阅读说明：本技术 一种大功率的充电模块 (High-power charging module ) 是由 刘阳 于 2020-08-06 设计创作，主要内容包括：本发明提供一种大功率的充电模块(60Kw),采用工频电源,包括将三相工频电源转换成直流的AC/DC单元和将AC/DC单元转换成充电电压的DC/DC变换单元；所述的AC/DC单元为输入三相三线制380VAC,输出800VDC,功率66-70Kw的一个独立单元；所述的DC/DC变换单元包括相同结构的三部分,每部分是一个完整的20Kw双路独立输出150-500VDC的单元。本发明的大功率的充电模块采用模块化,可多种冷却散热方式,适用性强。(The invention provides a high-power charging module (60Kw), which adopts a power frequency power supply and comprises an AC/DC unit for converting a three-phase power frequency power supply into direct current and a DC/DC conversion unit for converting the AC/DC unit into charging voltage; the AC/DC unit is an independent unit which inputs 380VAC of a three-phase three-wire system, outputs 800VDC and has power of 66-70 Kw; the DC/DC conversion unit comprises three parts with the same structure, wherein each part is a complete unit with 20Kw two-way independent output of 150 and 500 VDC. The high-power charging module provided by the invention is modularized, can be cooled in various ways, and has strong applicability.)

1. A high-power charging module (60Kw) adopts a power frequency power supply and comprises an AC/DC unit for converting a three-phase power frequency power supply into direct current and a DC/DC conversion unit for converting the AC/DC unit into charging voltage; the method is characterized in that:

the AC/DC unit is an independent unit which inputs 380VAC of a three-phase three-wire system, outputs 800VDC and has power of 66-70 Kw;

the DC/DC conversion unit comprises three parts with the same structure, wherein each part is a complete unit with 20Kw two-way independent output of 150 and 500 VDC.

2. The high power charging module according to claim 1, wherein: the AC/DC unit comprises APFC which respectively adopts PWM rectification power modules for A, B, C phases of a power frequency power supply, the power modules are provided with driving and absorbing circuits, and in the APFC, an inductor and a transformer are integrated together to form an integrated magnetic device.

3. The high power charging module according to claim 2, wherein: the topological structure of the APFC adopting the PWM rectification power module is a three-phase staggered three-tube three-level PWM rectification circuit; the random interleaved three-tube three-level PWM rectifying circuit comprises rectifier bridge stacks DQ1 and DQ2, diodes DA1, DA2, DA3 and DA4, and switching tubes QA1 and QA2 controlled by a control unit;

the diode DA1, the switching tube QA1 and the diode DA3 are connected in sequence; the diode DA2, the switching tube QA2 and the diode DA4 are connected in sequence; after being processed by EMC, the A alternating current is divided into two paths to enter rectifier bridge stacks DQ1 and DQ2, and the output anode of the rectifier bridge stack DQ1 is connected with the common end of the anode of the diode DA1 connected with the D pole of the switch tube QA 1; the output cathode of the rectifier bridge stack DQ1 is connected to the common end of the S pole of the switching tube and the cathode of the diode DA 3; the anode of the output of the rectifier bridge stack DQ2 is connected to the common end of the anode of the diode DA2 connected with the D pole of the switching tube QA2, and the cathode of the output of the rectifier bridge stack DQ2 is connected to the common end of the S pole of the switching tube connected with the cathode of the diode DA 4;

the cathode of the diode DA1 is connected with the cathode of the diode DA2 to form an output anode;

the anode of the diode DA3 and the anode of the diode DA4 are connected to form an output cathode;

electrolytic capacitors EA2 and EA1 are connected in series between the output positive electrode and the output negative electrode.

4. High power charging module according to claim 1 or 2 or 3, characterized in that: the AC/DC unit adopts an independent aluminum substrate power module for each phase.

5. The high power charging module according to claim 1, wherein: the DC/DC conversion unit comprises an EMC circuit connected with the 800VDC output by the AC/DC unit, a double-path independent half-bridge LLC conversion circuit, a rectification circuit, a filtering circuit and an output circuit, wherein the EMC circuit is used for converting the 800VDC output by the AC/DC unit into a voltage output by the charging pile; the double-path independent half-bridge LLC conversion circuit converts 800VDC input into a post-rectification, filtering and output circuit to output 500 VDC; in a double-path independent half-bridge LLC conversion circuit and a rectification, filtering and output circuit, a transformer and a resonant inductor are integrated together to form an integrated magnetic device.

6. The high power charging module according to claim 5, wherein: the two-way independent half-bridge LLC conversion circuit topology structure comprises switching tubes MQ1, MQ2, MQ3 and MQ4 controlled by a control unit; diodes D5, D6, D7, D8, D9, D10, D11, D13, D14; resonant inductor capacitances LX, CW 2; electrolytic capacitors E10, E8; a filter inductor L0, a transformer TR 2;

the switching tubes MQ1, MQ2, MQ3 and MQ4 are connected with the D pole of the next switching tube according to the S pole of the previous switching tube; the +400VDC output by the AC/DC unit is connected with the D pole of the switching tube MQ1, and the-400 VDC output by the AC/DC unit is connected with the S pole of the switching tube MQ 4;

the diode D7 is arranged between the common terminal connected with the S pole of the switching tube MQ1 and the D pole of the switching tube MQ2 and the ground, the diode D8 is arranged between the common terminal connected with the S pole of the switching tube MQ3 and the D pole of the switching tube MQ4 and the ground, and the anode of the diode D7 and the cathode of the diode D8 are grounded;

a diode D6 and a diode D5 are connected in series between the D pole of the switching tube MQ1 and the S pole of the switching tube MQ4, the anode of the diode D6 is connected with the cathode of the diode, the cathode of the diode D6 is connected with the D pole of the switching tube MQ1, and the anode of the diode D5 is connected with the S pole of the switching tube MQ 4;

the common end of the anode of the diode D6, which is connected with the cathode of the diode D5, is connected with one end of an inductor LX, and the other end of the inductor LX and the common end of the S pole of the switching tube MD2, which is connected with the D pole of the switching tube MD3, are respectively connected with two ends of the primary coil of the transformer TR 2;

the secondary side of the transformer TR2 is connected with two input ends of a rectifying full bridge consisting of diodes D9, D10, D13 and D14, and the output end of the rectifying full bridge is connected with a pi-type filter consisting of electrolytic capacitors E8, E10 and an inductor L0 and then outputs 500VDC through a diode D11.

7. High power charging module according to claim 1 or 5 or 6, characterized in that: the DC/DC conversion unit adopts a double-path independent aluminum substrate power unit.

8. The high power charging module according to claim 7, wherein: the radiator of the charging module is arranged in the charging pile cabinet body; for setting up at the internal independent heat dissipation channel of electric pile cabinet that fills.

9. The high power charging module according to claim 8, wherein: the charging module has six paths of outputs, and the minimum power distribution of each path is 10 Kw.

10. The high power charging module according to claim 8, wherein: the AC/DC unit and the DC/DC conversion unit can also be used as a glue-sealed high-power charging module or an oil-cooled high-power charging module.

Technical Field

The invention relates to the field of charging storage batteries and lithium batteries, in particular to a high-power charging module such as a charging pile and the like which is arranged in a parking lot and the like and used for charging electric vehicles.

Background

The module of charging is along with filling electric pile's popularization demand bigger and bigger. The cost of the charging module accounts for 50-70% of the total cost of the charging pile, and the reliability accounts for more than 70%.

Chinese patent application publication No. 109941124a discloses a charging pile, a charging module thereof, and a charging voltage stabilization control method, wherein the charging module includes: the DC/DC three-level phase-shifted full-bridge circuit is used for converting input voltage into output voltage required by charging, and comprises a bleeder circuit, a capacitor and a capacitor, wherein the bleeder circuit is arranged at the output side of the DC/DC three-level phase-shifted full-bridge circuit and is connected with the output capacitor in parallel; the bleeding circuit includes: a bleeder resistor and a switching tube Q9, wherein the switching tube Q9 is connected with the bleeder resistor in series and used for controlling the connection or disconnection of the bleeder circuit; the control unit is connected with the switching tube Q9 and used for controlling the switching tube Q9 to be conducted when a shutdown instruction of the charging module is received; the control unit is further configured to control the switching tube Q9 to be turned on or off at a preset frequency when the output voltage of the charging module is greater than a given voltage, so as to control the output voltage to be reduced to the given voltage.

Charging modules in the market at present are derived from indoor power supply modules such as communication power supplies and power operation power supplies, so that the problem of adaptability of application places is brought by nature: low reliability and poor environmental adaptability.

In the invention

The invention provides a high-power charging module aiming at the defects of low reliability and poor environmental adaptability of the charging module of the existing charging pile.

The technical scheme for realizing the technical purpose of the invention is as follows: a high-power charging module adopts a power frequency power supply and comprises an AC/DC unit for converting a three-phase power frequency power supply into direct current and a DC/DC conversion unit for converting the AC/DC unit into charging voltage; the AC/DC unit is an independent unit which inputs 380VAC of a three-phase three-wire system, outputs 800VDC and has power of 66-70 Kw; the DC/DC conversion unit comprises three parts with the same structure, wherein each part is a complete unit with 20Kw two-way independent output of 150 and 500 VDC.

Further, in the high-power charging module: the AC/DC unit comprises APFC which respectively adopts PWM rectification power modules for A, B, C phases of a power frequency power supply, the power modules are provided with driving and absorbing circuits, and in the APFC, an inductor and a transformer are integrated together to form an integrated magnetic device.

Further, in the high-power charging module: the topological structure of the APFC adopting the PWM rectification power module is a three-phase staggered three-tube three-level PWM rectification circuit; the random interleaved three-tube three-level PWM rectifying circuit comprises rectifier bridge stacks DQ1 and DQ2, diodes DA1, DA2, DA3 and DA4, and switching tubes QA1 and QA2 controlled by a control unit;

the diode DA1, the switching tube QA1 and the diode DA3 are connected in sequence; the diode DA2, the switching tube QA2 and the diode DA4 are connected in sequence; after being processed by EMC, the A alternating current is divided into two paths to enter rectifier bridge stacks DQ1 and DQ2, and the output anode of the rectifier bridge stack DQ1 is connected with the common end of the anode of the diode DA1 connected with the D pole of the switch tube QA 1; the output cathode of the rectifier bridge stack DQ1 is connected to the common end of the S pole of the switching tube and the cathode of the diode DA 3; the anode of the output of the rectifier bridge stack DQ2 is connected to the common end of the anode of the diode DA2 connected with the D pole of the switching tube QA2, and the cathode of the output of the rectifier bridge stack DQ2 is connected to the common end of the S pole of the switching tube connected with the cathode of the diode DA 4;

the cathode of the diode DA1 is connected with the cathode of the diode DA2 to form an output anode;

the anode of the diode DA3 and the anode of the diode DA4 are connected to form an output cathode;

electrolytic capacitors EA2 and EA1 are connected in series between the output positive electrode and the output negative electrode.

Further, in the high-power charging module: the AC/DC unit adopts an independent aluminum substrate power module for each phase.

Further, in the high-power charging module: the DC/DC conversion unit comprises an EMC circuit connected with the 800VDC output by the AC/DC unit, a double-path independent half-bridge LLC conversion circuit, a rectification circuit, a filtering circuit and an output circuit, wherein the EMC circuit is used for converting the 800VDC output by the AC/DC unit into a voltage output by the charging pile; the double-path independent half-bridge LLC conversion circuit converts 800VDC input into a post-rectification, filtering and output circuit to output 500 VDC; in a double-path independent half-bridge LLC conversion circuit and a rectification, filtering and output circuit, a transformer and a resonant inductor are integrated together to form an integrated magnetic device.

Further, in the high-power charging module: the two-way independent half-bridge LLC conversion circuit topology structure comprises switching tubes MQ1, MQ2, MQ3 and MQ4 controlled by a control unit; diodes D5, D6, D7, D8, D9, D10, D11, D13, D14; electrolytic capacitors E10, E8; a resonant inductor LX and a filter inductor L0; a transformer TR 2; the resonant capacitance CW 2.

The switching tubes MQ1, MQ2, MQ3 and MQ4 are connected with the D pole of the next switching tube according to the S pole of the previous switching tube; the +400VDC output by the AC/DC unit is connected with the D pole of the switching tube MQ1, and the-400 VDC output by the AC/DC unit is connected with the S pole of the switching tube MQ 4;

the diode D7 is arranged between the common terminal connected with the S pole of the switching tube MQ1 and the D pole of the switching tube MQ2 and the ground, the diode D8 is arranged between the common terminal connected with the S pole of the switching tube MQ3 and the D pole of the switching tube MQ4 and the ground, and the anode of the diode D7 and the cathode of the diode D8 are grounded;

a diode D6 and a diode D5 are connected in series between the D pole of the switching tube MQ1 and the S pole of the switching tube MQ4, the anode of the diode D6 is connected with the cathode of the diode, the cathode of the diode D6 is connected with the D pole of the switching tube MQ1, and the anode of the diode D5 is connected with the S pole of the switching tube MQ 4;

the common end of the anode of the diode D6, which is connected with the cathode of the diode D5, is connected with one end of an inductor LX, and the other end of the inductor LX and the common end of the S pole of the switching tube MD2, which is connected with the D pole of the switching tube MD3, are respectively connected with two ends of the primary coil of the transformer TR 2;

the secondary side of the transformer TR2 is connected with two input ends of a rectifying full bridge consisting of diodes D9, D10, D13 and D14, and the output end of the rectifying full bridge is connected with a pi-type filter consisting of electrolytic capacitors E8, E10 and an inductor L0 and then outputs 500VDC through a reverse resistance diode D11.

Further, in the high-power charging module: the DC/DC conversion unit adopts a double-path independent aluminum substrate power unit.

Further, in the high-power charging module: the radiator of the charging module is arranged in the charging pile cabinet body; for setting up at the internal independent heat dissipation channel of electric pile cabinet that fills.

Further, in the high-power charging module: the charging module has six paths of outputs, and the minimum power distribution of each path is 10 Kw.

Further, in the high-power charging module: the AC/DC unit and the DC/DC conversion unit are glue-sealed high-power charging modules or oil-cooled high-power charging modules.

The invention has the following advantages:

the module power is increased from 20Kw to 60Kw, and the output is increased from 1 path to 6 paths; the heat dissipation mode is changed from a forced air cooling mode to an external air cooling heat dissipation mode (a fan inside the charging pile is utilized); the magnetic device is changed into an integrated magnetic device from series connection and parallel connection of single devices; the process is changed from the process of fixing the traditional power device on a radiator into the process of an aluminum substrate. And is modular; the performance design and the reliability design of the charging module are unified, and the reliability and the environmental adaptability of the charging module are greatly improved; the design of the high-power charging pile heat dissipation system becomes easy and multiple schemes are optional.

The invention will be explained in more detail below with reference to the drawings and examples.

Drawings

FIG. 1 is a schematic block diagram of the present invention.

Fig. 2 is a schematic block diagram of an AC/DC unit according to embodiment 1 of the present invention.

Fig. 3 is a schematic diagram of the topology of the APFC of the PWM rectification power module of the a phase in the AC/DC unit according to embodiment 1 of the present invention.

Fig. 4 is a schematic diagram of the topology of the APFC of the PWM rectification power module of the B phase in the AC/DC unit according to embodiment 1 of the present invention.

Fig. 5 is a schematic diagram of the topology of the APFC of the C-phase PWM rectification power module in the AC/DC unit according to embodiment 1 of the present invention.

Fig. 6 is a block diagram of a DC/DC conversion unit according to embodiment 1 of the present invention.

Fig. 7 is a topology structure diagram of a two-way independent half-bridge LLC circuit in embodiment 1 of the present invention.

Detailed Description

The embodiment is a charging module in a charging pile, which is a high-power charging module, and as shown in fig. 1, the inventor invents a novel external heat-dissipation high-power charging module according to years of research and development experience of the charging module and the current situation of market application, so that the pain of the existing charging pile product is solved, and the user experience and the charging pile cost performance are improved. The novel external heat-dissipating high-power charging module of the embodiment is as follows:

in this embodiment, the first part of the charging module: the three-phase AC/DC converter mainly comprises an AC/DC unit and a DC/DC conversion unit, wherein the AC/DC unit converts a three-phase power frequency power supply into direct current with power of 66-70Kw, inputs the three-phase three-wire system 380VAC and outputs 800 VDC. As a separate unit.

The schematic block diagram of the AC/DC unit is shown in fig. 2, and the three power module (homemade IPM) circuit topologies for PWM rectification are shown in fig. 3, 4 and 5. As shown in fig. 2, the AC/DC unit includes APFCs using PWM rectification power modules for A, B, C phases of the power frequency power supply, respectively, and the power modules have their own driving and absorption circuits, and in the APFCs, an inductor and a transformer are integrated together to form an integrated magnetic device. The topological structure of the APFC adopting the PWM rectification power module is a three-phase staggered three-tube three-level PWM rectification circuit; the random interleaved three-tube three-level PWM rectifying circuit comprises rectifier bridge stacks DQ1 and DQ2, diodes DA1, DA2, DA3 and DA4, and switching tubes QA1 and QA2 controlled by a control unit; as shown in fig. 3, 4, 5.

The diode DA1, the switching tube QA1 and the diode DA3 are connected in sequence; the diode DA2, the switching tube QA2 and the diode DA4 are connected in sequence; after being processed by EMC, the A alternating current is divided into two paths to enter rectifier bridge stacks DQ1 and DQ2, and the output anode of the rectifier bridge stack DQ1 is connected with the common end of the anode of the diode DA1 connected with the D pole of the switch tube QA 1; the output cathode of the rectifier bridge stack DQ1 is connected to the common end of the S pole of the switching tube and the cathode of the diode DA 3; the anode of the output of the rectifier bridge stack DQ2 is connected to the common end of the anode of the diode DA2 connected with the D pole of the switching tube QA2, and the cathode of the output of the rectifier bridge stack DQ2 is connected to the common end of the S pole of the switching tube connected with the cathode of the diode DA 4.

The cathode of the diode DA1 is connected with the cathode of the diode DA2 to form an output anode; the anode of the diode DA3 and the anode of the diode DA4 are connected to form an output cathode; electrolytic capacitors EA2 and EA1 are connected in series between the output positive electrode and the output negative electrode.

The AC/DC unit adopts an independent aluminum substrate power module for each phase.

In this embodiment, the AC/DC unit adopts an APFC of three PWM rectification power modules (homemade IPM), that is, A, B, C phases of each power module are shown in fig. 3, 4, and 5. The power module is provided with a driving and absorbing circuit. The topological structure is a three-phase staggered three-tube three-level PWM rectifying circuit. When the power module is applied to low power, the power module is a complete three-phase PWM rectification module. The power module is used as a one-phase power module in high-power application.

The DC/DC conversion unit has three parts with the same structure, and each part is a complete unit with 20Kw two-way independent output (150 and 500 VDC). Each unit can realize the constant power output in a segmented mode. Each part is a complete unit with 20Kw two-way independent output (150 VDC and 500 VDC). Each unit can realize the constant power output in a segmented mode.

The block diagram of the DC/DC conversion unit is shown in FIG. 6, and the topology structure of the two-way independent half-bridge LLC circuit is shown in FIG. 7; the DC/DC conversion unit comprises an EMC circuit connected with the 800VDC output by the AC/DC unit, a double-path independent half-bridge LLC conversion circuit, a rectification circuit, a filtering circuit and an output circuit, wherein the EMC circuit is used for converting the 800VDC output by the AC/DC unit into a voltage output by the charging pile; the double-path independent half-bridge LLC conversion circuit converts 800VDC input into a post-rectification, filtering and output circuit to output 500 VDC; in a double-path independent half-bridge LLC conversion circuit and a rectification, filtering and output circuit, a transformer and a resonant inductor are integrated together to form an integrated magnetic device.

The topology structure of the double-path independent half-bridge LLC conversion circuit is shown in FIG. 7 and comprises switching tubes MQ1, MQ2, MQ3 and MQ4 controlled by a control unit; diodes D5, D6, D7, D8, D9, D10, D11, D13, D14; electrolytic capacitors E10, E8; a resonant inductor LX and a filter inductor L0; a transformer TR 2; the resonant capacitance CW 2.

The switching tubes MQ1, MQ2, MQ3 and MQ4 are connected with the D pole of the next switching tube according to the S pole of the previous switching tube; the +400VDC output by the AC/DC unit is connected with the D pole of the switching tube MQ1, and the-400 VDC output by the AC/DC unit is connected with the S pole of the switching tube MQ 4;

the diode D7 is arranged between the common terminal connected with the S pole of the switching tube MQ1 and the D pole of the switching tube MQ2 and the ground, the diode D8 is arranged between the common terminal connected with the S pole of the switching tube MQ3 and the D pole of the switching tube MQ4 and the ground, and the anode of the diode D7 and the cathode of the diode D8 are grounded;

a diode D6 and a diode D5 are connected in series between the D pole of the switching tube MQ1 and the S pole of the switching tube MQ4, the anode of the diode D6 is connected with the cathode of the diode, the cathode of the diode D6 is connected with the D pole of the switching tube MQ1, and the anode of the diode D5 is connected with the S pole of the switching tube MQ 4;

the common end of the anode of the diode D6, which is connected with the cathode of the diode D5, is connected with one end of an inductor LX, and the other end of the inductor LX and the common end of the S pole of the switching tube MD2, which is connected with the D pole of the switching tube MD3, are respectively connected with two ends of the primary coil of the transformer TR 2;

the secondary side of the transformer TR2 is connected with two input ends of a rectifying full bridge consisting of diodes D9, D10, D13 and D14, and the output end of the rectifying full bridge is connected with a pi-type filter consisting of electrolytic capacitors E8, E10 and an inductor L0 and then outputs 500VDC through a reverse resistance diode D11. Here the cathode output of diode D11.

In this embodiment, each phase of the AC/DC part is an independent power module of the aluminum substrate, and similarly, the DC/DC part is a dual-channel independent power unit of the aluminum substrate.

The magnetic device is designed into an integrated magnetic device according to integration, and the transformer and the resonant inductor are integrated together.

In this embodiment, the heat dissipation manner is: the aluminum substrate is arranged on the aluminum plate to form an AC/DC unit without a radiator and three DC/DC conversion units without radiators. A radiator required by the charging module is moved into the charging pile cabinet body; fill the internal independent heat dissipation channel of design of electric pile cabinet.

In this embodiment, the latest external heat dissipation design concept is adopted, and the module itself does not have a heat sink. And the AC/DC unit is separated from the DC/DC conversion unit. One AC/DC unit with three DC/DC units; the AC/DC unit employs an APFC of three PWM rectified power modules (homemade IPMs), i.e., A, B, C phases each. The power module is provided with a driving and absorbing circuit. The topological structure is a three-phase staggered three-tube three-level PWM rectifying circuit. When the power module is applied to low power, the power module is a complete three-phase PWM rectification module. The power module is used as a one-phase power module in high-power application.

Three DC/DC are provided, which are independent from each other and have the same topological structure and control. The topology is a two-way half-bridge LLC converter. The two paths of the output are independent and can be connected in series or in parallel. The magnetic devices of the AC/DC unit and the DC/DC conversion unit are all designed into integrated magnetic devices (special dies); and power distribution is supported, the minimum power distribution is 10KW (one charging module has six paths of output), and smoother flexible charging can be realized. The air-cooled modules on the market today also support power distribution, but the minimum distributed power is 20KW (one complete module), 30KW (one complete module). The module protection grade can be IP20-30, and the protection grade can be improved to IP65 by filling heat-conducting glue or oil-immersed application and the like. The air cooling module cannot do so.

In particular, in this embodiment, the adopted heat dissipation method is very suitable for heat dissipation of power supplies and the like: the AC/DC part adopts an independent aluminum substrate power module of each phase, the aluminum substrate is arranged on an aluminum plate to form an AC/DC unit without a radiator and three DC/DC conversion units without the radiator. A radiator required by the charging module is moved into the charging pile cabinet body; fill the internal independent heat dissipation channel of design of electric pile cabinet. The reliability of the charging module is improved.

In addition, the high-power charging module of the embodiment supports power distribution, the minimum power distribution is 10Kw (one charging module has six outputs), and smooth flexible charging can be performed. The air-cooled modules currently on the market also support power distribution, but the minimum distributed power is 20Kw (one complete module), 30Kw (one complete module).

The AC/DC and DC/DC units in the module of the embodiment can be filled with heat-conducting glue, so that the protection grade is improved; the protection level can also be improved in the oil tank in an oil immersion mode. Therefore, the high-power charging module can be derived as a glue-sealed high-power charging module and an oil-cooled high-power charging module. Both belong to high protection level, high reliable module of charging.