The first solution

Based on your previous focus on the configuration of wind power full chain circuit breakers and overcurrent protection, the following is a detailed breakdown of the selection, configuration, parameter requirements, and adaptation conditions of button switches, switch power supplies, and circuit breakers in new energy charging solutions:


1、 Button switch
1. Selection requirements
The emergency stop switch must comply with the GB/T 18487.1 standard, with a rated current of ≥ 10A (AC220V), a contact configuration of at least 1NO+1NC, and possess CCC mandatory certification.
The locking switch of the charging gun adopts a miniature limit switch, with a rated current of 1-5A, a lifespan of ≥ 50000 times, and a protection level of IP67.
The mode switch should be a toggle/boat type switch with a rated current of 10-25A and a protection level of IP54 or above.
2. Configuration points
The emergency stop switch is installed on the side of the charging pile at a distance of 1.2-1.5 meters from the ground. It is marked with a red mushroom head and a yellow background, and can cut off the main charging circuit with one click. The response time is ≤ 100ms.
The lock switch is built into the charging gun head, which realizes the functions of locking the gun after insertion, unlocking after charging completion, and emergency release in case of malfunction.
3. Adapt to working conditions
Outdoor outdoor charging stations should be equipped with IP68 waterproof, 304 stainless steel shell models, resistant to a wide temperature range of -40 ℃~+125 ℃, and pass 1000 hours of salt spray testing, suitable for high corrosion scenarios in the wild and coastal areas.
2、 Switching power supply


1. Selection requirements

Select ultra-thin metal shell industrial grade models, 90V-264V full voltage input, working efficiency ≥ 89%, no-load power consumption ≤ 0.1W, meeting energy-saving requirements.
The output voltage is adapted to the 24V/12V control circuit requirements of the charging pile, and has comprehensive protection functions for overvoltage, overcurrent, and overheating.
2. Configuration points
Concentrated in the charging pile control cabin, providing stable low-voltage power supply for BMS communication, indicator lights, relays, and auxiliary control circuits to avoid strong electrical interference in the main circuit.
3. Adapt to working conditions
Suitable for a full range of charging stations including 7kW AC slow charging and 200kW DC fast charging, supporting 24-hour uninterrupted standby operation of the station and strong resistance to grid voltage fluctuations.
3、 Circuit breaker


1. Selection requirements
The AC side leakage protection switch complies with the GB 14048.2 standard, with a leakage action current of 30mA and an action time of ≤ 0.1s. B-type leakage specifications are preferred and can detect smooth DC leakage.
The breaking capacity of the DC side main circuit plastic shell circuit breaker covers the maximum short-circuit current. High power DC piles must use DC dedicated circuit breakers, and AC switches are prohibited from replacing them.
The branch miniature circuit breaker adopts a compact model with leakage protection, which reduces the volume by 30% -50% compared to conventional products and is suitable for compact cabinet layout.
2. Configuration points
Configure a primary circuit breaker on the input side of the communication system to achieve overload, short circuit, and leakage protection for the entire machine; Each charging gun on the DC output side is independently equipped with a branch circuit breaker, and a single gun failure does not affect the operation of other circuits.
All circuit breakers must have three-stage protection function, adapt to the contact heat dissipation requirements under harmonic working conditions, and avoid false tripping caused by harmonics.
3. Adapt to working conditions
Household 7kW AC pile compatible with 220V single-phase 32A specification circuit breaker; Commercial DC piles are suitable for 380V three-phase high current specifications, supporting frequent switching start stop conditions caused by wind power fluctuations, and adapting to power grid fluctuation scenarios.

1、 Selection of core power components

 


1. Charging module (power module)
As the “heart” of the charging station, it accounts for about 50% of the hardware cost. The DC station needs to efficiently convert AC power into DC power. It is preferred to choose models that support wide voltage output and are compatible with new energy vehicles of different voltage platforms. The protection level should not be lower than IP20, and the efficiency should be higher than 95%. The high-power liquid cooling module should meet the dust and waterproof requirements of IP54 or above.
For special scenarios such as wireless charging of underwater rescue robots, the Baiyi New Energy 60-600W sealed wireless charging solution can be selected, with a protection level of IP67, supporting 24V/36V/48V multi voltage input, non-contact charging efficiency of over 90%, and built-in over temperature protection.
2. Car power supply matching
The on-board charger OBC prioritizes the use of integrated silicon carbide solutions, supporting 11kW/22kW high-power AC charging, compatible with bidirectional V2G charging and discharging functions, and adapted to 800V high-voltage vehicle architecture to reduce vehicle space occupation and operational losses.
2、 Configuration of distribution protection components

 


1. Circuit breaker
The plastic shell circuit breaker for the main circuit of the DC charging pile adopts models with leakage protection such as CDM6HL-125L, which has full dimensional protection for overload, short circuit, undervoltage, and leakage, and supports remote status monitoring; The branch miniature residual current circuit breaker adopts the Knight series CDB6HLES, covering A-type and AC type residual current protection specifications, with a compact size that can save 30% to 50% of cabinet space.
2. Contactors and fuses
The high-voltage DC contactor adopts the CDEV6I series and adopts a high and low voltage insulation separation design. By controlling the high-voltage on/off through low voltage, it ensures safe connection and disconnection capabilities; The fuse needs to match the maximum short-circuit current of the circuit, which can break tens of times the rated current of the fault energy, quickly extinguish the arc and cut off the fault circuit to avoid the spread of the fault.
3. Surge and auxiliary power supply
Install surge protectors at the power inlet to resist lightning strikes and power grid surges; The auxiliary switching power supply adopts an ultra-thin metal shell model, with a full voltage input of 90V-264V, a working efficiency of not less than 89%, and a no-load power consumption as low as 0.1W, meeting energy-saving requirements.
3、 Mandatory requirements for core parameters

 

All components must meet the requirements of wide temperature operation from -40 ℃ to 70 ℃, have resistance to salt spray and dust, and be suitable for the complex operating environment of outdoor stations.
Industrial grade models such as TMS320F28034 series are preferred for control chips, which are equipped with isolation amplifiers and voltage stabilization chips to ensure signal acquisition accuracy and avoid protection misoperation caused by harmonic interference.
Copper bars, cables and other current carrying components need to reserve more than 1.5 times the current carrying redundancy, and can withstand a short-term impact of 10 times the rated current. The temperature rise should be controlled within the allowable range of the national standard to avoid overheating and fire under high current.