A safety linkage structure of a high-voltage energy system of an electric vehicle

Abstract

This invention relates to the field of high-voltage electrical technology for electric vehicles, specifically a safe linkage connection structure for a high-voltage energy system in electric vehicles. It includes an integrated power battery assembly, a motor-control integrated power assembly, a DC&OBC&PDU three-in-one charging and distribution assembly, a national standard fast charging port, a national standard slow charging port, a VCU module, and an LV-PDU low-voltage distribution box. The power battery assembly integrates multiple types of dedicated sockets, and each high-voltage component is electrically connected through corresponding sockets, high-voltage hard wires, and low-voltage control lines. The entire vehicle is equipped with a full-link closed-loop HVIL high-voltage interlock circuit, covering all high-voltage components and external interfaces, and monitoring the connection status of high-voltage connectors in real time. Simultaneously, multiple CAN communication buses and low-voltage control lines are deployed to achieve centralized scheduling of high-voltage energy, charging and discharging separation, high-low voltage linkage, and full-link safety protection. The structure is compact, highly safe, and suitable for the high-voltage energy system requirements of unmanned logistics vehicles.

Description

Technical Field

[0001] This invention relates to the field of high-voltage electrical technology for electric vehicles, and in particular to a safety linkage connection structure for a high-voltage energy system of an electric vehicle. Background Technology

[0002] Currently, the high-voltage energy systems of unmanned logistics vehicles still have many technical shortcomings in terms of structural design and safety control. High-voltage components are mostly connected in a decentralized manner, resulting in a chaotic electrical layout for the power battery, drive assembly, charging / discharging interfaces, and power conversion modules, with a lack of unified planning for wiring routes. Existing high-voltage interlock circuits mostly provide localized monitoring, covering only core components and failing to form a complete closed-loop monitoring network. Incomplete high-voltage interlock coverage makes it difficult to monitor the high-voltage connection status in real time throughout the entire process. Furthermore, the linkage between the high-voltage system and the low-voltage control system is insufficient, leading to low energy conversion and scheduling efficiency. The signal interaction at the charging / discharging interfaces is not standardized, and the selection and wiring standards for high-voltage connectors are inconsistent, easily causing safety hazards such as high-voltage leakage, loose connections, and communication abnormalities.

[0003] Since unmanned logistics vehicles are in a state of being unattended for a long time, existing technologies cannot achieve centralized control and full-process safety protection of high-voltage energy, making it difficult to meet the usage requirements of stable operation, efficient power distribution and comprehensive safety protection of high-voltage systems in unmanned logistics vehicles. Summary of the Invention

[0004] The purpose of this invention is to overcome the problems of the prior art and provide a safe linkage connection structure for the high-voltage energy system of electric vehicles. This structure addresses the issues of dispersed connections, incomplete high-voltage interlocks, poor coordination between high and low voltages, significant safety hazards, and low energy efficiency in existing unmanned logistics vehicle high-voltage energy systems. By implementing a full-link closed-loop HVIL high-voltage interlock, multi-circuit high-voltage connections, multi-channel CAN communication, and high-low voltage linkage control, the invention achieves safe, stable, and efficient operation of the high-voltage energy system.

[0005] The above objectives are achieved through the following technical solutions: A safety linkage connection structure for a high-voltage energy system of an electric vehicle includes an integrated power battery assembly, a motor and electronic control power assembly, a DC&OBC&PDU three-in-one charging and distribution assembly, a national standard fast charging port, a national standard slow charging port, a VCU module, and an LV-PDU low-voltage distribution box. The power battery assembly integrates a discharge socket, a charging socket, a distribution socket, and a communication socket. Each high-voltage component is electrically connected through corresponding sockets, high-voltage hard wires, and low-voltage control lines. The vehicle is equipped with a full-link closed-loop HVIL high-voltage interlock circuit. The HVIL high-voltage interlock circuit starts from the HVIL signal terminal of the power battery pack, and sequentially connects the HVIL terminals of the motor and electronic control integrated powertrain and the HVIL terminals of the DC&OBC&PDU three-in-one charging and distribution assembly, and finally connects back to the HVIL detection terminal of the power battery pack to form a closed-loop low-voltage monitoring circuit to monitor the physical connection integrity of all high-voltage connectors in real time. The vehicle also deploys multiple CAN communication buses and low-voltage control lines to realize centralized management and control of the high-voltage energy system, as well as high- and low-voltage linkage and full-link safety protection.

[0006] Furthermore, the discharge socket and the charging socket of the power battery assembly adopt the Tyco 2408619-1 model socket, the power distribution socket adopts the Tyco 2310540_1-CodeA model socket, and the communication socket adopts the Sumitomo 6188-6160 sheath and 8230-5418 terminal. Each socket is functionally assigned to realize the directional transmission of high-voltage energy and communication docking.

[0007] Furthermore, the discharge socket is directly connected to the high-voltage input terminal of the motor and electronic control power assembly via a high-voltage hard wire, the charging socket is connected to the high-voltage input terminal of the national standard fast charging port via a high-voltage hard wire, and the power distribution socket is connected to the high-voltage DC terminal of the DC&OBC&PDU three-in-one charging and power distribution assembly via a high-voltage hard wire, thus forming a drive power supply circuit, a DC fast charging circuit, and a high-voltage power distribution circuit, respectively.

[0008] Furthermore, the DC&OBC&PDU three-in-one charging and power distribution assembly includes a DC-CDC module and an OBC module. The high-voltage DC terminal of the DC-CDC module is connected to the power distribution socket of the power battery assembly, and the output terminal is connected to the low-voltage battery via a fuse and in parallel with the LV-PDU low-voltage distribution box. The LV-PDU low-voltage distribution box is used by the VCU module to realize the low-voltage power distribution and protection of the whole vehicle through LVPDU-CAN.

[0009] Furthermore, the national standard slow charging port is connected to the AC input terminal of the OBC module through the L and N pins. The CC and CP signals of the national standard slow charging port are connected to the charging control port of the DC&OBC&PDU three-in-one charging and power distribution assembly. The output terminal of the OBC module is connected to the power distribution socket. External AC power is converted into DC power by the OBC module to complete AC slow charging of the power battery.

[0010] Furthermore, the VCU module is connected to the power battery assembly, the motor and electronic control integrated power assembly, the DC&OBC&PDU three-in-one charging and distribution assembly, and the national standard fast charging port via the CHASSIS-CAN bus, forming a centralized communication network to realize the status acquisition and command issuance of each high-voltage component.

[0011] Furthermore, the power battery assembly and the DC&OBC&PDU three-in-one charging and distribution assembly are respectively connected to the CC1, CC2, A+, and A- connection terminals of the national standard fast charging port and the CC and CP signal terminals of the national standard slow charging port through internal signal links to complete the charging connection confirmation of DC fast charging and AC slow charging.

[0012] Furthermore, the constant power lines of the KL30 and the ignition power lines of the KL15 are respectively connected to the power battery assembly and the DC&OBC&PDU three-in-one charging and distribution assembly, providing wake-up signals and enable control for the high-voltage system, and realizing the orderly start-up, shutdown and state switching of the high-voltage system.

[0013] Furthermore, the HVIL high-voltage interlock circuit adopts a low-voltage signal series monitoring method. When any high-voltage connector becomes loose, falls off, or a component is opened, the circuit is immediately disconnected. The power battery assembly cuts off the high-voltage output in milliseconds, which is suitable for the unmanned safety requirements of unmanned logistics vehicles.

[0014] The present invention provides a safety linkage connection structure for a high-voltage energy system of an electric vehicle. By setting up multiple types of dedicated sockets to organize high-voltage electrical connections, it realizes the functional zoning of high-voltage circuits. By building a full-link closed-loop high-voltage interlock circuit, it realizes real-time safety monitoring of high-voltage points throughout the vehicle. By deploying multiple communication and low-voltage control lines, it realizes centralized management and control of the high-voltage energy of the whole vehicle and high-low voltage linkage, effectively improving the operational safety and stability of the high-voltage system of unmanned logistics vehicles. Attached Figure Description

[0015] Figure 1 This is a structural block diagram of a safety linkage connection structure for a high-voltage energy system of an electric vehicle according to the present invention; Figure 2 This is an electrical connection diagram of a safety linkage connection structure for a high-voltage energy system of an electric vehicle as described in this invention. Detailed Implementation

[0016] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments. The described embodiments are merely some, not all, of the embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0017] like Figure 1and Figure 2 As shown, this solution provides a safety linkage connection structure for a high-voltage energy system of an electric vehicle, including an integrated power battery assembly, a motor and electronic control power assembly, a DC&OBC&PDU three-in-one charging and distribution assembly, a national standard fast charging port, a national standard slow charging port, a VCU module, and an LV-PDU low-voltage distribution box. The power battery assembly integrates a discharge socket, a charging socket, a power distribution socket, and a communication socket. Each high-voltage component is electrically connected through its corresponding socket, high-voltage hard wire, and low-voltage control line. The vehicle is equipped with a full-link closed-loop HVIL high-voltage interlock circuit. This circuit starts from the HVIL signal terminal of the power battery assembly, sequentially connects the HVIL terminals of the motor and electronic control integrated power assembly and the HVIL terminals of the DC, OBC, and PDU three-in-one charging and distribution assembly, and finally connects back to the HVIL detection terminal of the power battery assembly to form a closed-loop low-voltage monitoring circuit, which monitors the physical connection integrity of all high-voltage connectors in real time. The vehicle also deploys multiple CAN communication buses and low-voltage control lines to achieve centralized management and control of the high-voltage energy system, high-low voltage linkage, and full-link safety protection.

[0018] The power battery assembly integrates a discharge socket, a charging socket, a power distribution socket, and a communication socket, corresponding to power output, DC fast charging, high-voltage power distribution, and centralized communication functions, respectively. The discharge socket connects to the integrated motor and electronic control powertrain, providing driving energy to the vehicle; the charging socket connects to the national standard fast charging port for DC high-voltage charging; and the power distribution socket connects to the DC, OBC, and PDU three-in-one charging and power distribution assembly, enabling high-voltage power distribution, DC-DC step-down, and OBC AC charging.

[0019] The national standard slow charging port provides AC power to the OBC module through L and N, and the CC and CP signals are connected to the three-in-one charging and power distribution assembly to complete the charging control; the DCDC module converts high voltage to low voltage to power the low-voltage battery and LV-PDU, and the LV-PDU is controlled by VCU to realize the low-voltage power distribution of the whole vehicle; the power battery assembly establishes CAN communication with all high-voltage components through the communication socket.

[0020] The full-link closed-loop HVIL high-voltage interlock circuit covers all high-voltage components and external interfaces. Any abnormality in any high-voltage connector will immediately trigger a high-voltage power outage. Combined with the KL30 and KL15 low-voltage control signals, it forms a complete high-voltage safety linkage structure.

[0021] As a specific embodiment of this solution, the following is an example: First, the power battery assembly is assembled. The power battery assembly integrates a BMS battery management module to complete the connection of voltage, current and temperature acquisition lines. The power battery assembly integrates a discharge socket, a charging socket, a power distribution socket and a communication socket. The discharge socket and charging socket use Tyco 2408619-1 sockets, the power distribution socket uses Tyco 2310540_1-CodeA sockets, and the communication socket uses Sumitomo 6188-6160 sheaths and 8230-5418 terminals. Each socket is functionally assigned to realize the directional transmission of high-voltage energy and communication docking.

[0022] Next, the drive power supply circuit is built. The discharge socket is directly connected to the high-voltage input terminal of the motor and electronic control powertrain through a high-voltage hard wire to form the vehicle drive power supply circuit. The power battery pack directly supplies power to the drive system through the discharge socket.

[0023] Next, the DC fast charging circuit is built by connecting the charging socket to the high-voltage input terminal of the national standard fast charging port through a high-voltage hard wire to form a DC fast charging circuit. External DC power enters the power battery assembly through the national standard fast charging port and the charging socket to charge the power battery. The communication socket of the power battery assembly is connected to the CC1, CC2, A+, and A- terminals of the national standard fast charging port through an internal signal link to complete the charging connection confirmation and communication interaction for DC fast charging.

[0024] Subsequently, the high-voltage power distribution circuit was constructed. The power distribution socket was connected to the high-voltage DC terminal of the DC&OBC&PDU three-in-one charging and power distribution assembly via a high-voltage hard wire, forming a high-voltage power distribution circuit. The high-voltage power from the power battery supplies power to the DC&OBC&PDU three-in-one charging and power distribution assembly through the power battery assembly and the power distribution socket. The DC&OBC&PDU three-in-one charging and power distribution assembly includes a DC-DC module and an OBC module. The high-voltage DC terminal of the DC-DC module is connected to the power distribution socket of the power battery assembly, and the output terminal is connected to the low-voltage battery via a fuse and connected in parallel to the LV-PDU low-voltage power distribution box. The control terminal of the LV-PDU low-voltage power distribution box is connected to the VCU module, and the VCU module realizes the low-voltage power distribution and protection actions of the whole vehicle through the LVPDU-CAN. The output terminal of the OBC module is connected to the power distribution socket, and the external AC power is converted into DC power by the OBC to complete the AC slow charging of the power battery.

[0025] Next, the AC slow charging circuit is built by connecting the L and N pins of the national standard slow charging port to the AC input terminal of the DC&OBC&PDU three-in-one charging and power distribution assembly via hard wires. Only AC power is transmitted. The CC and CP signals of the national standard slow charging port are connected to the charging control port of the DC&OBC&PDU three-in-one charging and power distribution assembly to form an AC slow charging circuit. External AC power is used to charge the power battery through the national standard slow charging port, OBC module, power distribution socket, and power battery assembly.

[0026] Next, the vehicle's CAN communication network was built. The communication socket of the power battery assembly was connected to the CAN interfaces of the integrated motor and electronic control powertrain, VCU module, DC & OBC & PDU three-in-one charging and distribution assembly, and national standard fast charging port via the CAN bus, forming a centralized communication network. CHASSIS-CAN was connected to the vehicle chassis control system to realize vehicle chassis communication. CHARGE-CAN was connected to the national standard fast charging port and national standard slow charging port to realize AC slow charging communication and DC fast charging communication. LVPDUCAN was connected to the LV-PDU low-voltage distribution box to realize low-voltage power distribution communication. The VCU module was connected to the power battery assembly, integrated motor and electronic control powertrain, DC & OBC & PDU three-in-one charging and distribution assembly, and national standard fast charging port via the CHASSIS-CAN bus to realize the status acquisition and command issuance of each high-voltage component.

[0027] Then, a closed-loop HVIL high-voltage interlock circuit was built. A low-voltage signal series monitoring method was adopted. Starting from the HVIL signal terminal of the power battery assembly, the HVIL terminals of the motor and electronic control integrated power assembly and the HVIL terminals of the DC, OBC and PDU three-in-one charging and distribution assembly were connected in series through the low-voltage control line, and finally connected back to the HVIL detection terminal of the power battery assembly to form a closed-loop low-voltage monitoring circuit. All high-voltage connectors have integrated HVIL interlock contacts. Following the mechanical logic of disconnecting the high voltage first and then disconnecting the interlock, the circuit is immediately disconnected when any high-voltage connector is loose, falls off or the component is opened. The power battery assembly cuts off the high voltage output in milliseconds, completely eliminating the risk of high voltage leakage and electric shock, and adapting to the safety requirements of unmanned logistics vehicles.

[0028] Finally, the low-voltage control wiring was completed, connecting the KL30 constant power and KL15 ignition power lines of the vehicle to the power battery assembly and the DC&OBC&PDU three-in-one charging and distribution assembly, respectively, to provide wake-up signals and enable control for the high-voltage system, and to realize the orderly start-up and shutdown and state switching of the high-voltage system.

[0029] The components in this implementation have clear connection paths and complete electrical logic. It can simultaneously realize high-voltage drive, DC fast charging, AC slow charging, high-voltage power distribution, high and low voltage linkage, multi-channel CAN communication coordination, and full-link safety protection functions. The overall structure is compact and the linkage is reliable, making it suitable for unmanned logistics vehicle operation scenarios.

[0030] The above description is merely illustrative of the embodiments of the present invention and is not intended to limit the present invention. For those skilled in the art, any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A safety linkage connection structure for a high-voltage energy system of an electric vehicle, characterized in that, It includes an integrated power battery assembly, a motor and electronic control two-in-one power assembly, a DC&OBC&PDU three-in-one charging and distribution assembly, a national standard fast charging port, a national standard slow charging port, a VCU module, and an LV-PDU low-voltage distribution box; the power battery assembly integrates a discharge socket, a charging socket, a power distribution socket, and a communication socket, and each high-voltage component is electrically connected through corresponding sockets, high-voltage hard wires, and low-voltage control lines; The vehicle is equipped with a full-link closed-loop HVIL high-voltage interlock circuit. The HVIL high-voltage interlock circuit starts from the HVIL signal terminal of the power battery pack, and sequentially connects the HVIL terminals of the motor and electronic control integrated powertrain and the HVIL terminals of the DC&OBC&PDU three-in-one charging and distribution assembly, and finally connects back to the HVIL detection terminal of the power battery pack to form a closed-loop low-voltage monitoring circuit to monitor the physical connection integrity of all high-voltage connectors in real time. The vehicle also deploys multiple CAN communication buses and low-voltage control lines to realize centralized management and control of the high-voltage energy system, as well as high- and low-voltage linkage and full-link safety protection.

2. The safety linkage connection structure for a high-voltage energy system of an electric vehicle according to claim 1, characterized in that, The discharge socket and the charging socket of the power battery assembly adopt the Tyco 2408619-1 model socket, the power distribution socket adopts the Tyco 2310540_1-CodeA model socket, and the communication socket adopts the Sumitomo 6188-6160 sheath and 8230-5418 terminal. Each socket is functionally assigned to realize the directional transmission of high-voltage energy and communication docking.

3. A safety linkage connection structure for a high-voltage energy system of an electric vehicle according to claim 1 or 2, characterized in that, The discharge socket is directly connected to the high-voltage input terminal of the motor and electronic control power assembly via a high-voltage hard wire. The charging socket is connected to the high-voltage input terminal of the national standard fast charging port via a high-voltage hard wire. The power distribution socket is connected to the high-voltage DC terminal of the DC&OBC&PDU three-in-one charging and power distribution assembly via a high-voltage hard wire, forming a drive power supply circuit, a DC fast charging circuit, and a high-voltage power distribution circuit, respectively.

4. The safety linkage connection structure of a high-voltage energy system for electric vehicles according to claim 1, characterized in that, The DC&OBC&PDU three-in-one charging and power distribution assembly includes a DC-DC module, an OBC module, and a power distribution circuit. The high-voltage DC terminal of the DC-DC module is connected to the power distribution socket of the power battery assembly, and the output terminal is connected to the low-voltage battery via a fuse and in parallel with the LV-PDU low-voltage distribution box. The LV-PDU low-voltage distribution box is used by the VCU module to realize the low-voltage power distribution and protection of the whole vehicle through LVPDU-CAN.

5. The safety linkage connection structure for a high-voltage energy system of an electric vehicle according to claim 1, characterized in that, The national standard slow charging port is connected to the AC input terminal of the OBC module through the L and N pins. The CC and CP signals of the national standard slow charging port are connected to the charging control port of the DC&OBC&PDU three-in-one charging and power distribution assembly. The output terminal of the OBC module is connected to the power distribution socket. External AC power is converted into DC power by the OBC module to complete AC slow charging of the power battery.

6. The safety linkage connection structure of a high-voltage energy system for electric vehicles according to claim 1, characterized in that, The VCU module is connected to the power battery assembly, the motor and electronic control integrated power assembly, and the DC&OBC&PDU three-in-one charging and distribution assembly via the CHASSIS-CAN bus, forming a centralized communication network to realize the status acquisition and command issuance of each high-voltage component.

7. The safety linkage connection structure for a high-voltage energy system of an electric vehicle according to claim 1, characterized in that, The power battery assembly and the DC&OBC&PDU three-in-one charging and distribution assembly are respectively connected to the CC1, CC2, A+, and A- connection terminals of the national standard fast charging port and the CC and CP signal terminals of the national standard slow charging port through internal signal links to complete the charging connection confirmation for DC fast charging and AC slow charging.

8. The safety linkage connection structure of a high-voltage energy system for electric vehicles according to claim 1, characterized in that, The constant power lines of the KL30 and the ignition power lines of the KL15 are respectively connected to the power battery assembly and the DC&OBC&PDU three-in-one charging and distribution assembly, providing wake-up signals and enable control for the high-voltage system, and realizing the orderly start-up, shutdown and state switching of the high-voltage system.

9. The safety linkage connection structure for a high-voltage energy system of an electric vehicle according to claim 1, characterized in that, The HVIL high-voltage interlock circuit adopts a low-voltage signal series monitoring method. If any high-voltage connector becomes loose, falls off, or the cover of any component is opened, the circuit will be immediately disconnected.

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