CN115648983A - A boost charging device and method for electric vehicles - Google Patents

Abstract

The invention relates to a boost charging device and method for an electric vehicle. The boost charging device includes a module housing, and the side of the module housing is provided with an input end high voltage connector and an output end high voltage connector and Control signal line, water channel interface, etc.; the inside of the module housing is composed of a boost inductor, a high voltage relay, a high voltage filter component, a film capacitor, a control circuit, and a fixed support. The high-voltage connector at the input end is connected to the boost inductor; a high-voltage connector is provided on the side of the module housing, and the high-voltage connector is connected to the boost inductor. The present invention can be applied to charging piles with different output voltages, thereby improving the compatibility of the charging modes of automobiles, and realizing the fast charging function under charging piles with different output voltages.

Description

A boost charging device and method for electric vehicles

technical field

The invention belongs to the technical field of boost charging, in particular to a boost charging device and method for electric vehicles.

Background technique

Compared with the current integrated PDU charging device, there are too many layout functions, the internal structure is intertwined and complicated, the heat dissipation shares a cooling water circuit, the overall heat dissipation performance is poor, the high voltage and low voltage are densely arranged, the interference is large, and disassembly and maintenance are troublesome.

The output voltage of most charging piles on the market is relatively low, and the general integrated PDU device cannot take advantage of high-voltage and high-power charging to achieve the real fast charging function. If the car companies build their own charging piles, firstly, there is no way to cover a large range of charging stations nationwide, and secondly, different car companies have different charging modes and interface data, resulting in poor compatibility. If the output voltage of the charging pile is too low, it will take too long for the car to charge and affect the charging efficiency. Therefore, the fast charging of electric vehicles has always been an urgent problem for many car companies. One is to solve the problem of charging. The speed is slow, and the second is to solve the safety problem of charging.

In order to solve the above problems, it is necessary to design a boost charging device and method for electric vehicles.

Contents of the invention

In view of the above problems, the present invention provides a boost charging device for electric vehicles, the boost charging device includes a module housing,

The side of the module housing is provided with an input-end high-voltage connector and an output-end high-voltage connector; the inside of the module housing is provided with a boost inductor, and the input-end high-voltage connector is connected to the boost inductor ; The side of the module housing is provided with a high-voltage connector, and the high-voltage connector is connected with the boost inductor.

Preferably, a relay, a high-voltage filter assembly, a film capacitor and a positive relay are sequentially connected between the high-voltage connector at the input end and the high-voltage connector;

A negative relay is also connected between the film capacitor and the high voltage connector;

The side of the module housing is also provided with a low-voltage control signal connector.

Preferably, a waterway is arranged inside the module housing, and the boost inductor is arranged above the waterway;

The side part of the module housing is provided with a water inlet and outlet mouth connected with the water channel.

Preferably, a support shielding plate is provided above the boost inductor, a control circuit board is provided above the support shielding plate, and the relay, the negative relay and the positive relay are all connected to the control circuit board.

Preferably, a high-voltage relay is provided inside the module housing, the high-voltage relay is connected to the high-voltage connector at the input end, and the high-voltage relay is connected to the high-voltage filter assembly.

Preferably, the high-voltage filter assembly includes a fixing base, and a filtering PCB board is arranged on the fixing base, and a first filtering capacitor and a second filtering capacitor are arranged on the filtering PCB board.

Preferably, the side of the fixing seat has a filter magnetic ring and a magnetic ring cover plate, and the fixing seat is integrated into the copper bar through injection molding, and the filter PCB board is fixed on the fixing seat by bolts, so that the lead-out pins of the copper bar are welded In the filter PCB board hole.

Preferably, the boost inductor includes an inductance shell, an inductor core is provided inside the inductor shell, and a coil is wound outside the inductor core; a thermistor signal line is also provided inside the inductor shell;

Both sides of the inductance iron core are provided with fixing parts, and the fixing parts are connected with the inductance shell.

Preferably, a large housing cover is provided on the module housing, and the large housing cover matches the upper end surface of the module housing.

Preferably, the bottom of the boost inductor is coated with thermally conductive silicone grease and or is fixedly connected with a thermally conductive gasket.

Preferably, a heat dissipation plate is provided at the inner bottom of the module housing, and the bottom of the inductor housing is fixedly connected with the heat dissipation plate.

The present invention also proposes a boost charging method for an electric vehicle, the boost charging method comprising:

The charging gun of the charging pile passes through the high-voltage charging socket of the vehicle, input current, and the positive current flows from the high-voltage connector at the input end, then flows to the boost inductor, and then flows to the high-voltage connector;

The negative current flows from the high-voltage connector at the input end, then flows to the high-voltage connector, and finally flows to the overall circuit of the motor controller of the car.

Preferably, before performing the boost charging method, including:

Judging whether the external input DC voltage is greater than the car battery voltage, if it is greater than the car battery voltage, the direct charging mode is performed;

If it is less than or equal to the car battery voltage, the boost charging method is performed;

Wherein, the direct charging mode includes: current flows in from the high-voltage connector at the input end, then flows out from the high-voltage connector at the output end, and finally flows to the overall circuit of the motor controller of the vehicle.

Preferably, the boost charging method also includes:

After the positive current flows in from the high-voltage connector at the input end, it is filtered and removed by the high-voltage filter component, and then flows into the boost inductor;

After the negative current flows in from the high-voltage connector at the input end, it passes through the high-voltage filter component to remove impurities, and then flows to the high-voltage connector.

The present invention has the following beneficial effects:

(1) The present invention can realize the function of boost charging when the output voltage of the charging pile is lower than the rated charging voltage of the battery by arranging a boost inductor inside the charging device. Compared with the existing charging device, The present invention can be applied to charging piles with different output voltages, thereby improving the compatibility of the charging modes of automobiles, and realizing the fast charging function under charging piles with different output voltages;

(2) In the present invention, a high-voltage filter assembly is also provided between the high-voltage connector at the input end and the high-voltage connector, which can remove impurities and filter the current inside the charging device to improve the charging effect of the device, and the high-voltage filter assembly The integrated and modular design integrates multiple filter components together, which can ensure the maximum improvement of the filter capability of the module in a limited space. The overall layout is compact and tidy, and the space utilization is reasonable.

Additional features and advantages of the invention will be set forth in the description which follows, and in part will be apparent from the description, or may be learned by practice of the invention. The objectives and other advantages of the invention may be realized and attained by the structure pointed out in the written description, claims hereof as well as the appended drawings.

Description of drawings

In order to more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the following will briefly introduce the drawings that need to be used in the description of the embodiments or the prior art. Obviously, the accompanying drawings in the following description These are some embodiments of the present invention. Those skilled in the art can also obtain other drawings based on these drawings without creative work.

Figure 1 shows a schematic diagram of the internal structure of a boost charging device in an embodiment of the present invention;

Fig. 2 shows an exploded schematic view of the internal structure of the boost charging device in the embodiment of the present invention;

Fig. 3 shows a schematic diagram of a high-voltage filter assembly in an embodiment of the present invention;

FIG. 4 shows a schematic structural diagram of a boost inductor module in an embodiment of the present invention;

Fig. 5 shows a flow chart of a boost charging method in an embodiment of the present invention.

In the figure: 1. Input high-voltage connector; 2. Output high-voltage connector; 3. Relay; 4. High-voltage filter component; 401, first filter capacitor; 402, second filter capacitor; 403, magnetic ring cover; 404, filter PCB board; 405, fixed seat; 406, filter magnetic ring; 407, copper bar; 5, film capacitor; 6, support shielding plate; 7, control circuit board; 8, negative relay; 9, boost inductor ;901, thermistor signal line; 902, coil; 903, inductance iron core; 904, fixing piece; 905, inductance shell; 10, high-voltage connector; 11, low-voltage control signal connector; 1. The large cover plate of the shell; 14. The module shell; 15. The positive relay; 16. The high voltage relay.

Detailed ways

In order to make the purpose, technical solutions and advantages of the embodiments of the present invention more clear, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments It is a part of embodiments of the present invention, but not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by persons of ordinary skill in the art without making creative efforts belong to the protection scope of the present invention.

The present invention provides a boost charging device for electric vehicles, as shown in Figure 1, the device includes a module housing 14, the side of the module housing 14 is provided with an input end high-voltage connector 1 and an output end A high-voltage connector 2; the inside of the module housing 14 is provided with a boost inductor 9, and the input high-voltage connector 1 is connected to the boost inductor 9; the side of the module housing 14 is provided with a high-voltage Connector 10 , the high voltage connector 10 is connected with the boost inductor 9 . A relay 3, a high-voltage filter component 4, a film capacitor 5 and a positive relay 15 are sequentially connected between the input high-voltage connector 1 and the high-voltage connector 10. When the detection voltage is greater than 800V, the relay 3 is disconnected, and when the voltage is less than 800V When the relay 3 conducts the step-up circuit; the negative relay 8 is also connected between the film capacitor 5 and the high-voltage connector 10, and the setting of the positive relay 15 and the negative relay 8 can play a role of safety protection to avoid circuit overvoltage damage equipment. The side of the module housing 14 is also provided with a low-voltage control signal connector 11 .

As shown in Figure 2, the inside of the module housing 14 is provided with a water channel, and the boost inductor 9 is arranged above the water channel, so as to avoid the high ambient temperature of the boost inductor 9 during work; the module housing 14 The side is provided with an inlet and outlet nozzle 12 connected to the water channel. The high-voltage connector 10, the low-voltage control signal connector 11 and the inlet and outlet nozzle 12 are fixed on the side wall of the module housing 14 by bolts, and the inlet and outlet nozzle 12 is connected to the heat dissipation water pump. The top of the boost inductor 9 is provided with a support shield 6, which reduces the overall weight, blocks the interference of the high voltage of the boost inductor below to the control board, and also ensures the insulation strength. The top of the support shield 6 is provided with Control circuit board 7, said control circuit board 7 is connected with low-voltage control signal connector 11, relay 3, negative pole relay 8 and positive pole relay 15 are all connected to control circuit board 7, control circuit board 7 can control relay 3, negative pole relay 8 and the on-off of positive relay 15. The control circuit board 7 is also connected to the temperature line of the boost inductor 9 and can monitor the temperature of the boost inductor 9 . The control circuit board 7 is also connected with the interlock wiring harness of the high-voltage connector 1 at the input end, the high-voltage connector 2 at the output end and the high-voltage connector 10, and can monitor the high-voltage on-off. The outside of the control circuit board 7 is connected with the low-voltage control signal connector 11 to realize the signal transmission function. The module housing 14 is provided with a high-voltage relay 16 inside, and the high-voltage relay 16 is locked on the bottom of the module housing 14 by bolts. Filtering components 4 are connected. The module casing 14 is provided with a large casing cover 13 , and the large casing cover 13 is matched with the upper end surface of the module casing 14 .

As shown in Figure 3, the high-voltage filter assembly 4 includes a fixed seat 405, on which a filter PCB board 404 is provided, and on the filter PCB board 404, a first filter capacitor 401 and a second filter capacitor 402 are provided . The side of the fixing seat 405 has a filter magnetic ring 406 and a magnetic ring cover plate 403. The fixing seat 405 is integrated into the copper bar 407 through injection molding, and the filter PCB board 404 is fixed on the fixing seat 405 by bolts, so that the copper bar The pins leading out from the surface of 407 are welded in the hole 404 of the filter PCB. The above design integrates many filter components through an integrated and modular design, which can ensure that the filter capability of the module can be maximized in a limited space.

As shown in FIG. 4 , the boost inductor 9 includes an inductance housing 905 made of high-efficiency heat-dissipating and environmentally friendly materials. In this embodiment, the inductance housing 905 is made of an aluminum shell, which serves as a fixed cavity. The inductor shell 905 is provided with an inductor core 903 inside, and a coil 902 is wound on the outside of the inductor core 903, and the inductor core 903 is encapsulated in the inductor shell 905 by using a potting process, effectively ensuring high-power heat dissipation requirements ; The inductance shell 905 is also provided with a thermistor signal line 901 inside. In the present embodiment, what the thermistor signal line 901 adopts is an NTC thermistor signal line, which can monitor the temperature change of the inductance under working conditions, thereby effectively Control the working power of the equipment to ensure that the device will not be lost or overloaded at high temperatures. Make the equipment stable and long-term safe operating conditions. Both sides of the inductor core 903 are provided with fixing pieces 904 , the fixing pieces 904 are connected with the inductor casing 905 , and the fixing pieces 904 and the inductor casing 905 are used to fix the inductor core 903 . The bottom of the step-up inductor 9 is coated with thermally conductive silicone grease and or fixedly connected with a thermally conductive gasket. The use of thermally conductive silicone grease and thermally conductive gasket can reduce the heat dissipation medium, and when the heat is dissipated through the water channel, the heat will be taken away by the cooling water faster , so as to maximize the cooling efficiency. The inner bottom of the module housing 14 is provided with a heat dissipation plate, and the bottom of the inductor housing 905 is fixedly connected with the heat dissipation plate.

The present invention also provides a boost charging method for an electric vehicle. As shown in FIG. 5, the boost charging method includes: the charging gun of the charging pile passes through the high-voltage charging socket of the whole vehicle, and the input current and the positive current from the input terminal The high-voltage connector 1 flows in, then flows to the boost inductor 9, and then flows to the high-voltage connector 10; the negative current flows in from the input high-voltage connector 1, then flows to the high-voltage connector 10, and finally flows to the overall circuit of the motor controller of the car.

Before performing the boost charging method, it includes: judging whether the external input direct current voltage is greater than the vehicle battery voltage, if it is greater than the vehicle battery voltage, then performing the direct charging mode; if it is less than or equal to the vehicle battery voltage, then performing the boost charging method; Wherein, the direct charging mode includes: current flows in from the high-voltage connector 1 at the input end, then flows out from the high-voltage connector 2 at the output end, and finally flows to the overall circuit of the motor controller of the vehicle.

The boost charging method also includes: after the positive current flows in from the high-voltage connector 1 at the input end, filtering and removing impurities through the high-voltage filter component 4, and then flowing into the boost inductor 9; after the negative current flows in from the high-voltage connector 1 at the input end, , through the high-voltage filter assembly 4 to remove impurities, and then flow to the high-voltage connector 10 .

Those of ordinary skill in the art should understand that: although the present invention has been described in detail with reference to the foregoing embodiments, it is still possible to modify the technical solutions described in the foregoing embodiments, or perform equivalent replacements for some of the technical features; and these modifications Or replacement, does not make the essence of the corresponding technical solutions deviate from the spirit and scope of the technical solutions of the various embodiments of the present invention.

Claims (14)

1. A boost charging apparatus for an electric vehicle, the boost charging apparatus comprising a module housing (14),

an input end high-voltage connector (1) and an output end high-voltage connector (2) are arranged on the side part of the module shell (14); a boost inductor (9) is arranged in the module shell (14), and the input end high-voltage connector (1) is connected with the boost inductor (9); the side of the module shell (14) is provided with a high-voltage connector (10), and the high-voltage connector (10) is connected with the boost inductor (9).

2. A boost charging apparatus for electric vehicle according to claim 1,

a relay (3), a high-voltage filter assembly (4), a thin-film capacitor (5) and an anode relay (15) are sequentially connected between the input end high-voltage connector (1) and the high-voltage connector (10);

a negative relay (8) is also connected between the thin-film capacitor (5) and the high-voltage connector (10);

and a low-voltage control signal connector (11) is also arranged on the side part of the module shell (14).

3. A boost charging apparatus for electric vehicle according to claim 1,

a water channel is arranged in the module shell (14), and the boost inductor (9) is arranged above the water channel;

and a water inlet and outlet nozzle (12) communicated with the water channel is arranged on the side part of the module shell (14).

4. A boost charging apparatus for electric vehicle according to claim 2,

the boost type transformer is characterized in that a supporting shielding plate (6) is arranged above the boost inductor (9), a control circuit board (7) is arranged above the supporting shielding plate (6), and the control circuit board (7) is connected with the relay (3), the negative relay (8) and the positive relay (15).

5. A boost charging apparatus for electric vehicle according to claim 1,

the module is characterized in that a high-voltage relay (16) is arranged in the module shell (14), the high-voltage relay (16) is connected with the input end high-voltage connector (1), and the high-voltage relay (16) is connected with the high-voltage filtering assembly (4).

6. A boost charging apparatus for electric vehicle according to claim 2,

the high-voltage filter assembly (4) comprises a fixed seat (405), a filter PCB (404) is arranged on the fixed seat (405), and a first filter capacitor (401) and a second filter capacitor (402) are arranged on the filter PCB (404).

7. A boost charging apparatus for electric vehicle according to claim 6,

the side of the fixed seat (405) is provided with a filtering magnetic ring (406) and a magnetic ring cover plate (403), the fixed seat (405) is integrally embedded into a copper bar (407) through injection molding, and the filtering PCB (404) is fixed on the fixed seat (405) through bolts, so that pins led out from the surface of the copper bar (407) are welded in holes (404) of the filtering PCB.

8. A boost charging apparatus for electric vehicle according to claim 1,

the boost inductor (9) comprises an inductor shell (905), an inductor core (903) is arranged inside the inductor shell (905), and a coil (902) is wound outside the inductor core (903); a thermistor signal wire (901) is also arranged in the inductor shell (905);

both sides of inductance core (903) all are equipped with mounting (904), and mounting (904) are connected with inductance housing (905).

9. A boost charging apparatus for electric vehicle according to claim 1,

the module shell (14) is provided with a shell large cover plate (13), and the shell large cover plate (13) is matched with the upper end face of the module shell (14).

10. A boost charging apparatus for electric vehicles according to any one of claims 1 to 8,

the bottom of the boost inductor (9) is coated with heat-conducting silicone grease and/or a heat-conducting gasket fixedly connected with the boost inductor.

11. A boost charging apparatus for electric vehicle according to claim 8,

the bottom is equipped with the heating panel in module casing (14), inductance housing (905) bottom and heating panel fixed connection.

12. A boost charging method for an electric vehicle, characterized by comprising:

a charging gun of the charging pile inputs current through a high-voltage charging socket of the whole vehicle, and positive current flows in from the input end high-voltage connector (1), then flows to the boost inductor (9) and then flows to the high-voltage connector (10);

the negative current flows from the input end high-voltage connector (1), then flows to the high-voltage connector (10), and finally flows to the whole circuit of the motor controller of the automobile.

13. The boost charging method for electric vehicles according to claim 12, comprising, before performing the boost charging method:

judging whether the external input direct current voltage is greater than the voltage of the automobile battery, and if so, performing a direct charging mode;

if the voltage is less than or equal to the voltage of the automobile battery, executing a boosting charging method;

wherein the direct charging mode comprises: the current flows in from the input end high-voltage connector (1), then flows out from the output end high-voltage connector (2), and finally flows to the whole circuit of the motor controller of the automobile.

14. The boost charging method for an electric vehicle according to claim 12,

the boost charging method further includes:

after the positive current flows in from the input end high-voltage connector (1), filtering and impurity removal are carried out through the high-voltage filtering assembly (4), and then the positive current flows into the boost inductor (9);

after the negative current flows from the input end high-voltage connector (1), impurities are removed through the high-voltage filtering assembly (4), and then the negative current flows to the high-voltage connector (10).

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