CN219277260U - Intelligent high-frequency charger for charging storage battery of electric forklift - Google Patents
Intelligent high-frequency charger for charging storage battery of electric forklift Download PDFInfo
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- CN219277260U CN219277260U CN202320868600.4U CN202320868600U CN219277260U CN 219277260 U CN219277260 U CN 219277260U CN 202320868600 U CN202320868600 U CN 202320868600U CN 219277260 U CN219277260 U CN 219277260U
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Abstract
The utility model discloses an intelligent high-frequency charger for charging a storage battery of an electric forklift, which comprises a direct-current power supply converter, a processor, a voltage sampling unit, a charging switch controlled by the processor and a sampling switch, wherein the direct-current power supply converter, the charging switch and a power storage battery are sequentially connected to form a charging loop; the power storage battery, the sampling switch, the voltage sampling unit and the processor are sequentially connected to form a voltage sampling loop; the processor is electrically connected with the direct-current power supply converter and automatically adjusts the output voltage and the output current of the direct-current power supply converter according to the detected current voltage of the power storage battery. The utility model can meet the charging requirements of most of power storage batteries with different voltage levels and different types, and realizes multiple purposes and universal use.
Description
Technical Field
The utility model relates to the technical field of electric forklift charging, in particular to an intelligent high-frequency charger for charging a storage battery of an electric forklift.
Background
Electric forklifts are forklifts that use electricity as energy to perform field operations, and include various types of electric series material handling equipment such as four-way electric forklifts, electric pallet trucks, electric tractors, and the like. Most electric forklifts use a power storage battery as a source power to drive a running motor and a hydraulic system motor, so that running and loading and unloading operations are realized. The electric forklift has the advantages of no pollution, easy operation, energy conservation, high efficiency and the like.
After the power storage battery of the electric forklift is discharged, direct current is used for passing through the storage battery in the direction opposite to the discharging current, so that the working capacity of the electric forklift is recovered, the process is called a storage battery charging process, and different charging currents and charging voltage curves have influences on charging time and direct influences on the capacity and service life of the battery. It is therefore necessary to select a suitable charging profile for the different battery types in order to maintain the battery in an optimal state.
In the process of charging the power storage battery, the influence of an incorrect charging mode on the service life of the battery is relatively large, and the influence of a discharging process is relatively small. At present, a plurality of electric forklift chargers have different performances according to different manufacturers, but basically have simpler circuits and poorer protection functions, and are not charged according to the charging curve of the battery, so that the service life of the battery can be influenced.
Disclosure of Invention
The utility model aims to overcome the defects and the shortcomings of the prior art, and provides an intelligent high-frequency charger for charging a storage battery of an electric forklift, which can meet the charging requirements of most power storage batteries with different voltage levels and different types, and can automatically adapt to the power storage batteries with different voltage levels.
In order to achieve the above purpose, the present utility model provides the following technical solutions:
an intelligent high-frequency charger for charging an electric fork-lift storage battery, wherein the output end of the charger is connected with a charging interface of a power storage battery, and the intelligent high-frequency charger is characterized in that: the charger comprises a direct-current power supply converter, a processor, a voltage sampling unit, a charging switch and a sampling switch, wherein the output end of the direct-current power supply converter, the charging switch and a charging interface of the power storage battery are sequentially connected to form a charging loop for charging the power storage battery; the charging interface, the sampling switch, the voltage sampling unit and the processor of the power storage battery are sequentially connected to form a voltage sampling loop for detecting the current voltage of the power storage battery; the processor is electrically connected with the direct-current power supply converter and is used for automatically adjusting the output voltage and the output current of the direct-current power supply converter according to the detected current voltage of the power storage battery; the charging switch and the sampling switch are controlled by the processor to be closed and opened.
When the charging switch is turned off, the electrical connection between the charger and the power storage battery is broken.
According to different electric fork-lift types and functions, the working voltage of the power storage battery can be divided into 24V, 48V, 36V, 72V, 80V and other different voltages, and the power storage battery is usually matched according to the load capacity of the fork-lift and the rated power of a motor, and is mostly 2V single battery voltage. Such as: the power storage battery of the 48V forklift is formed by connecting 24 2V batteries in series, can reach 52V under the condition of full charge, and has high capacity. In order to automatically adapt to different voltage grades of the power storage battery, the utility model is provided with a voltage sampling unit, when the charger does not output direct current, the current voltage of the power storage battery is detected, and corresponding charging voltage and charging current are selected according to the current voltage.
Furthermore, the input end of the direct current power supply converter is externally connected with a three-phase alternating current power supply and is used for converting external alternating current into direct current and outputting the direct current.
Further, the direct-current power supply converter is formed by connecting a plurality of power supply conversion modules in parallel.
Further, the sampling switch is connected between the positive end of the charging interface of the power storage battery and the input end of the voltage sampling unit, after the sampling switch is closed, the voltage of the power storage battery is applied to the voltage sampling unit, and the processor obtains the current voltage of the power storage battery through isolation sampling.
Further, the sampling signal input end of the processor is connected with the output end of the voltage sampling unit, the processor communicates with the direct current power supply converter through a CAN network, the processor sends different output voltage and output current requests to the direct current power supply converter through the CAN network according to the detected current voltage of the power storage battery, and after the charging switch is closed, the direct current power supply converter outputs direct current with corresponding voltage and current to charge the power storage battery.
Further, the charging switch is a power type high-current switch, and is controlled by the processor, and is used for connecting the output end of the direct-current power supply converter with a charging interface of the power storage battery to charge the power storage battery.
Further, the sampling switch is a small-current signal switch, and is controlled by the processor, and is used for loading the voltage of the power storage battery end to the voltage sampling end of the voltage sampling unit and sampling the voltage of the power storage battery in real time.
Further, the charger also comprises a display screen connected with the processor.
Further, the display screen adopts a touch screen, is connected with the processor through a serial port, and is used for displaying the current charging voltage, charging current, charging power, total charging time and current charging state, charging time and fault information, and is also used for adjusting and setting corresponding charging parameters.
Compared with the prior art, the utility model has the beneficial effects that:
1. the utility model adopts a direct current converter with wide direct current voltage output, the voltage sampling unit samples the current voltage of the power storage battery, the grade of the current voltage of the power storage battery is judged, the corresponding charging parameter is called to charge the power storage battery, and after the charger is connected and started to charge, the processor automatically adjusts the output voltage and current of the charger according to the voltage parameter of the current power storage battery to charge the power storage battery.
2. According to the utility model, a constant-current charging, constant-voltage charging and pulse floating charging three-section charging mode is adopted, constant current is used for charging in a constant-current stage, the charging voltage of the power storage battery slowly rises along with the charging, when the voltage of the power storage battery rises to 2.45V per grid, constant-voltage charging is carried out, in the constant-voltage charging process, the charging voltage of the power storage battery is nearly unchanged, the charging current gradually falls, when the charging current falls to half of the constant-current charging current, the constant-voltage charging is ended, the charging current in the stage is changed into a pulse floating charging stage, the charging current in the stage is smaller, long-time charging is allowed, the power storage battery is maintained, meanwhile, in the stage, the smooth current is changed into pulse direct current charging, the electric quantity of the power storage battery can be fully charged to be nearly 100%, meanwhile, the excessive charging current is prevented from causing overcharge and loss of the power storage battery, and the effect of eliminating negative pole sulfuration is achieved.
3. The utility model adopts corresponding output current and output voltage by automatically measuring the current voltage of the power storage battery, dynamically adjusts the time of constant current, constant voltage and pulse floating charge stages, charging current and charging voltage according to the current voltage change of the power storage battery, leads the charger to be connected with electric fork vehicles with different battery types and different voltage grades, automatically switches to corresponding charging modes according to the collected information and charges the electric fork vehicles, realizes one machine with multiple purposes and one machine with universal use, improves the use efficiency of equipment, reduces the quantity of the charger equipped in large factories, commercial power or other large transportation places, and reduces the equipment investment.
Drawings
Fig. 1 is a schematic block diagram of the structure of the present utility model.
Fig. 2 is a schematic circuit diagram of a voltage sampling unit according to the present utility model.
Detailed Description
The following description of the embodiments of the present utility model will be made clearly and completely with reference to the accompanying drawings, in which it is apparent that the embodiments described are only some embodiments of the present utility model, but not all embodiments. 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.
Referring to fig. 1, an intelligent high-frequency charger for charging a storage battery of an electric forklift is provided, wherein the output end of the charger is connected with a charging interface of a power storage battery, the charger comprises a direct-current power supply converter, a processor, a voltage sampling unit, a charging switch J2 and a sampling switch J1, and the output end of the direct-current power supply converter, the charging switch J2 and the charging interface of the power storage battery are sequentially connected to form a charging loop for charging the power storage battery; the charging interface of the power storage battery, the sampling switch J1, the voltage sampling unit and the processor are sequentially connected to form a voltage sampling loop for detecting the current voltage of the power storage battery; the processor is electrically connected with the direct-current power supply converter and is used for automatically adjusting the output voltage and the output current of the direct-current power supply converter according to the detected current voltage of the power storage battery; the charging switch J2 and the sampling switch J1 are controlled by a processor to be closed and opened.
The input end of the direct current power supply converter is externally connected with a three-phase alternating current power supply and is used for converting external alternating current into direct current and outputting the direct current.
In addition, the charging switch J2 is a power type high-current switch and is controlled by the processor, and can charge the power storage battery by using tens of amperes to one hundred amperes of current for connecting the output end of the direct-current power supply converter with the charging interface of the power storage battery.
The sampling switch J1 is a small-current signal switch and is also controlled by the processor, and can be used for loading the voltage of the power storage battery end to the voltage sampling end of the voltage sampling unit through the current of the milliamp level so as to sample the voltage of the power storage battery in real time.
Specifically, the direct-current power supply converter is formed by connecting a plurality of power supply conversion modules in parallel, and can realize wide-range direct-current voltage output so as to meet the charging voltage and charging current requirements of the power storage battery.
The sampling switch J1 is connected between the positive end of the charging interface of the power storage battery and the input end of the voltage sampling unit, after the sampling switch J1 is closed, the voltage of the power storage battery is applied to the voltage sampling unit, and the processor obtains the current voltage of the power storage battery through isolation sampling.
The sampling signal input end of the processor is connected with the output end of the voltage sampling unit, the processor is communicated with the direct current power supply converter through the CAN network, the processor sends different output voltage and output current requests to the direct current power supply converter through the CAN network according to the detected current voltage of the power storage battery, and after the charging switch J2 is closed, the direct current power supply converter outputs direct current of corresponding voltage and current to charge the power storage battery.
The charger also comprises a display screen connected with the processor.
The display screen adopts a touch screen and is connected with the processor through a serial port, and is used for displaying the current charging voltage, charging current, charging power, total charging time, current charging state, charging time, fault information and the like, and is also used for carrying out corresponding charging parameter adjustment, setting and the like.
Referring to fig. 2, the voltage sampling unit of the present utility model can avoid that the ground terminal inside the charger shares the same ground terminal with the negative electrode of the power storage battery, specifically is an isolated voltage sampling unit, wherein the sampling resistor is a high-precision series resistor network, and is composed of resistors R1, R2, R3 and a capacitor C1, the voltage on the power storage battery is divided by the resistor network and then is sent to the 2 pins of the ADC sampling unit U1, that is, the reference voltage Verin is input to the non-inverting input terminal of the 12-bit ADC sampling module MCP3201, the inverting input terminal thereof is connected with the ground terminal of the power storage battery, the control input terminal of the ADC sampling module MCP3201 is connected with the processor by three isolated optical couples U2, U3, U4, when the processor needs to sample, only the ADC sampling module MCP3201 needs to be gated and corresponding clock pulses are sent, and the current sampling voltage value is converted into the actual voltage of the power storage battery according to the proportion after the falling edge readout data of the clock.
The utility model is further described below with reference to the accompanying drawings:
the utility model specifically comprises the following steps when a power storage battery is charged:
s1, online stage: after the charger is electrified, the processor starts to work, the sampling switch J1 is controlled to be closed, after the output end of the charger is connected with the charging interface of the power storage battery, the voltage on the power storage battery is applied to the voltage sampling unit through the charging switch J1, the voltage is sampled through the ADC sampling module MCP3201, and finally the sampling value is converted into the current voltage of the power storage battery by the processor. The working voltage of the power storage battery can be generally divided into 24V, 48V, 36V, 72V and 80V, the processor compares the sampled voltage value with the voltage value to find the nearest voltage value, the voltage value is used as the working voltage of the current power storage battery, the voltage is used as the charging parameter of the charger for charging preparation, in order to explain the working principle of the power storage battery in more detail, the 48V voltage is used as the working voltage of the power storage battery, and the charging methods of the power storage battery with other voltage values are similar to the above, and no further description is given.
S2, a precharge phase: the processor detects the current voltage of the power storage battery and judges the level of the current voltage of the power storage battery, the voltage of the single battery is usually 2V, the power storage battery is formed by connecting 24 batteries in series on the assumption that the voltage of the power storage battery is 48V, the static series voltage of the power storage battery is about 51V, the maximum charging voltage of the single battery is 2.45V in the charging process, and the maximum charging voltage of the series connection of the single battery is 58.8V.
The processor sends CAN instructions to the direct-current power supply converter through a CAN network, and controls the charging switch J2 to be closed, the processor increases the output voltage and the output current step by step, when the output voltage and the output current of the direct-current power supply converter are increased to set values, namely, the voltage value 48V and the current value 25A required by preheating the power storage battery are increased, the direct-current power supply converter charges the power storage battery by the current 25A, at the moment, the output voltage and the output current of the direct-current power supply converter are not increased any more, the power storage battery is precharged, after the charging is maintained for 40 seconds, the output voltage and the output current of the direct-current power supply converter are increased to the designated values again, namely, the charging voltage is increased to 58.8V, and the charging current is changed into a constant-current charging stage after the charging current is increased to 65A. At this time, the actual charging current of the power storage battery is 65A, and the actual charging voltage is about 51-55V according to the discharging condition before charging.
S3, constant-current charging stage: the processor sends a request to the direct current power supply converter through the CAN network according to the detected current voltage of the power storage battery, constant-current charging is carried out by using the designated voltage (58.8V) and current (65A), in the process, the charging voltage of the power storage battery slowly rises from 51V, at the moment, the actual charging current of the power storage battery is 65A, and when the charging voltage of the power storage battery rises to a jump value V1 (58.8V), the constant-voltage charging stage is changed.
S4, constant voltage charging: the processor sends a request to the direct current power supply converter through the CAN network according to the detected current voltage of the power storage battery, constant voltage charging is carried out by the appointed voltage (namely 60V) and current (namely 65A), in the process, the charging current of the power storage battery slowly drops from 65A, at the moment, the actual charging voltage of the power storage battery is close to 60V, and when the charging current of the power storage battery drops to a jump value I1 (namely < 32.5A), the pulse floating charging mode is changed.
S5, pulse floating charging: before entering the pulse floating charge stage, the electric quantity of the power storage battery is basically full, the pulse floating charge stage is a process of floating charge and maintenance of the power storage battery, the total duration of the pulse floating charge stage is more than 3 hours, the power storage battery is respectively charged by two different currents in a plurality of floating charge stages, the charging voltage is 60V when the power storage battery is charged by small current, and the charging voltage can be slightly higher than 60V when the power storage battery is charged by large current, so that the periodic change of the charging current is facilitated, and the effect of pulse charging is achieved.
Wherein the first floating charge stage takes 4 minutes as a charging period, in each charging period, the charging current changes once every minute, and is sequentially 13A,39A and 39A, and N periods are executed until the first floating charge stage is finished; the second floating charge phase takes 4 minutes as a charging period, in each charging period, the charging current changes once every minute, and is sequentially 13A,39A and 39A, and N periods are executed until the second floating charge phase is finished; the third float charging phase takes 4 minutes as a charging period, and in each charging period, the charging current changes once every minute, namely 13A,13A and 39A, in sequence until the charging current of the power storage battery drops to be smaller than a set value I2 (namely < 5A), and the power storage battery is switched to a shutdown mode.
S6, a shutdown stage: in the pulse floating charge stage, when the charging current is reduced to be smaller than a set value I2 (namely < 5A), or the total charging time is longer than 10 hours after the power-on, the power-off process is started.
At this time, the processor enters a soft shutdown mode, in the soft shutdown mode, the processor sends a request to the direct current power supply converter through the CAN network, the charging voltage and the charging current of the power storage battery are reduced step by step, and when the charging voltage and the charging current of the power storage battery are reduced to specified values (namely, the charging voltage is lower than the actual voltage by 10V and the charging current is lower than 10A), the processor sends a shutdown instruction to the direct current converter, and controls the charging switch J2 to be disconnected, so that the connection between the charger and the power storage battery is disconnected.
Although the present disclosure describes embodiments, not every embodiment is described in terms of a single embodiment, and such description is for clarity only, and one skilled in the art will recognize that the embodiments described in the disclosure as a whole may be combined appropriately to form other embodiments that will be apparent to those skilled in the art.
Therefore, the above description is only of the preferred embodiments of the present application and is not intended to limit the scope of the present application; all changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.
Claims (9)
1. An intelligent high-frequency charger for charging an electric fork-lift storage battery, wherein the output end of the charger is connected with a charging interface of a power storage battery, and the intelligent high-frequency charger is characterized in that: the charger comprises a direct-current power supply converter, a processor, a voltage sampling unit, a charging switch and a sampling switch, wherein the output end of the direct-current power supply converter, the charging switch and a charging interface of the power storage battery are sequentially connected to form a charging loop for charging the power storage battery; the charging interface, the sampling switch, the voltage sampling unit and the processor of the power storage battery are sequentially connected to form a voltage sampling loop for detecting the current voltage of the power storage battery; the processor is electrically connected with the direct-current power supply converter and is used for automatically adjusting the output voltage and the output current of the direct-current power supply converter according to the detected current voltage of the power storage battery; the charging switch and the sampling switch are controlled by the processor to be closed and opened.
2. The intelligent high-frequency charger for charging a storage battery of an electric forklift as claimed in claim 1, wherein: the input end of the direct current power supply converter is externally connected with a three-phase alternating current power supply and is used for converting external alternating current into direct current and outputting the direct current.
3. The intelligent high-frequency charger for charging a storage battery of an electric forklift as claimed in claim 2, wherein: the direct-current power supply converter is formed by connecting a plurality of power supply conversion modules in parallel.
4. The intelligent high-frequency charger for charging a storage battery of an electric forklift as claimed in claim 1, wherein: the sampling switch is connected between the positive end of the charging interface of the power storage battery and the input end of the voltage sampling unit, after the sampling switch is closed, the voltage of the power storage battery is applied to the voltage sampling unit, and the processor obtains the current voltage of the power storage battery through isolation sampling.
5. The intelligent high-frequency charger for charging a storage battery of an electric forklift as claimed in claim 1, wherein: the sampling signal input end of the processor is connected with the output end of the voltage sampling unit, the processor is communicated with the direct current power supply converter through a CAN network, the processor sends different output voltage and output current requests to the direct current power supply converter through the CAN network according to the detected current voltage of the power storage battery, and after the charging switch is closed, the direct current power supply converter outputs direct current of corresponding voltage and current to charge the power storage battery.
6. The intelligent high-frequency charger for charging a storage battery of an electric forklift as claimed in claim 1, wherein: the charging switch is a power type high-current switch and is controlled by the processor, and the charging switch is used for connecting the output end of the direct-current power supply converter with a charging interface of the power storage battery to charge the power storage battery.
7. The intelligent high-frequency charger for charging a storage battery of an electric forklift as claimed in claim 1, wherein: the sampling switch is a small-current signal switch and is controlled by the processor, and the sampling switch is used for loading the voltage of the power storage battery end to the voltage sampling end of the voltage sampling unit and sampling the voltage of the power storage battery in real time.
8. The intelligent high-frequency charger for charging a storage battery of an electric forklift as claimed in claim 1, wherein: the charger also comprises a display screen connected with the processor.
9. The intelligent high-frequency charger for charging a battery of an electric forklift as claimed in claim 8, wherein: the display screen adopts a touch screen, is connected with the processor through a serial port, and is used for displaying the current charging voltage, charging current, charging power, total charging ampere time, current charging state, charging time and fault information, and is also used for corresponding charging parameter adjustment and setting.
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN116278963A (en) * | 2023-04-18 | 2023-06-23 | 安徽威斯姆电子科技有限公司 | Intelligent high-frequency charger of electric forklift and charging method thereof |
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN116278963A (en) * | 2023-04-18 | 2023-06-23 | 安徽威斯姆电子科技有限公司 | Intelligent high-frequency charger of electric forklift and charging method thereof |
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