PCB Technical - Understand charging pile cloning and related processes

The function of the charging pile is similar to the refueling machine in a gas station. It can be fixed on the ground or wall and installed in public buildings (public buildings, shopping malls, public parking lots, etc.) and residential district parking lots or charging stations. It can be based on different PCB voltages. The level is for charging various types of electric vehicles. The input end of the PCB charging pile is directly connected to the AC grid, and the output end is equipped with a charging plug for charging electric vehicles.Charging piles generally provide two charging methods: conventional charging and fast charging. People can use a specific charging card to swipe the card on the human-computer interaction interface provided by the charging pile to perform operations such as the corresponding charging method, charging time, and cost data printing. The charging pile display screen can display PCB data such as charging amount, cost, and charging time.

my country is a major consumer and producer of new energy vehicles. There are a large number of pure electric cars on the market. Charging piles are in rapid development. Many companies want to invest in this industry. However, because charging piles are not general products, there are few experienced personnel who understand design. 

PCB copy board (PCB copy board) can copy out the PCB data of the circuit board 1:1, and then inverse the schematic diagram according to the BOM (bill of materials). According to the schematic diagram, we can analyze the advantages and disadvantages of similar products in the design to improve Our product design.

Technical requirements for AC charging pile (bolt)

Environmental requirements

1. Working environment temperature: -20 degree Celsius～+50 degree Celsius;

2. Relative humidity: 5%～95%;

3. Altitude: ≤1000m;

The equipment should be able to withstand three continuous sine waves acting simultaneously, and the safety factor should be greater than 1.67;

Structural requirements

1. The shell of AC charging pile (bolt) should be firm;

2. The structure must prevent hands from easily touching the exposed parts;

3. The AC charging pile (bolt) should use a steel composite structure with a thickness of 1.0 or more, and the surface should be treated with plastic dipping, and the requirements for heat dissipation should be fully considered. The charging pile (bolt) should have a good shielding function against electromagnetic interference;

4. The charging pile (bolt) should have sufficient support strength, and necessary facilities should be provided to ensure the correct lifting, transportation, storage and installation of equipment, and anchor bolt holes should be provided;

5.The bottom of the pile (bolt) body should be fixedly installed on a foundation not less than 200mm above the ground. The area of the base should not be greater than 500mm*500mm;

Power requirements

1.Input voltage: single-phase 220V;

2.Output power: single-phase 220V/5KW;

3.Frequency: 50Hz±2Hz;

4.The allowable voltage fluctuation range is: single-phase 220V±15%;

Electrical requirements

1. After the correct connection of the plug and the socket is confirmed, the load can be opened and closed before the circuit can be closed to realize the power supply to the socket;

2. The leakage protection device should be installed on the inlet side of the power supply cable;

3. The protection of low-voltage power distribution equipment and lines should meet the relevant regulations in the "Code for Design of Low-Voltage Power Distribution" (GB/50053);

4. For IT system power distribution lines, when the first ground fault occurs, the insulation monitoring device should send out audio or light signals, and when the second out-of-phase ground fault occurs, the overcurrent protection appliance or the leakage current action protector should be used Cut off the faulty circuit;

5. In the lighting power distribution system, the lighting and socket circuits should not be powered by the same circuit. The power side of the socket circuit should be equipped with a residual current action protection device, and its rated operating current is 30mA

7.IP protection level

The AC charging pile (bolt) should comply with IP54 (outdoor), and be equipped with necessary rain and sun protection devices;

8.Three-proof (anti-moisture, anti-mildew, anti-salt fog) protection

The printed circuit boards, connectors and other circuits in the charger should be treated with moisture, mildew, and salt spray. The salt spray corrosion resistance meets the requirements of GB/T 4797.6-1995 "Natural Environmental Conditions for Electrical and Electronic Products, Dust, Sand, Salt The requirements of Table 9 in "Fog" enable the charger to operate normally in an outdoor humid and salty fog environment;

9.Anti-rust (anti-oxidation) protection

The iron casing of the charging pile (bolt) and the exposed iron brackets and parts should take double-layer anti-rust measures, and the non-ferrous metal casing should also have an anti-oxidation protective film or be treated with anti-oxidation;

10.Wind protection

The chargers installed on the platform and the exposed parts should be able to withstand the relative wind speed at different areas and at different heights as specified in Table 9 of GB/T 4797.5-9 "Natural Environmental Conditions for Electrical and Electronic Products, Precipitation and Wind";

11.Anti-theft protection

The shell door of the electric pile (bolt) should be equipped with an anti-theft lock, and the bolts for fixing the AC charging pile (bolt) must be installed or disassembled after the shell door is opened;

12.Temperature rise requirements

The AC charging pile (bolt) runs continuously for a long time under the rated load, and the temperature rise of the internal heating components and various parts should not exceed the requirements in Table 2 of Q/GDW 397\2009;

13.Mean time between failures (MTBF)

MTBF should not be less than 8760h;

14.The vertical inclination of installation does not exceed 5%;

15.The equipment installation site must not have explosive dangerous media, and the surrounding media does not contain harmful gases and conductive media that can corrode metals and damage insulation

DC type

a) Charging pile (bolt) power input voltage: three-phase four-wire 380VAC±15%, frequency 50Hz±5%;

b) The charging pile (bolt) should satisfy the charging object

c) The output of the charging pile (bolt) is direct current, and the output voltage meets the battery standard requirements of the charging object;

d) The maximum output current meets the charging requirements of the battery standard 1C of the charging object, and is backward compatible;

e) The charging method is divided into two methods: conventional and fast, the conventional is the 5-hour charging method, and the fast is the 1-hour charging method (selected for different battery types);

f) Realize smart IC management;

g) Each charging pile (bolt) has its own operating device for users to select charging methods and operating instructions, and display the battery status of the electric vehicle and the user's IC card tariff information, so as to realize unmanned management;

h) The charging pile (bolt) interface should comply with the relevant regulations of the DC charging interface in GB/TXXXXXXXX electric vehicle conductive charging interface (temporary);

i) The communication interface of the charging pile (bolt) adopts the CAN communication interface, and the communication protocol is implemented in accordance with the provisions of the communication protocol (temporary) between the GB/TXXXXXXXX electric vehicle battery management system and the off-board charger (the charging object is lithium battery electric vehicles) ;

j) The charging pile (bolt) shall have corresponding alarm and protection functions for abnormal conditions during the charging process;

k) The charging pile (bolt) should monitor the battery status, and automatically adjust according to the battery temperature, voltage versus charging curve, charging current, and charging voltage;

Overview

The fast charging pile (bolt) equipment adopts an integrated AC and DC structure. It can realize PCB DC charging or AC charging. When there is a lot of charging business during the day, the DC method is used for fast charging, and when there are few users at the charging station at night, the PCB AC charging can be used for slow charging.

Appearance characteristics

1.Ergonomic design, fully considering the characteristics of the Chinese, after installation, the height of the whole machine, the height of the screen, the height of the keyboard, and the height of the charging connector slot are suitable for operation;

2.The form of the upper outlet, saves half of the operator's physical strength;

3.Considering people's usage habits and durability, the touch screen and keyboard are mutually backed up, and the touch screen and keyboard are designed with rain and dustproof PCB;

4.Equipped with an emergency stop switch for emergency shutdown; equipped with a charging connector slot, which can be waterproof.