CN108495522B - Non-vehicle-mounted charger and active adaptation and self-diagnosis method of heat dissipation system of non-vehicle-mounted charger - Google Patents
Non-vehicle-mounted charger and active adaptation and self-diagnosis method of heat dissipation system of non-vehicle-mounted charger Download PDFInfo
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- CN108495522B CN108495522B CN201810310808.8A CN201810310808A CN108495522B CN 108495522 B CN108495522 B CN 108495522B CN 201810310808 A CN201810310808 A CN 201810310808A CN 108495522 B CN108495522 B CN 108495522B
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- H—ELECTRICITY
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- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K7/00—Constructional details common to different types of electric apparatus
- H05K7/20—Modifications to facilitate cooling, ventilating, or heating
- H05K7/2089—Modifications to facilitate cooling, ventilating, or heating for power electronics, e.g. for inverters for controlling motor
- H05K7/20909—Forced ventilation, e.g. on heat dissipaters coupled to components
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
- B60L53/00—Methods of charging batteries, specially adapted for electric vehicles; Charging stations or on-board charging equipment therefor; Exchange of energy storage elements in electric vehicles
- B60L53/30—Constructional details of charging stations
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
- B60L53/00—Methods of charging batteries, specially adapted for electric vehicles; Charging stations or on-board charging equipment therefor; Exchange of energy storage elements in electric vehicles
- B60L53/30—Constructional details of charging stations
- B60L53/31—Charging columns specially adapted for electric vehicles
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K7/00—Constructional details common to different types of electric apparatus
- H05K7/20—Modifications to facilitate cooling, ventilating, or heating
- H05K7/20009—Modifications to facilitate cooling, ventilating, or heating using a gaseous coolant in electronic enclosures
- H05K7/20136—Forced ventilation, e.g. by fans
- H05K7/20145—Means for directing air flow, e.g. ducts, deflectors, plenum or guides
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- H05K7/00—Constructional details common to different types of electric apparatus
- H05K7/20—Modifications to facilitate cooling, ventilating, or heating
- H05K7/20009—Modifications to facilitate cooling, ventilating, or heating using a gaseous coolant in electronic enclosures
- H05K7/20136—Forced ventilation, e.g. by fans
- H05K7/20172—Fan mounting or fan specifications
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K7/00—Constructional details common to different types of electric apparatus
- H05K7/20—Modifications to facilitate cooling, ventilating, or heating
- H05K7/20009—Modifications to facilitate cooling, ventilating, or heating using a gaseous coolant in electronic enclosures
- H05K7/20136—Forced ventilation, e.g. by fans
- H05K7/20181—Filters; Louvers
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K7/00—Constructional details common to different types of electric apparatus
- H05K7/20—Modifications to facilitate cooling, ventilating, or heating
- H05K7/20009—Modifications to facilitate cooling, ventilating, or heating using a gaseous coolant in electronic enclosures
- H05K7/20136—Forced ventilation, e.g. by fans
- H05K7/2019—Fan safe systems, e.g. mechanical devices for non stop cooling
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K7/00—Constructional details common to different types of electric apparatus
- H05K7/20—Modifications to facilitate cooling, ventilating, or heating
- H05K7/2089—Modifications to facilitate cooling, ventilating, or heating for power electronics, e.g. for inverters for controlling motor
- H05K7/20945—Thermal management, e.g. inverter temperature control
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T10/00—Road transport of goods or passengers
- Y02T10/60—Other road transportation technologies with climate change mitigation effect
- Y02T10/70—Energy storage systems for electromobility, e.g. batteries
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T10/00—Road transport of goods or passengers
- Y02T10/60—Other road transportation technologies with climate change mitigation effect
- Y02T10/7072—Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T90/00—Enabling technologies or technologies with a potential or indirect contribution to GHG emissions mitigation
- Y02T90/10—Technologies relating to charging of electric vehicles
- Y02T90/12—Electric charging stations
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- Charge And Discharge Circuits For Batteries Or The Like (AREA)
Abstract
The invention discloses an off-board charger and a heat dissipation system active adaptation and self-diagnosis method thereof, which comprise a cabinet body, and a charging module, a main control module, a temperature sensor and a plurality of cooling fans which are arranged in the cabinet body, wherein the charging module, the cooling fans and the temperature sensor are electrically connected with the main control module; the main control module acquires the output power of the charging module, the ambient temperature acquired by the first sensor and the internal temperature data of the equipment acquired by the second sensor, compares the acquired data with the pre-stored standard reference data, generates a corresponding execution instruction and sends the corresponding execution instruction to the corresponding execution unit when the acquired internal temperature of the equipment exceeds the reasonable range of the corresponding internal temperature expected value of the equipment in the standard reference data, and the execution unit responds to the execution instruction. According to the invention, the main control module can rapidly make the execution instruction according to the operation state of the equipment to ensure the operation safety of the equipment, and can perform early warning when the heat dissipation system fails.
Description
Technical Field
The invention relates to a charging device, in particular to a heat dissipation system for an off-board charger and self-diagnosis thereof, and belongs to the technical field of electric vehicle charging.
Background
The performance of the heat dissipation system directly affects the running state and the service life of the alternating current and direct current charging equipment, but when the heat dissipation system breaks down or the performance of the heat dissipation system is reduced, the heat dissipation system is not easy to detect and is easy to ignore, so that the risk of potential equipment and personal safety hazards and property loss exists.
The power module of the off-board charger is generally formed by connecting a plurality of unit power modules in parallel, and the larger the output power is, the more the number of the required unit power modules is, and the larger the heating value is. Heat dissipation is a difficult problem when multiple unit power modules are located close together in a small cabinet space. In the prior art, although all the functional units in the cabinet are arranged and designed according to a certain rule, the functional units are still a communicated space, heat generated in a charging area can flow in the whole cabinet to influence the normal work of other functional units, and due to the overlarge space, the requirement on a heat dissipation system is higher, and the heat dissipation efficiency is also discounted. In addition, the non-vehicle machine that charges of electric automobile that uses in a large number on the existing market, the heat dissipation adopts the natural forced air cooling mode mostly, and does not have intelligent regulation and self-checking function, and the radiating effect relies on service environment at that time completely, including temperature, wind pressure, wind speed and fan behavior, and general service environment is abominable relatively, and the fan fault rate is high. The mode has the problems of harsh environment, lack of a detection device for the fan, lack of judgment on the heat dissipation effect and the like. And poor radiating effect can directly lead to filling electric pile trouble frequently, user experience is poor, also is a potential safety hazard simultaneously.
A heat radiation structure of a direct current charging pile of publication No. CN107087380A, the heat radiation structure includes: the air inlet assembly and the direct current charging pile form an air blowing duct, and the air outlet assembly and the direct current charging pile form an air suction duct; the charging module is arranged on the mounting frame of the direct current charging pile and is connected with the air inlet assembly; the fan detachably sets up on the air outlet subassembly. This patent application will charge module and fan and install the both sides at direct current charging pile, and keep apart mutually independent cavity wind channel, the radiating effect has been improved greatly and the life of fan has been improved, but not solve charging pile cooling system's initiative adaptation and self-diagnosis problem, the machine that charges only possesses the passive heat dissipation function, along with the increase of operating duration, the thermovent is blocked by the dust gradually, the fan performance also can descend, and not good because of heat dispersion, can lead to the temperature to rise rapidly, finally arouse the cable, plastics subassembly high temperature is smoked or even is burnt, cause the casualties, property economic loss.
The utility model discloses a be CN 206442655U's utility model discloses an intelligent control fan cooling system for filling electric pile, including the rack, be provided with air intake and air outlet relatively, main control board and a plurality of modules of charging rather than the electricity is connected, temperature sensor, radiator fan, the main control board is according to the temperature of the module air outlet department that charges of temperature sensor conveying, and the temperature of the inside radiator of the module conveying that charges, adjusts radiator fan's rotational speed, controls the rack in and the temperature of the module that charges, dispels the heat. On the premise of ensuring normal heat dissipation of the cabinet, unnecessary high-speed operation of the heat dissipation fan is avoided, the energy consumption of the heat dissipation fan is reduced, the system noise is reduced, the speed of rotation is reduced, and the maintenance frequency of the dust screen of the cabinet is reduced.
Disclosure of Invention
In order to solve the technical problem, the invention discloses an off-board charger and a cooling system active adaptation and self-diagnosis method thereof.
The invention discloses a non-vehicle-mounted charger, which comprises a cabinet body, and a charging module, a main control module, a temperature sensor and a plurality of cooling fans which are arranged in the cabinet body, wherein the charging module, the cooling fans and the temperature sensor are electrically connected with the main control module;
one side wall of the cabinet body is provided with an air inlet, and the other side wall opposite to the air inlet is provided with an air outlet;
the charging module comprises a plurality of charging units connected in parallel;
the plurality of radiating fans are respectively arranged at the air inlet and the air outlet and have a state feedback function;
the temperature sensor comprises a first sensor arranged at the air inlet and a second sensor arranged at the air outlet;
the main control module acquires the output power of the charging module, the ambient temperature acquired by the first sensor and the internal temperature data of the equipment acquired by the second sensor, compares the acquired data with the pre-stored standard reference data, generates a corresponding execution instruction and sends the corresponding execution instruction to a corresponding execution unit when the acquired internal temperature of the equipment exceeds a reasonable range of the expected value of the internal temperature of the equipment, and the execution unit responds to the execution instruction;
the standard reference data comprises corresponding expected values of the internal temperature of the equipment when the charging module outputs different powers under different environmental temperature conditions; the execution unit comprises a cooling fan and a charging module; the execution instruction comprises the starting and stopping of the cooling fan, the rotating speed or the steering adjustment, and the derating output or the stop operation of the charging module.
Preferably, a relatively independent charging area is arranged in the cabinet body, the charging module, the cooling fan and the temperature sensor are arranged in the charging area, and the main control module is arranged in the non-charging area of the cabinet body.
Preferably, the air outlet and the air inlet are designed in a staggered mode, and a part of the air outlet is higher than the air inlet; the charging units are arranged at intervals and incline upwards from the air inlet to the air outlet so as to form an air flow channel inclining upwards.
Preferably, the included angle between each charging unit and the horizontal direction is 15-30 DEG C
Preferably, the air inlet and the air outlet are provided with adjustable shutters and electrically connected with the main control module through a motor, the execution unit further comprises a motor, and the execution instruction further comprises angle adjustment of the adjustable shutter blades.
Preferably, the heat dissipation fan is a PWM temperature controlled fan.
The invention also discloses an active adaptation and self-diagnosis method of the cooling system, which is based on the off-board charger with the characteristics and comprises the following steps:
the method comprises the following steps that a first sensor arranged at an air inlet of a cabinet body and a second sensor arranged at an air outlet of the cabinet body are used for respectively collecting the ambient temperature and the internal temperature of equipment, and the collected temperature data are sent to a main control module; the main control module receives the temperature data sent by the first sensor and the second sensor, simultaneously obtains the output power of the charging module, and then searches the expected value of the internal temperature of the equipment corresponding to the charging module under the condition of the output power and the ambient temperature in the pre-constructed standard reference data; comparing the internal temperature of the equipment acquired by the second sensor with the searched expected value of the internal temperature of the equipment, and sending a corresponding execution instruction to a corresponding execution unit when the acquired internal temperature of the equipment exceeds the reasonable range of the expected value of the internal temperature of the equipment; the execution unit responds to the execution instruction;
the pre-constructed standard reference data comprises corresponding expected values of the internal temperature of the equipment when the charging module outputs different powers under different environmental temperature conditions;
the execution unit comprises a cooling fan and a charging module; the execution instruction comprises the starting and stopping of the cooling fan, the rotating speed or the steering adjustment, and the derating output or the stop operation of the charging module.
Preferably, the execution unit further includes a motor electrically connected to the adjustable louvers arranged at the air inlet and the air outlet, and the execution instruction further includes an angle adjustment of the adjustable louver blades.
Preferably, the method further comprises setting priorities for the execution instructions, wherein the priorities of the execution instructions for the angle adjustment of the adjustable shutter blades, the rotation speed adjustment of the cooling fan, the derating output of the charging module and the stop of the charging module are sequentially reduced.
Preferably, when the collected ambient temperature is lower than a preset direction-adjusting temperature value, the main control module sends a direction-adjusting instruction of the cooling fan.
Preferably, the reasonable range of the expected value of the internal temperature of the device is 0.5 to 1.15 times the expected value of the internal temperature of the device.
Compared with the prior art, the invention has the following beneficial effects:
(1) the design of a relatively independent charging area is adopted in the off-board charger, so that the influence of hot air on the normal work of other functional units is avoided.
(2) Through the design that the air inlet and the air outlet are partially staggered, and the air outlet is higher than the air inlet, and the design of the charging module which is inclined upwards from the air inlet to the air blowing port is matched, an air flow channel which is inclined upwards is formed in a charging area, and the hot air is discharged.
(3) The design of the adjustable shutter at the air inlet and the air outlet is convenient for adjusting the contact area of the cabinet and the outside air according to the requirement.
(4) The cooling fan can regulate the speed in multiple stages, and can regulate the steering and rotating speed according to the requirement so as to ensure that the temperature of a charging area is proper; the cooling fan also has a state feedback function, and can feed back the running state to the main control module in real time, so that the main control module can monitor the running state of the cooling fan in real time and master the performance of the cooling fan.
(5) The off-board charger with the active adaptation and self-diagnosis of the heat dissipation system can analyze and judge according to the acquired environment temperature, equipment temperature data and heat dissipation effect feedback information reflected by the output power of the charging module, and adjust the size of an air inlet and an air outlet, the steering and rotating speed of a heat dissipation fan, the output power and the running state of the charging module and the like in real time, so that the purpose of active adaptation of the heat dissipation system is achieved; and corresponding reactions can be made in real time when the cooling fan is monitored to have faults, so that the self-diagnosis function is realized, and the running safety of the charger is ensured.
(6) And the fault or performance reduction of the heat dissipation system can be diagnosed according to the comparison between the actual temperature rise and a standard fitting curve constructed in advance, so that the contradiction between the internal temperature and components such as a power module and the like in a severe high-temperature environment is effectively solved, the damage of the components is avoided, and the friendly interaction between equipment and a user is realized. Meanwhile, the constructed standard fitting curve has certain guiding significance on the layout and design of the heat dissipation system.
Drawings
FIG. 1 is a schematic diagram of the internal structure of an off-board charger;
FIG. 2 is a schematic diagram of the internal structure of the charging area;
FIG. 3 is a schematic diagram of the electrical connections of the off-board charger;
FIG. 4 is a schematic diagram of a standard fit curve of output power versus ambient temperature versus internal temperature of the device;
FIG. 5 is a schematic diagram of the operation of the off-board charger;
fig. 6 is a schematic diagram of the work flow of the off-board charger.
Detailed Description
The preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings.
The non-vehicle-mounted charger disclosed by the invention is characterized in that a part of the non-vehicle-mounted charger is longitudinally intercepted in a cabinet to serve as a relatively independent charging area, the charging area can be positioned in the middle of the cabinet, and also can be positioned at the upper part or the lower part of the cabinet and used for placing a charging module, the charging area is separated from other functional units (such as a charging control unit, a charging controller, a meter, a charging interface, a human-computer interaction interface and the like), the relatively independent area is designed in the cabinet, and a heat dissipation system is designed in a targeted manner, so that hot air is prevented from flowing in the whole cabinet, and the normal work of other functional units is ensured.
As shown in fig. 1, the embodiment discloses an off-board charger, which mainly includes a cabinet body 1, and a charging module 2 (i.e., a power module) disposed in the cabinet body 1, a cooling fan 3, a main control module 4, a motor 5 (not shown in the figure), a temperature sensor 6, a temperature sensor 7, a communication module 8, a power supply interface 9, and a human-computer interface 10. Wherein the charging module 2, the cooling fan 3, the motor 5 and the temperature sensor are arranged in the charging area, and other functional modules are designed in other areas in the cabinet outside the area.
In the charging area, an air inlet 11 and an air outlet 12 are arranged on the side wall of the cabinet body 1. Specifically, the air inlet 11 and the air outlet 12 are respectively located on the left side wall and the right side wall of the cabinet body 1, and the portions of the air inlet 11 and the air outlet 12 are arranged oppositely, and the position of the air outlet 12 is higher than that of the air inlet 11 in a horizontal view. The air inlet 11 and the air outlet 12 are both provided with an adjustable shutter 13 connected with the motor 5. Preferably, the design of an electric control shutter can be adopted, the electric control shutter is similar to an air outlet grille of an air conditioner, the inclination angle of the blades of the adjustable shutter 13 is controlled through the motor 5, so that the size of the air outlet is controlled, the ventilation with the outside air can be increased as required, the heat dissipation is accelerated, and the constant temperature in the cabinet body 1 is kept.
The charging module 2 may be designed at a middle position of the charging area and is composed of a plurality of parallel charging units 21 (i.e., unit power modules). According to the principle that hot air rises and cold air falls, the charging units 21 are arranged in an upward inclined manner at a certain angle from the air inlet 11 to the air outlet 12, and each charging unit 21 is spaced at a certain distance to form an air flow channel which is inclined upward, so that air can freely circulate from bottom to top.
The cooling fans 3 comprise a plurality of cooling fans, the cooling fans can be fixed at the air inlet and the air outlet in the cabinet body 1 through supports, and the specific number and the arrangement mode can be designed according to the sizes of the air inlet and the air outlet. The cooling fan 3 has a state feedback function (i.e. whether the cooling fan is in a fault state or a normal state is judged by the fed-back wind speed), and a speed and direction regulating strategy is established for the cooling fan 3 through the main control module 4. Specifically, the cooling fan 3 can adjust the rotating speed according to the temperature change so as to accelerate the cooling; the turning direction of the radiator fan 3 is adjusted under a special scene, for example, under a normal temperature, the radiator fan 3 rotates in a positive direction to discharge hot air, but in a particularly cold region; under the extremely low temperature, radiator fan 3 counter rotation blows wind outwards, hinders cold air admission rack, also can adjust the wind gap of shutter to less this moment of course. The cooling fan 3 can preferentially select a PWM temperature control fan, the rotating speed of the cooling fan 3 is adjusted based on a speed regulating instruction issued by the main control module 4, and any temperature measuring device is not required to be installed on the cooling fan 3. The main control module 4 issues corresponding speed regulating instructions according to the collected different temperatures, the PWM temperature control fan has different rotation speed regulation corresponding to the speed regulating instructions, and the rotation speed change of the fan can be four stages, five stages or even more, and basically stepless speed change is realized. Due to the real-time adjustment of the pulse width signal, the change of the rotating speed of the PWM temperature control fan is very sensitive, and the speed regulation or direction regulation instruction of the main control module 4 can be responded immediately. When the off-board charger is in standby state, the PWM temperature control fan can be kept at a very low rotating speed, and therefore running noise is greatly reduced. The maximum speed is more than four thousand revolutions and only occurs when the charging zone temperature approaches the limit temperature, e.g. 75-80 degrees. Therefore, compared with the traditional cooling fan, the cooling fan has a larger rotating speed control range, and better solves the problems of noise and performance. The PWM temperature control fan can be started up at the moment, the rotating speed can be increased to the highest value, and the rotating speed is reduced to a standby low rotating speed level after lasting for several seconds.
According to the above description, the non-vehicle-mounted charger innovatively adopts the independent bin hydrodynamics design in the cabinet, the independent bin which is separated from other functional units is designed in the middle of the charging pile body to serve as a charging area for the charging module 2 to charge, and the design of the closed independent bin can prevent hot air from flowing to other places of the cabinet to influence other functional units like the heat dissipation mode of the conventional charger. And, a heat dissipation system with active adaptation and self-diagnosis is designed for the area, which mainly comprises an air inlet 11 and an air outlet 12 of the cabinet body 1, a heat dissipation fan 3, a main control module 4, a motor 5, a temperature sensor 6, a temperature sensor 7 and the like, wherein heat dissipated in the charging process is smoothly discharged through an air flow channel which inclines upwards according to the principle of hydrodynamics, the sizes of air openings of shutters of the air inlet 11 and the air outlet 12 and the rotation direction and the rotation speed of the heat dissipation fan 3 can be adjusted, air convection is ensured, so as to ensure the temperature in the area, for example, when full power is output, the ambient temperature is about 20 degrees, and the temperature in the area is controlled at about 34 degrees.
As shown in fig. 3, the main control module 4 is electrically connected to the charging module 2, the cooling fan 3, the motor 5, the temperature sensor 6, the temperature sensor 7, the communication module 8, the power supply interface 9, and the human-machine interface 10.
The temperature sensor 6 and the temperature sensor 7 are respectively arranged at the air inlet 11 and the air outlet 12, and are used for acquiring the external environment temperature (for short, the environment temperature) of the equipment during operation and the temperature of a charging area in the cabinet (for short, the internal temperature of the equipment), and transmitting the acquired temperature data to the main control module 4. In an embodiment, we can select a PT1000 resistor which is specially used for collecting temperature as the temperature sensor.
In the operation process, the main control module 4 performs analysis and judgment according to the acquired temperature data sent by the temperature sensor and the power data output by the charging module 2, and then issues corresponding execution instructions to the execution units (the cooling fan 3, the motor 5, and the charging module 2), for example, for speed regulation and direction regulation instructions of the cooling fan 3, an adjustment instruction of the motor 5 for the angle of the louver 13 adjustable at the air inlet and the air outlet, a power reduction output or operation stop instruction of the charging module 2, and a fault reporting instruction of the communication module 8. In specific implementation, the main control module 4 can adopt a mature Enzhipu chip LPC1768, which has relatively stable performance and can meet the functional requirements of the scheme.
The communication module 8 can be set to a wired, wireless or combined communication mode according to actual requirements.
The cooling system of the off-board charger disclosed in the embodiment has active adaptation and self-diagnosis.
The active adaptation means that the heat dissipation system can actively adjust the heat dissipation scheme according to the running condition of the non-vehicle-mounted charger to ensure the running safety of the equipment. Specifically, the main control module 4 compares and analyzes the acquired data of temperature, power and the like with the pre-established and stored standard reference data (which may be represented by a table or a fitted curve graph) related to the output power (the actual output power of the charging module 2) -the ambient temperature-the internal temperature of the device, generates a corresponding execution instruction and sends the corresponding execution instruction to the corresponding execution unit (the cooling fan 3, the motor 5 and the charging module 2) when the comparison result exceeds a reasonable range of a preset internal temperature expected value of the device, and the execution unit responds to the execution instruction to make a corresponding cooling adjustment scheme so as to ensure that the temperature of the charging area is appropriate.
It should be noted that, when the execution instruction is designed, the priority of the execution instruction is designed according to the sequence of the motor 5, the cooling fan 3 and the charging module 2, that is, when the previous execution unit runs to the maximum limit or the set value, the execution instruction of the next execution unit is sent out, or when the previous execution unit fails, the next execution unit can be directly started to respond, so that on the premise of ensuring the running safety of the equipment, on one hand, the energy consumption can be saved, and on the other hand, the power output can be ensured as much as possible. The standard reference data comprises corresponding expected values of the internal temperature of the equipment when the charging module outputs different powers under different environmental temperature conditions; the execution unit comprises a cooling fan and a charging module; the execution instruction comprises the steps of adjusting the angle of the adjustable shutter 13 through the motor 5, starting and stopping the hot air fan 3 or adjusting the rotating speed in a rotating direction, derating the output or stopping the operation of the charging module 2 and the like. The standard reference data can be obtained according to actual experience of field operation and corresponding national standards.
When the device is applied specifically, the influence of the heat dissipation performance on the temperature rise inside the device can be analyzed through a large amount of experimental data, and standard reference data related to output power, environment temperature and device internal temperature are obtained. In the embodiment, table 1 may be used to show the reference value that the internal temperature of the device should maintain at different output powers under different environmental temperatures, and further, the reference value may be visually shown by a fitting graph as shown in fig. 4. The corresponding expected value of the internal temperature of the device may be designed according to specific requirements, for example, in table 1, when the off-board charger with the ambient temperature of 0 degrees requires an output power of 30KW, the expected value of the internal temperature of the device is 10 degrees, and the ranges of "0.5 × expected value of the internal temperature of the device to 1.15 × expected value of the internal temperature of the device" may be designed to be reasonable ranges. The obtained standard reference data or standard fitting curve related to the output power, the ambient temperature and the internal temperature of the equipment can be used as a reference standard for self-diagnosis of the state of the cooling system of the alternating current and direct current charging equipment.
Table 1 output power-ambient temperature-device internal temperature standard reference data
The self-diagnostic property means that the cooling system can feed back the operation condition to the control module 4 to diagnose whether the cooling system is normal or not, and meanwhile, the operation condition can be reported to a background monitoring system through the communication module to perform early warning. Specifically, when the charging device is running, the main control module 4 compares three parameters of the ambient temperature, the internal temperature of the device, and the output power, which are obtained in real time, with corresponding points of standard reference data, and if the internal temperature error of the device exceeds a reasonable range expected by the internal temperature of the corresponding device under the current internal temperature of the charger and the ambient temperature corresponding to the output power, and reaches a certain execution limit or a set value, it is determined that a fault or performance of the cooling system of the charging device is significantly reduced, and then a corresponding execution instruction is sent or early warning is performed, for example, power output of the device is reduced, and if the fault is a serious fault, the device is immediately shut down and reports the fault to the background monitoring system through the communication module 8.
As shown in fig. 4 and 5, the operating principle of the off-board charger is as follows:
after the airflow enters the cabinet body 1 from the air inlet 11, the cooling fan 3 arranged at the air inlet 11 sucks the airflow into the charging module 2, when the airflow passes through the charging module 2, the heat generated when each charging unit 21 works is taken away through the airflow channel which is inclined upwards, the cooling fan 3 arranged at the air outlet 12 blows the airflow to the air outlet 12, and finally the airflow is discharged out of the off-board charger from the air outlet 12.
In the process, the temperature sensor 6 and the temperature sensor 7 acquire the ambient temperature and the internal temperature of the equipment in real time and transmit the ambient temperature and the internal temperature to the main control module 4, the main control module 4 simultaneously acquires the output power of the charging module 2, compares and analyzes the acquired ambient temperature, the internal temperature of the equipment and the output power with the internally stored standard reference data, generates a corresponding execution instruction and transmits the corresponding execution instruction to the corresponding execution unit when the comparison result exceeds a set threshold value, and the execution unit responds to the execution instruction transmitted by the main control module 4 to control the temperature of a charging area, so that the running safety of the equipment is ensured, and the self-adaption of the heat dissipation system is realized.
Referring to fig. 6, the execution unit is set with execution priorities, that is, the angle of the electric louver 13 is adjusted, the rotation speed of the cooling fan 3 is adjusted, the derating output of the charging module 2 is performed, and the charging module 2 stops operating. When the internal temperature of the equipment is judged not to be within the reasonable range of the corresponding expected value, the control module 4 sends a command, preferentially calls the execution unit with high priority to execute the operation, and if the execution unit cannot reduce the temperature to be within the reasonable range of the expected value after executing, starts the execution unit with the next priority to execute the corresponding command, and so on. It should be noted that if the electric louver 13 is opened to the maximum and the cooling fan 3 is required to operate at the maximum rotation speed, and the information feedback of the cooling fan 3 is combined to determine that the cooling system of the charging device has a fault or the performance of the cooling system is obviously reduced, advance warning is performed, the power output of the charging module 2 can be controlled to be reduced, if the fault is serious, the charging module is immediately stopped and reports the fault through the communication module 8, so that self-diagnosis of the system is realized. It should be noted that, in practice, the failure of the heat dissipation system mainly refers to the failure of the heat dissipation fan 3, and in practical application, the heat dissipation level can be classified into good, general, abnormal, and failure levels according to the actual situation, and the state level is determined according to the operation state of the heat dissipation fan 3 which can be fed back in real time.
In conclusion, the charging area is isolated independently, so that the influence of heat generated by charging on the normal operation of other functional modules is prevented; designing an air flow channel which inclines upwards so that air can freely circulate from bottom to top; through the adjustable inlet and outlet shutter and the airflow channel which is obliquely arranged upwards, the power module can be effectively contacted with the outside air, and the smooth flowing of the airflow is ensured. Through PWM radiator fan can guarantee the quick convection current of the interior air of rack, effectively reduce the inside temperature of rack. The real-time sampling actual temperature and output power are compared with standard reference data, whether the internal temperature of the equipment is within a reasonable range or not can be judged under the current output power, if the internal temperature is abnormal, the main control module can rapidly send an execution instruction to the execution unit so as to ensure the running safety of the equipment, and meanwhile, the diagnosed state of the heat dissipation system is sent to a background monitoring system through the communication module so as to remind maintenance personnel to overhaul or pay attention.
In addition, the standard reference data, especially the fitting curve, of the output power, the ambient temperature and the internal temperature of the equipment, which are constructed and continuously optimized through empirical data, have certain guiding significance on the design of the applied heat dissipation system, for example, the selection of a plurality of heat dissipation fans with high power, the arrangement of a plurality of heat dissipation fans, the design of the area size of an air inlet and an air outlet, and the like, which are not available in the prior art.
The above description is only for the preferred embodiment of the present application, but the scope of the present application is not limited thereto, and any changes or substitutions that can be easily conceived by those skilled in the art within the technical scope of the present application should be covered within the scope of the present application. Therefore, the protection scope of the present application shall be subject to the protection scope of the claims.
Claims (10)
1. A non-vehicle-mounted charger comprises a cabinet body, and a charging module, a main control module, a temperature sensor and a plurality of cooling fans which are arranged in the cabinet body, wherein the charging module, the cooling fans and the temperature sensor are electrically connected with the main control module;
one side wall of the cabinet body is provided with an air inlet, and the other side wall opposite to the air inlet is provided with an air outlet;
the charging module comprises a plurality of charging units connected in parallel;
the plurality of radiating fans are respectively arranged at the air inlet and the air outlet and have a state feedback function;
the temperature sensor comprises a first sensor arranged at the air inlet and a second sensor arranged at the air outlet;
the main control module acquires the output power of the charging module, the ambient temperature acquired by the first sensor and the internal temperature data of the equipment acquired by the second sensor, compares the acquired data with the pre-stored standard reference data, generates a corresponding execution instruction and sends the corresponding execution instruction to a corresponding execution unit when the acquired internal temperature of the equipment exceeds a reasonable range of the expected value of the internal temperature of the equipment, and the execution unit responds to the execution instruction; the standard reference data comprises corresponding expected values of the internal temperature of the equipment when the charging module outputs different powers under different environmental temperature conditions;
the execution unit comprises a cooling fan and a charging module; the execution instruction comprises the starting and stopping of the cooling fan, the rotating speed or the steering adjustment, and the derating output or the running stopping of the charging module;
the execution unit is provided with execution priority, and when the execution unit with high priority runs to an execution limit or a set value, the execution unit sends out an execution instruction of the execution unit with low priority, or when the execution unit with high priority fails, the execution unit with low priority is directly started to respond.
2. The off-board charger according to claim 1, characterized in that: the main control module is arranged in a non-charging area of the cabinet body.
3. The off-board charger according to claim 1, characterized in that: the air outlet and the air inlet are designed in a staggered way, and a part of the air outlet is higher than the air inlet; the charging units are arranged at intervals and incline upwards from the air inlet to the air outlet so as to form an air flow channel inclining upwards.
4. The off-board charger according to claim 3, characterized in that: the included angle between each charging unit and the horizontal direction is 15-30 ℃.
5. The off-board charger according to claim 1, wherein the air inlet and the air outlet are provided with adjustable shutters, and are electrically connected with the main control module through a motor, the execution unit further comprises a motor, and the execution instruction further comprises angle adjustment of blades of the adjustable shutters.
6. An active adaptation and self-diagnosis method for a heat dissipation system is characterized in that: the off-board charger according to claim 1, comprising:
the method comprises the following steps that a first sensor arranged at an air inlet of a cabinet body and a second sensor arranged at an air outlet of the cabinet body are used for respectively collecting the ambient temperature and the internal temperature of equipment, and the collected temperature data are sent to a main control module;
the main control module receives the temperature data sent by the first sensor and the second sensor, simultaneously obtains the output power of the charging module, and then searches the expected value of the internal temperature of the equipment corresponding to the charging module under the condition of the output power and the ambient temperature in the pre-constructed standard reference data; comparing the internal temperature of the equipment acquired by the second sensor with the searched expected value of the internal temperature of the equipment, and sending a corresponding execution instruction to a corresponding execution unit when the acquired internal temperature of the equipment exceeds the reasonable range of the expected value of the internal temperature of the equipment;
the execution unit responds to the execution instruction;
the pre-constructed standard reference data comprises corresponding expected values of the internal temperature of the equipment when the charging module outputs different powers under different environmental temperature conditions;
the execution unit comprises a cooling fan and a charging module; the execution instruction comprises the starting and stopping of the cooling fan, the rotating speed or the steering adjustment, and the derating output or the running stopping of the charging module;
the execution unit is provided with execution priority, and when the execution unit with high priority runs to the maximum limit or a set value, the execution unit with low priority sends out an execution instruction of the execution unit with high priority, or when the execution unit with high priority fails, the execution unit with low priority can be directly started to respond.
7. The method of claim 6, wherein: the execution unit further comprises a motor electrically connected with the adjustable shutters arranged at the air inlet and the air outlet, and the execution instruction further comprises angle adjustment of the adjustable shutter blades.
8. The method of claim 7, wherein: the method further comprises the step of setting priority levels for the execution instructions, wherein the priority levels of the execution instructions for adjusting the angle of the adjustable louver blades, adjusting the rotating speed of the cooling fan, derating the charging module and stopping the charging module are sequentially reduced.
9. The method of claim 6, wherein: and when the collected environmental temperature is lower than a preset direction-adjusting temperature value, the main control module sends a radiating fan direction-adjusting instruction.
10. The method of any of claims 6 to 9, wherein: a reasonable range of expected device internal temperature values is from 0.5 to 1.15 expected device internal temperature values.
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