops. Disconnecting the air pump and reconnecting the charging cable restores the charging function. Therefore, the device does not damage the wiring harness and can be reused.

[0048] A three-color indicator light (e.g., red, yellow, green) is installed on the control box. The processor inside the control box determines the current safe charging status based on the acquired data and illuminates one of the corresponding red, yellow, or green indicator lights to issue an alarm. Different indicator light colors are used to provide alerts based on whether the current charging status is normal or what state is in case of an abnormality. Specifically:

[0049] When the processor determines that the current charging is in a normal state, it drives the three-color indicator light to light up in the first color state (e.g., green); when it determines that it is in a warning state, it drives the three-color indicator light to light up in the second color state (e.g., yellow); when it determines that it is in a thermal runaway abnormal state, it controls the three-color indicator light to light up in the third color state (e.g., red).

[0050] To achieve safety protection and control under different charging states, the protection device in this embodiment also includes a heat dissipation module installed inside the charging pile. The processor of the control box outputs a control signal to the heat dissipation module to control it to start cooling when the indicator light is in a warning state. That is, when it is determined that the charging is in a warning state, the yellow indicator light is illuminated and the heat dissipation module is activated simultaneously. The heat dissipation module includes, but is not limited to, cooling fans, water cooling, and other cooling systems installed in the charging pile, as well as cooling systems installed inside the vehicle. It controls the cooling of the battery, motor, etc., inside the vehicle by calling the vehicle's cooling system. To enable the operation of calling and controlling the vehicle's cooling system, the processor of the control box is connected to the CAN network of the charging vehicle via a CAN signal to issue a cooling command to the charging vehicle to activate the charging vehicle's battery cooling system when the warning state is activated.

[0051] In one alternative implementation of this application, the control box is located on the cable between the charging pile and the electric vehicle and is an independent unit, with the cable passing through the control box; the power source of the control box is an external 220V power input, or it can be powered by its own battery, and the entire control device is started and stopped by a power input switch.

[0052] The charging status of the electric vehicle is indicated by signal indicator lights; the CAN signal connection line inside the control box is separated to collect parameter data at both ends of the vehicle and the charging pile in real time, such as at a frequency of 1HZ.

[0053] By isolating the CAN signal connection line through the control box enclosure, it is possible to collect parameter data at both ends of the vehicle and the charging pile. It also enables the control box to process the data from both ends of the vehicle and the charging pile. When it is necessary to dissipate heat from the battery, motor, etc. in the vehicle, the control box can issue a command to start the battery cooling system based on the CAN signal transmission capability, so that the coolant circulates to cool the battery.

[0054] Furthermore, the control box is only capable of sending commands related to the battery cooling system. By restricting the types of CAN signals that the control box can send, its control capabilities over the electric vehicle are limited, preventing the control box from abusing CAN signals to perform control functions unrelated to the charging safety of the electric vehicle. For example, during the fast charging process of an electric vehicle, when the charging gun is inserted into the charging station, the device identification information of the control box is obtained based on the CAN signal. Based on the device identification information, commands sent by the control box other than the first command related to the battery cooling system are blocked.

[0055] In this embodiment, a power switch button and a manual cut-off button are provided on the control box panel. The power switch button controls whether the control box receives power. The output of the manual cut-off button is connected to a processor, which controls the working state of the cable cutting device based on the state of the manual cut-off button. The power switch button controls the power supply to components such as the processor inside the charging box. The control box is equipped with a charging port to supply power to the control box. The manual cut-off switch primarily provides a basis for manual control by the user. In case of a fault, the user can adjust and control whether to cut off the charging circuit based on their own judgment, thus realizing the user's initiative in control.

[0056] In a preferred embodiment of this application, the output of the processor in the control box is connected to the controller of the charging pile or the controller of the charging station where the charging pile is located. This is used to upload a charging anomaly signal to control the charging of the charging pile or the entire charging station and its connection to the power grid based on the anomaly signal. When the processor in the control box determines that an anomaly is currently occurring, it first illuminates an indicator light in red and simultaneously controls a wire disconnection device to disconnect the charging circuit cable, thus interrupting the charging process. Simultaneously, the processor sends a request to the controller of the charging pile or charging station to disconnect the high-voltage power supply to the abnormal charging pile, putting the charging pile in a power-off and non-operating state. This provides a basis for subsequent rescue operations and avoids the safety hazards of rescuing a charging pile while it is energized. Furthermore, it monitors the temperature data of other charging piles in the charging station in real time and determines whether the thermal runaway of this charging pile has spread to other charging piles based on the temperature data of other charging piles. If the temperature of other charging piles rises to a certain value within a set time range, it is determined that the thermal runaway has spread to other charging piles. At this time, the controller of the charging station or the processor of the control box sends a request signal to the controller of the charging station. At this time, the entire charging station is controlled to disconnect from the high-voltage mains power, thereby ensuring the safety of the entire charging station, avoiding the safety hazards caused by rescuing while the power is energized, and also preventing the impact of the charging station failure on the power grid.

[0057] As shown in Figures 1-4, this embodiment presents a method and device for electric vehicle charging early warning and runaway protection. This method can monitor the status of the electric vehicle and the charging pile during the charging process. When an abnormality occurs, it will issue an alarm to remind the operator. This device can also isolate the chain effect on other equipment when the electric vehicle or the charging pile spontaneously combusts, intelligently solving the problems mentioned in the background art.

[0058] A method for electric vehicle charging early warning and runaway protection includes the following steps: The control box acquires in real time the charging capacity of the electric vehicle during fast charging, the temperature sequence of each battery module under dynamic power, and the SOC of the battery; it also acquires in real time parameters such as the output power and temperature of the charging pile and the charging interface temperature during fast charging. When the signal interaction is normal, the control box indicator light is green; if the highest temperature of the electric vehicle battery module group or the internal temperature of the charging pile is detected to exceed the set temperature range, the charging pile fan is activated to cool the charging pile or the electric vehicle battery cooling system is activated to cool the electric vehicle battery module group; during this process, the control box indicator light is yellow; if the output current of the charging pile is detected to be greater than the electric vehicle's required current, or the charging interface temperature is abnormal, the control box indicator light is red, an alarm sounds, and the cable is immediately and automatically cut off to prevent further deterioration.

[0059] This invention provides a device for electric vehicle charging early warning and runaway protection, comprising a control box, a power cord, a charging cable connection inlet, and a charging cable connection outlet. The control box is located on the cable between the charging pile and the electric vehicle, and is an independent unit, with the cable passing through it. The control box is powered by an external 220V power input or its own battery. The entire control device is started and stopped via a power input switch, and the charging status of the electric vehicle is indicated by indicator lights. The CAN signal connection line inside the control box is isolated, and parameter data from both ends of the vehicle and the charging pile are collected in real time at a frequency of 1Hz. The control box contains a cable cutting device; when the charging indicator light is red, this device is immediately activated to cut the cable, or the cable can be cut manually via a button on the control panel.

[0060] The control panel features a power switch, a power input socket, three charging signal indicator lights (red, yellow, and green), and a manual cut-off button. The charging pile cable connection inlet and outlet are located on either side of the control panel. During charging, the charging status is determined by collecting CAN signal data from both ends of the charging pile. When the indicator light is green, it indicates that all parameters are operating normally within the working range. When the indicator light is yellow, it indicates that the internal temperature of the charging pile is within the warning range. At this time, the control panel processor will send a command to the charging pile fan controller to rotate the fan to cool the charging pile. Alternatively, if the vehicle battery temperature is within the warning range, the control panel processor will send a command to the vehicle battery cooling system to circulate cooling for the battery. When the indicator light is red, it indicates that the charging process parameters are out of control. At this time, the control panel automatically activates the cable cut-off device and emits a continuous alarm sound. Personnel can also manually cut the cable using the cut-off button on the control panel to stop the power supply and prevent accidents.

[0061] To address the problems existing in the prior art, embodiments of the present invention provide a method and apparatus for early warning and runaway protection of electric vehicles.

[0062] The working principle of this method is shown in Figure 1. Specifically, it is as follows: First, connect the warning device, insert the charging gun, and start charging. During the charging process, the charging demand information of the electric vehicle, charging voltage and current, the temperature of each battery module, the voltage and current output of the charging pile, the temperature of the charging pile, the temperature of the charging interface, and other parameters are monitored in real time. The parameters are analyzed to assess the safety of the charging process.

[0063] (1) When all parameters are operating normally within the set working range, specifically, the charging pile temperature is ≤ the first pile body temperature threshold (e.g., denoted as A1), the vehicle battery temperature is < the first vehicle temperature threshold (e.g., denoted as B1), the charging interface temperature is ≤ the first interface temperature threshold (e.g., denoted as C1), the vehicle charging current is < the vehicle demand current, and the warning control box indicator light is green.

[0064] (2) When the relevant parameters are within the set warning temperature range, the indicator light on the control box will turn yellow and the warning protection function will be activated. Specifically, when the temperature threshold of the first charging pile is less than the temperature of the charging pile and less than the temperature threshold of the second charging pile (for example, denoted as A2), the control box will issue a fan start command to the charging pile, and the fan will run to cool the charging pile. When the temperature threshold of the first vehicle is less than or equal to the temperature threshold of the vehicle battery and less than or equal to the temperature threshold of the second vehicle (for example, denoted as B2), the control box will issue a battery cooling system start command to the vehicle, and the coolant will circulate to cool the battery. When the temperature of the charging pile or the battery drops to the temperature range of step (1), the indicator light on the control box will change from yellow to green, thereby repeatedly monitoring the status of each charging parameter.

[0065] (3) When the parameters exceed the set boundary conditions, specifically, the charging pile temperature ≥ the second pile body temperature threshold, the vehicle battery temperature > the second vehicle temperature threshold, the charging interface temperature ≥ the first interface temperature threshold (for example, denoted as C1), the vehicle charging current > the vehicle demand current, the control box indicator light will turn red, an alarm sound will be emitted, and the automatic cut-off device will be activated immediately to disconnect the connection between the vehicle and the pile.

[0066] The temperature thresholds, including the first pile body temperature threshold, the second pile body temperature threshold, the first vehicle temperature threshold, the second vehicle temperature threshold, and the first interface temperature threshold, are all pre-calibrated and can be set according to the temperature resistance parameters of the charging station, vehicle, etc.

[0067] Figure 2 shows a connection diagram of an electric vehicle early warning and runaway protection device. The control box 4 has a charging cable inlet 5 connecting to the charging pile 2 and a charging cable outlet 6 connecting to the electric vehicle 1. The device also requires a 220V external power input 3 to provide power for monitoring parameters and issuing commands. The control panel, shown in Figure 3, includes an external power socket, an external power switch, a manual disconnect switch, and a charging signal indicator. The external power socket connects to the external power input 3. After connection, the adjacent control switch needs to be turned on. This switch is also part of the charging process safety protection; when the control switch is closed, charging is disconnected; when the control switch is closed, charging starts. The manual disconnect switch allows manual disconnection of the charging cable when the indicator light is red, even if the control box has not automatically disconnected the connection between the charging pile and the vehicle. The charging signal indicator shows the charging status: green indicates normal operation, yellow indicates slightly high charging pile or battery temperature but no immediate risk, and red indicates abnormal operation accompanied by an alarm sound, alerting the operator.

[0068] Figure 4 illustrates the working principle of an electric vehicle charging early warning and runaway protection device. The control box independently connects the CAN high and CAN low loops on the charging cable, monitoring the charging pile temperature, charging voltage, current, battery module temperature, and battery SOC in real time during the charging process, and sending these parameters to the control box. The control box processor analyzes and judges the safety of the charging process. If there are no problems, monitoring continues; if the signal value is within the warning range, it sends a command to the charging pile motor controller or the vehicle battery cooling system to cause the motor or cooling system to work cyclically to cool it down; if the signal value is within the runaway range, it directly disconnects the connection between the charging pile and the vehicle and cuts off the external power supply connection to the control box.

[0069] Obviously, the specific implementation of this invention is not limited to the above-described methods. Any non-substantial improvements made using the inventive concept and technical solution of this invention are within the protection scope of this invention.

Claims

An electric vehicle charging early warning and runaway protection device, characterized in that, The device includes a charging control box installed on the charging circuit between the charging pile and the vehicle charging port; the charging control box is equipped with an indicator light to indicate the corresponding state of thermal runaway. The charging control box is used to acquire vehicle charging information of the electric vehicle during the fast charging process. The vehicle charging information is used to indicate the battery parameter information of the electric vehicle during the fast charging process. The charging control box is also used to acquire the charging information of the charging pile during the fast charging process, and the charging information is used to indicate the charging output parameters of the charging pile. The charging control box is also used to control the display status of the indicator light according to the battery parameter information and the charging output parameters. An electric vehicle charging early warning and runaway protection device according to claim 1, characterized in that, The charging control box includes a processor and a cable cutting device; the output of the processor is connected to the cable cutting device, and the processor is used to control whether the charging circuit cable for charging the vehicle is cut off. An electric vehicle charging early warning runaway protection device according to claim 1 or 2, characterized in that, A three-color indicator light is installed on the body of the charging control box; the processor inside the charging control box determines the current safe charging status based on the acquired data, and controls the three-color indicator light to light up one of the colors corresponding to the safe status. The electric vehicle charging early warning runaway protection device according to claim 3 is characterized in that, The processor is also used for at least one of the following: When it is determined that the charging is in a normal state, the three-color indicator light is driven to illuminate in the first color state; When it is determined that the charging is in a warning state, the three-color indicator light is driven to light up in the second color state; When it is determined that the charging is in a thermal runaway abnormal state, the three-color indicator light is controlled to light up in the third color state. An electric vehicle charging early warning and runaway protection device according to claim 4, characterized in that, The protection device also includes a heat dissipation module installed inside the charging pile. The processor of the charging control box outputs a control signal to the heat dissipation module to control the heat dissipation module to start heat dissipation when the indicator light is in the warning state. The method according to claim 1, characterized in that, The electric vehicle charging early warning runaway protection device described in any one of 1-5 is characterized in that... The vehicle charging information includes at least one of the following: the charging capacity of the electric vehicle, the temperature sequence of each battery module under dynamic power, and the state of charge (SOC) of the battery. And / or, the charging output parameters include at least one of the following: the output power of the charging pile, the temperature, and the charging interface temperature. An electric vehicle charging early warning runaway protection device according to any one of claims 1-5, characterized in that, The charging control box panel is equipped with a power switch button and a manual cut-off button; the power switch button is used to control the power input to or from the charging control box; the output of the manual cut-off button is connected to a processor, and the processor controls the working state of the cable cutting device according to the state of the manual cut-off button. An electric vehicle charging early warning runaway protection device according to any one of claims 1-5, characterized in that, The processor of the charging control box is connected to the vehicle CAN network of the electric vehicle via a CAN signal, and is used to issue a cooling command to the charging vehicle in the early warning state to activate the battery cooling system of the charging vehicle. An electric vehicle charging early warning runaway protection device according to any one of claims 1-5, characterized in that, The output of the processor in the charging control box is connected to the controller of the charging pile or the controller of the charging station where the charging pile is located. It is used to upload charging abnormal signals so as to control the charging of the charging pile or the entire charging station and the connection with the power grid based on the abnormal signals. A method for preventing electric vehicle charging runaway, characterized in that, The method is performed by a charging control box installed on the charging circuit between the charging pile and the vehicle charging port. The charging control box is equipped with indicator lights to indicate the corresponding state of thermal runaway; the method includes: Acquire vehicle charging information of an electric vehicle during the fast charging process, wherein the vehicle charging information is used to indicate battery parameter information of the electric vehicle during the fast charging process; Acquire charging information of the charging pile during the fast charging process, wherein the charging information is used to indicate the charging output parameters of the charging pile; The display status of the indicator light is controlled based on the battery parameter information and the charging output parameters. A method for electric vehicle charging early warning and runaway protection according to claim 10, characterized in that, A three-color indicator light is installed on the casing of the charging control box; controlling the display status of the indicator light according to the battery parameter information and the charging output parameters includes: The processor inside the charging control box determines the current safe charging status based on the acquired data, and controls the three-color indicator lights to illuminate one of the colors corresponding to the safe status. A method for electric vehicle charging early warning and runaway protection according to claim 10, characterized in that, Based on the safety status, the three-color indicator light is illuminated to one of the following colors: When charging is in normal condition, the indicator light on the charging control box will be green. If the highest temperature of the electric vehicle battery module group or the internal temperature of the charging pile is detected to exceed the set temperature range, the charging pile fan will be activated to cool the charging pile or the electric vehicle battery cooling system will be activated to cool the electric vehicle battery module group. The indicator light on the charging control box will then turn yellow. If the output current of the charging pile is detected to be greater than the current required by the electric vehicle, or if the temperature of the charging interface is abnormal, the indicator light on the charging control box will turn red, an alarm will sound, and the cable will be automatically cut off immediately. The protection method of the electric vehicle charging early warning runaway protection device as described in claim 12 is characterized in that, When charging is in a normal state, the indicator light on the charging control box will turn green, including: When all parameters are operating normally within the set working range, i.e., the charging pile temperature ≤ the first pile body temperature threshold, the vehicle battery temperature < the first vehicle temperature threshold, the charging interface temperature ≤ the first interface temperature threshold, and the vehicle charging current < the vehicle demand current, the warning control box indicator light will be green. And / or, if the highest temperature of the electric vehicle battery module group or the internal temperature of the charging pile is detected to exceed the set temperature range, the charging pile's fan is activated to cool the charging pile, or the electric vehicle's battery cooling system is activated to cool the electric vehicle battery module group. The indicator light on the charging control box will then turn yellow, including: When the parameters are within the set warning temperature range, the control box indicator light turns yellow and the warning protection function is activated. Specifically, when the first charging pile temperature threshold is less than the second charging pile temperature threshold, the control box sends a fan start command to the charging pile, and the fan runs to cool the charging pile. When the first vehicle temperature threshold is less than or equal to the vehicle battery temperature, and less than or equal to the second vehicle temperature threshold, the control box sends a battery cooling system start command to the vehicle, and the coolant circulates to cool the battery. When the charging pile temperature or battery temperature drops to within the threshold of the first charging pile temperature threshold and the first vehicle temperature threshold, the control box indicator light changes from yellow to green. And / or, when the output current of the charging pile is detected to be greater than the demand current of the electric vehicle, or the charging interface temperature is abnormal, the indicator light on the charging control box turns red, an alarm sounds, and the cable is immediately and automatically disconnected, including: When the parameters exceed the set boundary conditions, i.e., the charging pile temperature is greater than or equal to the second pile body temperature threshold, the vehicle battery temperature is greater than the second vehicle temperature threshold, the charging interface temperature is greater than or equal to the first interface temperature threshold, or the vehicle charging current is greater than the vehicle's required current, the control box indicator light will turn red, an alarm sound will be emitted, and the automatic cut-off device will be activated immediately to disconnect the connection between the vehicle and the charging pile.

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