CN101938160B - Damage-free quick charger for vehicle power battery pack and charge control method - Google Patents

Abstract

The invention relates to a charge method of a damage-free quick charger for a vehicle power battery pack, belonging to the technical field of quick charge control of storage batteries. The charger comprises an input/output overcurrent and undervoltage protection module, a power factor correction module, a half-bridge inversion module, a half-bridge drive module, an inversion output rectifying and voltage stabilizing module, a dynamic storage battery parameter sampling module, an intelligent charge control module, an internal power supply auxiliary power module, an electric integrated instrument interface and a remote control interface, wherein the electric integrated instrument interface is connected with a signal data communication module through a CAN (Controller Area Network)-BUS data communication mode. The charge control method comprises the following steps of: judging the ovecurrent and undervoltage conditions of a civil grid; displaying the state of the grid on an instrument panel; detecting the state of the storage battery; calculating the maximum initial charge current capable of being obtained by the storage battery; carrying out a quick charge process of the storage battery by adopting a slow-pulse charge control mode, and the like. The invention has the advantages of no limit by the power of the civil grid, short charge time, battery protection, and the like.

Description

The charging method of nondestructive fast charger of power battery pack for vehicle

Technical field

The charging method of nondestructive fast charger of power battery pack for vehicle belongs to boost battery charge control technology field.

Background technology

At present, for electric bicycle, it is ripe that the quick charge technology of storage battery for motorcycle (battery capacity is generally below 20AH) has been tending towards, various pulse charger take Maas three laws as the basis are widely used in the market, generally accepted by the consumer, actual charging effect is more satisfactory, and various quick charge stations also appear at each large supermarket in succession, market and important traffic intersection, it is greatly convenient to bring to people's trip.

On the other hand, the quick charge technology of synchronous Prospect of EVS Powered with Batteries group is limited by the power upper limit of family expenses electrical network with it, and this technical barrier always difficulty has breakthrough, most production firm or supporting traditional three-step charger when selling electric automobile; But because the capacity of Prospect of EVS Powered with Batteries group is mostly more than 120AH, and the charging current upper limit of conventional charger maintains about 20A substantially mostly, the charging interval of one Battery pack at least will be more than 8 hours, obviously can not satisfy the demands of consumers, and electric automobile is harsh more than electric automobile and battery-operated motor cycle for the demand of battery power, and is therefore also just more urgent for the requirement of quick charge.

Summary of the invention

The technical problem to be solved in the present invention is: for present Vehicular dynamic battery group charging technique present situation, a kind of charging method of nondestructive fast charger of power battery pack for vehicle is provided, solving family expenses electrical network Power Limitation, long and battery of charging interval easily fills bad problem.

The technical solution adopted for the present invention to solve the technical problems is: the charging method of this nondestructive fast charger of power battery pack for vehicle, it is characterized in that: comprise input and output overcurrent under-voltage protection module, power factor correction module, the semi-bridge inversion module, the half-bridge driven module, inversion output rectifying and voltage-stabilizing module, accumulator parameter dynamic sampling module, the charging intelligent control module, in-line power accessory power supply module, the signal data communication module, charger LCD MODULE, electric motor car integrative instrument interface and RCI; Input and output overcurrent under-voltage protection module links to each other with power factor correction module, power factor correction module links to each other with the semi-bridge inversion module, the half-bridge driven module links to each other with the semi-bridge inversion module, the semi-bridge inversion module links to each other with inversion output rectifying and voltage-stabilizing module, inversion output rectifying and voltage-stabilizing module connects storage battery to be charged, accumulator parameter dynamic sampling module connects storage battery to be charged, the charging intelligent control module respectively with input and output overcurrent under-voltage protection module, the half-bridge driven module, accumulator parameter dynamic sampling module links to each other with in-line power accessory power supply module, in-line power accessory power supply module also with input and output overcurrent under-voltage protection module, power factor correction module, the half-bridge driven module, accumulator parameter dynamic sampling module links to each other, signal data communication module and the interconnection of charging intelligent control module, the signal data communication module links to each other with the charger LCD MODULE, RCI links to each other with the signal data communication module by the RS232 data communication mode, and electric motor car integrative instrument interface links to each other with the signal data communication module by the CAN_BUS data communication mode;

Concrete steps are as follows:

1.1 after the input of family expenses electrical network, the judgement of overcurrent undervoltage condition is carried out in charger inside, if circuit overcurrent or undervoltage condition occur, then changes step 1.9 over to, otherwise, change step 1.2 over to;

1.2 panel board shows that electric network state is normal, button starts in-line power accessory power supply control switch, and charger charge inside control module is carried out the software and hardware initialization operation, changes step 1.3 over to;

Detect 1.3 carry out battery condition, judge that storage battery has or not short circuit or failure phenomenon, if short circuit or then panel board prompting and early warning of failure phenomenon occur, change step 1.9 over to, otherwise, change step 1.4 over to;

1.4 charger charge inside control module, is judged whether power shortage of storage battery by the battery condition parameter of sampling, if, then change step 1.5 over to, otherwise, change step 1.9 over to;

1.5 charger charge inside control module is by battery condition parameter and the household electric net state parameter of sampling, the obtainable maximum initial charge current of calculating accumulator, if 1/20 of the not enough battery capacity value of the charging current value of calculating then changes step 1.9 over to, otherwise changes step 1.6 over to;

1.6 charger charge inside control module is according to the charging current value that obtains, the charging control mode that adopts Bradycardia to rush is carried out the quick charge process of storage battery, allow maximum temperature values if continue to exceed storage battery default in the charge control module in the charging process in the temperature sampling value certain hour of storage battery, then change simultaneously step 1.8 and step 1.3 over to, otherwise, change step 1.7 over to;

1.7 if quick charge is carried out continuing to exceed the maximum voltage value that allows under the low gassing rate of storage battery default in the charge control module in the terminal voltage sampled value certain hour of storage battery in the process, then change step 1.3 over to, if not, then continue the quick charge process;

1.8 panel board sends temperature pre-warning, charging process is suspended and is pointed out whether button stops the internal auxiliary power supply power supply;

1.9 charger charge inside control module is sent level signal, control relay makes the outage of charger main circuit.

Described accumulator parameter dynamic sampling module comprises multistage analog switch U4, triode Q7, Q8, Q9, potentiometer R29, R60, every straight filter capacitor C24, electrochemical capacitor C25, resistance R 27, R33, R35, R36, R37, R38, R40, R41, R42, R44, R45, R46, R54, R56, R58, R59, R65, internal digital 0 ~ 7 expression eight way switch passages of multistage analog switch U4, external digital 1 ~ 16 expression pin, it is characterized in that: 3 pin of 15 pin, the one side joint Hall current sensor U10 of multistage analog switch U4, one side is series resistor R35 successively, R38, R42, R46, R54, R58 and potentiometer R60 enter signal ground, the side of the positive electrode of battery is series resistor R27 successively, potentiometer R29, resistance R 33, resistance R 37, resistance R 40, resistance R 44 enters signal ground, 20 pin of socket P3 are connected between potentiometer R29 and the resistance R 33,19 pin of socket P3 are connected between resistance R 42 and the R46,4 pin of multistage analog switch U4 are connected between resistance R 35 and the resistance R 38,5 pin of multistage analog switch U4 are connected between resistance R 46 and the resistance R 54,1 pin of multistage analog switch U4 is connected between resistance R 38 and the resistance R 42,12 pin of multistage analog switch U4 are connected between resistance R 33 and the resistance R 37,13 pin of multistage analog switch U4 are connected between resistance R 40 and the resistance R 44,14 pin of multistage analog switch U4 are connected between resistance R 54 and the resistance R 58, and 2 pin of multistage analog switch U4 are connected between resistance R 58 and the potentiometer R60.

Described electric motor car integrative instrument interface links to each other with the signal data communication module by the CAN_BUS data communication mode, it is characterized in that: the CAN_BUS datel circuit comprises CAN transceiver MU3, exclusion MP1, insert row MP2, buzzer LS1, potentiometer MR25, triode MQ4, every straight filter capacitor MC10, MC22, MC25, MC26, MC27, MC41, MC42, electrochemical capacitor MC19, MC21, interface MJ4, resistor MR 17, MR18, MR20, MR26,1 pin of CAN transceiver MU3 connects 19 pin of CPU MCU, 4 pin of CAN transceiver MU3 connect 20 pin of CPU MCU, 3 pin of CAN transceiver MU3 connect+5V, 2 pin connect signal ground, 8 pin series resistor MR17 enter signal ground, series resistor MR20 between 6 pin of CAN transceiver MU3 and 7 pin, 1 pin of the 7 pin connection interface MJ4 of CAN transceiver MU3,2 pin of the 6 pin connection interface MJ4 of CAN transceiver MU3; Be connected in series respectively electrochemical capacitor MC19 between+5V and the signal ground, MC21, every straight filter capacitor MC41, MC22, MC25, MC26, MC42,1 pin of exclusion MP1 connects+5V; 1 pin of insert row MP2 connects signal ground, 2 pin connect+5V, 20 pin connect signal ground, and 15 pin connect signal ground, and 19 pin connect+5V, 4 pin connect 30 pin of CPU MCU, 5 pin of insert row MP2 connect 29 pin of CPU MCU, and 6 pin of insert row MP2 connect 31 pin of CPU MCU, serial connection potentiometer MR25 between 3 pin of insert row MP2 and 18 pin, series resistor MR26 between 17 pin of insert row MP2 and 19 pin, serial connection is every straight filter capacitor MC27 between 15 pin of insert row MP2 and 17 pin; The base stage series resistor MR18 of triode MQ4 connects 26 pin of CPU MCU, and collector electrode connects signal ground through buzzer LS1, and emitter connects+5V, is connected in series every straight filter capacitor MC10 between+5V and the signal ground.

Described in-line power accessory power supply module adopts small-power switching power-supply.

Compared with prior art, the beneficial effect that has of the charging method of nondestructive fast charger of power battery pack for vehicle of the present invention is:

1. take full advantage of the family expenses grid power, promote active power usefulness 15% ~ 30%;

2. charging process is strictly monitored battery temp and upper voltage limit threshold value, the line output of going forward side by side overcurrent protection, and the not damaged quick charge reaches quick charge and does not damage the purpose of battery to storage battery carrying capacity more than 95% in 3.5 hours;

3. the charging target is had the function of self-adapting detecting, charging control section is divided the detection information that adopts transducer (electric current, voltage), consists of two closed-loop controls;

4. the target component of charging collection is exported in real time by the CAN-BUS communication interface board, is convenient to demonstration and monitoring with full car control bus interface and auto meter system.

5. charger has RCI, the adjustment of the strategy that can charge at any time.

Description of drawings

The charging method schematic block circuit diagram of Fig. 1 nondestructive fast charger of power battery pack for vehicle of the present invention;

Fig. 2 input and output overcurrent under-voltage protection modular circuit schematic diagram;

Fig. 3 power factor correction module circuit theory diagrams;

Fig. 4 half-bridge driven modular circuit schematic diagram;

Fig. 5 semi-bridge inversion modular circuit schematic diagram;

Fig. 6 inversion output rectifying and voltage-stabilizing modular circuit schematic diagram;

Fig. 7 accumulator parameter dynamic sampling modular circuit schematic diagram;

Fig. 8 intelligent control module microcontroller circuit schematic diagram that charges;

Fig. 9 intelligent control module reset circuit schematic diagram that charges;

Figure 10 CAN communicating circuit schematic diagram;

Figure 11 button and RS232 data transfer circuit schematic diagram;

Figure 12 in-line power accessory power supply modular circuit schematic diagram;

Figure 13 socket pins schematic diagram.

Figure 14 charge control method schematic diagram.

The charging process flow process of filling modular converter is filled/marked to Figure 15 CPU soon.

Accompanying drawing 1-15 is the charging method most preferred embodiment of nondestructive fast charger of power battery pack for vehicle of the present invention.

Wherein: among Fig. 2: the RV1-RV3 piezo-resistance; The bipolar gas discharge tube of DV1; The F1 fuse; P1, P6, P7 crosspointer socket; J1, J2, J3, J4, J6, J7, J8, J11, J12, J18, J19 interface; The RT1 Anti-surge resistor; L2 common mode filtering inductance; The B1 isolating transformer; The BD1 rectifier bridge; The U3NPN transistor array; The K1 relay; The U13RS trigger; The high linear analogue optocoupler of U7; U6, U11 single power supply double operational; The two voltage comparators of U14; D10, D11, D12 Ultrafast recovery diode; D13, D14, D15, D16, D18, D20, D23, D24 small-signal Schottky diode; The common plastic packaging rectifier diode of D17; C1, C4, C9, C37, C54, C55, C56, C57, C59, C61, C62, C63 is every straight filter capacitor; C23, the C28 electrochemical capacitor; R24, R26, R30, R34, R39, R43, R48, R51, R55, R57, R70, R71, R75, R80, R81 resistance; R25, the R79 potentiometer;

Among Fig. 3: the L1 filter inductance that boosts; Q1, the Q3 power switch pipe; U1 power pipe driving chip; U2 power factor correction chip; The J9 interface; The D1 Ultrafast recovery diode; C6, C7, C11, C12, C17, C26 electrochemical capacitor; C15, C21, C22, C27, C29, C31, C32 is every straight filter capacitor; R1, R2, R5, R9, R13, R15 power resistor; R11, R12, R21, R31, R32 resistance;

Among Fig. 4: U8PWM exports control chip; U9, U12 single channel high speed photo coupling; U5 gate-drive chip; The U10 Hall current sensor; The D19 Ultrafast recovery diode; The Q10 triode; R28, R49, R50, R52, R53, R62, R63, R64, R66, R67, R69, R72, R73, R74, R76 resistance; C33, C36, C41, C42, C44, C47 electrochemical capacitor; C30, C34, C35, C38, C39, C40, C43, C45, C46, C48, C49, C51, C52, C53, C58 is every straight filter capacitor;

Among Fig. 5: Q2, Q4, Q5, Q6 super power transistor; D3, the D9 Zener diode; D2, D8 high efficiency rectification diode; T1 half-bridge transformer; R3, R4, R7, R10, R16, R18, R19, R22 power resistor; R6, R14, R20, R23 resistance; C2, the C16 electrochemical capacitor; C8, C10, C19 is every straight filter capacitor;

Among Fig. 6: D4, D5, D7, D25 Ultrafast recovery diode; R8, the R17 power resistor; C3, C18 is every straight filter capacitor; C13, the C14 electrochemical capacitor; L3 filtering voltage regulation inductance;

Among Fig. 7: U4 multistage analog switch; Q7, Q8, Q9 triode; R29, the R60 potentiometer; C24 is every straight filter capacitor; The C25 electrochemical capacitor; R27, R33, R35, R36, R37, R38, R40, R41, R42, R44, R45, R46, R54, R56, R58, R59, R65 resistance;

Among Fig. 8: MCU CPU, MD2, MD3, MD4, MD5, MD6, MD7, MD8, MD9, MD10, MD11 high-speed switch diode; MC2, MC3, MC4, MC5, MC6, MC7, MC9 filtering capacitance; The MC8 electrochemical capacitor; The Y1 crystal oscillator; MR6, MR14, MR15, MR16 resistance;

Among Fig. 9: MJ2 program download interface; MU1CPU monitors chip; MD1 small-signal Schottky diode; The MS1 push-button switch; The MJ1 interface; The MC1 electrochemical capacitor; MR1, MR2, MR3, MR4, MR5, MR13 resistance;

Among Figure 10: the MU3CAN transceiver; The MP1 exclusion; The MP2 insert row; The LS1 buzzer; The MR25 potentiometer; The MQ4 triode; MC10, MC22, MC25, MC26, MC27, MC41, MC42 is every straight filter capacitor; MC19, the MC21 electrochemical capacitor; The MJ4 interface; MR17, MR18, MR20, MR26 resistance;

Among Figure 11: MU4 multichannel RS-232 driver, MDB1 serial communication interface, MLED1, MLED2, MLED3 light-emitting diode; KEY1, KEY2, KEY3, KEY4 button; The MRT1 thermistor; MQ5, MQ6, MQ7 triode; MC11, MC12, MC14, MC16, MC17, MC18, MC38, MC39 is every straight filter capacitor; The MC15 electrochemical capacitor; MR19, MR21, MR22, MR23, MR24, MR30, MR31, MR32 resistance;

Among Figure 12: the NT1 flyback transformer; NU3 off-line current mode controller; The controlled optocoupler of NU4; DSLED1 numeral light-emitting diode; NU1, NU2, NU5, NU6, NU7 three-terminal voltage-stabilizing power supply; The reference of NQ1 programmable precision; NC1, NC2, NC5, NC9, NC11, NC12, NC13, NC21, NC22, NC24, NC25 electrochemical capacitor; NC3, NC4, NC6, NC7, NC10, NC15, NC16, NC17, NC18, NC19, NC20, NC23, NC26, NC27 is every straight filter capacitor; The NR6 power resistor; NR1, NR2, NR3, NR4, NR5, NR7, NR8, NR9, NR10, NR11 resistance; ND1, ND4 overspeed switch diode; ND2, ND3, ND4, ND5, ND6, ND7, ND8, ND9 is rectifying tube rapidly and efficiently;

Among Figure 13: P3, P4, P5 socket.

Embodiment

Below in conjunction with accompanying drawing 1-15, the charging method of nondestructive fast charger of power battery pack for vehicle of the present invention is described in further details.

As shown in Figure 1

The charging method of nondestructive fast charger of power battery pack for vehicle of the present invention comprises input and output overcurrent under-voltage protection module, power factor correction module, semi-bridge inversion module, half-bridge driven module, inversion output rectifying and voltage-stabilizing module, accumulator parameter dynamic sampling module, charging intelligent control module, in-line power accessory power supply module, the signal data communication module, the charger LCD MODULE, electric motor car integrative instrument, Long-distance Control; Input and output overcurrent under-voltage protection module links to each other with power factor correction module; power factor correction module links to each other with the semi-bridge inversion module; the half-bridge driven module links to each other with the semi-bridge inversion module; the semi-bridge inversion module links to each other with inversion output rectifying and voltage-stabilizing module; inversion output rectifying and voltage-stabilizing module connects storage battery; accumulator parameter dynamic sampling module connects storage battery; the charging intelligent control module respectively with input and output overcurrent under-voltage protection module; the half-bridge driven module; accumulator parameter dynamic sampling module links to each other with in-line power accessory power supply module; in-line power accessory power supply module also with input and output overcurrent under-voltage protection module; power factor correction module; the half-bridge driven module; accumulator parameter dynamic sampling module links to each other; signal data communication module and the interconnection of charging intelligent control module; the signal data communication module links to each other with the charger LCD MODULE; RCI links to each other with the signal data communication module by the RS232 data communication mode, and electric motor car integrative instrument interface links to each other with the signal data communication module by the CAN_BUS data communication mode.

As shown in Figure 2

Input and output overcurrent under-voltage protection modular circuit schematic diagram, 13 pin of NPN transistor array U3 are succeeded the end of electrical equipment K1, and and+the 12V power supply between serial connection Ultrafast recovery diode D12; Be connected to electrochemical capacitor C23 between 8 pin of NPN transistor array U3 and 9 pin, 8 pin access signal ground; 1 pin of socket P1 connects the N utmost point that exchanges input, and 2 pin connect the L utmost point that exchanges input by relay K 1; 1 pin of high linear analogue optocoupler U7 connects power supply ground, 2 pin of high linear analogue optocoupler U7 are by 1 pin of resistance R 48 access single power supply double operational U6,8 pin of the 3 pin order Power supply double operational U6 of high linear analogue optocoupler U7,2 pin of the 4 pin order Power supply double operational U6 of high linear analogue optocoupler U7,3 pin of the 5 pin order Power supply double operational U11 of high linear analogue optocoupler U7,8 pin of the 6 pin order Power supply double operational U11 of high linear analogue optocoupler U7; Series connection is every straight filter capacitor C37 between 1 pin of single power supply double operational U6 and 2 pin, the 3 pin series resistor R51 of single power supply double operational U6 enter power supply ground, series resistance R57 between 3 pin of single power supply double operational U6 and 4 pin, 4 pin of single power supply double operational U6 connect power supply ground, 5 pin of single power supply double operational U6 connect power supply ground, and 6 pin of single power supply double operational U6 link to each other with 7 pin; 1 pin of single power supply double operational U11 is connected with 2 pin, series resistance R55 between 3 pin of single power supply double operational U11 and 4 pin, 5 pin of single power supply double operational U11 connect signal ground, 6 pin of single power supply double operational U11 link to each other with 7 pin, 8 pin of single power supply double operational U11 connect+the 5V power supply, and and signal ground between be serially connected with every straight filter capacitor C63; 1 pin of two voltage comparator U14 connects the outlet side of small-signal Schottky diode D23, and and signal ground between be serially connected with every straight filter capacitor C57,2 pin of two voltage comparator U14 connect current out end, and between signal ground, be serially connected with every straight filter capacitor C55, be serially connected with resistance R 70 between 3 pin of two voltage comparator U14 and 8 pin, and and signal ground between series connection potentiometer R68,4 pin of two voltage comparator U14 connect signal ground, 6 pin connect the short end, 7 pin of two voltage comparator U14 connect the outlet side of small-signal Schottky diode D24,8 pin connect+the 5V power supply, series resistance R80 between 5 pin of two voltage comparator U14 and 8 pin, and series connection potentiometer R79 between 5 pin and the signal ground, series connection is every straight filter capacitor C59 between 8 pin of two voltage comparator U14 and the signal ground; 1 pin of rest-set flip-flop U13 connects+the 5V power supply by series resistance R71, and connect the RS1 port by series resistor R75, other 1 pin of the rest-set flip-flop U13 that also is connected on of the input side of small-signal Schottky diode D23 and D24,3 pin of rest-set flip-flop U13 connect the Shutd end, the 6 pin series resistor R81 of rest-set flip-flop U13 connect+5V, be serially connected with between 1 pin of rest-set flip-flop U13 and 6 pin every straight filter capacitor C56, C61; Between straight filter capacitor C56 and C61, connect signal ground.

J6, J7 are relay forceful electric power interface, are used for the access opportunity of control Anti-surge resistor RT1, and protection rectifier bridge BD1 avoids the destruction of electric network peak; Socket P1, P6, P7 are relay light current interface, are controlled respectively the break-make of mains circuit by NPN transistor array U3 driving, the break-make of the break-make of Anti-surge resistor circuit and radiator fan circuit; Isolating transformer B1 is used for the overcurrent voltage of sensor circuit, carry out rectification also through after the filtering by small-signal Schottky diode D13-D16, export the negative feedback end of two voltage comparator U14 one side U14B to, control the high-low level of Shutd end by rest-set flip-flop, thereby the shutoff of control PWM output control chip U8, thereby realize whole circuit is inputted overcurrent protection, the negative feedback termination of the opposite side U14A of simultaneously two voltage comparator U14 enters current out end and carries out the output overcurrent protection; By single power supply double operational U6, the side of the positive electrode of the circuit access rectification output that U11 and high-speed linear optocoupler U7 form, and the A/D value of output sent into 14 pin of socket P3 waits for that central processor MCU carries out the under-voltage protection of circuit and operate.

As shown in Figure 3

The power factor correction module circuit theory diagrams, the incoming end of the filter inductance L1 that boosts is interface J3, output links to each other with the drain electrode of power switch pipe Q1; Power switch pipe Q1 and Q3 are connected in parallel between the ac input end, the gate pole serial connection power resistor R2 of power switch pipe Q1, the gate pole serial connection power resistor R9 of power switch pipe Q3, series resistance R11 between the gate pole of power switch pipe Q1 and the source electrode, series resistance R12 between the gate pole of power switch pipe Q3 and the source electrode, the source electrode of power switch pipe Q1 and Q3 connects respectively power supply ground; The power resistor R1 that connects between the drain electrode of the input side joint power switch pipe Q3 of Ultrafast recovery diode D1, output and power supply ground, R5 and R13; Connect power supply ground behind the interface J9 series connection power resistor R15, interface J9 also is serially connected with resistance R 21 successively, enters power supply ground every straight filter capacitor C22; 1 pin of power switch tube drives chip U1 links to each other with 6 pin, and be connected on 4 pin of socket P5, and and power supply ground between respectively string electrochemical capacitor C17 is arranged and every straight filter capacitor C15,3 pin of power switch tube drives chip U1 connect power supply ground, 7 pin are connected on power resistor R2, the input side of R9,2 pin connect 8 pin of power factor correction chip U2; The 3 pin serial connection of power factor correction chip U2 enters power supply ground every straight filter capacitor C22,1 pin of power factor correction chip U2 connects power supply ground, 6 pin are connected between power resistor R5 and the R13, and serial connection enters power supply ground every straight filter capacitor C21, the 2 pin serial connection of power factor correction chip U2 enters power supply ground every straight filter capacitor C31, the 4 pin series resistor R31 of power factor correction chip U2 enter power supply ground, 5 pin, one side of power factor correction chip U2 is series resistor R32 and enter power supply ground every straight filter capacitor C32 successively, the opposite side serial connection enters power supply ground every straight filter capacitor C29,4 pin of 7 pin combination hub P5 of power factor correction chip, and enter power supply ground by serial connection electrochemical capacitor C26 with every straight filter capacitor C27 respectively.

Power factor correction chip U2 by 3 pin place in circuit electric currents reference voltage level and the branch pressure voltage value after the boosting of 6 pin access, relatively export gate electrode drive signals through inside, and come power ratio control switching tube Q1 by power switch tube drives chip U1, the switch opportunity of Q3, guarantee that output voltage stabilization is at 380V/DC, namely consist of so-called pair of closed control circuit, Effective Raise active power value reduces harmonic pollution.

As shown in Figure 4

Half-bridge driven modular circuit schematic diagram, by PWM output control chip U8, single channel high speed photo coupling U9, U12, gate-drive chip U5 and peripheral circuit thereof form, between 9 pin of PWM output control chip U8 and 1 pin, establish compensator, compensator comprises resistance R 67, R69, capacitor C 48, C49, C52 and C53, after resistance R 67 and capacitor C 48 are in series again with capacitor C 52 and connect, 9 pin of resistance R 67 and capacitor C 52 1 termination PWM output control chip U8,1 pin of capacitor C 48 and capacitor C 52 1 termination PWM output control chip U8,1 pin of PWM output control chip U8 is by capacitor C 53 ground connection, resistance R 69 and capacitor C 49 also meet 1 pin that a termination PWM exports control chip U8, another chip termination U4.

As shown in Figure 5

Semi-bridge inversion modular circuit schematic diagram, super power transistor Q2 and Q4 are in parallel, the drain electrode of Q2 connects the 380V/DC input, source electrode connects 6 pin of gate-drive chip U5, is connected on 7 pin of gate-drive chip U5 behind the base stage serial connection power resistor R3, series resistor R6 between base stage and the source electrode, the drain electrode of Q3 connects the 380V/DC input, source electrode connects 6 pin of gate-drive chip U5, is connected on 7 pin of gate-drive chip U5 behind the base stage serial connection power resistor R10, series resistor R14 between base stage and the source electrode; Super power transistor Q5 and Q6 are in parallel, the drain electrode of Q5 connects 6 pin of gate-drive chip U5, source electrode connects power supply ground, be connected on 4 pin of gate-drive chip U5 behind the base stage serial connection power resistor R16, series resistor R20 between base stage and the source electrode, the drain electrode of Q6 connects 6 pin of gate-drive chip U5, and source electrode connects power supply ground, be connected on 4 pin of gate-drive chip U5 behind the base stage serial connection power resistor R22, series resistor R23 between base stage and the source electrode; Be connected to Zener diode D3 between 6 pin of 380V/DC input and gate-drive chip U5; Be attempted by between 6 pin of 380V/DC input and gate-drive chip U5 with connecting every straight filter capacitor C10 after high efficiency rectification pipe D2 and resistance R 4 are in parallel; Be connected to Zener diode D9 between 6 pin of utmost point driving chip U5 and 4 pin of gate-drive chip U5; After high efficiency rectification pipe D8 and resistance R 18 are in parallel with 4 pin of connect every straight filter capacitor C19 6 pin that are attempted by utmost point driving chip U5 and gate-drive chip U5 between; Be attempted by between 380V/DC input and the power supply ground after electrochemical capacitor C12 and the C16 series connection; Be attempted by between 380V/DC input and the power supply ground after resistance R 7 and resistance R 19 series connection; The series connection of the primary side Same Name of Ends of half-bridge transformer T1 behind straight filter capacitor C8 a side joint between resistance R 7 and R19, opposite side is connected between electrochemical capacitor C2 and the C16, the primary side of half-bridge transformer T1 is to connect successively from top to bottom the T11 end of half-bridge transformer T1, the T12 end of half-bridge transformer T1 and the T13 end of half-bridge transformer T1 headed by the Same Name of Ends.

Power switch pipe Q2, Q4 is in parallel, power switch pipe Q5, Q6 is in parallel, is intended to increase the load current of half-bridge transformer T1 primary side, thereby promotes the adjusting range of primary side output current, saves the charging interval; Power switch pipe Q2 wherein, Q4, Q5, all be added with load resistance between the gate pole of Q6 and the source electrode, purpose is to power switch pipe Q2, Q4, Q5, the capacitor discharge of Q6 inside suppresses current spike, prevent that power switch pipe from generating heat serious and booster, and up and down two brachium pontis of half-bridge inversion circuit are added with absorption network and the Zener diode D3 of RDC, and D9 has guaranteed the robustness of half-bridge transformer input electric current effectively, prevent the overheated and magnetic bias of half-bridge transformer T1, the generation of magnetic saturation phenomenon.

As shown in Figure 6

Inversion output rectifying and voltage-stabilizing modular circuit schematic diagram, power resistor R8 and after straight filter capacitor C3 series connection, be attempted by the two ends of Ultrafast recovery diode D5; Power resistor R17 and after straight filter capacitor C18 series connection, be attempted by the two ends of Ultrafast recovery diode D7; The T11 end of the input side joint half-bridge transformer T1 of Ultrafast recovery diode D5, the input side of output side joint filtering voltage regulation inductance L 3; The T13 end of the input side joint half-bridge transformer T1 of Ultrafast recovery diode D7, the input side of output side joint filtering voltage regulation inductance L 3; The T12 termination battery cathode side of half-bridge transformer T1; Connect the anode side after Ultrafast recovery diode D4 and the D5 parallel connection; The input side of the output side joint Ultrafast recovery diode D4 of filtering voltage regulation inductance L 3; Between the input side of Ultrafast recovery diode D5 and the signal ground successively and be connected to electrochemical capacitor C13 and electrochemical capacitor C14.

Inversion output rectifying and voltage-stabilizing module is when keeping RDC absorption network, add again the larger electrochemical capacitor of one-level capacitance at rectification output end and carry out current stabilization, and simultaneously at output cathode side two Ultrafast recovery diode D4 in parallel, D25 guarantees the robustness of charging voltage and the coefficient of safety of raising charging circuit.

As shown in Figure 7

Accumulator parameter dynamic sampling modular circuit schematic diagram, internal digital 0 ~ 7 expression eight way switch passages of multistage analog switch U4, external digital 1 ~ 16 expression pin, wherein 6 pin connect signal ground; 11 pin of the collector electrode one side joint multistage analog switch U4 of triode Q7, opposite side series resistor R36 connects+15V, 16 pin of combination hub P3 behind the base stage series resistor R41 of triode Q7, the emitter of triode Q7 connects signal ground; 10 pin of the collector electrode one side joint multistage analog switch U4 of triode Q8, opposite side series resistor R45 connects+15V, 17 pin of combination hub P3 behind the base stage series resistor R56 of triode Q8, the emitter of triode Q8 connects signal ground; 9 pin of the collector electrode one side joint multistage analog switch U4 of triode Q9, opposite side series resistor R59 connects+15V, 8 pin of combination hub P3 behind the base stage series resistor R65 of triode Q9, the emitter of triode Q9 connects signal ground; Enter signal ground after 7 pin of multistage analog switch U4 and 8 pin join, 16 pin of multistage analog switch U4 connect+15V, are serially connected with successively between+15V and the signal ground every straight filter capacitor C24 and electrochemical capacitor C25; 3 pin of 15 pin, the one side joint Hall current sensor U10 of multistage analog switch U4, a side is series resistor R35 successively, R38, R42, R46, R54, R58 and potentiometer R60 enter signal ground; The side of the positive electrode of battery is series resistor R27 successively, potentiometer R29, and resistance R 33, resistance R 37, resistance R 40, resistance R 44 enters signal ground; 20 pin of socket P3 are connected between potentiometer R29 and the resistance R 33, and 19 pin of socket P3 are connected between resistance R 42 and the R46; 4 pin of multistage analog switch U4 are connected between resistance R 35 and the resistance R 38,5 pin of multistage analog switch U4 are connected between resistance R 46 and the resistance R 54,1 pin of multistage analog switch U4 is connected between resistance R 38 and the resistance R 42,12 pin of multistage analog switch U4 are connected between resistance R 33 and the resistance R 37,13 pin of multistage analog switch U4 are connected between resistance R 40 and the resistance R 44,14 pin of multistage analog switch U4 are connected between resistance R 54 and the resistance R 58, and 2 pin of multistage analog switch U4 are connected between resistance R 58 and the potentiometer R60.

Adopt triode Q7,9 of Q8 and Q9 control multistage analog switch U4,10 and 11 pin, guaranteed that three pins have the signal of sufficient intensity, guaranteed the work robustness of multistage analog switch U4, in addition 14 of multistage analog switch U4,15,12,1,5,2,4 pins obtain voltage signal from the precision resistance that is connected in series to signal ground and precision potentiometer sampling respectively, and the dividing potential drop strategy that combines of battery two ends parallel precise resistance and precision potentiometer, make charging control more accurately and timely, improved charge efficiency.

As shown in Figure 8

Charging intelligent control module microcontroller circuit schematic diagram, 8 pin of the 1 pin combination hub P3 of CPU MCU, 17 pin of 2 pin combination hub P3,16 pin of 4 pin combination hub P3,15 pin of 5 pin combination hub P3,20 pin of 35 pin combination hub P3,10 pin of 36 pin combination hub P3,19 pin of 37 pin combination hub P3,14 pin of 38 pin combination hub P3,9 pin of 43 pin combination hub P3,18 pin of 44 pin combination hub P3,33 pin connect signal ground, and 10 pin connect signal ground; Series resistor MR14 between 11 pin of CPU MCU and 12 pin, series resistor MR15 between 11 pin of CPU MCU and 13 pin, series resistor MR16 between 11 pin of CPU MCU and 14 pin, 11 pin of CPU MCU connect+5V; The 9 pin serial connection electrochemical capacitor MC8 of CPU MCU enters signal ground, the 6 pin series resistor MR6 of CPU MCU enter signal ground, the 7 pin serial connection of CPU MCU enters signal ground every straight filter capacitor MC7, the 7 pin serial connection of CPU MCU enters signal ground every straight filter capacitor MC9, serial connection crystal oscillator Y1 between 7 pin of CPU MCU and 8 pin, 32 pin of CPU MCU connect+5V.

As shown in Figure 9

Charging intelligent control module reset circuit schematic diagram, what electrify restoration circuit used is the electrification reset function that CPU monitors chip MU1.

As shown in figure 10

CAN communicating circuit schematic diagram, 1 pin of CAN transceiver MU3 connects 19 pin of CPU MCU, 4 pin of CAN transceiver MU3 connect 20 pin of CPU MCU, 3 pin of CAN transceiver MU3 connect+5V, 2 pin connect signal ground, and 8 pin series resistor MR17 enter signal ground, series resistor MR20 between 6 pin of CAN transceiver MU3 and 7 pin, 1 pin of the 7 pin connection interface MJ4 of CAN transceiver MU3,2 pin of the 6 pin connection interface MJ4 of CAN transceiver MU3.

As shown in figure 11

Button and RS232 data transfer circuit schematic diagram, MLED1, MLED2, MLED3 are used for demonstration and are full of, fault and fill soon the indicator light of state, KEY1, KEY2, KEY3, four buttons of KEY4 are used for startup and stop charged state, quick charge and standard charging are switched, and internal auxiliary power supply starts halted state, the control of data communication mode channel selecting.

As shown in figure 12

In-line power accessory power supply modular circuit schematic diagram, after flyback transformer NT1 primary side obtains comparison signal by programmable precision with reference to NQ1, send photosignal to off-line switching power supply current mode controller NU3 via controlled optocoupler NU4, adjust the primary side input duty cycle in order to control, reach the purpose of automatically adjusting output according to circuit load, this design mainly is in order to guarantee the robustness of circuit supply.

As shown in figure 14

Be charge control method schematic diagram of the present invention, concrete steps are as follows:

After the input of 1 family expenses electrical network, the judgement of overcurrent undervoltage condition is carried out in charger inside, if circuit overcurrent or undervoltage condition occur, then changes step 9 over to; Otherwise, change step 2 over to;

2 panel boards show that electric network state is normal, and button starts in-line power accessory power supply control switch, and charger charge inside control module is carried out the software and hardware initialization operation, changes step 3 over to;

3 carry out battery condition detects, and judges that storage battery has or not short circuit or failure phenomenon, if short circuit or then panel board prompting and early warning of failure phenomenon occur, changes step 9 over to; Otherwise, change step 4 over to;

4 charger charge inside control modules are judged whether power shortage of storage battery, if then change step 5 over to by the battery condition parameter of sampling; Otherwise, change step 9 over to;

5 charger charge inside control modules are by battery condition parameter and the household electric net state parameter of sampling, the obtainable maximum initial charge current of calculating accumulator, if the not enough battery capacity value of the charging current value of calculating 1/20, then change step 9 over to; Otherwise change step 6 over to;

6 charger charge inside control modules are according to the charging current value that obtains, the charging control mode that adopts Bradycardia to rush is carried out the quick charge process of storage battery, allow maximum temperature values if continue to exceed storage battery default in the charge control module in the charging process in the temperature sampling value certain hour of storage battery, then change simultaneously step 8 and step 3 over to; Otherwise, change step 7 over to;

If 7 quick charges are carried out continuing to exceed the maximum voltage value that allows under the low gassing rate of storage battery default in the charge control module in the terminal voltage sampled value certain hour of storage battery in the process, then change step 3 over to; If not, then continue the quick charge process;

8 panel boards send temperature pre-warning, and charging process is suspended and pointed out whether button stops the internal auxiliary power supply power supply;

9 charger charge inside control modules are sent level signal, and control relay makes the outage of charger main circuit.

Now carry out some specific descriptions with regard to the course of work of a certain unit of intelligent charge control module:

As shown in figure 15,

Take Zibo torch battery charging process as example, the charging process flow process of filling modular converter is filled/marked to the charging method CPU of nondestructive fast charger of power battery pack for vehicle of the present invention soon partly to be described, the 6 joint 12V/120AH cell series connection of Zibo torch battery pack, fill soon the charging interval at 3.5 hours ~ 3.7 hours, the standard charging time is more than 8 hours.Concrete charging process flow process is as follows:

The intelligent charge control module is at first carried out initialization operation, and detects whether place in circuit of storage battery, if not, then returns the init state of intelligent charge control module; Otherwise will carry out the artificial selection charge mode: standard charging or quick charge.

Intelligent charge control module is then judged the value of charging sign runstate if choice criteria is charged, confirm as the standard charging pattern after, carry out first accumulator failure and detect, in case find storage battery short circuit or other faults then stop immediately charging process; If the intelligent charge control module detects the storage battery fault-free, then at first carry out the restorative charging of battery, and judge that the state value of charging sign runstate is 0; If the time judges that a minutes does not arrive, then Graphics Processing charging sign runstate value continues restorative charging; If a minutes arrives, then the value of charging sign runstate add 2 and Graphics Processing judge charging sign runstate value and enter constant current charge stage of 23A, judge whether accumulator voltage surpasses this value of 84.6V(and be conservative value this moment, the value of this voltage is obtained according to the storage battery actual parameter by the intelligent charge control module in the reality, be generally between 84.6V～87.6V), add 1 if surpass then the charge value of sign runsta of this voltage threshold, through Graphics Processing and judge its flag bit data value and enter the 15A constant current charge stage; Otherwise Graphics Processing charging sign and judge its flag bit data value after continue 23A constant current charge process; When entering 15A constant current charge process, judge still whether accumulator voltage exceeds 84.6V, if do not exceed then Graphics Processing charging sign and judge that its flag bit data proceed the constant current charge process of 15A, otherwise, charging sign runstate value adds 1, enter the constant voltage charge stage behind Graphics Processing and the judgement charging flag bit numerical value, change into this moment and judge whether charging current value is conservative value less than this value of 5A(, the value of this electric current is obtained according to the storage battery actual parameter by the intelligent charge control module in the reality, be generally battery rating about 1/20), then continue if not the constant voltage charge process, otherwise the complete charge process.

If the selection quick charge, then the intelligent charge control module is judged the value of charging sign runstate, confirm as fast charge mode after, carry out first accumulator failure and detect, in case find storage battery short circuit or other faults then stop immediately charging process; If the intelligent charge control module detects the storage battery fault-free, then at first carry out the restorative charging of battery, and judge that the state value of charging sign runstate is 0; If the time judges that a minutes does not arrive, then Graphics Processing charging sign runstate value continues restorative charging; If a minutes arrives, then the value of charging sign runstate add 1 and Graphics Processing judge charging sign runstate value and the constant current Bradycardia that enters 46A rushes the charging stage, judge whether accumulator voltage surpasses this value of 84.6V(and be conservative value this moment, the value of this voltage is obtained according to the storage battery actual parameter by the intelligent charge control module in the reality, be generally between 84.6V ~ 87.6V), add 1 if surpass then the charge value of sign runsta of this voltage threshold, through Graphics Processing and judge its flag bit data value and enter 32A constant current Bradycardia and rush the charging stage; Otherwise Graphics Processing charging sign and judge its flag bit data value after continue 46A constant current Bradycardia and rush charging process; When entering 32A constant current Bradycardia and rushing charging process, judge still whether accumulator voltage exceeds 84.6V, if do not exceed then Graphics Processing charging sign and judge that its flag bit data proceed the constant current Bradycardia of 32A and rush charging process, otherwise, charging sign runstate value adds 1, when entering 20A constant current Bradycardia and rushing charging process, judge still whether accumulator voltage exceeds 84.6V, if do not exceed then Graphics Processing charging sign and judge that its flag bit data proceed the constant current Bradycardia of 20A and rush charging process, otherwise, charging sign runstate value adds 1, enter the constant voltage Bradycardia behind Graphics Processing and the judgement charging flag bit numerical value and rush the charging stage, change into this moment and judge whether charging current value is conservative value less than this value of 9A(, the value of this electric current is obtained according to the storage battery actual parameter by the intelligent charge control module in the reality, be generally battery rating about 1/20), then continue if not the constant voltage charge process, otherwise the complete charge process.

The above only is preferred embodiment of the present invention, is not to be the restriction of the present invention being made other form, and any those skilled in the art may utilize the technology contents of above-mentioned announcement to be changed or be modified as the equivalent embodiment of equivalent variations.But every technical solution of the present invention content that do not break away to any simple modification, equivalent variations and remodeling that above embodiment does, still belongs to the protection range of technical solution of the present invention according to technical spirit of the present invention.

Claims (2)

1. the charging method of a nondestructive fast charger of power battery pack for vehicle, it is characterized in that: comprise input and output overcurrent under-voltage protection module, power factor correction module, semi-bridge inversion module, the half-bridge driven module, inversion output rectifying and voltage-stabilizing module, accumulator parameter dynamic sampling module, charging intelligent control module, in-line power accessory power supply module, the signal data communication module, charger LCD MODULE, electric motor car integrative instrument interface and RCI; Input and output overcurrent under-voltage protection module links to each other with power factor correction module, power factor correction module links to each other with the semi-bridge inversion module, the half-bridge driven module links to each other with the semi-bridge inversion module, the semi-bridge inversion module links to each other with inversion output rectifying and voltage-stabilizing module, inversion output rectifying and voltage-stabilizing module connects storage battery to be charged, accumulator parameter dynamic sampling module connects storage battery to be charged, the charging intelligent control module respectively with input and output overcurrent under-voltage protection module, the half-bridge driven module, accumulator parameter dynamic sampling module links to each other with in-line power accessory power supply module, in-line power accessory power supply module also with input and output overcurrent under-voltage protection module, power factor correction module, the half-bridge driven module, accumulator parameter dynamic sampling module links to each other, signal data communication module and the interconnection of charging intelligent control module, the signal data communication module links to each other with the charger LCD MODULE, RCI links to each other with the signal data communication module by the RS232 data communication mode, and electric motor car integrative instrument interface links to each other with the signal data communication module by the CAN_BUS data communication mode;

Concrete steps are as follows:

1.1 after the input of family expenses electrical network, the judgement of overcurrent undervoltage condition is carried out in charger inside, if circuit overcurrent or undervoltage condition occur, then changes step 1.9 over to, otherwise, change step 1.2 over to;

1.2 panel board shows that electric network state is normal, button starts in-line power accessory power supply control switch, and charger charge inside control module is carried out the software and hardware initialization operation, changes step 1.3 over to;

Detect 1.3 carry out battery condition, judge that storage battery has or not short circuit or failure phenomenon, if short circuit or then panel board prompting and early warning of failure phenomenon occur, change step 1.9 over to, otherwise, change step 1.4 over to;

1.4 charger charge inside control module, is judged whether power shortage of storage battery by the battery condition parameter of sampling, if, then change step 1.5 over to, otherwise, change step 1.9 over to;

1.5 charger charge inside control module is by battery condition parameter and the household electric net state parameter of sampling, the obtainable maximum initial charge current of calculating accumulator, if 1/20 of the not enough battery capacity value of the charging current value of calculating then changes step 1.9 over to, otherwise changes step 1.6 over to;

1.6 charger charge inside control module is according to the charging current value that obtains, the charging control mode that adopts Bradycardia to rush is carried out the quick charge process of storage battery, allow maximum temperature values if continue to exceed storage battery default in the charge control module in the charging process in the temperature sampling value certain hour of storage battery, then change simultaneously step 1.8 and step 1.3 over to, otherwise, change step 1.7 over to;

1.7 if quick charge is carried out continuing to exceed the maximum voltage value that allows under the low gassing rate of storage battery default in the charge control module in the terminal voltage sampled value certain hour of storage battery in the process, then change step 1.3 over to, if not, then continue the quick charge process;

1.8 panel board sends temperature pre-warning, charging process is suspended and is pointed out whether button stops the internal auxiliary power supply power supply;

1.9 charger charge inside control module is sent level signal, control relay makes the outage of charger main circuit.

2. the charging method of nondestructive fast charger of power battery pack for vehicle according to claim 1 is characterized in that: described in-line power accessory power supply module employing small-power switching power-supply.

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