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一種智能型全自動快速充電機的設計

2019/4/3 9:10:35??????點擊:
1 充電機的(de)現狀(zhuang)
    目(mu)前,礦用(yong)電(dian)(dian)機(ji)(ji)車蓄電(dian)(dian)池的(de)(de)充(chong)(chong)(chong)電(dian)(dian),無論是(shi)(shi)恒流(liu)(liu)(liu)充(chong)(chong)(chong)電(dian)(dian)、恒壓(ya)充(chong)(chong)(chong)電(dian)(dian)或是(shi)(shi)先恒流(liu)(liu)(liu)再恒壓(ya)的(de)(de)分段式充(chong)(chong)(chong)電(dian)(dian),都有(you)一個共同的(de)(de)問(wen)題,就是(shi)(shi)這種小(xiao)電(dian)(dian)流(liu)(liu)(liu)慢充(chong)(chong)(chong)方式,蓄電(dian)(dian)池初充(chong)(chong)(chong)需(xu)70小(xiao)時以(yi)上,進(jin)行普通(tong)充(chong)(chong)(chong)電(dian)(dian)也需(xu)10小(xiao)時以(yi)上,這種充(chong)(chong)(chong)電(dian)(dian)方式在充(chong)(chong)(chong)電(dian)(dian)過程的(de)(de)初期,充(chong)(chong)(chong)電(dian)(dian)電(dian)(dian)流(liu)(liu)(liu)遠小(xiao)于蓄電(dian)(dian)池可(ke)接受的(de)(de)充(chong)(chong)(chong)電(dian)(dian)電(dian)(dian)流(liu)(liu)(liu),因而拉長了充(chong)(chong)(chong)電(dian)(dian)時間,造成電(dian)(dian)能的(de)(de)浪(lang)費。而在充(chong)(chong)(chong)電(dian)(dian)過程的(de)(de)后(hou)期,充(chong)(chong)(chong)電(dian)(dian)電(dian)(dian)流(liu)(liu)(liu)又大(da)(da)于蓄電(dian)(dian)池可(ke)接受的(de)(de)電(dian)(dian)流(liu)(liu)(liu),蓄電(dian)(dian)池內部(bu)溫度升(sheng)高,產生大(da)(da)量析氣,并形成內部(bu)硫(liu)化結晶,大(da)(da)大(da)(da)縮(suo)短了蓄電(dian)(dian)池的(de)(de)循環使用(yong)壽命,甚(shen)至有(you)可(ke)能永久性(xing)地損壞電(dian)(dian)池。這不(bu)僅造成了浪(lang)費,也增加了對環境(jing)的(de)(de)污(wu)染。同時,這種傳統(tong)充(chong)(chong)(chong)電(dian)(dian)機(ji)(ji)采用(yong)變壓(ya)器變壓(ya)整(zheng)流(liu)(liu)(liu),可(ke)控硅控制的(de)(de)途徑(jing),技(ji)術落后(hou),設備笨重(zhong),可(ke)靠性(xing)也差。
    美國科學家(jia)馬斯(si)通過(guo)(guo)(guo)對(dui)鉛酸蓄(xu)(xu)電(dian)(dian)(dian)(dian)池(chi)(chi)(chi)的(de)(de)大(da)量試(shi)驗(yan)研究,提出了(le)一條(tiao)鉛酸蓄(xu)(xu)電(dian)(dian)(dian)(dian)池(chi)(chi)(chi)可(ke)接受(shou)的(de)(de)充(chong)(chong)(chong)電(dian)(dian)(dian)(dian)電(dian)(dian)(dian)(dian)流(liu)曲線。在(zai)充(chong)(chong)(chong)電(dian)(dian)(dian)(dian)過(guo)(guo)(guo)程(cheng)的(de)(de)初期,蓄(xu)(xu)電(dian)(dian)(dian)(dian)池(chi)(chi)(chi)可(ke)接受(shou)的(de)(de)充(chong)(chong)(chong)電(dian)(dian)(dian)(dian)電(dian)(dian)(dian)(dian)流(liu)很大(da)。隨著充(chong)(chong)(chong)電(dian)(dian)(dian)(dian)過(guo)(guo)(guo)程(cheng)的(de)(de)延續,充(chong)(chong)(chong)電(dian)(dian)(dian)(dian)電(dian)(dian)(dian)(dian)流(liu)逐漸按指數規(gui)律減小。讓充(chong)(chong)(chong)電(dian)(dian)(dian)(dian)機的(de)(de)充(chong)(chong)(chong)電(dian)(dian)(dian)(dian)電(dian)(dian)(dian)(dian)流(liu)按這樣一條(tiao)理(li)想(xiang)電(dian)(dian)(dian)(dian)流(liu)曲線變化(hua)(hua),就可(ke)以(yi)最大(da)限(xian)度(du)(du)的(de)(de)提高充(chong)(chong)(chong)電(dian)(dian)(dian)(dian)效率。同時,試(shi)驗(yan)表明,采用(yong)脈(mo)沖式(shi)的(de)(de)充(chong)(chong)(chong)電(dian)(dian)(dian)(dian)方式(shi)是消(xiao)除各(ge)種極(ji)(ji)(ji)化(hua)(hua)現(xian)象,提高充(chong)(chong)(chong)電(dian)(dian)(dian)(dian)速度(du)(du),延長蓄(xu)(xu)電(dian)(dian)(dian)(dian)池(chi)(chi)(chi)循(xun)(xun)環使(shi)用(yong)壽(shou)命的(de)(de)有效途徑。這種充(chong)(chong)(chong)電(dian)(dian)(dian)(dian)方式(shi)是在(zai)對(dui)蓄(xu)(xu)電(dian)(dian)(dian)(dian)池(chi)(chi)(chi)充(chong)(chong)(chong)電(dian)(dian)(dian)(dian)的(de)(de)過(guo)(guo)(guo)程(cheng)中適時暫停(ting)充(chong)(chong)(chong)電(dian)(dian)(dian)(dian),并適當(dang)加(jia)(jia)入放電(dian)(dian)(dian)(dian)脈(mo)沖。當(dang)電(dian)(dian)(dian)(dian)池(chi)(chi)(chi)充(chong)(chong)(chong)電(dian)(dian)(dian)(dian)停(ting)止時,電(dian)(dian)(dian)(dian)池(chi)(chi)(chi)的(de)(de)歐姆(mu)極(ji)(ji)(ji)化(hua)(hua)消(xiao)失(shi),濃差(cha)極(ji)(ji)(ji)化(hua)(hua)和電(dian)(dian)(dian)(dian)化(hua)(hua)學極(ji)(ji)(ji)化(hua)(hua)減弱。若能在(zai)電(dian)(dian)(dian)(dian)池(chi)(chi)(chi)充(chong)(chong)(chong)電(dian)(dian)(dian)(dian)過(guo)(guo)(guo)程(cheng)中讓其(qi)反向放電(dian)(dian)(dian)(dian),則極(ji)(ji)(ji)化(hua)(hua)現(xian)象迅速消(xiao)失(shi),電(dian)(dian)(dian)(dian)池(chi)(chi)(chi)內部溫(wen)度(du)(du)也會因放電(dian)(dian)(dian)(dian)而得(de)到有效控制。脈(mo)沖電(dian)(dian)(dian)(dian)流(liu)充(chong)(chong)(chong)放電(dian)(dian)(dian)(dian)對(dui)電(dian)(dian)(dian)(dian)池(chi)(chi)(chi)極(ji)(ji)(ji)板有加(jia)(jia)強其(qi)韌性的(de)(de)效果(guo),可(ke)以(yi)大(da)大(da)提高蓄(xu)(xu)電(dian)(dian)(dian)(dian)池(chi)(chi)(chi)的(de)(de)循(xun)(xun)環使(shi)用(yong)壽(shou)命。同時,由于(yu)電(dian)(dian)(dian)(dian)池(chi)(chi)(chi)極(ji)(ji)(ji)化(hua)(hua)現(xian)象的(de)(de)消(xiao)失(shi),脈(mo)沖電(dian)(dian)(dian)(dian)流(liu)又(you)可(ke)以(yi)深層次地激活電(dian)(dian)(dian)(dian)池(chi)(chi)(chi)內部的(de)(de)活性物質,從(cong)而大(da)幅(fu)度(du)(du)提高蓄(xu)(xu)電(dian)(dian)(dian)(dian)池(chi)(chi)(chi)的(de)(de)充(chong)(chong)(chong)電(dian)(dian)(dian)(dian)有效容量。
    當(dang)前(qian),帶有(you)自(zi)適應控制技術的脈沖式(shi)充電(dian)機(ji)已成為礦用電(dian)機(ji)車充電(dian)機(ji)的主要發展方(fang)向。因(yin)此,開發新一代(dai)的智(zhi)能快速(su)充電(dian)機(ji)不(bu)僅可以(yi)提高充電(dian)效率,降(jiang)低使用單位的運營成本,同時也具(ju)有(you)節能、環(huan)保等諸方(fang)面的社會意(yi)義。
2 一種智能型全自動快速充電機(ji)
2.1 電(dian)氣(qi)原理
    充電機電氣(qi)原(yuan)理框圖見圖1。電氣(qi)原(yuan)理分為(wei)三大部分,即逆(ni)變主通(tong)道、檢測控制(zhi)單元(yuan)(yuan)和對話單元(yuan)(yuan)(顯示操作(zuo)單元(yuan)(yuan))。
    逆(ni)變主通道將(jiang)380 V交(jiao)流(liu)電(dian)(dian)源變換(huan)為可對電(dian)(dian)池進(jin)行充電(dian)(dian)的可控直(zhi)流(liu)電(dian)(dian)源,由輸入(ru)回(hui)路、工(gong)頻整流(liu)濾波(bo)電(dian)(dian)路、移相全橋(ZVT-PWM)變換(huan)電(dian)(dian)路、高頻整流(liu)電(dian)(dian)路濾波(bo)電(dian)(dian)路、輸出(chu)回(hui)路及放電(dian)(dian)回(hui)路組(zu)成。
    輸入回(hui)(hui)(hui)路即供電(dian)回(hui)(hui)(hui)路,在非運行狀態時,可切(qie)斷主通道(dao)電(dian)源(yuan)。輸入回(hui)(hui)(hui)路設(she)計有(you)軟啟動功(gong)能,避免啟動沖擊(ji)對回(hui)(hui)(hui)路元件造成的(de)損傷。
    工頻整(zheng)流(liu)濾波(bo)電(dian)路將380 V交流(liu)電(dian)整(zheng)流(liu)為約550 V的直流(liu)電(dian),如圖2所示。
    移(yi)相(xiang)全橋功(gong)率(lv)變換電路是主通(tong)道的(de)核心,完(wan)成(cheng)從(cong)直(zhi)流到(dao)(dao)(dao)交流再到(dao)(dao)(dao)直(zhi)流的(de)變換。如圖(tu)3所示。通(tong)過改(gai)(gai)變橋臂(bei)IGBT控制信號(hao)的(de)相(xiang)位,來改(gai)(gai)變耦合(he)到(dao)(dao)(dao)高頻(pin)變壓器的(de)波形寬度,從(cong)而(er)改(gai)(gai)變輸出(chu)給(gei)被充電池(chi)的(de)電流、電壓值。
    高頻(pin)(pin)整流(liu)(liu)濾波電路將(jiang)高頻(pin)(pin)變(bian)壓器副邊(bian)的(de)高頻(pin)(pin)交流(liu)(liu)電,整流(liu)(liu)為(wei)電池(chi)充電要求的(de)平滑直流(liu)(liu)電。
    輸出開關(guan)電(dian)路在(zai)非(fei)充電(dian)狀態下保證主通(tong)道與被充電(dian)池的(de)(de)隔(ge)離(li),防止發(fa)生反接造成的(de)(de)危險。
    放(fang)(fang)電電路(lu)實現"充(chong)-停-放(fang)(fang)-停-充(chong)"的充(chong)電方式,從而改善電池(chi)的充(chong)電效果和(he)恢復電池(chi)的性能(neng)。此外,還可(ke)以對電能(neng)未消(xiao)耗完的待(dai)充(chong)電池(chi)進行(xing)放(fang)(fang)電處理。
    控制(zhi)單(dan)元接(jie)收來自對話單(dan)元給定的(de)參(can)數(shu)和(he)命(ming)令,并通過對主通道(dao)各(ge)相關參(can)數(shu)的(de)實時(shi)檢測,動(dong)態控制(zhi)主通道(dao)的(de)工(gong)作,實現(xian)要求的(de)充電功能和(he)充電進程。同時(shi)為設備提供多種保護(hu)。
    控(kong)(kong)(kong)制單元采用最(zui)新嵌入式(shi)內核芯片ARM設計。采集(ji)模擬量為:4路溫(wen)度、輸(shu)出電(dian)流、放(fang)電(dian)電(dian)流、輸(shu)出電(dian)壓和電(dian)池電(dian)壓。控(kong)(kong)(kong)制量為:輸(shu)入開關(guan)、軟(ruan)啟動(dong)、輸(shu)出開關(guan)、輸(shu)出電(dian)容放(fang)電(dian)和ZVT-PWM變換(huan)控(kong)(kong)(kong)制等
    控制單(dan)(dan)元與對(dui)話(hua)單(dan)(dan)元之間為RS232全雙工通(tong)信。控制單(dan)(dan)元接收(shou)來自對(dui)話(hua)單(dan)(dan)元的(de)各種控制命令,并向對(dui)話(hua)單(dan)(dan)元實時(shi)發送數據。
    對話單(dan)元是整機操(cao)作(zuo)(zuo)平臺,接收并實現(xian)操(cao)作(zuo)(zuo)者的(de)各(ge)種工(gong)(gong)作(zuo)(zuo)指令,完成各(ge)種工(gong)(gong)作(zuo)(zuo)方式的(de)參(can)數(shu)(shu)設定(ding)、記憶及(ji)各(ge)種動靜態(tai)參(can)數(shu)(shu)顯示。對話單(dan)元由(you)控(kong)制芯片、LCM、參(can)數(shu)(shu)存儲器和操(cao)作(zuo)(zuo)按鍵(jian)組(zu)成。
    當充(chong)電(dian)機進入工作狀態(tai)時,設備首先進行自檢。自檢項目包(bao)括充(chong)電(dian)電(dian)池是否(fou)反接、主通道各部分(fen)是否(fou)正常。
    自(zi)檢(jian)結(jie)果(guo)將發(fa)送給對話單元。
    自檢正(zheng)常(chang)時,設備處于待(dai)命(ming)(ming)狀態,準備接收(shou)由對(dui)話單元發來的各種命(ming)(ming)令及(ji)參(can)數,并按要求開始(shi)相應(ying)的工(gong)作進程(cheng)。
    自(zi)檢故障(zhang)(zhang)時,對話(hua)單元顯示故障(zhang)(zhang)編號,等待檢修。
2.2 工(gong)作方(fang)式
    智能型全自(zi)動快速充電機設計了三種工作方式:便(bian)捷方式、智能方式和放電方式。
    便(bian)捷(jie)方(fang)(fang)式(shi)。一種(zhong)常規的恒(heng)流限壓(ya)定時充(chong)電(dian)(dian)(dian)工(gong)作方(fang)(fang)式(shi),此方(fang)(fang)式(shi)工(gong)作時,充(chong)電(dian)(dian)(dian)機(ji)以設(she)定電(dian)(dian)(dian)流向負載電(dian)(dian)(dian)瓶恒(heng)流充(chong)電(dian)(dian)(dian),當(dang)充(chong)電(dian)(dian)(dian)電(dian)(dian)(dian)壓(ya)達到(dao)(dao)限制電(dian)(dian)(dian)壓(ya)時,電(dian)(dian)(dian)壓(ya)不(bu)再上(shang)升(sheng),而充(chong)電(dian)(dian)(dian)電(dian)(dian)(dian)流逐(zhu)漸(jian)減小(xiao)。當(dang)充(chong)電(dian)(dian)(dian)時間(jian)達到(dao)(dao)設(she)定時間(jian)時,充(chong)電(dian)(dian)(dian)機(ji)自動結(jie)束充(chong)電(dian)(dian)(dian)過(guo)程(cheng)。此種(zhong)模式(shi)充(chong)電(dian)(dian)(dian),電(dian)(dian)(dian)流不(bu)宜(yi)超過(guo)100 A,否則電(dian)(dian)(dian)瓶不(bu)易充(chong)滿,且析(xi)氣量大。
    智能方(fang)式。一(yi)種針對(dui)不同規格型號的(de)(de)電池(chi)采取不同整定(ding)參數充(chong)電的(de)(de)工作方(fang)式。而對(dui)每一(yi)種電池(chi)又有三種充(chong)電模(mo)(mo)式,即初充(chong)模(mo)(mo)式、恒(heng)流模(mo)(mo)式和快速模(mo)(mo)式。
    a.初(chu)充(chong)(chong)模(mo)式。為兩階(jie)段的定(ding)電(dian)流、定(ding)時間(jian)的自動(dong)充(chong)(chong)電(dian)方式。主要為新電(dian)池初(chu)充(chong)(chong)設計(ji)。此(ci)模(mo)式充(chong)(chong)電(dian),兩階(jie)段電(dian)流均不宜(yi)過大,
    b.恒流模式(shi)。開始充電時為(wei)恒流工(gong)作,當電壓升高到設(she)定值時轉入(ru)穩壓工(gong)作,當充電時間(jian)達到設(she)定時間(jian)或充電容量(liang)滿(man)時自(zi)動(dong)停(ting)止充電,這是基本進程。當充電時間(jian)足夠長時,基本進程會疊加周期性的放電脈沖,疊加后的充電過程為(wei)"充-停(ting)-放-停(ting)-充"。
    c. 快速(su)模式。快速(su)模式包含三個順(shun)序階段(duan):恒(heng)(heng)(heng)流(liu)(liu)(liu)、恒(heng)(heng)(heng)壓(ya)和小電(dian)(dian)(dian)(dian)(dian)(dian)(dian)流(liu)(liu)(liu)維持。恒(heng)(heng)(heng)流(liu)(liu)(liu)段(duan)以(yi)大電(dian)(dian)(dian)(dian)(dian)(dian)(dian)流(liu)(liu)(liu)充(chong)(chong)電(dian)(dian)(dian)(dian)(dian)(dian)(dian)為(wei)特征,當充(chong)(chong)電(dian)(dian)(dian)(dian)(dian)(dian)(dian)量(liang)達到(dao)(dao)設(she)定(ding)(ding)(ding)容(rong)量(liang)或充(chong)(chong)電(dian)(dian)(dian)(dian)(dian)(dian)(dian)時(shi)(shi)間達到(dao)(dao)設(she)定(ding)(ding)(ding)值(zhi)或電(dian)(dian)(dian)(dian)(dian)(dian)(dian)壓(ya)升至限定(ding)(ding)(ding)值(zhi)時(shi)(shi)結(jie)束(shu),轉(zhuan)入(ru)(ru)恒(heng)(heng)(heng)壓(ya)段(duan)。恒(heng)(heng)(heng)流(liu)(liu)(liu)段(duan)可使電(dian)(dian)(dian)(dian)(dian)(dian)(dian)瓶(ping)恢復(fu)80%左右的容(rong)量(liang)。恒(heng)(heng)(heng)壓(ya)段(duan)則維持恒(heng)(heng)(heng)流(liu)(liu)(liu)充(chong)(chong)電(dian)(dian)(dian)(dian)(dian)(dian)(dian)結(jie)束(shu)時(shi)(shi)的電(dian)(dian)(dian)(dian)(dian)(dian)(dian)壓(ya),而電(dian)(dian)(dian)(dian)(dian)(dian)(dian)流(liu)(liu)(liu)逐漸(jian)減小,當恒(heng)(heng)(heng)壓(ya)充(chong)(chong)電(dian)(dian)(dian)(dian)(dian)(dian)(dian)達到(dao)(dao)設(she)定(ding)(ding)(ding)時(shi)(shi)間時(shi)(shi),自動轉(zhuan)入(ru)(ru)維持充(chong)(chong)電(dian)(dian)(dian)(dian)(dian)(dian)(dian)過(guo)(guo)(guo)程(cheng)。快速(su)模式和恒(heng)(heng)(heng)流(liu)(liu)(liu)模式一樣,當充(chong)(chong)電(dian)(dian)(dian)(dian)(dian)(dian)(dian)時(shi)(shi)間足夠長時(shi)(shi),基本進(jin)程(cheng)會疊加周期性的放電(dian)(dian)(dian)(dian)(dian)(dian)(dian)脈(mo)沖,疊加后的充(chong)(chong)電(dian)(dian)(dian)(dian)(dian)(dian)(dian)過(guo)(guo)(guo)程(cheng)為(wei)"充(chong)(chong)-停-放-停-充(chong)(chong)"。恒(heng)(heng)(heng)壓(ya)過(guo)(guo)(guo)程(cheng)結(jie)束(shu)時(shi)(shi),電(dian)(dian)(dian)(dian)(dian)(dian)(dian)瓶(ping)容(rong)量(liang)可恢復(fu)95%以(yi)上。當充(chong)(chong)電(dian)(dian)(dian)(dian)(dian)(dian)(dian)進(jin)程(cheng)轉(zhuan)入(ru)(ru)維持充(chong)(chong)電(dian)(dian)(dian)(dian)(dian)(dian)(dian)過(guo)(guo)(guo)程(cheng)時(shi)(shi),脈(mo)沖疊加停止。放電(dian)(dian)(dian)(dian)(dian)(dian)(dian)方(fang)式是(shi)為(wei)人(ren)工對電(dian)(dian)(dian)(dian)(dian)(dian)(dian)瓶(ping)放電(dian)(dian)(dian)(dian)(dian)(dian)(dian)而設(she)計的功能。進(jin)入(ru)(ru)該方(fang)式時(shi)(shi),電(dian)(dian)(dian)(dian)(dian)(dian)(dian)瓶(ping)按照(zhao)設(she)定(ding)(ding)(ding)電(dian)(dian)(dian)(dian)(dian)(dian)(dian)流(liu)(liu)(liu)放電(dian)(dian)(dian)(dian)(dian)(dian)(dian),當電(dian)(dian)(dian)(dian)(dian)(dian)(dian)瓶(ping)電(dian)(dian)(dian)(dian)(dian)(dian)(dian)壓(ya)降(jiang)到(dao)(dao)設(she)定(ding)(ding)(ding)值(zhi)時(shi)(shi)自動停止放電(dian)(dian)(dian)(dian)(dian)(dian)(dian)。
2.3 技術性能和參數
    1)額定輸入電(dian)壓:380 VAC±10%50 Hz;
    2)額定輸出功率:30 kW;
    3)直流(liu)輸出電流(liu):5-200 A;
    4)直(zhi)流輸出電(dian)壓(ya):30~300 V;
    5)工作(zuo)模式(shi):三種,便捷充電(dian)、智(zhi)能充電(dian)和自動放電(dian)。智(zhi)能充電(dian)模式(shi)分為三種充電(dian)方式(shi),即初(chu)充方式(shi)、恒流(liu)方式(shi)和快速(su)方式(shi);
    6)具有自檢功(gong)能;
    7)具有電池反接保護功能;
    8)具有過流、過載、短路(lu)和超溫等保護功能;
3 結語(yu)
    本設計以大功率IGBT為核心,嵌入先進的智能控制系統,在充電過程中實時檢測電池的充電情況,自動調整充電參數,實現最佳的模式控制。通過"充-停-放-停-充"的脈沖充電方式,實現了可控的去極化功能和最佳的充電工藝要求,提高了充電效率和電池的充電容量,延長了電池的使用壽命,同時設備還具有自檢及多種保護功能,有著廣闊的應用前景。上(shang)海施能(neng)電器設備有限公司始建于1984年,上海市高新技術企業,中國工業車輛優秀配套供應商,上海電器行業名優產品,主要生產工頻系列充電機,高頻系列充電機,鋰電池充電機系列放電機系列充放電機等電器產品。
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