Charging Pile Power System with Dynamic Series-Parallel Switching
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Solution Overview
Problem
Existing charging piles face challenges in meeting the increasing voltage and current requirements of electric vehicles due to limited capacity expansion, inefficient heat dissipation, and high maintenance costs associated with dust filter replacement.
Innovation Solution
A charging pile design featuring a power system with two power units connected in series or parallel via switch transistors, a heat sink for natural heat dissipation, and an IP65 protection design, allowing flexible voltage and current adjustments and reducing the need for dust filters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the output voltage range of the charging module is extended to 200V-900V to meet future electric vehicle requirements, then the charging pile can accommodate higher voltage vehicles, but the charging module works in a non-optimal state for most of the time causing low efficiency and high energy consumption
Solution Approach 1:
The charging pile divides the power output into multiple independent charging modules (e.g., two modules each with 200V-500V range). These modules can be connected in series to achieve higher voltage (e.g., 400V-1000V) or in parallel for higher current. This segmentation allows each module to operate within its optimal voltage range while the system adapts to different vehicle requirements, avoiding the inefficiency of a single wide-range module operating in non-optimal states.
2Power
If more charging modules are connected in parallel to increase charging current for fast charging, then the maximum output power increases, but the system heat dissipation capability becomes a limiting factor and capacity cannot be expanded
Solution Approach 1:
The charging pile employs dynamic switching between series and parallel connections of charging modules based on real-time charging requirements. When high voltage is needed, modules connect in series; when high current is needed, they connect in parallel. This dynamic reconfiguration allows the system to scale power output without being constrained by fixed heat dissipation capabilities, as the thermal load is distributed and managed adaptively across different operating configurations.
3Ease of operation
If the charging pile uses IP54 protection design with direct ventilation for heat dissipation, then the cabinet can be deployed outdoors, but dust and oil stains are easily inhaled into the cabinet resulting in extremely high annualized failure rate and low reliability
Solution Approach 1:
The charging pile replaces the mechanical direct ventilation system with a heat sink-based passive heat dissipation system. The heat sink dissipates heat through thermal radiation and natural convection without requiring air intake that would draw dust and contaminants into the cabinet. This substitution maintains outdoor deployment capability while dramatically improving reliability by eliminating the dust inhalation problem associated with direct ventilation.
4Object-affected harmful factors
If dust filters are installed in the direct ventilation manner for heat dissipation, then the cabinet can filter incoming air, but the dust filter needs to be replaced regularly causing extremely high maintenance costs
Solution Approach 1:
The charging pile extracts and eliminates the dust filter component entirely by replacing the direct ventilation system with a heat sink-based heat dissipation system. Since the heat sink does not require air intake, there is no dust filter to install or maintain. This extraction of the problematic component resolves the contradiction by providing continuous dust-free operation without the need for regular filter replacement, thereby eliminating maintenance costs associated with filter upkeep.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design enables flexible charging voltage and current outputs, enhances reliability, reduces maintenance costs, and optimizes energy efficiency by eliminating the need for dust filters and fans, effectively addressing the limitations of existing charging piles.
Implementation Method 1
a heat sink for natural heat dissipation
Data Source
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AI summary
The present invention discloses a charging pile, including a power system and a charging terminal. The power system includes a first power unit, a second power unit, a power control unit, and a heat sink. The first power unit is connected to the second power unit, and the first power unit and the second power unit have same output voltages and same output currents. The power control unit is configured to control the output voltages and the output currents of the two power units. The charging terminal includes a charging control module, a direct-current distribution unit, and a charging plug. The charging plug is configured to connect to a to-be-charged battery and charge the to-be-charged battery. The direct-current distribution unit is configured to allocate a power supply to the charging plug. The charging control module is configured to bill and display the charging. In embodiments of the present invention, a flexible charging voltage and a flexible charging current are provided for the to-be-charged battery by using a flexible connection between the two power units. In this way, an existing difficulty in capacity expansion of a charging pile is overcome, and an increasingly high requirement of an electric vehicle for a charging voltage and a charging current is met.