CN219154254U - Output interface conversion system of charger for industrial vehicle - Google Patents
Output interface conversion system of charger for industrial vehicle Download PDFInfo
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- CN219154254U CN219154254U CN202223585607.XU CN202223585607U CN219154254U CN 219154254 U CN219154254 U CN 219154254U CN 202223585607 U CN202223585607 U CN 202223585607U CN 219154254 U CN219154254 U CN 219154254U
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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
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- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
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Abstract
The utility model provides an output interface conversion system of a charger for an industrial vehicle, which comprises an input and output unit, a power supply unit, an insulation detection unit, a charging gun locking control unit, a remote communication unit and a main control unit, wherein the power supply unit is connected with the main control unit and supplies power to the system; the input/output unit comprises a power input interface, a CAN communication interface, a power output interface and a CAN communication interface, wherein the power input interface and the CAN communication interface are both connected with a charger end, and the power output interface and the CAN communication interface are both connected with a lithium battery end; the utility model expands and reforms the output end of the existing charger, expands the application range of the existing charger, and adopts different output units, so that the existing charger can accord with various lithium battery charging protocols for industrial vehicles and national standard direct current charging gun standards.
Description
Technical Field
The utility model relates to the technical field of electric vehicles, in particular to a charger output interface conversion system for an industrial vehicle.
Background
Today, electric industrial vehicles are spreading at a high speed, and the application of lithium phosphate batteries as power sources thereof is growing, so that the use of lithium batteries on industrial vehicles has been widely accepted in the industry. However, a unified industry standard is not established for the lithium battery for the industrial vehicle, and a Battery Management System (BMS) practical in the lithium battery does not adopt the unified communication protocol standard, so that a charger matched with the lithium battery adopts different charging communication protocols, and cannot achieve effective unification, and an output interface conversion system of the charger for the industrial vehicle is required to complete communication and interface conversion between different lithium batteries and the charger, so that the application range of the existing charger is expanded.
Disclosure of Invention
The utility model aims to provide a charger output interface conversion system for an industrial vehicle.
In order to achieve the above object, the technical scheme of the present utility model is as follows:
the output interface conversion system of the charger for the industrial vehicle is characterized by comprising an input and output unit, a power supply unit, an insulation detection unit, a charging gun locking control unit, a remote communication unit and a main control unit, wherein the power supply unit is connected with the main control unit and supplies power to the system, and the insulation detection unit, the charging gun locking control unit and the remote communication unit are all connected with the main control unit;
the input/output unit comprises a power input interface, a CAN communication interface, a power output interface and a CAN communication interface, wherein the power input interface and the CAN communication interface are both connected with a charger end, and the power output interface and the CAN communication interface are both connected with a lithium battery end;
the power supply unit comprises an input fuse, an input EMC circuit, an AC/DC conversion circuit and an output filter circuit which are connected in sequence;
the main control unit comprises a main control MCU, an isolated CAN transceiver, an analog signal detection circuit, a relay control circuit and a remote communication circuit;
the insulation detection unit comprises a positive electrode detection unit and a negative electrode detection unit, the positive electrode detection unit comprises an output unit positive electrode, a positive electrode sampling resistor, a positive electrode control relay, a positive electrode voltage dividing resistor and a positive electrode isolation operational amplifier which are sequentially connected, the positive electrode isolation operational amplifier is connected with a main control MCU through a sampling circuit, the main control MCU calculates the insulation resistance value of the positive electrode of the output unit through sampling voltage detection,
the negative electrode detection unit comprises an output unit negative electrode, a negative electrode sampling resistor, a negative electrode control relay, a negative electrode voltage dividing resistor and a negative electrode isolation operational amplifier which are sequentially connected, the negative electrode isolation operational amplifier is connected with a main control MCU through a sampling circuit, the main control MCU calculates the insulation resistance value of the negative electrode of the output unit through voltage detection, and an isolation DC/DC power supply is arranged between the positive electrode isolation operational amplifier and the negative electrode isolation operational amplifier;
the charging gun locking control unit comprises an input interface, a pair of Schottky diodes, a control relay, a capacitor array and an output interface.
Further, the insulation detection unit is provided with a reference voltage source circuit and a leakage detection circuit, the reference voltage source circuit provides VREF2.5V, the leakage detection circuit comprises an anode detection circuit and a cathode detection circuit, the anode detection circuit is provided with an anode isolation operational amplifier and an anode control relay, and the cathode detection circuit is provided with a cathode isolation operational amplifier and a cathode control relay.
Further, the main control MCU detects a sampling voltage when the positive control relay and the negative control relay are simultaneously closed, a sampling voltage when the positive control relay is closed and the negative control relay is opened, and a sampling voltage when the positive control relay is opened and the negative control relay is closed, respectively, so as to judge an insulation resistance value of the output unit.
Further, the main control unit comprises a first isolated CAN transceiver and a second isolated CAN transceiver, and the main control MCU is connected with the first isolated CAN transceiver and performs CAN data interaction with the charger; and the main control MCU is connected with the second isolation CAN transceiver and performs CAN data interaction with the lithium battery.
Further, the main control MCU is connected with the analog signal detection circuit to detect insulation data, voltage data, temperature data and connection state of the charging interface in the charging process.
Further, the main control MCU obtains the temperature of the charging connection part of the output unit through the temperature resistor and the analog signal detection circuit.
The utility model expands and reforms the output end of the existing charger, expands the application range of the existing charger, and adopts different output units, so that the existing charger can accord with various lithium battery charging protocols for industrial vehicles and national standard direct current charging gun standards.
The internal multiple functional modules CAN be selected and matched according to requirements, when a standard industrial vehicle charging interface is adopted, the insulation detection unit and the charging gun locking control unit CAN be omitted, and the single charger and multiple BMS charging protocols CAN be effectively matched only by virtue of the CAN protocol conversion function of the main control unit; when the national standard direct current charging gun is used as an output unit interface, all functional units in the national standard direct current charging gun are required to be equipped so as to meet the requirements of national standard charging.
Drawings
FIG. 1 is a system block diagram of the present utility model;
FIG. 2 is a system structure diagram of an input unit and an output unit of the present utility model;
FIG. 3 is a system block diagram of a power supply unit of the present utility model;
FIG. 4 is a schematic circuit diagram of a power supply unit according to the present utility model;
FIG. 5 is a system configuration diagram of a master control unit according to the present utility model;
FIG. 6 is a schematic circuit diagram of a master control unit according to the present utility model;
FIG. 7 is a system configuration diagram of an insulation detection unit according to the present utility model;
FIG. 8 is a schematic diagram of a reference voltage source circuit according to the present utility model;
FIG. 9 is a schematic diagram of a leakage detection circuit according to the present utility model;
FIG. 10 is a block diagram of a system of a gun lock control unit according to the present utility model;
FIG. 11 is a schematic diagram of a latch control circuit according to the present utility model.
Detailed Description
The following description of the embodiments of the present utility model will be made apparent and fully in view of the accompanying drawings, in which some, but not all embodiments of the utility model are shown. All other embodiments, which can be made by those skilled in the art based on the embodiments of the utility model without making any inventive effort, are intended to be within the scope of the utility model.
The embodiment discloses a charger output interface conversion system for an industrial vehicle, which comprises a power input/output unit, a power supply unit, a main control unit, an insulation detection unit, a charging gun locking control unit and a remote communication unit which are sequentially connected as shown in fig. 1.
As shown in fig. 2, the input/output unit includes a power input interface and a CAN communication interface connected with the charger end, and a power output interface and a CAN communication interface connected with the lithium battery end, where the output interface may be an industrial vehicle standard charging plug or a dc charging gun plug conforming to national standards.
As shown in fig. 3 and 4, the power supply unit includes an input fuse, an input EMC circuit, an AC/DC conversion circuit, and an output filter circuit, the input fuse is connected with the input EMC circuit, the input EMC circuit is connected with the AC/DC conversion circuit, the AC/DC conversion circuit is connected with the output filter circuit, the input voltage range of the power supply is 90-528VAC wide voltage input, and the output voltage is 12VDC.
As shown in fig. 5, the main control unit comprises a main control MCU, an isolated CAN transceiver, an analog signal detection circuit, a relay control circuit, a remote communication circuit, and the like.
The remote communication can interact with the background, the background can obtain the running data of the conversion system in operation, and meanwhile, the MCU can update the online program through the remote communication.
As shown in fig. 6, the main control MCU is connected with the relay control circuit, and the main control MCU can perform locking operation of the national standard direct current charging gun through the relay control circuit; the main control MCU can perform the on-off operation of the insulation detection unit detection loop through the relay control circuit.
The main control MCU is connected with the first isolated CAN transceiver and performs CAN data interaction with the charger; the main control MCU is connected with the second isolation CAN transceiver and performs CAN data interaction with the lithium battery.
The main control MCU performs effective CAN interaction protocol conversion on the communication protocol between the unmatched charger and the lithium battery through the first isolation CAN transceiver and the second isolation CAN transceiver, so that the charging function expansion of the original charger is realized.
The main control MCU is connected with the analog signal detection circuit and can detect the connection states of insulation data, voltage data, temperature data and a charging interface in the charging process; the main control MCU obtains the temperature of the charging connection part of the output unit through the temperature resistor and the corresponding analog signal detection circuit.
The insulation detection unit comprises a control relay, an isolation operational amplifier, an isolation DC/DC power supply and a sampling resistor.
As shown in fig. 8 and 9, U6 and U7 are relays for switching measurement paths, R13, R14, R15, R16, R17 and R18 are resistors used in the positive-electrode high-resistance detection path, and R20, R21, R22, R23, R24 and R25 are resistors used in the negative-electrode high-resistance detection path, R12 and R19 are series resistors for insulation current measurement, and U5 is a resistor with V REF And a 2.5V bias reference voltage operational amplifier configured for measurement.
Normally, when only U6 is closed, no leakage current enters the loop because the current has no closed path.
In an ideal state, the reference voltage V REF 2.5V potential is set in series with respect to resistors R13, R14, R15, R16, R17 and R18 of the housing ground, so that when only U6 is closed, the value of the detection voltage V_POS should be equal to V according to the operational amplifier characteristics REF 2.5V is the same. The same principle, when only U7 is closed, the value of the detection voltage V_NEG should be equal to V REF 2.5V is the same.
If U6 and U7 are closed at the same time, leakage current between the positive and negative electrodes of the battery will flow through the casing, adjusting the resistance values of R13, R14, R15, R16, R17, R18, R20, R21, R22, R23, R24 and R25 so that the leakage current is very small (< 1 mA).
Since the reference voltage VREF2.5V and the series resistance are fixed, the voltage values of v_pos and v_neg can be calculated, and the following formula is obtained:
in the formula:
R ps ＝R13+R14+R15+R16+R17+R18；
R ns ＝R20+R21+R22+R23+R24+R25；
V REF ＝2.5V；
HV_BATT is the voltage between HV_POS and HV_NEG, please refer to the isolated voltage sampling circuit diagram.
In an abnormal situation, the system suffers from a leakage fault, and when only U6 is closed, the battery has two leakage current paths, one from the positive terminal of the output unit (the positive terminal of the battery) to the housing, the magnitude of which depends on the positive voltage (relative to the housing) and the positive insulation resistance, here designated Risop.
Another leakage current flows from the negative terminal of the output unit (the negative terminal of the battery) to the housing, the magnitude of which depends on the negative voltage (relative to the housing) and the negative insulation resistance value.
According to kirchhoff's current law, the following formula is obtained:
in the formula:
V a the voltage value of the positive electrode of the battery relative to the shell;
R ps ＝R13+R14+R15+R16+R17+R18；
V REF ＝2.5V；
when only U7 is closed, the following formula is obtained:
in the formula:
V a for the voltage value of the battery cathode relative to the housing
R ns ＝R20+R21+R22+R23+R24+R25；
V REF ＝2.5V；
Combining the two cases to obtain the following combination
In the formula:
HV BATT1 when only U6 is closed, the detected voltage total voltage is detected;
HV BATT2 the total voltage is the voltage detected when only U7 is closed.
And obtaining Risop and Rison resistance values through formula conversion, and judging whether the system has leakage faults or not.
As shown in fig. 7, the positive electrode of the output unit, the positive electrode sampling resistor, the positive electrode control relay, the voltage dividing resistor and the isolation operational amplifier are sequentially connected, the isolation operational amplifier is connected with the main control MCU through the sampling circuit, and the main control MCU calculates the insulation resistance value of the positive electrode of the output unit through sampling voltage detection;
the output unit cathode, the cathode sampling resistor, the cathode control relay, the divider resistor and the isolation operational amplifier are sequentially connected, the isolation operational amplifier is connected with the main control MCU through the sampling circuit, and the main control MCU calculates the insulation resistance value of the output unit cathode through voltage detection.
The main control MCU controls the on-off of the positive and negative electrode control relays of the insulation detection unit through the relay control circuit, and detects the sampling voltage when the positive and negative electrode control relays are simultaneously closed, the sampling voltage when the positive electrode control relay is closed and the negative electrode control relay is opened, and the sampling voltage when the positive electrode control relay is opened and the negative electrode control relay is closed; the main control MCU obtains the sampling voltages under the three conditions through the related analog signal detection circuit, and judges the insulation resistance value of the output unit through corresponding calculation.
The isolated DC/DC power supply is connected with the isolated operational amplifier and provides power for the isolated operational amplifier.
The insulation detection unit adopts an isolation scheme design, and voltage sampling isolation is carried out between the main control unit and the insulation detection unit, so that the operation safety and reliability of the main control unit are ensured.
As shown in fig. 10 and 11, the charging gun lock control unit includes a pair of schottky diodes, a control relay, a capacitor array, and an input-output interface.
The input interface is connected with the control circuit of the main control unit relay, the output interface is connected with the charging gun locking device, and the input interface, the Schottky diode, the control relay, the capacitor array and the output interface are sequentially connected.
The input interface receives the signal of the main control unit to close the control relay, the main control relay is closed, the control voltage charges the capacitor array through the control relay, the capacitor array generates voltage change due to the positive terminal and the negative terminal of the capacitor, a forward voltage pulse is generated, and the pulse provides a locking signal for the charging gun locking device through the output interface.
The input interface receives the signal of the main control unit to disconnect the control relay, the main control relay is disconnected and loses control voltage, the capacitor array discharges through a loop to generate a negative voltage pulse, and the pulse provides an unlocking signal for the charging gun locking device through the output interface.
When the power supply of the charging machine output interface conversion system is abnormal, the charging gun locking control unit still provides an unlocking signal for the charging gun locking device because of losing control voltage, and the situation that the charging gun cannot be unlocked because of abnormal power supply of the system is avoided.
According to the embodiment, the application range of the existing charger is expanded by expanding and reforming the output end of the existing charger, different output units are adopted, the existing charger CAN meet the lithium battery charging protocol for various industrial vehicles and the national standard direct current charging gun standard, a plurality of internal functional modules CAN be selected and matched according to requirements, when a standard industrial vehicle charging interface is adopted, an insulation detection unit and a charging gun locking control unit CAN be omitted, and the single charger and a plurality of BMS charging protocols CAN be effectively matched only by virtue of the CAN protocol conversion function of the main control unit, and meanwhile, when the national standard direct current charging gun is adopted as an output unit interface, all the internal functional units are required to be equipped, so that the national standard charging requirement is met.
The embodiment has the remote updating function of the main control MCU program, can update the charging protocol in real time according to the application condition of the client, and improves the function and the protocol matching performance.
The embodiment adopts a simple LED representation mode, and the LED flickering frequency and the color change show that the conversion system is respectively in the states of work, standby, abnormal and the like, so that a user can know the running state of the conversion system when using the conversion system.
Finally, it should be noted that: the above embodiments are only for illustrating the technical solution of the present utility model, and not for limiting the same; although the utility model has been described in detail with reference to the foregoing embodiments, it will be understood by those of ordinary skill in the art that: the technical scheme described in the foregoing embodiments can be modified or some or all of the technical features thereof can be replaced by equivalents; such modifications and substitutions do not depart from the spirit of the utility model.
Claims (6)
1. The output interface conversion system of the charger for the industrial vehicle is characterized by comprising an input and output unit, a power supply unit, an insulation detection unit, a charging gun locking control unit, a remote communication unit and a main control unit, wherein the power supply unit is connected with the main control unit and supplies power to the system, and the insulation detection unit, the charging gun locking control unit and the remote communication unit are all connected with the main control unit;
the input/output unit comprises a power input interface, a CAN communication interface, a power output interface and a CAN communication interface, wherein the power input interface and the CAN communication interface are both connected with a charger end, and the power output interface and the CAN communication interface are both connected with a lithium battery end;
the power supply unit comprises an input fuse, an input EMC circuit, an AC/DC conversion circuit and an output filter circuit which are connected in sequence;
the main control unit comprises a main control MCU, an isolated CAN transceiver, an analog signal detection circuit, a relay control circuit and a remote communication circuit;
the insulation detection unit comprises a positive electrode detection unit and a negative electrode detection unit, the positive electrode detection unit comprises an output unit positive electrode, a positive electrode sampling resistor, a positive electrode control relay, a positive electrode voltage dividing resistor and a positive electrode isolation operational amplifier which are sequentially connected, the positive electrode isolation operational amplifier is connected with a main control MCU through a sampling circuit, the main control MCU calculates the insulation resistance value of the positive electrode of the output unit through sampling voltage detection,
the negative electrode detection unit comprises an output unit negative electrode, a negative electrode sampling resistor, a negative electrode control relay, a negative electrode voltage dividing resistor and a negative electrode isolation operational amplifier which are sequentially connected, the negative electrode isolation operational amplifier is connected with a main control MCU through a sampling circuit, the main control MCU calculates the insulation resistance value of the negative electrode of the output unit through voltage detection, and an isolation DC/DC power supply is arranged between the positive electrode isolation operational amplifier and the negative electrode isolation operational amplifier;
the charging gun locking control unit comprises an input interface, a pair of Schottky diodes, a control relay, a capacitor array and an output interface.
2. The battery charger output interface conversion system for an industrial vehicle according to claim 1, wherein the insulation detection unit is provided with a reference voltage source circuit and a leakage detection circuit, the reference voltage source circuit provides VREF2.5V, the leakage detection circuit includes a positive electrode detection circuit provided with a positive electrode isolation operational amplifier and a positive electrode control relay, and a negative electrode detection circuit provided with a negative electrode isolation operational amplifier and a negative electrode control relay.
3. The battery charger output interface switching system for an industrial vehicle according to claim 2, wherein the main control MCU detects the sampling voltage when the positive electrode control relay and the negative electrode control relay are simultaneously closed, the sampling voltage when the positive electrode control relay is closed and the negative electrode control relay is opened, and the sampling voltage when the positive electrode control relay is opened and the negative electrode control relay is closed, respectively, to determine the insulation resistance value of the output unit.
4. The battery charger output interface conversion system for industrial vehicles according to claim 1, wherein the main control unit comprises a first isolated CAN transceiver and a second isolated CAN transceiver, and the main control MCU is connected with the first isolated CAN transceiver and performs CAN data interaction with the battery charger; and the main control MCU is connected with the second isolation CAN transceiver and performs CAN data interaction with the lithium battery.
5. The battery charger output interface conversion system for industrial vehicles according to claim 4, wherein the main control MCU is connected with an analog signal detection circuit to detect insulation data, voltage data, temperature data and connection state of the charging interface during charging.
6. The system according to claim 4, wherein the main control MCU obtains the temperature of the charging connection of the output unit through a temperature resistor and an analog signal detection circuit.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202223585607.XU CN219154254U (en) | 2022-12-30 | 2022-12-30 | Output interface conversion system of charger for industrial vehicle |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202223585607.XU CN219154254U (en) | 2022-12-30 | 2022-12-30 | Output interface conversion system of charger for industrial vehicle |
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| CN219154254U true CN219154254U (en) | 2023-06-09 |
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| CN202223585607.XU Active CN219154254U (en) | 2022-12-30 | 2022-12-30 | Output interface conversion system of charger for industrial vehicle |
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- 2022-12-30 CN CN202223585607.XU patent/CN219154254U/en active Active
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